Modular Cushion Structure with Anti-Static Segmented Members
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Solution Overview
Problem
Existing cushion structures for packaging often require multiple components assembled with adhesives, leading to contamination risks, high costs, and inefficiencies due to adhesive mismatches or damage, and lack adaptability for varied object shapes and sizes.
Innovation Solution
A modular cushion structure comprising a flexible anti-static first member and a second member with docking slots and portions, allowing secure, adhesive-free coupling and easy replacement, suitable for static-sensitive objects with varying shapes and sizes, using materials like Pink Poly foam and acrylonitrile butadiene styrene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives are used to assemble cushion components, then the components can be connected, but contamination risks increase and operational costs increase due to adhesive mismatches or damage
Solution Approach 1:
The cushion structure is divided into multiple detachable members (first member, second member, third member) that can be assembled without adhesives. Each member has specific geometric features (recesses, protrusions, docking portions) that enable mechanical interconnection, eliminating the need for adhesive bonding and thus preventing contamination while maintaining connection security.
Solution Approach 2:
The patent replaces the chemical bonding system (adhesives) with a mechanical bonding system. The members are connected through mechanical features such as recesses receiving protrusions, docking slots accommodating docking portions, and interlocking geometries, thereby substituting chemical adhesion with mechanical interlocking to avoid contamination.
2Adaptability or versatility
If multiple components are assembled to achieve diverse functions, then functional versatility is improved, but device complexity increases
Solution Approach 1:
The cushion structure uses universal detachable members that can be configured in different arrangements to serve multiple functions. The same basic member types (with standardized connection interfaces) can be used to create different cushion configurations for various packaging needs, reducing the number of unique component designs while maintaining functional versatility.
Solution Approach 2:
The cushion is segmented into multiple independent members that can be selectively assembled. This segmentation allows the system to achieve diverse functions by combining different numbers and types of members, rather than requiring each function to be built into a single complex component, thereby managing complexity through modularity.
3Reliability
If cushion members are permanently bonded, then connection security is improved, but adaptability for varied object shapes decreases
Solution Approach 1:
The cushion structure transitions from a static permanently bonded configuration to a dynamic reconfigurable system. The detachable members with standardized connection interfaces allow the cushion to be dynamically reconfigured into different shapes and sizes by assembling or disassembling members, enabling adaptation to various object shapes while maintaining secure connections through mechanical interlocking.
Solution Approach 2:
The same set of universal members can be assembled in different configurations to match various object shapes and sizes. This universality allows the cushion system to adapt to diverse packaging requirements without compromising connection security, as each member maintains reliable mechanical connections regardless of its position in the overall structure.
4Ease of manufacture
If adhesives are used for assembly, then manufacturing is simplified, but operational costs increase due to adhesive mismatches or damage requiring replacement
Solution Approach 1:
The detachable member design enables individual members to be recovered and reused. If one member becomes damaged, only that specific member needs to be replaced rather than the entire cushion assembly, reducing operational costs. The standardized connection interfaces facilitate easy recovery and reassembly of undamaged members with new ones.
Solution Approach 2:
By segmenting the cushion into separate detachable members, the system allows for selective replacement of individual components. This segmentation reduces operational costs by enabling repair through single-member replacement rather than complete assembly replacement, while the mechanical connection system maintains assembly simplicity through standardized interfaces.
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 modular design provides secure connections, reduces operational costs, prevents contamination, and adapts to different object shapes, ensuring effective protection and ease of assembly for sensitive electronic devices during packaging.
Implementation Method 1
the first member comprises a flexible and anti-static material and is configured to come into contact with the object disposed in the packaging case
Data Source
AI summary
A cushion structure for use with a packaging case provides cushion and protection of an object. The cushion structure includes a first member and a second member. The first member is configured to snuggly receive the object; the second member is configured to be mounted onto a case body of the packaging case; and the first member and the second member are detachably coupled.