Thermoformed Packaging Wings for Large Electronics Shock Protection
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Solution Overview
Problem
Existing packaging methods are labor-intensive and costly, and fail to effectively protect large and heavy electronic items like flat-screen television sets and computer monitors during storage and transit, as they are too large for conventional thermoformed plastic sheet packaging cases.
Innovation Solution
A one-piece thermoformed packaging device with elongate wings hinged together, featuring upstanding flanges that form channels for shock protection, with ridge-groove patterns for interlocking and resilient retention, allowing for flexible adaptation to article profiles and providing comprehensive protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional thermoformed plastic sheet packaging cases are used, then shock protection is provided for small articles, but large electronic items cannot be accommodated
Solution Approach 1:
The packaging device is divided into multiple elongate wings that can be independently configured. Each wing can be adapted to different article shapes and sizes, allowing the packaging to accommodate large electronic items while maintaining shock protection capabilities.
Solution Approach 2:
The packaging transitions from a conventional enclosed case structure to an open-wing configuration that can wrap around and conform to large flat objects. The wings can be positioned in multiple dimensions to accommodate articles of varying sizes, particularly large electronic items that exceed traditional case dimensions.
2Reliability
If traditional packaging materials and methods are used, then comprehensive protection is achieved, but material usage and costs increase substantially
Solution Approach 1:
Multiple protective functions are merged into a single packaging device. The thermoformed wings provide both structural support and shock absorption in one integrated component, eliminating the need for separate protective materials and reducing overall material consumption.
Solution Approach 2:
The packaging uses thermoformed plastic with varying density and resilience parameters in different zones. The material properties are optimized to provide adequate protection while using less material overall compared to traditional uniform-density packaging materials.
3Reliability
If conventional packaging assembly methods are used, then protection is provided, but labor intensity and assembly time increase
Solution Approach 1:
The packaging device is pre-formed as a single thermoformed piece with integrated hinge connections and interlocking features. This preliminary formation eliminates the need for complex assembly operations, allowing workers to simply open and position the packaging around the article, thereby improving productivity while maintaining protection reliability.
Solution Approach 2:
The packaging device features self-aligning and self-locking mechanisms through its ridge-and-groove interlocking system. Once positioned around the article, the wings automatically engage and lock into place without requiring additional assembly steps or tools, enhancing both productivity and reliability.
Data Source
AI summary
A one-piece thermoformed packaging cap for article shock-protection which has two elongate wings integrally hinged and have upstanding shoulders which define a channel that receives part of the article. Ridges and grooves run along the shoulders of each wing such that when the wings are folded abut each other, the ridges and grooves of one wing nest within those of the other wing and provide cushioning and lateral interlocking between the wings. Caps can have four wings and wrap the entire perimeter of the article and may incorporate a locking tab to secure the wrap. Alternatively, an assembly of partial wrap-components can be locked via flap-tabs. For locking, a projection of one wing enters into a recess of another wing, and a locking flap of the latter wing is folded and a projection of the flap is snapped into the reverse recess of the thermoformed projection.