Metal Packaging Channel with Swedged Ends for Bundle Stability
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Solution Overview
Problem
Traditional wooden dunnage for packaging elongated bundles of parts is prone to instability, breakage, handling issues, insect infestation, flammability, and twisting, warping, which leads to shifting and damage during transit.
Innovation Solution
A metal packaging channel system with swedged ends and rolled hem flanges is used to create a stable bundle configuration, featuring channels with arced or bent designs to secure parts tightly without causing abrasion, made from durable materials like AISI S100 and ASTM A653 steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wooden channels are used for packaging bundles, then the packaging structure can be formed easily, but the wood breaks during transit causing bundles to shift and become unstable
Solution Approach 1:
The patent changes the material parameter from wood to metal (steel or aluminum), transforming the packaging channel from organic to inorganic material. This parameter change eliminates the breakage issue while maintaining structural formation capability through metal forming processes, thereby resolving the contradiction between ease of manufacture and bundle stability.
Solution Approach 2:
The patent employs composite construction by combining metal channels with wooden or plastic blocking elements. This composite approach leverages the strength and stability of metal while incorporating the ease of formation and cost-effectiveness of wood or plastic, thus resolving the contradiction between manufacturing ease and reliability.
2Ease of manufacture
If wooden channels are used for packaging, then the packaging can be produced cost-effectively, but wood is prone to twisting, warping, bowing, splitting, and cracking
Solution Approach 1:
The patent changes the material parameter from wood to metal, eliminating the dimensional instability characteristics of wood (twisting, warping, bowing, splitting, cracking) while maintaining cost-effectiveness through the use of metal forming processes and standardized metal profiles.
Solution Approach 2:
The patent uses composite materials by combining metal channels with wooden or plastic blocking elements, where the metal component provides dimensional stability and the wooden or plastic components provide cost-effectiveness and ease of formation.
3Ease of manufacture
If wooden channels are used for packaging, then the packaging structure can be formed flexibly, but wood leaves splinters in operators' hands creating handling issues
Solution Approach 1:
The patent changes the material parameter from wood to metal, eliminating the splintering issue that causes handling problems. Metal surfaces are smooth and non-splintering, thereby improving operator safety while maintaining the flexibility needed for packaging structure formation through metal forming processes.
Solution Approach 2:
The patent employs composite materials where metal channels provide a smooth, safe surface for handling, while wooden or plastic blocking elements maintain the flexibility and cost-effectiveness of the overall packaging structure.
4Ease of manufacture
If wooden channels are used for packaging, then the packaging can be produced easily, but wood is susceptible to insect infestation which can spread to the product
Solution Approach 1:
The patent changes the material parameter from wood to metal, completely eliminating the risk of insect infestation since metals are naturally resistant to insects. This parameter change maintains production ease through metal forming processes while providing complete protection against insect-related contamination.
Solution Approach 2:
The patent uses composite materials where metal channels provide inherent insect resistance and product protection, while wooden or plastic blocking elements maintain production ease and cost-effectiveness.
5Ease of manufacture
If wooden channels are used for packaging, then the packaging structure can be formed simply, but wood is inherently flammable unless treated
Solution Approach 1:
The patent changes the material parameter from wood to metal, eliminating flammability completely as metals are non-flammable materials. This parameter change maintains the simplicity of structure formation through metal forming processes while providing inherent fire protection.
Solution Approach 2:
The patent employs composite materials where metal channels provide inherent fire resistance and product protection, while wooden or plastic blocking elements maintain structural formation simplicity and cost-effectiveness.
Data Source
AI summary
A packaged bundle using a special designed packaging channel for dunnage is disclosed. The packaging channel dunnage has a channel with hemmed edges and swedged ends exhibiting a two-curved profile to provide a more secure bundle and improved safety during transport and handling.