Enhancement of cushioning performance with paperboard crumple inserts

This paper introduces a novel approach to using multi-layered corrugated paperboard to provide improved protection against severe mechanical shocks and drops. Conventionally, cushion design requires the determination of the maximum expected shock levels or drop heights as well as their probability of occurrence. These are usually determined from statistical analysis of original field measurements or published drop height distribution data. With this approach, it is acknowledged that the cushioning element will provide adequate protection for statistically likely events but not for extreme, statistically unusual, events. A multi-layer cushioning system made entirely of corrugated paperboard, designed to extend the cushioning protection range to include these extreme events, has been investigated. The main feature of the cushion is the inclusion of a corrugated paperboard crumple element designed to provide the necessary energy absorption for high compression stress levels. The effect of the complex deceleration produced by the crumple element on the product is analysed by means of the shock response spectrum. Experiments have shown that the paperboard crumple insert dramatically extends the protection range of the cushioning system by generally lowering the shock response spectrum, thus extending the cushion curve static load range. This results in a significant increase in the allowable drop height for a limited number of extreme events. Although this approach may be extended to a combination of conventional cushioning materials, the benefits of providing product protection with recyclable paperboard material are significant