Cardboard Cushion with Folded Baffle Flaps for Impact Protection
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Solution Overview
Problem
Conventional cardboard cushions for protecting electronic products during shipping are prone to damage due to their simple structure and complex assembly processes, leading to higher manufacturing costs.
Innovation Solution
A solid cardboard cushion structure formed by folding multiple interconnected baseboards with baffle flaps and supporting boards, which simplifies assembly and enhances rigidity, using foldable baseboards and baffle flaps to create a concave shape with a supporting structure to cover the opening, thereby forming a strengthened integrated structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional cardboard cushions are assembled using multiple fastened elements and slots, then the cushion can be formed with basic protective function, but the structure becomes simple and prone to damage during long-time shipment
Solution Approach 1:
The patent integrates multiple fastened elements and bearing base components into a single integrated cardboard structure. The cushion comprises a bearing base with integrated fastening features where the lateral walls, bottom wall, and fastening slots are all part of one continuous folded cardboard structure, eliminating the need for separate fastened elements and reducing assembly steps while enhancing structural integrity
Solution Approach 2:
The cushion is divided into multiple functional sections within a single integrated structure: a bearing base portion with bottom and lateral walls, fastening portions with slots, and reinforcing portions. This segmentation allows each area to perform its specific function while maintaining overall structural strength and durability during shipment
2Reliability
If conventional cushions are assembled by multiple components with fastened elements, then basic protection is achieved, but the assembling procedures become complex resulting in more manufacturing time and higher cost
Solution Approach 1:
The patent combines multiple separate components (bearing base, fastened elements, reinforcing structures) into a single integrated cardboard cushion. The entire cushion is formed from one continuous piece of folded cardboard with all functional features (bottom wall, lateral walls, slots, and reinforcing elements) integrated into a unified structure, dramatically simplifying assembly procedures and reducing manufacturing complexity
3Ease of operation
If conventional cushions use multiple separate components, then the cushion can be assembled, but the structure lacks rigidity and is easy to be damaged during long-time shipment
Solution Approach 1:
The patent merges multiple components into one integrated cardboard structure where the bearing base, fastening elements, and reinforcing portions are all interconnected as a single rigid unit. This integration creates a more rigid and damage-resistant structure while maintaining ease of assembly from a single folded cardboard piece
Solution Approach 2:
The integrated structure is segmented into reinforcing portions and bearing base portions that work together to enhance rigidity. The lateral walls, bottom wall, and integrated fastening slots are positioned to create a rigid box-like structure that resists damage during shipment while still allowing simple assembly
Data Source
AI summary
A cushion, which is a solid structure formed by a cardboard, includes a first baseboard, a second baseboard, a third baseboard, a fourth baseboard, a fifth baseboard and at least one supporting board that are joined to each other. Those junctions are foldable. The fourth baseboard has a first baffle flap and a plurality of the first cut lines. The fifth baseboard has a second baffle flap and a plurality of the second cut lines. When the first baffle flap and the second baffle flap are side matched to form the solid structure, the portion of the fourth baseboard between the first cut lines and the portion of the fifth baseboard between the second cut lines are folded toward each other to form a concave. The supporting board is joined to a lateral side of the opening of the solid structure and folded to be a supporting structure to cover the opening.