Suspension Packaging Structure with Tensioned Flexible Sheets
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Solution Overview
Problem
Existing packaging structures for shipping sensitive items are complex, expensive, and require substantial materials, failing to provide efficient and cost-effective protection against impact and movement damage.
Innovation Solution
A suspension packaging structure featuring a support frame with a platform panel and pivotally connected side panels, overlaid with flexible sheets that are tensioned to create a flexible support panel, reducing material usage and assembly complexity while providing effective protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional suspension packaging structures are used to protect articles from impact and movement damage, then protection effectiveness is improved, but device complexity and material consumption increase
Solution Approach 1:
The patent combines the support frame and suspension elements into a single integrated structure. The side panels are directly attached to the base panel to form a unified support frame, eliminating the need for separate suspension components. This merging reduces structural complexity while maintaining protection effectiveness through the integrated rigid framework.
Solution Approach 2:
The support frame serves multiple functions simultaneously: it provides structural support, creates spacing from container walls, and immobilizes the article. The side panels both form the structural framework and act as suspension elements when tensioned with the flexible sheet, reducing the need for dedicated suspension components.
2Reliability
If traditional suspension packaging structures are used to protect articles from impact and movement damage, then protection effectiveness is improved, but material consumption increases
Solution Approach 1:
The flexible sheet is integrated directly onto the support frame structure, combining the cushioning function with the structural framework. This eliminates the need for separate cushioning materials and reduces overall material consumption while maintaining protection effectiveness.
Solution Approach 2:
The patent uses a flexible sheet (thin film) attached to the support frame to provide cushioning and protection. This thin film approach consumes less material compared to traditional bulky cushioning materials while maintaining protection effectiveness against impact and movement damage.
3Reliability
If traditional suspension packaging structures are used to protect articles from impact and movement damage, then protection effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
The integrated support frame structure with attached flexible sheet reduces the number of separate components that need to be manufactured and assembled. This simplification reduces manufacturing complexity and associated costs while maintaining protection effectiveness.
Solution Approach 2:
The side panels are designed to be tensioned by the user during assembly, creating the suspension effect without requiring additional fasteners or complex assembly mechanisms. This self-tensioning approach simplifies manufacturing by eliminating the need for separate fastening components and reduces assembly complexity.
4Strength
If rigid support panels are used in packaging structures, then structural strength is improved, but material consumption and weight increase
Solution Approach 1:
The patent replaces rigid support panels with a flexible sheet attached to a minimal rigid support frame. This flexible film approach provides sufficient structural support and protection while consuming significantly less material compared to traditional rigid panel constructions.
Solution Approach 2:
The support frame uses rigid materials only where structurally necessary (at the base panel and attachment points), while the remaining support function is provided by the flexible sheet. This localized use of rigid materials reduces overall material consumption while maintaining structural strength where needed.
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 solution enables efficient, cost-effective, and recyclable packaging that effectively protects items from impact and movement damage during shipping by using less material and simplifying manufacturing processes.
Implementation Method 1
A second flexible sheet overlies at least a portion of the first flexible sheet and is coupled to the pair of opposed side panels to allow the second flexible sheet to be tensioned when the side panels are pivoted away from the first face of the platform panel
Data Source
AI summary
A packaging structure that is adapted for insertion into an outer container. The packaging structure includes a support frame including at least a platform panel having opposed first and second faces and at least a pair of opposed side panels pivotally connected to the platform panel. A first flexible sheet overlies at least a portion of the first face of the platform panel and a second flexible sheet overlies at least a portion of the first flexible sheet and is coupled to the pair of opposed side panels to allow the second flexible sheet to be tensioned when the side panels are pivoted away from the first face of the platform panel.