How can the cushioning structure design of express boxes reduce the product breakage rate?
Release Time : 2025-12-03
As a core packaging container in commodity transportation, the design of the express box's cushioning structure directly affects the safety of goods during handling, stacking, and transport. A reasonable cushioning structure can significantly reduce the risk of damage by dispersing impact force, absorbing vibration energy, and limiting commodity displacement. Its design needs to comprehensively consider material properties, structural form, and commodity characteristics to form a multi-layered protection system.
One of the core functions of the cushioning structure is dispersing impact force. When the carton is impacted by external forces, the internal cushioning structure transforms concentrated stress into dispersed stress through deformation, preventing the commodity from experiencing excessive pressure in any localized area. For example, setting corrugated cardboard corners or honeycomb support structures on the inner wall of the carton can create multi-directional force support, allowing the impact force to be transmitted along multiple paths, reducing the possibility of direct force on the commodity. Furthermore, filling the gaps between the commodity and the carton with cushioning materials (such as bubble wrap or expanded polyethylene foam) can further fill the gaps and prevent secondary collisions caused by the commodity shaking.
Absorbing vibration energy is another crucial function of the cushioning structure. Bumps and vibrations during transportation cause continuous friction between the commodity and the packaging, easily leading to surface scratches or loosening of the internal structure. By designing an elastic cushioning layer inside the carton, such as using EPE pearl cotton or EVA foam board, the elastic deformation of the material can absorb vibration energy, reducing the intensity of vibration transmitted to the goods. For precision instruments or fragile items, air column bags or spring structures can be embedded in the cushioning layer to form a dynamic cushioning system that adjusts the level of protection for the goods in real time.
Restricting the movement of goods is the fundamental function of the cushioning structure. Free movement of goods within the carton increases the risk of collision, so it is necessary to fix the position of the goods through structure. Common methods include setting grooves or clips inside the carton that match the shape of the goods, so that the goods cannot wobble after being embedded; or using cross-shaped cardboard partitions to divide the carton into multiple independent spaces, with each item fixed in a specific area. For irregularly shaped goods, customized cushioning molds can be designed to achieve all-around fixation by precisely fitting the contours of the goods.
The choice of materials for the cushioning structure directly affects the protective effect. Corrugated cardboard, due to its multi-layered structure and high compressive strength, has become the main material for carton cushioning. By adjusting the corrugation type (such as A-flute, B-flute, C-flute) and the number of layers, the protection needs of goods of different weights can be matched. For example, heavy goods are suitable for double-walled or triple-walled cardboard, while light goods can be handled by single-walled cardboard. Furthermore, the application of composite materials (such as paper-plastic composites and paper-aluminum composites) can improve the moisture-proof and anti-static properties of the cushioning structure, expanding its applicable scenarios.
The coordinated design of the cushioning structure and the overall carton is crucial. The cushioning structure must match the carton size, opening method, and stacking requirements to avoid structural conflicts that reduce protective effectiveness. For example, a foldable cushioning cover on the top of the carton facilitates loading and provides top protection when closed; tearable cushioning strips on the sides allow for quick access to goods while maintaining structural integrity. In addition, the cushioning structure should include ventilation holes or drainage channels to prevent damage to goods due to humidity changes.
Customizing the cushioning structure according to the characteristics of different goods is key to improving the accuracy of protection. Fragile items (such as glassware and ceramics) require high-density cushioning materials (such as foamed polypropylene) and a fully enclosed design to reduce any potential points of impact. Electronic products need to be both shockproof and anti-static, achieving double protection by adding conductive fibers or coatings to the cushioning layer. Liquid goods require special protection for the bottle opening and bottom, using ring-shaped cushioning sleeves or thickened bottom designs to prevent leakage.
By dispersing impact force, absorbing vibration energy, limiting product displacement, optimizing material selection, coordinating overall design, and customizing adaptations, the express box's cushioning structure forms a three-dimensional protective network, significantly reducing product breakage rates. As the logistics industry's requirements for packaging safety and environmental protection increase, future cushioning structure designs will develop towards lightweight, biodegradable, and intelligent directions. For example, using recyclable plant fiber materials or embedding sensors to monitor product status in real time, providing more reliable protection for product transportation.