Modeling and Analysis of Cushioning Performance for Multi-layered Corrugated Structures

Purpose: The objective of this study was to develop cushion curves models and analyze the cushioning performance of multi-layered corrugated structures (MLCS) using a method based on dynamic stress-energy relationship. Methods: Cushion tests were performed for developing cushion curve models under 12 combinations of test conditions: three different combinations of drop height, material thickness, and static stress for each of four levels of energy densities between 15 and $60kJ/m^3$. Results: Dynamic stress and energy density for MLCS followed an exponential relationship. Cushion curve models were developed as a function of drop height, material thickness, and static stress for different paperboards and flute types. Generally, the differences between the shock pulse (transmitted peak acceleration) and cushion curve (position and width of belly portion) for the first drop and the averaged second to fifth drop were greater than those for polymer-based cushioning materials. Accordingly, the loss of cushioning performance of MLCS was estimated to be greater than that of polymer-based cushioning materials with the increasing number of drops. The position of the belly of the cushion curve of MLCS tends to shift upward to the left with increasing drop height, and the belly portion became narrower. However, depending on material thickness, under identical conditions, the cushion curve of MLCS showed an opposite tendency. Conclusions: The results of this study can be useful for environment-friendly and optimal packaging design as shock and vibrations are the key factors in cushioning packaging design.