Packaging System With Nested Support Member
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Solution Overview
Problem
Existing packaging systems lack efficiency and cost-effectiveness in securely transporting components like automotive parts, as they often require excessive materials and complex assembly processes.
Innovation Solution
A multi-component packaging system comprising a support member with a base, head portion, and leg, and a packing component with apertures and perforations, allowing for efficient assembly and reduced material usage by folding and engaging components within a container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional packaging systems are used to securely transport automotive parts, then the parts are protected during transportation, but excessive materials are required and assembly processes become complex
Solution Approach 1:
The packaging system is divided into multiple functional components: a base tray for the part, a support member with base/head/leg structure for positioning, and a closure component. Each segment serves a specific protective function, allowing the system to provide secure transport while using only the necessary amount of packaging material for each function.
Solution Approach 2:
The support member is designed with a nested structure where the leg fits within a recess of the closure component, and the head portion engages with the base tray. This nesting arrangement allows multiple packaging elements to be integrated into a compact configuration, reducing overall material usage while maintaining structural integrity for secure transport.
2Reliability
If traditional packaging systems are used to securely transport automotive parts, then the parts are protected during transportation, but the assembly processes become complex
Solution Approach 1:
The support member combines multiple functions into a single component: the base provides structural support, the head portion engages with the base tray to secure the part, and the leg interfaces with the closure component. This merging of functions reduces the number of separate assembly steps while ensuring secure transport through integrated positioning and retention features.
Solution Approach 2:
The packaging components are designed with self-aligning and self-securing features. The support member's head portion automatically engages with the base tray, and the leg fits into the closure component's recess, allowing the assembly to secure itself without complex fastening operations. This self-service mechanism simplifies the assembly process while maintaining transport security.
3Reliability
If excessive packaging materials are used to protect parts, then the parts are securely protected, but manufacturing cycle time and costs increase
Solution Approach 1:
The support member and closure component are pre-configured with complementary geometries - the leg's cross-sectional shape matches the recess's cross-section, and the head portion's dimensions are predetermined to engage with the base tray. This preliminary design of fitment relationships eliminates the need for time-consuming adjustments or complex assembly operations during manufacturing, thereby reducing cycle time while maintaining adequate part protection.
Solution Approach 2:
The packaging system uses standardized dimensional parameters for the support member components - the leg's cross-sectional dimensions, the recess's dimensions, and the head portion's size are all defined by specific parameters that optimize the balance between protection and assembly efficiency. By carefully selecting these parameters, the system achieves sufficient protection with minimal material and simplified assembly, improving manufacturing productivity.
Data Source
AI summary
A packaging system included a support member and a packing component. The support member includes a base, a head portion, and a leg. The head portion extends from the base in a first direction. The leg extends from the base in a second direction opposite the first direction. The packing component includes a first portion and a second portion. The first portion defines a first aperture configured to receive the leg. The second portion defines a second aperture configured to receive the head portion.