Memory Foam Bedding Dual-Roll Packing for Shelf Space Reduction
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Solution Overview
Problem
Memory foam bedding articles, when rolled and packed, leave significant void space in containers due to their circular cross-sectional shape, leading to inefficient use of storage and display space, particularly on retail shelves where containers are stacked or aligned.
Innovation Solution
Rolling the bedding articles into two portions that form a rectangular prism shape, allowing them to be packed in containers with a rectangular cross-section, which reduces void space and optimizes shelf space usage by aligning containers without exceeding standard shelf depths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the bedding article is rolled into a cylindrical shape for transportation and storage, then it is easy to handle and pack, but significant void space is created in the container reducing storage efficiency
Solution Approach 1:
The bedding article is divided into multiple sections during rolling, with at least one section having a different rolling direction from others. This segmentation allows the rolled article to be packed more efficiently into rectangular containers, reducing void space while maintaining ease of handling during transportation and storage.
Solution Approach 2:
Instead of rolling the entire bedding article in a single symmetric cylindrical shape, the invention applies asymmetric rolling where different sections are rolled in opposite directions. This creates a more space-efficient configuration that better fits rectangular containers, reducing the container volume required while preserving operational ease.
2Productivity
If containers are arranged on retail shelves with standard depth, then display space is optimized, but containers with circular cross-sections leave wasted shelf space
Solution Approach 1:
By segmenting the bedding article into sections with different rolling directions, the resulting rolled configuration better fits rectangular containers. This allows containers to be arranged more efficiently on retail shelves, maximizing the use of standard shelf depth and improving retail store efficiency without wasting shelf space.
Solution Approach 2:
The invention changes the dimensional configuration of the rolled bedding article from a simple cylinder to a multi-sectional form with varying orientations. This dimensional adjustment allows the container to utilize shelf depth more effectively, enabling better space utilization on retail shelves and improving productivity.
3Volume of moving object
If the bedding article is compressed into a tight roll, then transportation space is reduced, but the circular shape creates void space in rectangular containers
Solution Approach 1:
The bedding article is compressed into multiple tight roll sections with different orientations. This segmentation allows the compressed volume to be better utilized within rectangular containers, reducing both the moving object volume and the required container volume simultaneously by eliminating void spaces created by single-direction cylindrical rolling.
Data Source
AI summary
A bedding article is compressed and rolled from two side edges to form a rolled bedding article having two rolled portions. The rolled bedding article is fitted into a rectangular prism-shaped container. The container depth is smaller than the container width or height. The depth extends in a depth dimension that is perpendicular to the roll axes of the rolled portions. Multiple containers that contain such rolled bedding articles are placed on a retail-store merchandise shelf. The shelf has a shelf depth that extends in the depth dimension. A first container is disposed on the shelf in front of the second container. The combined depth of the aligned containers is made to be approximately the same as the shelf depth in order to reduce the amount of wasted shelf space in the retail store.