Multi-slit Support Insert for Appliance Door Packaging
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Solution Overview
Problem
Existing packaging assemblies are ineffective in securely stabilizing and protecting appliance doors, such as those of front-loading laundry washers and dryers, during shipping and storage, as they fail to efficiently distribute impact forces and provide adequate protection against damage.
Innovation Solution
A packaging assembly incorporating corrugated corner elements with alternating ridges and grooves, endcap elements with corner recesses, and a support insert with a void and scalloped relief recess, allowing for flexible positioning and enhanced protection of appliance doors through frictional engagement and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional packaging assemblies are used, then the structure is simple and easy to manufacture, but they fail to effectively secure and protect appliance doors during shipping and storage
Solution Approach 1:
The packaging assembly is divided into distinct functional components: support inserts with recesses for door positioning, corner elements for structural support, and cushioning layers for impact protection. This segmentation allows each component to perform its specific function effectively while maintaining overall simplicity in manufacturing.
Solution Approach 2:
The door is nested within the support insert that has a recess specifically shaped to accommodate the door. The support insert is then nested within the larger packaging assembly structure. This nesting arrangement ensures the door is securely held in place while integrating smoothly with the overall packaging system.
2Productivity
If packaging assemblies are placed atop one another for storage and shipping, then storage efficiency improves, but the risk of impact damage increases without adequate cushioning and force distribution
Solution Approach 1:
Cushioning layers are pre-positioned between the door/support insert assembly and the packaging walls, as well as between stacked packages. This beforehand cushioning ensures that when packages are stacked or subjected to impact during shipping, the force is absorbed and distributed before reaching the protected door.
Solution Approach 2:
The packaging structure converts impact forces into beneficial distributed pressures through the cushioning layers and support elements. When an impact occurs during stacking or shipping, the force is transformed from a concentrated harmful impact into a distributed protective pressure that stabilizes the door within its recess.
3Reliability
If a support insert with recesses and relief features is used to secure the door, then protection and stability improve, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The support insert is pre-formed with recesses, relief features, and positioning elements during the molding or fabrication process. This preliminary action ensures that when the insert is installed in the packaging assembly, the door can be directly positioned and secured without requiring additional assembly steps or complex adjustments.
Solution Approach 2:
The support insert design incorporates specific geometric parameters such as recess depth, relief feature dimensions, and wall thickness ratios that are optimized to provide maximum door stabilization. These parameter changes are built into the manufacturing process, allowing complex functionality to be achieved through precise dimensional control rather than complex assembly procedures.
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 assembly provides increased protection and stability to appliance doors by distributing impact forces effectively, reducing damage risk during handling and storage, while allowing for compact storage and easy assembly, thus lowering costs and enhancing compressional strength.
Implementation Method 1
frictional engagement and structural support
Implementation Method 2
distributing impact forces effectively
Data Source
AI summary
A packaging assembly, including corrugated corner elements, each having a first corner post element leg and a second corner post element leg, each corner post element leg having one or more alternating ridges and grooves; endcap elements, each having a support layer portion and a tray layer portion, wherein the tray layer portion includes a corner recess formed proximate each corner of the support layer portion, wherein each corner recess is formed to allow at least a portion of one of the corrugated corner elements at least partially therein; and a multi-slit support insert having slits formed along at least a portion of the multi-slit support insert body, leaving a remaining portion of the multi-slit support insert body defining a web, wherein at least a portion of the multi-slit support insert body is bent to be fitted within a portion of the packaging assembly.