Composite Cushioning Material for Lightweight Device Packaging
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Solution Overview
Problem
Existing cushioning materials for electronic devices lack versatility in achieving high cushioning effects while accommodating varying cushioning characteristics required by different types of devices, necessitating specific configurations based on thickness, number of layers, and material selection.
Innovation Solution
A cushioning material comprising a support plate with integrated first and second cushioning portions, where the first cushioning portion is made of corrugated cardboard and the second of foamed resin, arranged in parallel to enhance cushioning characteristics, with specific stress-strain properties to optimize impact absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cushioning sheets with different strengths are laminated in series, then cushioning effect is enhanced, but versatility across different electronic device types deteriorates
Solution Approach 1:
The cushioning material is divided into multiple cushioning sheets with different cushioning characteristics (different strengths, thicknesses, and materials). Each sheet is configured to address specific cushioning requirements, allowing the system to provide enhanced overall cushioning while maintaining adaptability through selective combination of sheet properties.
Solution Approach 2:
The cushioning material is designed with a standardized multi-sheet structure that can universally accommodate different types of electronic devices. By using sheets with varying characteristics (soft, medium, hard cushioning sheets), the same basic structure can be adapted to protect diverse devices without requiring complete redesign for each device type.
2Strength
If various conditions such as thickness, number of layers, and material are selected, then cushioning characteristics are optimized for specific devices, but production complexity increases
Solution Approach 1:
Different regions of the cushioning material (different sheets) are assigned different local qualities (cushioning characteristics). Soft sheets provide gentle cushioning for sensitive components, medium sheets provide balanced protection, and hard sheets provide structural support. This local differentiation allows optimization for specific devices while maintaining a standardized production process.
Solution Approach 2:
The cushioning material uses composite construction with multiple sheets of different materials and characteristics laminated together. This composite approach allows the system to achieve optimized cushioning characteristics for various devices by selecting and combining appropriate sheet types, rather than requiring completely different material formulations for each application.
3Strength
If corrugated cardboard is used with multiple cushioning sheets, then cushioning effect is enhanced, but packaging size and weight increase
Solution Approach 1:
The cushioning sheets utilize porous or cellular structures (such as air-filled corrugated layers or foam structures) that provide effective cushioning through air compression and deformation. These porous materials achieve high cushioning performance with low density, reducing overall packaging weight while maintaining protective capabilities.
Solution Approach 2:
The cushioning effect is enhanced by utilizing the three-dimensional corrugated structure of the cardboard sheets. The fluted geometry creates air pockets and deformation zones that provide cushioning in multiple directions, achieving effective protection with thinner, lighter materials compared to solid alternatives.
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 composite cushioning material provides enhanced cushioning capacity and resistance to resonance, reducing the size and weight of packaging while maintaining effective protection against impacts and humidity effects.
Implementation Method 1
maximum stress in an elastic region of the first cushioning portion is larger than maximum stress in an elastic region of the second cushioning portion
Implementation Method 2
a slope indicating a ratio of stress with respect to strain in a plastic region of the first cushioning portion takes a value of zero or close to zero, and a slope indicating a ratio of stress with respect to strain in a plastic region of the second cushioning portion takes a positive value
Data Source
AI summary
A cushioning material cushions an external force applied to an electronic device. The cushioning material includes a support plate and a cushioning portion. The support plate is a member configured to support the electronic device. The cushioning portion is included in the support plate and cushions an external force applied to the electronic device. The cushioning portion includes a first cushioning portion and a second cushioning portion. The first cushioning portion has a first surface fixed to the support plate and a second surface facing the electronic device. The second cushioning portion has a third surface fixed to the support plate and a fourth surface facing the electronic device. In a graph where the vertical axis represents the external force applied to the electronic device and the horizontal axis represents the time since the external force starts to be applied to the electronic device, the types of waveforms of the graph of the first cushioning portion and the second cushioning portion are different.