Single-Piece Insulative Liner with Hinged Flap
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Solution Overview
Problem
Packaging that requires insulation can be complex and difficult to manufacture and assemble, often involving multiple components and complicated processes.
Innovation Solution
A single-piece liner comprising a body portion and a flap portion made of insulative material, where the flap is hingedly connected to the top end of the body, allowing for easy assembly into a box by folding to enclose a cavity, with the liner and box designed to accommodate various shapes and sizes for efficient insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If insulation packaging is used, then thermal insulation performance is improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The liner integrates multiple functions (insulation, structural support, closure mechanism) into a single component. The insulative material forms both the body portion and flap portion as one piece, eliminating the need for separate insulation layers and simplifying manufacturing while maintaining thermal insulation performance.
Solution Approach 2:
The single-piece liner serves multiple purposes: it provides thermal insulation, defines the cavity structure, and creates the closure mechanism through the hinged flap. This multi-functional design reduces the number of components needed while achieving comprehensive packaging functionality.
2Temperature
If insulation packaging is used, then thermal insulation performance is improved, but assembly ease deteriorates
Solution Approach 1:
By combining the body and flap into a single hinged component, the assembly process is simplified to a single insertion motion. The hinge automatically positions the flap, eliminating complex assembly steps while maintaining effective insulation through the integrated design.
3Ease of manufacture
If a single-piece liner is used, then manufacturing complexity is reduced, but insulation effectiveness may be compromised
Solution Approach 1:
The liner is designed with varied thicknesses and densities in different regions to optimize insulation where needed. The insulative material properties can be adjusted locally within the single piece to provide enhanced thermal protection at critical areas while maintaining manufacturing simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution simplifies the assembly process, reduces material complexity, and provides effective insulation while being easy to manufacture and recyclable, maintaining a high repulpable percentage.
Implementation Method 1
The body portion and the flap portion comprise a single piece of insulative material
Data Source
AI summary
A liner comprising a body portion and a flap portion. The body portion comprises a front, a back, a first side, a second side, and a bottom. The body portion defines a cavity. The flap portion is hingedly connected to a top end of the back of the body portion. The flap portion is sized to cover the cavity. The body portion and the flap portion comprise a single piece of insulative material.