Cushioning Air Column Structure for Module Packaging

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Solution Overview

Problem

Conventional packaging methods for liquid crystal and backlight modules using expandable polyethylene (EPE), expandable polystyrene (EPS), or pulp are costly due to excessive material consumption for cushioning.

Innovation Solution

A package cushioning structure comprising a cushioning bottom board with spaced hollow sections and a cushioning band featuring alternately arranged air columns, which can be inflated to provide effective cushioning, reducing material and storage costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional cushioning materials (EPE, EPS, or pulp) are used entirely to package modules, then cushioning protection is provided, but material consumption increases and packaging cost rises

Engineering Contradiction:

Improvecushioning protectionVSAvoidmaterial consumption

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The cushioning structure is segmented into multiple functional zones: cushioning air columns for impact absorption, hollow sections for shock distribution, and bars for structural support. This segmentation allows each component to perform its specific function efficiently, reducing overall material consumption while maintaining protection levels.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces cushioning air columns (air bags) as a pneumatic cushioning element that can be inflated to provide cushioning protection. Air columns offer high cushioning performance with minimal material usage compared to solid foam materials, directly addressing the contradiction between protection and material consumption.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Reliability

If conventional cushioning materials (EPE, EPS, or pulp) are used entirely to package modules, then cushioning protection is provided, but packaging cost increases

Engineering Contradiction:

Improvecushioning protectionVSAvoidpackaging cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the physical state and properties of cushioning materials by introducing inflatable air columns that can be adjusted in firmness and volume. This parameter change allows optimization of cushioning performance while reducing material costs, as air columns are significantly cheaper than equivalent volumes of EPE or EPS materials.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The cushioning structure combines multiple materials with different properties: the cushioning bottom board (EPE/EPS/pulp), the cushioning band, and the inflatable air columns. This composite approach allows each material to be used where it provides the most value, optimizing both protection and cost-effectiveness.

Inventive Principle:

Principle #40Composite materials

3Quantity of substance

If cushioning air columns are inflated to provide cushioning support, then material usage is reduced, but structural complexity increases

Engineering Contradiction:

Improvematerial usageVSAvoidstructural complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The cushioning air columns are nested within the framework formed by the cushioning bottom board and cushioning band. The air columns fit into hollow sections of the bottom board, creating a nested structure that simplifies assembly while reducing material usage. This nesting approach allows complex functionality to be achieved through integrated design rather than separate components.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 structure offers improved cushioning efficiency while minimizing material usage, thereby lowering packaging costs and maintaining effective protection during transportation.

Implementation Method 1

Each of the cushioning air columns comprises an air-filling hole and a closure device for closing the air-filling hole

Methodology Applied

Scientific EffectAir inflation:

Implementation Method 2

The cushioning bottom board forms a plurality of spaced hollow sections. A bar is arranged between every two of the hollow sections. The cushioning band comprises a plurality of cushioning air columns mounted thereto at interval

Methodology Applied

Scientific EffectMechanical energy absorption: Damping

Data Source

PatentUS8708145B2Package cushioning structure for module

Publication Date: 2014.04.29 TCL CHINA STAR OPTOELECTRONICS TECHNOLOGY CO LTD

AI summary

The present invention provides a package cushioning structure for module, which includes a cushioning bottom board and a cushioning band extending through and interlaced with the cushioning bottom board. The cushioning bottom board forms a plurality of spaced hollow sections. A bar is arranged between every two of the hollow sections. The cushioning band includes a plurality of cushioning air columns mounted thereto at interval. The cushioning air columns are arranged alternately on the bars. To package, modules are each positioned on and born by each of the bars between two of the cushioning air columns. An alternate package cushioning structure includes a cushioning bottom board having a surface forming slots and a cushioning band arranged in the cushioning bottom board through a mounting channel extending through the bottom board from a side surface thereof. Air columns of the cushioning band are located in the slots to support modules.