Tapered Filling Module for Product Protection
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Solution Overview
Problem
Existing packaging fillers are cumbersome, difficult to handle, and inefficient in protecting products during transport, as they either cannot be disposed of with the packaging or require excessive space, leading to potential damage from shifting and direct contact with packaging walls.
Innovation Solution
A filling and support module composed of a tapering base segment, a tapering top segment, and transition zones that are easily compressible along one axis but stiff transversely, allowing controlled deformation to securely hold products in place while being lightweight and recyclable, made from cellulose-based materials like moulded pulp/fibre.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic filling bodies or air-filled bags are used, then product protection is improved, but disposal and processing becomes difficult and handling is cumbersome
Solution Approach 1:
The filling module changes its physical parameters from a rigid state during packaging to a compressible state during transport. The module is designed to be easily compressible in the longitudinal direction while remaining stiff transversely, allowing it to deform under load and protect the product, then be easily removed and disposed of with the packaging.
Solution Approach 2:
The filling module combines materials with different properties: the base segment and top segment provide structural stiffness, while the transition zones provide compressibility. This composite structure allows the module to simultaneously provide protection and ease of handling/disposal.
2Quantity of substance
If wads of paper are used, then filling material is available, but forming requires many operations and product fixation is inadequate
Solution Approach 1:
The filling modules are pre-formed into their final shape with integrated base segments, top segments, and transition zones before being placed in the packaging. This eliminates the need for on-site forming operations and allows for quick placement and adequate product fixation.
3Reliability
If air-filled bags are used, then product protection is provided, but the bags are relatively large and occupy excessive space
Solution Approach 1:
The filling module is designed to change its volume through controlled compression in the longitudinal direction while maintaining transverse stiffness. This allows the module to occupy minimal space during transport when compressed, yet provide adequate protection when expanded to support the product.
4Reliability
If filling material is used to hold product clear of walls, then product protection is improved, but the packaging is not wholly filled and walls are not supported
Solution Approach 1:
The filling module serves multiple functions simultaneously: it protects the product by holding it clear of packaging walls, supports the packaging walls through its stiff structure, and can be easily disposed of with the packaging. The module's dual stiffness-compressibility properties enable it to perform both protective and supportive functions.
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 module effectively reduces product damage by distributing loads uniformly, is easy to handle and dispose of, and can be customized for various packaging sizes, ensuring predictable deformation and efficient use of space within the packaging.
Implementation Method 1
the at least one transition zone connects a relatively narrow end of the base segment to a relatively wide end of the top segment... the at least one transition zone is relatively easily deformable. When the module is loaded the transition zone will thus deform while the base segment and the top segment remain intact
Implementation Method 2
the module has a longitudinal axis running through the base segment and top segment and is relatively easily compressible in the direction of the longitudinal axis but is relatively stiff in a direction transversely of the longitudinal axis... a product can be clamped and confined between a number of such modules in a packaging
Data Source
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AI summary
The invention describes a filling and/or support module for a packaging, comprising a tapering base segment and a tapering top segment connected thereto by a transition zone, wherein the a transition zone connects a relatively narrow end of the base segment to a relatively wide end of the top segment, and wherein the module has a longitudinal axis running through the base segment and top segment and is relatively easily compressible in the direction of the longitudinal axis but is relatively stiff in a direction transversely of the longitudinal axis. The invention further describes a packaging, comprising an outer packaging and two filling and/or support elements received therein with the top segments of the modules directed toward each other The invention also describes a method for packaging a product in such a packaging.