LED Bulb Packaging Using Flexible Bags and Connector Sleeves

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Solution Overview

Problem

Conventional packaging methods for light bulbs, especially LED bulbs, result in inefficient use of shipping container space due to excess volume, leading to increased shipping costs and reduced product availability for consumers.

Innovation Solution

The use of protective sleeves for Edison-style connectors and conformable polymer containers or bags allows for loose LED light bulbs to nest together, optimizing density within shipping containers and reducing packaging material, enabling more bulbs to be packed in the same volume compared to traditional incandescent bulb packaging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional packaging materials (rigid plastic, cardboard) are used to protect light bulbs, then bulb protection is improved, but shipping container space utilization deteriorates

Engineering Contradiction:

Improvebulb protectionVSAvoidpackaging volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent uses a flexible plastic bag as packaging material instead of rigid plastic or cardboard. The bag conforms to the shape of the bulbs and allows them to be nested closely together, eliminating the excess volume created by rigid packaging structures while still providing necessary protection during shipping.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If protective packaging is used for incandescent bulbs, then bulb damage is prevented, but product density in shipping containers decreases

Engineering Contradiction:

Improvebulb damage preventionVSAvoidbulb density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent enables bulbs to be nested within each other inside the flexible bag packaging. The rounded shape of bulbs allows them to fit into the spaces created by adjacent bulbs, maximizing the number of bulbs that can be packed into a given volume while maintaining protection through the flexible bag.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The flexible plastic bag provides protection against damage while allowing the bulbs to be packed in a space-efficient nested arrangement, unlike rigid packaging that creates excess volume and prevents close packing.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If Edison-style connectors are exposed during shipping, then bulb assembly is simplified, but adjacent bulbs are marked by the connectors

Engineering Contradiction:

Improveassembly simplicityVSAvoidconnector marking

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a protective sleeve as an intermediary component that covers the Edison-style connector. The sleeve prevents the metal connector from directly contacting and marking adjacent bulbs during shipping, while still allowing the bulb to be assembled and disassembled easily by removing the sleeve.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10759592B2Light emitting diode (LED) light bulb packaging

Publication Date: 2020.09.01 IN 2 DEV LLC

AI summary

A method includes obtaining a container sized to fit multiple high voltage light emitting diode (LED) lightbulbs, adding multiple loose high voltage LED lightbulbs to the container to fill the container, and sealing the container, such that the container contains a higher density of high voltage LED light bulbs than a same sized container can hold protective packaged equivalent watt incandescent bulbs.