Folded Cardboard Spring Cushioning for Impact Absorption
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Solution Overview
Problem
Current packaging materials, such as expanded polystyrene, are not environmentally friendly, while eco-friendly alternatives like cardboard are prone to permanent deformation after a single impact, lacking the elastic properties needed for effective cushioning and impact resistance.
Innovation Solution
A cardboard cushioning component featuring a folded cardboard spring portion with a stability wrap and stiffening elements, formed from a single sheet of corrugated cardboard, which absorbs impact energy through zig-zag folds and plastically deformed creases, maintaining shape and providing resilience similar to expanded polystyrene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If environmentally friendly materials such as molded fiber or cardboard structures are used, then environmental friendliness is improved, but the material is prone to permanent deformation after impact
Solution Approach 1:
The cardboard structure incorporates dynamic elements including zig-zag folds and spring portions that allow the material to flex and rebound during impact. These dynamic features enable the cardboard to absorb impact energy elastically rather than deforming permanently, while maintaining environmental friendliness through use of recyclable cardboard material.
Solution Approach 2:
The cardboard structure is divided into multiple functional segments including spring portions, zig-zag folds, and stability wrap portions. Each segment performs a specific function in the impact absorption process, allowing the overall structure to maintain stability while individual segments deform and recover elastically.
2Strength
If additional layers are added to cardboard structures, then impact absorption is improved, but weight and cost increase
Solution Approach 1:
The invention changes the structural parameters of the cardboard itself rather than adding more material. By modifying the geometry to include zig-zag folds, spring portions, and stability wraps, the cardboard achieves enhanced impact absorption with the same or reduced weight compared to traditional multi-layer approaches.
Solution Approach 2:
The invention creates a composite cardboard structure that combines multiple functional elements (spring portions, zig-zag folds, stability wrap) within a single cardboard component. This composite approach achieves superior impact absorption without the weight penalty of stacking separate cardboard layers.
3Strength
If traditional foam-type cushioning is used, then impact protection is improved, but environmental friendliness deteriorates
Solution Approach 1:
The invention uses disposable cardboard material that can be easily recycled, replacing traditional foam cushioning. The cardboard structure is designed to provide adequate impact protection for its intended use cycle while being environmentally friendly and recyclable, eliminating the need for persistent foam materials.
Solution Approach 2:
The invention changes the material parameter from foam to cardboard, achieving similar impact protection through structural design rather than material properties. The zig-zag folds and spring portions in the cardboard provide cushioning equivalent to foam while maintaining environmental friendliness.
4Stability of the object's composition
If cardboard structures are designed to be resilient, then elastic properties are improved, but structural complexity increases
Solution Approach 1:
The resilient cardboard structure is segmented into distinct functional portions (spring portions, zig-zag folds, stability wrap) that each contribute to the overall elastic behavior. This segmentation allows complex resilient properties to be achieved through relatively simple geometric features rather than intricate mechanisms.
Solution Approach 2:
The invention incorporates dynamic geometric features such as zig-zag folds and spring portions that provide elasticity through their geometry rather than through complex mechanical mechanisms. These dynamic structural elements enable resilient behavior while maintaining relative simplicity in the overall design.
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 cardboard cushioning system effectively absorbs repetitive impacts and vibrations, maintaining structural integrity and reducing environmental impact without adding weight or cost, offering a sustainable alternative to traditional packaging materials.
Implementation Method 1
a folded cardboard spring portion that is deflectable... maintaining shape through design innovations that give the finished components elastic properties
Implementation Method 2
The folded cardboard spring portion may include a plastically deformed crease
Implementation Method 3
absorbs impact energy... absorbs repetitive impacts and vibrations
Data Source
AI summary
Packaging may include cushioning components. Cardboard corrugate cushioning elements may be configured with a folded cardboard spring, lateral stability wrap, and stiffening element. The cushioning components may include mechanical bends formed as creases, that provide resistance to deformation, thereby allowing the cushioning component to absorb impact and vibration, and replacing the need for less environmentally friendly cushioning, such as expanded polystyrene or foam cushioning.