Packaging Insert Templates for Self-Bearing Duct Board Cutting

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Solution Overview

Problem

Existing methods for determining the size and shape of individual wall sections in self-bearing duct systems for HVAC applications are resource-intensive, environmentally unfriendly, and time-consuming, often leading to errors and wastage.

Innovation Solution

An insulation board package equipped with a packaging insert featuring markings that define predetermined templates, allowing for precise cutting of insulating board cutouts to form wall sections of self-bearing duct systems, reducing the need for manual calculation and drawing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional manual calculation and drawing methods are used to determine wall section shapes, then flexibility in customizing duct systems is achieved, but time consumption and error rates increase significantly

Engineering Contradiction:

Improveease of determining wall section shapeVSAvoidtime for cutting insulation boards

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-marking the packaging insert with template markings that define the exact shape and size of wall sections before the insulation boards are processed. This allows installers to directly trace or transfer these pre-calculated markings to the insulation boards, eliminating the need for on-site manual calculations and drawings, thus significantly reducing time consumption while maintaining customization flexibility.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The packaging insert serves as an intermediary carrier that holds the template markings. Instead of directly marking each insulation board individually, the markings are first created on the packaging insert, which then acts as a template that can be repeatedly used across multiple boards. This intermediary approach standardizes the transfer process and reduces errors.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If custom markings are created for each insulation board, then precision in wall section dimensions is improved, but resource waste and environmental impact worsen

Engineering Contradiction:

Improveprecision of insulation board cutoutsVSAvoidwaste of marking materials

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The packaging insert is designed to serve multiple functions: it protects the insulation boards during transport, provides structural support, and acts as a reusable template carrier. The template markings on the packaging insert can be used repeatedly for multiple insulation boards, eliminating the need to create separate markings for each board and thus reducing material waste while maintaining precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Instead of creating original markings on each insulation board, the patent uses the packaging insert as a master template that is copied or transferred onto multiple boards. This copying approach ensures consistent precision across all boards while minimizing the consumption of marking materials, as the same template can be reused numerous times.

Inventive Principle:

Principle #26Copying

3Adaptability or versatility

If complex calculations are performed on-site for non-straight duct sections, then adaptability to different duct configurations is achieved, but complexity of the process increases

Engineering Contradiction:

Improveadaptability to different duct shapesVSAvoidcomplexity of determination process

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-calculating and pre-marking the template shapes on the packaging insert for various duct configurations (straight sections, elbows, tees, etc.). This shifts the computational complexity from the installation phase to the manufacturing phase, where it can be handled more efficiently. During installation, workers simply need to select and trace the appropriate pre-marked template, dramatically simplifying the on-site process while maintaining adaptability to different duct shapes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4578795A1Insulation board package with packaging insert

Publication Date: 2025.07.02 URSA INSULATION

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Figure 2A~2D

AI summary

Embodiments of an insulation board package are provided herein. The insulation board package contains at least one insulating board for forming wall sections of a self-bearing duct system, a packaging material and a packaging insert (100). The packaging insert has at least one marking (111, 112, 113, 114, 115, 116) on a surface (101) of the packaging insert (100). The marking (111, 112, 113, 114, 115, 116) defines a predetermined template (180, 190) adapted in size and shape to be used when cutting an insulating board cutout (140, 150) from an insulating board so that the insulating board cutout (140, 150) is adapted for use as a wall section of a self-bearing duct system. Further, a method of forming an insulation board package, a method of forming a predetermined template from an insulation board package, a method of forming an insulating board cutout (140, 150) and a method of forming a self-bearing duct section are provided.