Modular Double-Layer Corner Protector for Adjustable Cushioning Fit
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Solution Overview
Problem
Single-wall plastic concave corner protectors lack cushioning effect, fail to clamp product corners tightly, and are prone to damage during transportation, especially for large products.
Innovation Solution
A combined double-layer buffering modular concave corner protector design featuring modular corner protectors affixed with screws and nuts, incorporating convex platforms and anti-slip ribs, and grooves for adjustable thickness to fit various product sizes, providing enhanced cushioning and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If single-wall plastic concave corner protector is used to cover corner edges, then the corner edges are protected from damage, but the collision force is transmitted to the product without cushioning effect
Solution Approach 1:
The patent employs a double-layer nested structure where an inner buffering layer (foam or bubble wrap) is placed inside the outer plastic shell. This nested configuration allows the outer layer to provide structural protection while the inner layer absorbs collision forces, resolving the contradiction between corner protection and collision force transmission.
Solution Approach 2:
The corner protector combines multiple materials with different properties: a rigid plastic material for the outer shell provides structural integrity and corner protection, while a compliant buffering material (foam or bubble wrap) for the inner layer provides cushioning. This composite material approach simultaneously achieves both corner damage protection and collision force reduction.
2Device complexity
If single-wall plastic concave corner protector is used, then the structure is simple, but the concave corner cannot clamp product corners tightly
Solution Approach 1:
The corner protector is divided into two functional segments: the outer plastic shell providing structural form and the inner buffering layer providing clamping force. This segmentation allows each layer to perform its specific function effectively, with the inner layer's elastic properties enabling tight clamping of product corners while maintaining overall structural simplicity.
3Object-generated harmful factors
If foam corner protector is used, then cushioning effect is provided, but the foam is easy to be crushed or pierced
Solution Approach 1:
The fragile foam buffering layer is nested inside a robust outer plastic shell. This nested configuration protects the foam from external crushing and piercing forces while allowing it to perform its cushioning function internally. The outer shell acts as a protective barrier that prevents direct exposure of the foam to damaging forces.
Solution Approach 2:
The composite structure combines the shock-absorbing foam material with a high-strength plastic protective layer. The foam provides collision force absorption, while the plastic shell provides mechanical strength and resistance to crushing or piercing, thereby maintaining foam durability while preserving cushioning effectiveness.
4Device complexity
If single-wall plastic concave corner protector is used, then the structure is simple, but tape wrapping or packing strap strapping is required to secure large products
Solution Approach 1:
The corner protector is segmented into an outer structural shell and an inner elastic buffering layer. The inner layer's elastic properties enable it to deform and clamp tightly onto product corners, providing self-securing functionality without requiring additional tape or straps. This segmentation intrinsicclamps large products securely through the elastic deformation of the inner layer.
Data Source
AI summary
A combined double-layer buffering modular concave corner protector, relating to technical field of packaging products. It includes modular corner protectors, and at least two modular corner protectors are provided, affixed to each other and locked by screws and nuts; a groove for assembling product is provided between two modular corner protectors, and a cavity is provided inside the modular corner protector. By combining the modular corner protectors two by two to form a groove, grooves of different sizes can be obtained by adjusting thickness of the first convex platform and second convex platform to protect corners of flat-panel products with a variety of thickness specifications; using screws to fit with nuts to fix two modular corner protectors and firmly press product corner so as to ensure that the product is not easy to fall off in transportation process without use of tape or packing strap.