Wedge-Shaped Paper Ramp With Interlocking Flaps

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Solution Overview

Problem

Existing packaging solutions for large, castered or wheeled articles do not effectively provide a ramp made entirely from paper that can withstand the load forces for easy unloading from a shipping base.

Innovation Solution

A paper ramp comprising a folded bottom member and a pre-formed top member, where the bottom member is made from a multi-layered paper blank folded into a wedge shape with closure flaps for additional load-bearing support, and the top member features raised guide rails for stability, allowing the ramp to be affixed to the bottom member.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a ramp is made from traditional materials like wood or metal, then the load-bearing strength is sufficient, but the ease of manufacture and packaging integration is reduced

Engineering Contradiction:

Improveload-bearing strengthVSAvoidease of manufacture

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the physical parameters of paper by folding it into a three-dimensional wedge shape with multiple layers, transforming it from a flat, weak material into a structurally strong ramp capable of bearing heavy loads

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses multiple layers of paperboard laminated together to create a composite structure that combines the advantages of paper (ease of manufacture, packaging integration) with the strength properties of layered composite materials

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If a paper ramp is made from a single layer, then the ease of manufacture is high, but the load-bearing strength is insufficient

Engineering Contradiction:

Improveease of manufactureVSAvoidload-bearing strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent employs multi-layer paperboard construction where multiple single layers are laminated together, maintaining ease of manufacture from individual sheets while achieving the required load-bearing strength through the composite layered structure

Inventive Principle:

Principle #40Composite materials

3Strength

If a ramp structure is made stable and strong, then the load-bearing capacity increases, but the device complexity increases

Engineering Contradiction:

Improveload-bearing capacityVSAvoiddevice complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The ramp is divided into distinct functional segments including a bottom member for structural support, a top member for load distribution, and closure flaps for stability, with each segment performing a specific function to achieve overall strength without excessive complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The closure flaps are nested within the wedge-shaped structure, folding inward to provide additional support while maintaining a compact form factor and avoiding protruding elements that would increase device complexity

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS8646140B2Paper ramp

Publication Date: 2014.02.11 SONOCO DEVELOPMENT INC

AI summary

A paper ramp for use in unloading a wheeled or castered product from a pallet or shipping base is provided. The ramp is wedge shaped and comprises a folded bottom member affixed to a pre-formed top member having integrally formed guide rails. The bottom member has closure flaps that fold together in interlocking fashion inside the wedged shaped ramp to support and stabilize the load bearing top surface of the ramp.