Packaging Sheet Cell Volume Reduction via Fluid Discharge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging sheets with improved heat insulation properties face challenges in minimizing volume without opening cells, leading to increased logistics costs due to large air caps and cumbersome cutting or needle-punching processes.
Innovation Solution
A method involving the formation of cells on a film, bonding a lower-side film to open the cells, filling them with fluid, closing the cells, and bonding an upper-side film, allowing for fluid release and winding, minimizes cell volume without cutting or needle-punching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cells are sealed in units of air caps, then heat insulation property is improved, but volume of air caps increases causing excessive increase in logistics costs
Solution Approach 1:
The patent changes the physical state of the insulation medium from gas (air) to liquid (water), which has different density and volume characteristics. The water-filled cells provide the same heat insulation property as air caps but with significantly reduced volume, thereby lowering logistics costs while maintaining thermal performance.
2Volume of moving object
If one side of packaging sheet is cut to discharge fluid, then volume is minimized, but this is a cumbersome work
Solution Approach 1:
The packaging sheet structure enables self-draining of the liquid filler through gravity and the designed cell configuration. The liquid automatically flows to the lower end of the packaging sheet where it can be discharged without requiring external cutting or needle-punching operations, simplifying the manufacturing process while achieving volume minimization.
3Volume of moving object
If part of packaging sheet is cut or needle-punched to minimize volume, then volume is reduced, but this is a cumbersome work
Solution Approach 1:
The packaging sheet is divided into multiple sealed cells that can be independently filled and controlled. This segmentation allows the liquid filler to be contained within specific regions and discharged from designated areas without requiring cutting or needle-punching of the entire packaging sheet, maintaining structural integrity while enabling volume reduction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances heat insulation while reducing packaging sheet volume, thereby lowering logistics costs and simplifying storage and transportation.
Implementation Method 1
a lower-side film compression roller for compressing the lower-side film unwound from a lower-side film roller onto the embossing roller
Implementation Method 2
an adhesive applying unit for applying an adhesive to the lower-side film unwound from a lower-side film roller at a predetermined interval
Implementation Method 3
the fluid may be temporarily filled in the plurality of cells by a fluid injector for injecting the fluid into the plurality of cells
Implementation Method 4
the plurality of cells may be temporarily closed when the plurality of cells passes through a compression unit in a state in which the fluid is temporarily filled in the plurality of cells, the compression unit compressing one sides or the other sides of the plurality of cells or compressing both the one sides and the other sides of the plurality of cells inwardly of the plurality of cells
Implementation Method 5
the upper-side film may be bonded onto the plurality of cells by an upper-side film compression roller for compressing a melt-extruded thermoplastic synthetic resin for manufacturing the upper-side film onto the plurality of cells
Implementation Method 6
a thermoplastic synthetic resin is melt-extruded to an embossing roller in which forming grooves having a shape corresponding to the cells are formed on an outer circumferential surface thereof at a regular interval
Data Source
AI summary
The present invention relates to a method of manufacturing a packaging sheet, the method being capable of not only greatly improve a heat insulation property of the packaging sheet, but also minimizing the volume of cells of the packaging sheet without opening the cells by partially cutting or needle-punching the cells, thereby facilitating storage and transportation of the packaging sheet.