Wine Packaging Using Planar Corrugated Sheet With Expandable Holes
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Solution Overview
Problem
Current wine packaging and shipping assemblies using molded fiber and corrugated materials face limitations due to non-standardized bottle sizes and manufacturing constraints, leading to increased assembly time, cost, material waste, and complexity, particularly with the need for a three-dimensional fiber molded top component and a corrugated divider to prevent bottle contact during shipment.
Innovation Solution
A wine packaging system featuring a vacuum molded base component with cylindrical concave columns, a planar single or double fluted corrugated sheet with expandable holes aligned with bottle necks, and an optional vacuum molded cap component, replacing the traditional three-dimensional divider to securely hold bottles within a corrugated box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a three-dimensional molded fiber top component and corrugated divider are used to prevent bottle contact, then bottle protection during shipping is improved, but device complexity and material cost increase
Solution Approach 1:
The patent removes the complex three-dimensional molded fiber top component and corrugated divider from the packaging assembly. Instead, it uses a simplified planar corrugated board with holes that bottles pass through, extracting only the essential function of preventing bottle contact while eliminating unnecessary structural complexity
Solution Approach 2:
Rather than using a solid three-dimensional structure to prevent bottle contact, the invention inverts the approach by using a planar board with holes that bottles penetrate. The protection mechanism is flipped from external containment to internal structural integration, where the corrugated board becomes part of the bottle assembly rather than a separate protective element
2Reliability
If a three-dimensional molded fiber top component is used, then bottle protection is improved, but manufacturing cost and material waste increase
Solution Approach 1:
The patent replaces expensive three-dimensional molded fiber components with a simple planar corrugated board that can be easily manufactured and disposed of. The corrugated board is a low-cost, single-use material that provides adequate protection without requiring complex manufacturing processes or expensive materials
Solution Approach 2:
The invention changes the structural parameters of the packaging material from three-dimensional molded fiber to two-dimensional corrugated board. This parameter change simplifies manufacturing while maintaining protective function, as the corrugated board's fluted structure provides adequate rigidity and protection without requiring complex molding processes
3Reliability
If traditional packaging materials and structures are used, then bottle protection is achieved, but assembly time and labor cost increase
Solution Approach 1:
The patent segments the packaging function into simple components: a base layer, a planar corrugated board with holes, and optionally a top layer. This segmentation allows for rapid assembly where bottles are simply placed through the holes in the corrugated board, eliminating time-consuming assembly operations required by complex three-dimensional structures
Solution Approach 2:
The corrugated board is pre-formed with holes at the appropriate positions and dimensions before assembly. This preliminary action eliminates the need for on-site modification or complex assembly operations, as the board is ready to receive bottles directly through its pre-configured holes, significantly reducing assembly time
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
This solution reduces material complexity and cost, enhances assembly efficiency, and effectively prevents bottle contact during shipping by using a planar corrugated sheet with expandable holes, accommodating various bottle sizes and shapes while maintaining environmental sustainability.
Implementation Method 1
a vacuum molded base component having a plurality of cylindrical concave columns within which respective bottles are placed; a vacuum molded cap component having a plurality of conical segments within which respective bottle necks are received
Data Source
AI summary
Methods and apparatus for packaging and shipping wine. A shipping container includes: a vacuum molded base component having a plurality of cylindrical concave columns within which respective bottles are received; a substantially planar corrugated separator sheet having a plurality of receptors aligned with the axes of the columns and configured to slidably receive respective bottle necks associated with the bottles; a vacuum molded cap component for receiving the bottle necks therewithin; and an outer corrugated box within which the bottles, base component, separator, cap component components are securely disposed.