Sustainable Modular Packaging for Pharmaceutical Containers Impact Protection

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Solution Overview

Problem

Conventional packaging systems for pharmaceutical containers, such as glass vials, lack protection against lateral, top load, and bottom impact, are not environmentally sustainable, and do not allow flexible packaging of containers of different sizes together.

Innovation Solution

A modular packaging system comprising a carton and insert made of sustainable materials, such as paperboard, that can accommodate multiple container sizes and protect against impacts using air cushioning and rib supports, allowing flexible packaging configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional packaging systems use fixed dimensions and sizes, then they can provide simple and easy-to-manufacture structures, but they cannot accommodate multiple container sizes together

Engineering Contradiction:

Improveaccommodation of multiple container sizesVSAvoidpackaging system structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The packaging system is divided into modular components including a base tray, removable inserts, and stacking sections. Each insert can be configured with different cavity arrangements to accommodate various container sizes (2R, 6R, 10R vials), allowing the same base structure to serve multiple packaging needs through component interchangeability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The base tray is designed with universal features including standardized flap configurations, multiple insert options, and stacking capabilities that allow a single packaging system to handle different container types and sizes. The system can be configured for single-layer or multi-layer packaging depending on the shipping requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional packaging systems use foam inserts or plastic trays to prevent container contact, then they provide protection from lateral impact, but they are not environmentally sustainable

Engineering Contradiction:

Improveprotection from lateral impactVSAvoidenvironmental harm

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The packaging system uses uniform paperboard material for all components including the base tray, inserts, and flaps. This homogeneous paperboard construction provides adequate cushioning and protection while being fully recyclable and environmentally sustainable, replacing the traditional foam or plastic materials

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The system changes the material parameter from non-recyclable foam/plastic to recyclable paperboard, while maintaining protective functionality through structural design elements such as cushioning flaps and container-specific cavity configurations

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conventional packaging systems do not provide rib supports or air cushioning, then they have simpler structures, but they cannot protect containers from top load and bottom impact

Engineering Contradiction:

Improveprotection from top load and bottom impactVSAvoidpackaging structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The packaging system incorporates pre-designed cushioning features including air gaps between container layers, rib supports positioned at critical impact zones, and flap configurations that create protective barriers. These elements are built into the structure before shipping to absorb and distribute top load and bottom impact forces

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The system adds vertical protection elements (ribs extending upward from the base tray) and layered cushioning structures that distribute impact forces across multiple dimensions. The stacking configuration creates a three-dimensional protective framework that protects containers from vertical impacts

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Productivity

If conventional packaging systems require separate packages for different container sizes, then they provide dedicated protection for each container type, but they increase the number of packaging systems needed

Engineering Contradiction:

Improvenumber of containers per packaging systemVSAvoiddedicated protection for each container type

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The packaging system allows dynamic reconfiguration through removable inserts that can be adjusted or replaced based on the specific container sizes being shipped. The same base tray can be adapted for different container configurations, maximizing space utilization while maintaining appropriate protection for each container type

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20250276826A1Sustainable and modular packaging systems for containers for pharmaceutical use

Publication Date: 2025.09.04 AMGEN INC

AI summary

Systems for packaging container(s) is disclosed. The system comprises a carton having a storage configuration where the carton is substantially flat and an assembled configuration. The carton comprises a bottom box, a lid coupled to the bottom box, a first flap extending from the first sidewall of the bottom box, and a second flap extending from the second sidewall of the bottom box. The first and second flaps define a set of cavities. The system also comprises an insert configured to be disposed within the bottom box of the carton. The insert has a storage configuration where the insert is substantially flat and an assembled configuration. The insert defines at least one cavity dimensioned to house at least one container.