Resilient Cushioning Device with 3D Structural Features for Shock Control
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Solution Overview
Problem
Existing product cushioning devices for shock-sensitive electronics, such as those made through thermoforming, often have inconsistent compression strength and deflection characteristics, leading to potential damage during shipping due to uneven material distribution and thickness variations.
Innovation Solution
A unitary product cushioning device is developed using a resilient plastics material with strategically introduced three-dimensional structural features, such as lines of weakness and air spaces, to control deflection and absorb impact forces, ensuring consistent protection regardless of geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional thermoforming molding techniques are used to create unitary cushioning devices, then manufacturing efficiency and cost-effectiveness are improved, but compression strength consistency and shock absorption reliability deteriorate due to uneven material distribution and thickness variations
Solution Approach 1:
The patent transitions from traditional two-dimensional thermoforming to three-dimensional molding processes (such as injection molding or compression molding) that can produce complex geometries with uniform material distribution. This dimensional change allows the creation of cushioning devices with consistent wall thickness and integrated structural features throughout the entire component, eliminating the uneven material distribution inherent in flat sheet thermoforming while maintaining manufacturing efficiency through single-step molding processes.
Solution Approach 2:
The patent applies local quality by incorporating varying material densities and structural characteristics at different locations within the cushioning device. Through multi-cavity molds or inserts, different regions can have optimized properties - such as higher density in impact-prone areas and lower density in non-critical regions - ensuring consistent compression strength throughout the device while maintaining overall manufacturing efficiency through integrated molding.
2Reliability
If cushioning devices are made with uniform thickness to improve compression strength consistency, then shock absorption reliability improves, but manufacturing flexibility and adaptability to different product geometries deteriorate
Solution Approach 1:
The patent utilizes parameter changes by allowing the molding process to vary material density, wall thickness, and structural complexity as controlled parameters rather than fixed specifications. Modern molding technologies enable real-time adjustment of these parameters during the molding cycle, allowing uniform thickness in critical areas while varying thickness or density in non-critical areas, thus maintaining shock absorption reliability while adapting to different product geometries and packaging requirements.
Solution Approach 2:
The patent applies segmentation through multi-cavity molds or multi-layer molding techniques that divide the cushioning device into functional zones. Each zone can have optimized thickness and material properties tailored to specific protection requirements, while the overall device maintains consistent quality through integrated molding. This segmentation approach enables adaptation to various product shapes and sizes without compromising shock absorption reliability.
3Strength
If complex three-dimensional structural features are added to control deflection, then protection effectiveness improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges multiple functions into a single integrated molding process. Complex three-dimensional structural features such as ribs, recesses, and varying wall thicknesses are incorporated directly into the mold cavity design, allowing all structural elements to be formed in one continuous molding operation. This eliminates the need for secondary operations or assembly steps, maintaining manufacturing efficiency while achieving the desired protection effectiveness through integrated structural complexity.
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 device effectively absorbs shock and reduces the risk of damage by providing controlled deflection and stiffness, meeting drop test standards and protecting sensitive products during shipping.
Implementation Method 1
A unitary product cushioning device for protecting a shock sensitive product during shipping may be molded from a resilient plastics material
Data Source
AI summary
Disclosed is a product cushioning device for supporting a shock sensitive product during shipping, said product cushioning structure being made of a moldable resilient plastics material. The device comprises a plurality of device surfaces suitably shaped and sized to accommodate the shock sensitive product, one of the plurality of device surfaces including a product supporting region at least partially surrounded by product contacting walls, and having a product supporting platform in the lower region thereof; and a three-dimensional structural feature formed into a least one of the plurality of device surfaces; wherein the three-dimensional structural feature serves to control the amount and rate of deflection in the event of impact. In one embodiment, the three-dimensional structural feature comprises a plurality of lines of weakness in a projecting part protruding from at least one device surface being formed of a male mold, wherein in use a top portion of the projecting part rests against the product. In another embodiment, the three-dimensional structural feature comprises at least one donut shaped cavity in the product receiving cavity. Also disclosed is a method of making a product cushioning device in accordance with the teachings of this invention.