Self-Adjustable Middle Dunnage for Secure Packaging
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Solution Overview
Problem
Conventional packaging solutions fail to securely and efficiently accommodate a variety of differently shaped articles, particularly wine bottles, due to limited adaptability and stability issues during transportation and storage.
Innovation Solution
A packaging unit comprising a carton with molded pulp fiber bottom and top trays, and a self-adjustable middle dunnage with holes and self-adjustable tabs, which allows for securement of articles through adjustable positions and foldable flaps to enhance stability and versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional packaging solutions are used, then the structure is simple, but the adaptability to differently shaped articles is poor
Solution Approach 1:
The middle dunnage is designed with self-adjustable tabs that can dynamically change position to accommodate articles of different shapes and sizes. The tabs move from a first position to a second position, allowing the packaging structure to adapt its configuration based on the loaded article dimensions without requiring multiple pre-configured packaging options.
Solution Approach 2:
The middle dunnage is divided into multiple functional segments including tabs, flaps, and engagement features that can independently adjust to fit different article geometries. This segmentation allows each component to perform specific adaptation functions while maintaining overall structural integrity.
2Stability of the object's composition
If conventional packaging solutions are used, then the manufacturing process is simple, but the stability during transportation is insufficient
Solution Approach 1:
The middle dunnage automatically adjusts and secures itself to the loaded article through self-adjustable tabs and engagement features without requiring external assistance or complex assembly procedures. The packaging structure performs its own stabilization function by adapting to the article shape and securing it in place.
Solution Approach 2:
The packaging structure changes its physical parameters (tab position, flap configuration, engagement depth) based on the loaded article dimensions to optimize stability. This allows the same packaging component to provide appropriate support for various article sizes and shapes by adjusting its configuration parameters.
3Strength
If a fixed packaging structure is used, then the design is simple, but the load-bearing capability is limited
Solution Approach 1:
The middle dunnage serves multiple functions simultaneously: it provides structural support, adjusts to different article sizes, secures the load, and maintains stacking stability. This multi-functionality increases load-bearing capability without proportionally increasing structural complexity.
Solution Approach 2:
The packaging unit combines molded pulp fiber trays with a corrugated carton, creating a composite structure that leverages the strengths of each material. The molded pulp provides cushioning and shape adaptation while the corrugated carton provides rigid structural support and stacking strength.
Data Source
AI summary
A packaging unit includes a carton having top and bottom surfaces and side walls extending between said top and bottom surfaces. The unit further includes molded pulp fiber bottom and top trays, with each tray defining a plurality of securement chambers. The unit further includes a self-adjustable, middle dunnage including a main body disposed between the molded fiber bottom and top trays. The main body includes a plurality of holes extending through the main body and a plurality of slots extending from a perimeter of each of the holes to define a plurality of self-adjustable tabs surrounding each of the holes. The middle dunnage further includes a first plurality of foldable flaps extending from the main body towards the bottom surface and a second plurality of foldable flaps extending the main body towards the top surface of the carton.