Nested Rolled Sheet Material Packages Optimizing Shipping Volume
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Solution Overview
Problem
The existing packaging of cylindrical rolls of sheet materials, such as paper and plastic films, results in wasted shipping volume due to the rectangular arrangement of rolls, which does not utilize the interior space efficiently.
Innovation Solution
A nested rolled sheet material package configuration where rolls of varying internal diameters are arranged in a telescopic manner, with a package fixture that fits within each roll, allowing smaller rolls to be nested inside larger ones, optimizing the use of space and making the product visible for consumer appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If multiple cylindrical rolls are packaged in a rectangular arrangement, then the packaging structure is simple and easy to manufacture, but shipping volume is wasted due to inefficient space utilization
Solution Approach 1:
The patent applies nesting by placing smaller diameter rolls inside larger diameter rolls in a telescopic arrangement. The rolls are nested concentrically with each roll positioned within the hollow interior of the next larger roll, creating a compact nested configuration that maximizes space utilization in the shipping container while maintaining structural simplicity.
2Volume of stationary object
If rolls are arranged vertically in rectangular groups, then packaging and shipping is straightforward, but the interior volume of cylindrical form tubes results in unused shipping volume
Solution Approach 1:
The patent implements nesting by arranging rolls in a telescopic configuration where each roll is positioned inside the hollow interior of the next larger roll. This nested arrangement eliminates wasted interior volume of form tubes and creates a compact packaging structure that is still straightforward to assemble and ship.
3Productivity
If rolls are nested in a telescopic arrangement, then shipping volume is optimized, but the package structure becomes more complex requiring package fixtures
Solution Approach 1:
The patent introduces package fixtures as intermediary components that facilitate the nested arrangement. These fixtures include support structures positioned within the hollow interiors of the rolls to maintain proper spacing and alignment, acting as mediators that enable the space-efficient nested configuration while managing the structural complexity through standardized support elements.
4Volume of stationary object
If rolls are arranged to maximize space utilization, then shipping volume waste is reduced, but product visibility for consumer appeal may be reduced
Solution Approach 1:
The patent applies segmentation by strategically positioning rolls of different diameters in the nested arrangement to create visible exterior surfaces. Larger diameter rolls are positioned to extend beyond smaller rolls, creating a stepped configuration that allows consumer products to be visible from multiple angles while maintaining the space-efficient nested structure within the shipping container.
Data Source
AI summary
Nested rolled sheet material packages have multiple rolls of sheet material each with unique internal and external diameters and nested and held in a telescoping arrangement by a package fixture which fits within a portion of each roll and which is contacted by an end of each roll so that a portion of each roll is visible. The package fixture may be generally planar, cylindrical or conical, and may further include steps for contact with ends of each of the rolls.