Rounded Edge Partition Assembly for Product Protection
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Solution Overview
Problem
Existing partition assemblies for containers often have sharp upper edges that can damage products, require additional clearance, and are not secure, with unstiffened partitions that can easily disassemble and tear.
Innovation Solution
A partition assembly with slotted partitions having rounded edges, made from a multi-layered material with a foam interior and fabric outer layers, where the edges are rounded using heat to create a secure and stiff unit, allowing for easy mass production with low costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If partitions are made with straight cut edges, then manufacturing is simple and fast, but the edges become sharp and can damage products or injure handlers
Solution Approach 1:
The patent applies curvature by rounding the upper edges of partitions using a heating element that softens the plastic material, allowing it to conform to a rounded profile. This eliminates sharp edges while maintaining manufacturing efficiency, as the rounding process is integrated into the standard cutting and forming operations.
2Ease of manufacture
If partitions are made from single-layer material, then manufacturing is simple, but the partitions lack stiffness and can easily disassemble or tear
Solution Approach 1:
The patent employs composite materials by constructing partitions from multiple layers of plastic material bonded together. This multi-layer construction provides enhanced stiffness, strength, and resistance to tearing compared to single-layer partitions, while still allowing for efficient manufacturing through integrated forming processes.
3Strength
If partition material stiffness is increased to prevent disassembly, then structural integrity improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent utilizes parameter changes by controlling the thermal properties of the plastic material during manufacturing. By applying heat to specific areas, the material becomes more pliable for forming rounded edges and securing connections, then cools to regain stiffness for structural integrity. This allows high strength without increased manufacturing complexity.
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
The rounded edges prevent damage to products, enhance security by preventing disassembly, and allow for customizable stiffness, reducing material and labor costs while ensuring the partitions remain intact during use.
Implementation Method 1
The foam substrate of the multiple layered partition blank is heated with a heat source
Implementation Method 2
heat from the heat source causes the foam substrate to become at least partially molten
Implementation Method 3
heat from the heat source causes the foam substrate to become at least partially molten and shrink or collapse
Data Source
AI summary
A partition assembly comprising a partition matrix made up of intersecting first and second slotted partitions, each of the partitions having at least one slot and a rounded edge. The slots of the partitions are engaged with each other at a plurality of intersections. The partitions are made by rounding an edge of a multi-layered blank using a rotatable tool and then cutting the partition material to a desired size. Slots may then be formed in the edge sealed material.