Wave-Core Paper Insulated Bag for Recyclable Thermal Shipping
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Solution Overview
Problem
The increasing use of non-reusable and non-recyclable insulation materials in shipping containers leads to significant waste, as existing insulation products lack recyclable or compostable alternatives that provide effective thermal insulation and cushioning while being lightweight and customizable.
Innovation Solution
Development of insulation products featuring a core made from a continuous sheet of paper formed into a wave pattern, attached to outer layers, which can be recycled or composted, and machines capable of on-demand manufacturing to produce customized insulation products with adjustable insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional insulation materials are used in shipping containers, then thermal insulation performance is achieved, but waste generation increases and recyclability is poor
Solution Approach 1:
The patent changes the material parameter from traditional non-recyclable insulation materials to paper-based materials that can be recycled or composted. The paper board is formed into wave patterns to achieve the required thermal insulation performance while maintaining recyclability, thus resolving the contradiction between insulation performance and waste reduction.
Solution Approach 2:
The patent uses composite construction by forming wave patterns within the paper board structure, creating a multi-layered configuration that provides effective thermal insulation. The composite paper-based material combines structural integrity with insulation properties while remaining recyclable, addressing both energy loss and substance loss concerns.
2Loss of substance
If recyclable paper-based insulation materials are used, then waste is reduced, but insulation effectiveness and cushioning properties must be maintained
Solution Approach 1:
The patent forms the paper board into wave patterns with curved surfaces. This curvature creates air pockets and increases the path length for heat transfer, significantly improving thermal insulation performance. The wave structure also provides cushioning properties by absorbing impact forces, thus maintaining reliability while using recyclable materials.
3Productivity
If pre-manufactured insulation products are used, then manufacturing efficiency is high, but customization flexibility is limited
Solution Approach 1:
The patent produces insulation products in flat panel form that can be easily cut, shaped, and assembled into different configurations. This segmentation allows the insulation material to be customized for various container sizes and shapes while maintaining efficient manufacturing through standardized panel production, thus balancing productivity and adaptability.
4Weight of moving object
If lightweight insulation materials are used, then shipping costs are reduced, but structural strength and durability decrease
Solution Approach 1:
The wave pattern formation creates a three-dimensional structure that distributes mechanical loads across the entire panel surface. This curved geometry provides exceptional strength-to-weight ratio, allowing the lightweight paper-based material to maintain structural integrity and durability comparable to heavier traditional materials, thus resolving the contradiction between weight and strength.
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 provides lightweight, recyclable or compostable insulation products that offer effective thermal insulation and cushioning, reducing waste and manufacturing costs by allowing for on-site customization and efficient use of materials.
Implementation Method 1
an insulation panel including a first paper layer, and core paper layer formed into a wave pattern and attached to at least the first paper layer
Data Source
AI summary
An insulated bag may include an integral structure. The integral structure may include a first portion comprising first and second extension portions. The integral structure may include a second portion and a third portion attached at corresponding edges and each extending approximately perpendicular from the first portion. The first, second, and third portions each may include a first layer and a paper sheet formed into a wave pattern attached to the first and second layers.