Shaped Flexible Shipping Package with Expandable Protection Chambers

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current shipping packages are inefficient, costly, and lack customization for the products being shipped, often requiring additional materials for protection and leading to damage, increased volume, and difficulty in handling and recycling.

Innovation Solution

A flexible package made from multi-layered polypropylene film with expandable chambers and expansion ports, allowing for customizable fit and protection, easy handling, and efficient use of materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If generic flexible pouch or box packaging is used, then the package can be used for many different types of goods, but it does not provide a custom fit leading to additional packaging requirements and increased volume

Engineering Contradiction:

Improvecompatibility with different productsVSAvoidshipping volume

Core Design Contradiction:

Adaptability or versatilityVSVolume of stationary object

Solution Approach 1:

The package uses expandable chambers that can be inflated to different volumes, allowing the same package structure to adapt to different product sizes and shapes. The chambers transition from a collapsed state during shipping to an expanded state during storage, dynamically adjusting the package volume to match the contents.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The package is divided into multiple expandable chambers that can be independently inflated or deflated. This segmentation allows different portions of the package to be activated based on the size and shape of the product being shipped, optimizing both fit and volume efficiency.

Inventive Principle:

Principle #1Segmentation

2Reliability

If additional protective materials are added to generic packages, then product protection is improved, but material usage, weight, and cost increase

Engineering Contradiction:

Improveproduct protectionVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The package utilizes flexible polypropylene film to create expandable chambers that conform to the product shape, providing protection through the flexible shell itself rather than requiring additional rigid protective materials. The thin film structure reduces material usage while maintaining protective functionality.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The expandable chambers are designed to be inflated with cushioning material before the product is placed in the package, providing pre-positioned protection that eliminates the need for additional protective materials during the packing process.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Weight of moving object

If flexible materials such as films and webs are used, then the package can be lightweight, but it is difficult to transport on conveyor equipment and to stack

Engineering Contradiction:

Improvepackage weightVSAvoidhandling and stacking

Core Design Contradiction:

Weight of moving objectVSEase of operation

Solution Approach 1:

The package structure dynamically changes from a rigid, stackable configuration during shipping to a collapsed, flexible configuration during transport and storage. The expandable chambers provide structural integrity when inflated, enabling stacking and conveyor handling, while collapsing to a flat profile when not in use.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The use of flexible polypropylene film allows the package to maintain strength and rigidity when inflated for shipping, yet collapse into a thin, manageable form for storage and transport, resolving the contradiction between weight and handling ease.

Inventive Principle:

Principle #30Flexible shells and thin films

4Loss of substance

If current flexible packages are used, then material usage can be minimized, but they are not weather or environment-resistant and can be damaged by precipitation, wet surfaces and humidity

Engineering Contradiction:

Improvematerial efficiencyVSAvoidweather and environmental resistance

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The package uses multi-layer composite polypropylene film that combines different material properties within a single structure. This composite construction provides both material efficiency and environmental resistance, protecting the package from precipitation, humidity, and other harmful factors while maintaining lightweight characteristics.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12378056B2Shaped flexible shipping package and method of making

Publication Date: 2025.08.05 PROCTER & GAMBLE CO

AI summary

A flexible package having an inner sheet having a first surface and a second surface. The flexible package has an article reservoir for accepting an article to be shipped and one or more expansion chambers. The expansion chambers can be inflated or otherwise expanded to provide structure to the flexible package and to protect the article in the article reservoir.