Molded Pulp Bottle Packaging with Cardboard Partition
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Solution Overview
Problem
Existing bottle shipment packaging solutions fail to effectively prevent breakage and label damage during transit, as they either disintegrate under stress or contact the bottles' midsections, leading to abrasion, fading, or tearing of labels.
Innovation Solution
A packaging system comprising a bottom tray, top tray, and corrugated cardboard partition, where the trays are made of molded pulp fiber and corrugated cardboard respectively, with securement chambers and crushable elements that axially engage bottles, providing structural support and avoiding contact with labels, allowing bottles to be shipped upright with minimal risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If molded pulp fiber trays are used to encase bottles laterally, then bottle breakage is prevented, but the trays disintegrate under repeated shaking and crushing forces during shipment
Solution Approach 1:
The packaging system combines molded pulp fiber trays with corrugated cardboard partitions and shock-absorbing inserts to create a composite structure that leverages the strengths of each material. The pulp fiber provides lateral encasement and bottle-shaped support, while the corrugated cardboard provides rigid structural framework and the shock-absorbing insert provides cushioning against crushing forces, collectively preventing tray disintegration under shipment stresses
Solution Approach 2:
The packaging is divided into multiple functional components: bottom tray, top tray, corrugated cardboard partitions, and shock-absorbing inserts. Each component performs a specific function - the trays provide lateral support, the partitions provide vertical separation and structural rigidity, and the inserts provide shock absorption. This segmentation allows each element to be optimized for its specific function while working together to maintain overall structural integrity
2Reliability
If molded shells with crushable projections are used to cushion bottles, then shaking is limited, but the projections contact the bottle midsection causing label damage
Solution Approach 1:
The harmful function of contact-based cushioning is extracted and replaced. Instead of using protrusions that directly contact the bottle midsection, the invention uses a shock-absorbing insert that cushions the bottle through indirect means, and corrugated cardboard partitions that provide support without contacting the labeled surfaces, thereby eliminating label damage while maintaining shock protection
Solution Approach 2:
The corrugated cardboard partitions and shock-absorbing inserts act as intermediary elements between the external forces and the bottle. These intermediaries absorb and distribute the shock forces before they can reach the bottle's labeled surfaces, providing cushioning without direct contact that would cause label damage
3Reliability
If insulated bodies and filler structures are used to surround bottles, then breakage is avoided, but lateral surface contact causes abrasion and fading of labels
Solution Approach 1:
The packaging provides different types of protection at different locations: the molded pulp fiber trays provide localized bottle-shaped support at the ends, the corrugated cardboard partitions provide vertical separation and structural support, and the shock-absorbing inserts provide localized cushioning. This localized approach allows protection where needed without creating continuous lateral contact that would cause label damage
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 packaging system securely holds bottles upright, resisting disintegration and label damage, while passing rigorous ISTA testing procedures, ensuring the integrity and aesthetic preservation of bottles during shipment.
Implementation Method 1
crushable elements that axially engage bottles, providing structural support
Implementation Method 2
corrugated cardboard partitioned support structure disposed therebetween. The support partition may be made of corrugated cardboard material and be arranged such that the flutes extend generally horizontally
Data Source
AI summary
A bottle packaging for shipment includes a bottom tray, and a top tray made of molded pulp fiber, such as newspaper pulp, and a cardboard partition support structure disposed between the trays. Cavities formed in the bottom and top trays are arranged to engage both ends of a bottle and include crushable elements that can axially engage each bottle. The support partition may be made of corrugated cardboard material and be arranged such that the cardboard flutes provide support for loads imparted to the sides of the carton when the carton is laying on its side. The partition forms a void surrounding each bottle in the area of its labels. In this way, structural support and cushioning can be provided to the packaged bottles from all directions.