Scored Corrugated Pad with Die-Cut Tabs for Shipping Suspension
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Solution Overview
Problem
Traditional product shipping methods fail to securely package and ship large, bulky, or heavyweight items, as they often result in the product becoming loose or damaged due to shifting within the master container.
Innovation Solution
A method and apparatus using a die-cut, scored corrugated pad with foldable portions and die-cut tabs, combined with restraining material like plastic sheeting or strapping, to securely position and suspend products within a master container, preventing movement and contact with container walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional shipping methods (corrugated pad with strapping or plastic sheet) are used, then small lightweight products are adequately protected, but large bulky heavyweight products become loose and shift within the container
Solution Approach 1:
The pad is divided into multiple functional zones: a central portion for product placement, upper and lower portions that fold over the product, and right and left portions with die-cut tabs for suspension. This segmentation allows each zone to perform a specific function, enabling the single pad structure to effectively secure products of varying sizes and weights.
Solution Approach 2:
The pad transitions from a flat two-dimensional structure to a three-dimensional configuration through folding the upper/lower portions over the product and extending the die-cut tabs vertically. This dimensional transformation creates multiple contact points and suspension levels, providing secure restraint for large bulky products that cannot be adequately secured by traditional flat packaging methods.
2Ease of manufacture
If traditional shipping methods are used for large bulky products, then packaging is simple, but the product becomes loose and contacts container walls causing damage
Solution Approach 1:
The pad's folded portions and die-cut tabs are designed to automatically position and secure the product without requiring additional external supports or complex assembly steps. The structure self-adjusts to accommodate the product, eliminating the need for multiple separate packaging components while preventing product movement and container wall contact.
3Productivity
If the pad structure is simplified for ease of use, then packaging is faster, but the product cannot be securely suspended within the container
Solution Approach 1:
The die-cut tabs and score lines are pre-formed during pad manufacturing, creating predetermined fold lines and attachment points. This preliminary preparation allows the pad to be quickly assembled on-demand without requiring complex cutting or shaping operations during the packaging process, while ensuring reliable product suspension through the pre-engineered tab structure.
Data Source
AI summary
A method for packaging a product and a product-shipping package. A pad includes upper and lower horizontal score lines inset from upper and lower edges, and right and left vertical score lines inset from right and left edges. The score lines define a central portion, upper and lower portions, and right and left portions. The product is placed on the central portion. The upper and lower portions fold toward the central portion, contacting the product. A wrap of restraining material is wrapped around the pad and the product. The right and left portions fold to an upright position perpendicular to the pad. The right and left vertical score lines include die-cut tabs. When the right and left portions fold to the upright position, the die-cut tabs extend to an aligned position below and perpendicular to the pad. The pad and the wrapped product insert into a master shipping container. The wrap holds the product in position on the pad. The upright right and left portions and the extended die-cut tab portions t suspend the pad and product within the container.