Thermoform Cushion Complex Shapes Tri-Axial Impact
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Solution Overview
Problem
Existing thermoform cushion designs require more material to achieve superior shock handling characteristics, leading to increased costs and material usage.
Innovation Solution
The use of a series of complex shapes in the structure of product cushioning devices, including tapered cushions with compressible channels and engineered ribs, allows for effective absorption of impact in tri-axial vector directions while reducing material requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If more material is used in conventional thermoform cushions, then shock handling capability is improved, but material cost and shipping cost increase
Solution Approach 1:
The cushion is divided into multiple zones with different thicknesses and material properties. Critical areas receive thicker material for enhanced shock absorption, while non-critical areas use thinner material to reduce overall material consumption. This zoned approach optimizes the balance between shock handling capability and material usage.
Solution Approach 2:
Different regions of the cushion are assigned different material qualities and thicknesses based on their specific shock exposure requirements. High-shock areas use denser, thicker material while low-shock areas use lighter, thinner material, creating a non-uniform structure that maximizes protection efficiency per unit of material.
2Reliability
If more material is used in conventional thermoform cushions, then shock handling capability is improved, but shipping cost increases
Solution Approach 1:
The cushion structure is segmented into high-protection and low-protection zones, allowing material to be concentrated where shock forces are most severe. This reduces the total weight of the cushion while maintaining adequate protection for critical product areas.
Solution Approach 2:
Material density and thickness are locally optimized based on shock risk assessment of different cushion regions. Critical areas receive heavier material construction while non-critical areas use lighter material, reducing overall cushion weight and shipping costs while preserving shock handling capability where needed.
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
This approach enables product cushioning devices to achieve desired shock handling characteristics with less material, thereby reducing costs and environmental impact while maintaining or improving performance.
Implementation Method 1
a tapered cushion disposed about a portion of the product receiving area to absorb impact in tri-axial vector directions
Implementation Method 2
compressible channels connects between the tapered inner wall and the cushion outer wall
Data Source
AI summary
A product cushioning device for protecting a shock sensitive product, said product cushioning device comprising wall structure that defines a product receiving area, the product receiving area extending from a product receiving area opening to a product receiving area base, the wall structure comprising a plurality of product contact portions. The product cushioning device includes a tapered cushion disposed about a portion of the product receiving area to absorb impact in tri-axial vector directions. The tapered cushion comprises a tapered inner wall, a cushion outer wall that is curved and tapered and a compressible channel structure connecting between the tapered inner wall and the cushion outer wall.