On-demand protective structures for packaging items

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Solution Overview

Problem

Conventional packaging methods for order fulfillment are inefficient and wasteful, often requiring excessive cushioning materials and larger containers, which can damage goods during shipment due to shifting and improper handling.

Innovation Solution

An on-demand packaging system that analyzes order items for specific characteristics to create custom packaging specifications, including container type, item arrangement, and protective structure configuration, using automated systems to rapidly manufacture and assemble protective structures optimized for each order.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional packaging uses excessive cushioning material to protect goods, then protection level improves, but material waste and container size increase

Engineering Contradiction:

Improveprotection levelVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The protective structure is designed with varying densities and configurations in different regions to match the specific protection needs of each item's location and characteristics, rather than using uniform cushioning material throughout the container

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system generates customized protective structure configurations dynamically based on the specific items being packaged, allowing the packaging design to adapt to each order's unique requirements rather than using static conventional methods

Inventive Principle:

Principle #15Dynamics

2Reliability

If conventional packaging uses large container volume to accommodate cushioning material, then protection level improves, but handling and shipping costs increase

Engineering Contradiction:

Improveprotection levelVSAvoidhandling efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The protective structure is divided into multiple portions that can be assembled together, allowing for compact packaging that fits items more efficiently and reduces overall container volume while maintaining protection levels

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system pre-determines the optimal protective structure configuration before packaging, enabling efficient assembly and reducing handling time and costs

Inventive Principle:

Principle #10Preliminary action

3Volume of stationary object

If conventional packaging fills remaining space with cushioning material, then space utilization improves, but item shifting and damage during shipment occur

Engineering Contradiction:

Improvespace utilizationVSAvoiditem stability

Core Design Contradiction:

Volume of stationary objectVSReliability

Solution Approach 1:

Different regions of the protective structure have different properties tailored to the specific items they protect, providing appropriate support and cushioning locally rather than using uniform material that may not prevent shifting

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system replaces conventional mechanical cushioning materials with a structured, form-fitting protective design that mechanically constrains items in optimal positions, preventing shifting through structural support rather than bulk material

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If conventional packaging uses standardized approaches, then packaging speed improves, but customization and optimization for specific items are lost

Engineering Contradiction:

Improvepackaging speedVSAvoidpackaging customization

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system dynamically generates customized protective structure configurations based on item characteristics while maintaining efficient packaging processes, eliminating the need for standardized one-size-fits-all approaches

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10370136B1On-demand protective structures for packaging items in a container

Publication Date: 2019.08.06 INTRINSIC INNOVATION LLC

AI summary

Example methods and systems are disclosed for on-demand packaging of one or more items. According to one example, a method can include receiving an order for the item(s) and determining characteristic-information for the item(s) using a computer system. The characteristic-information includes an indication of at least a size and a shape of the item(s). The method also includes processing the characteristic-information based on design criteria to determine an arrangement of the item(s) within at least one container volume, and a configuration for a protective structure to hold the item(s) in the arrangement within the container volume(s). The method can further include, in response to the processing the characteristic-information, forming the protective structure according to the configuration, placing the item(s) into the protective structure according to the arrangement, and placing the protective structure and the item(s) in the container volume(s).