Nested Pulp Buffer Structure for High-Impact Packaging
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Solution Overview
Problem
Existing buffer materials formed through pulp molding are prone to deformation under impact, requiring larger sizes to achieve sufficient buffering against large impacts, and there is a need for improved buffering performance per unit amount and footprint.
Innovation Solution
A buffer material design featuring a first and second buffer portion with equal or varying dimensions and angles, allowing simultaneous or sequential impact absorption, optimized for efficient impact distribution and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the buffer material size is increased to achieve sufficient buffering against large impacts, then the buffering performance is improved, but the material usage and footprint increase
Solution Approach 1:
The buffer material is divided into multiple projection portions (first projection portion, second projection portion, third projection portion) with different structures. Each projection portion has distinct characteristics (e.g., different curvature radii, heights, or cross-sectional shapes) that allow them to absorb impact energy in different ways, achieving superior buffering performance without requiring a single large buffer structure
Solution Approach 2:
Different projection portions are designed with locally optimized properties tailored to specific impact scenarios. For example, some projections may have larger curvature radii for distributed impact absorption, while others have smaller curvature radii for focused energy dissipation. This local differentiation allows the overall structure to achieve high buffering efficiency with reduced total material usage
2Reliability
If the buffer material size is increased to achieve sufficient buffering against large impacts, then the buffering performance is improved, but the footprint increases
Solution Approach 1:
The buffer material consists of multiple projection portions arranged in a compact configuration. By segmenting the buffering function across multiple smaller projections rather than using a single large buffer, the design achieves comprehensive impact coverage within a reduced overall footprint, allowing efficient space utilization in packaging applications
Solution Approach 2:
The multiple projection portions are arranged to nest within each other or interlock in space, with inner projections positioned within the envelope of outer projections. This nested arrangement maximizes the buffering capacity within a minimized external footprint, allowing the buffer material to maintain compact dimensions while providing multi-layered impact absorption
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 design provides enhanced buffering performance against impact loads while reducing material size and cost, with adjustable performance based on packed object mass and impact resistance.
Implementation Method 1
The buffer material formed through the pulp molding process is provided between the packing case and the packed object, and serves to alleviate the impact on the packed object
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A buffer material (1, 1A) includes a first planar portion (11), a first buffer portion (12, 12A), and a second buffer portion (13, 13A). The first planar portion includes a first face that is flat, and an opening. The first buffer portion includes a first cylindrical portion (14, 14A). The first cylindrical portion is extended from an outer circumferential edge of the first planar portion, in a direction opposite thereto. The second buffer portion includes a second cylindrical portion (16, 16A). The second cylindrical portion is located on an inner side of the first cylindrical portion of the first buffer portion, and is extended from an inner circumferential edge of the first planar portion, in a direction opposite thereto.