Vacuum-Formed Packaging Case with Ridge-Groove Shock Absorption
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Solution Overview
Problem
Existing packaging methods for protecting articles during storage and transit are labor-intensive and costly, requiring substantial material resources such as cardboard cases and plastic foam.
Innovation Solution
A packaging case with walls made of sheet material featuring recesses and edge-to-edge abutment with ridges and grooves for enhanced shock resistance and cushioning, which can be easily erected from a flat form and is constructed from moulded thermoplastic material with serpentine profile flanges for improved rigidity and shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional packaging materials (cardboard cases and plastic foam) are used, then protection against damage and shock is provided, but cost and material resources increase substantially
Solution Approach 1:
The patent combines multiple protective functions into a single integrated packaging case made from one piece of sheet material. The case integrates structural walls, strengthening recesses, and shock-absorbing ridge-groove features all in one component, eliminating the need for separate cardboard cases and foam inserts, thus reducing material resources while maintaining protection
Solution Approach 2:
The packaging case utilizes composite structural features within a single material - combining rigid wall sections with recessed strengthening elements and interlocking ridge-groove mechanisms. This composite approach within the sheet material provides both structural integrity and shock absorption without requiring multiple different materials
2Reliability
If traditional packaging materials (cardboard cases and plastic foam) are used, then protection against damage and shock is provided, but labor intensity increases
Solution Approach 1:
By merging all protective elements into one integrated case structure, the patent eliminates multiple assembly steps. The single-piece construction with pre-formed hinges and interlocking features requires minimal assembly labor compared to traditional methods that require assembling separate cardboard and foam components
Solution Approach 2:
The packaging case is pre-formed with all necessary features (walls, recesses, hinges, ridge-groove interfaces) integrated during manufacturing. This preliminary action of creating a complete, ready-to-use case eliminates on-site assembly labor that would otherwise be required to construct traditional packaging from multiple components
3Productivity
If the packaging case is made from moulded-sheet construction in one piece, then manufacturing efficiency is improved, but structural complexity increases
Solution Approach 1:
The single-piece sheet material is segmented into functional zones during molding - walls, recesses, hinges, and ridge-groove features are all defined as separate functional segments within the unified structure. This segmentation allows complex functionality to be achieved through a single manufacturing process rather than assembling multiple parts
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 packaging case effectively reduces material costs and provides enhanced protection against damage and shock through its ridge-within-groove nesting mechanism, allowing for efficient and economical packaging while maintaining structural integrity and ease of use.
Implementation Method 1
the abutting edges of the walls are each formed with ridges and grooves that nest with one another ridge-within-groove when in mutual abutment... the ridge-within groove nesting at abutting edges of the packaging case of the present invention is very effective for resisting and cushioning shock
Implementation Method 2
The flanges may be of serpentine profile, and in this event, the edge-to-edge abutment between one flange and another may be between flanges of substantially conformal, double- and single-hump serpentine profile respectively
Data Source
AI summary
A packaging case (C;C′) erected by folding from a one-piece vacuum-formed molded sheet, has rectangular walls (1-4;71-74) that fold, and are clipped closed, about an article (A;S) to be protected from shock. The ends of the case are almost-completely closed by conformal edge-to-edge abutment of end-flanges (8-11;78-81) of serpentine profile that are upstanding from the walls (1-4;71-74). The flange-edges are each molded with ridges (13, 15) and grooves (14, 16) that nest ridge-within-groove with those of the abutting edges, for absorbing shock. The walls (1-4;71-74) are hinged together edge-to-edge, and at their edges rise in steps (23,24,33.34,43,44) to a central plinth (22,32,42). The steps (23,24,33,34,43,44) of adjacent walls abut one another within the erected case for shock absorption, and each wall (1-4;71-74) is strengthened by circular recesses (25-28,35-38,45-49) of reducing diameter with depth, let into its plinth (22,32.42). The circular recesses produce frusto-conical shock-absorbing projections (57,58,60,62,63) on the outside of the case. The case (C′) may accommodate a stack (S) of component-carrying trays (T) protected by end-caps (83).