Modular Corrugated Container with Integrated Cushioning
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Solution Overview
Problem
Conventional packaging for information handling systems is inefficient, leading to excessive material usage, increased logistics costs, and environmental impact due to inadequate support against accelerations, which can cause damage to internal components during shipping.
Innovation Solution
A modular corrugated container with integrated cushioning using a support surface made of perforated corrugated material, featuring tabs that form feet to elevate the surface and distribute accelerations evenly, reducing product flexure and the need for additional cushioning materials like foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional corrugated packaging with foam cushioning is used, then product protection against accelerations is improved, but packaging material usage and weight increase
Solution Approach 1:
The patent combines the exterior container and interior cushioning support into a single integrated corrugated cardboard structure. The container walls are formed with integrated support surfaces that directly contact and protect the product, eliminating the need for separate foam cushioning materials while maintaining protection against accelerations and impacts.
Solution Approach 2:
The patent extracts and removes the foam cushioning materials from the packaging system, relying solely on the corrugated cardboard structure to provide both containment and cushioning functions. This extraction eliminates unnecessary materials while the corrugated structure's inherent compression and bending properties provide adequate protection.
2Strength
If more packaging material is used to increase stack strength, then exterior strength is improved, but package footprint and logistics efficiency worsen
Solution Approach 1:
The patent segments the container walls into multiple sections with integrated support surfaces, reinforcement ribs, and structural features distributed throughout the structure. This segmentation allows strength to be concentrated where needed without increasing overall package dimensions, optimizing the strength-to-footprint ratio.
3Reliability
If system-specific packaging is designed for each information handling system, then product fit and protection is improved, but packaging development time and inventory complexity increase
Solution Approach 1:
The patent designs a universal corrugated container with adjustable and reconfigurable support surfaces that can accommodate multiple different information handling system products. The integrated support structures can be configured to fit various device sizes and shapes, eliminating the need for product-specific packaging designs while maintaining adequate protection and fit.
Data Source
AI summary
A modular corrugated container integrates product cushioning with a product support surface formed from corrugated paper and having features that absorb transverse accelerations. The support surface has scored tabs that bend perpendicular to an interior support portion, forming feet that elevate the interior portion relative to a container bottom. The interior portion has perforations that absorb accelerations, such as a perforations formed around the outside perimeter of the location at which a product rests, perforations extending from corners of the support surface towards a central location of the support surface, and perforations at the scoring of the tabs. Voids formed along the tabs remove portions of the feet from contact with the container bottom to encourage constant dissemination of accelerations across the support surface.