Offset-Flute Corrugating Roller for Conformable Shipping Inserts
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Solution Overview
Problem
Conventional shipping containers are inefficient in terms of space utilization and recycling, leading to increased shipping and storage costs due to their fixed sizes and multi-material composition, which often results in improper recycling and environmental harm.
Innovation Solution
A shipping container made of a corrugated medium with offset flutes and score lines that allows for flexible conformability to product shape, reducing volume and enabling easy recycling by being made entirely of paper or plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional shipping containers are made of multiple materials (paper and plastic), then they provide adequate protection and cushioning, but they become difficult to recycle properly and harm the environment
Solution Approach 1:
The patent applies homogeneity by using a single material (either paper or plastic) for the entire shipping container structure, eliminating the need for manual separation of multiple materials. The container consists of a liner and corrugated medium made from the same material family, making it easily recyclable as a single material stream while maintaining adequate protection through the corrugated flute structure
2Adaptability or versatility
If conventional shipping containers are made larger to accommodate different product sizes, then they can ship more products, but they increase storage costs and volume efficiency decreases
Solution Approach 1:
The patent applies dynamics by making the container adaptable to different product shapes and sizes through its flexible corrugated structure. The container can be molded or formed to fit specific product contours, allowing the same base container design to accommodate various products without requiring multiple standardized container sizes, thus reducing storage volume requirements
Solution Approach 2:
The patent applies local quality by having the container structure adapt locally to the product shape. The corrugated medium with its flute pattern provides localized cushioning and conformability to match the specific contours of different products, allowing optimal space utilization within the container rather than requiring the entire container to be oversized
3Ease of manufacture
If conventional shipping containers use fixed standardized sizes, then they are easy to manufacture and store, but they waste space when shipping smaller products
Solution Approach 1:
The patent applies parameter changes by allowing the container dimensions and shape to be adjusted based on the specific product being shipped. The corrugated medium can be formed into different configurations and the container can be molded to match product contours, changing the volume parameters to match the actual shipping needs rather than using fixed standardized sizes
4Reliability
If conventional bubble mailers use air bubbles for cushioning, then they protect products during shipping, but they require manual separation for recycling
Solution Approach 1:
The patent applies homogeneity by integrating the cushioning function into the same material stream as the container structure. The corrugated medium made from the same material as the liner provides cushioning through its flute pattern without requiring separate air bubble layers, eliminating the need for manual separation of cushioning and container materials
Data Source
AI summary
The present disclosure is directed to a shipping container with a corrugated medium that lines an interior pocket of the shipping container as well devices and components (e.g., corrugating rollers, corrugating machines, scoring rollers, and scoring machines) that are utilized to manufacture the shipping containers. The corrugated medium has flutes that cushion, support, and protect a product that is shipped within the shipping container. The corrugated medium may include a first portion with first flutes and a second portion with second flutes that are offset relative to the first flutes. The offset first flutes and second flutes results in peaks of the first flutes nesting within valleys of the second flutes, and peaks of the second flutes nesting within valleys of the first flutes.