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Shock Absorption Characteristics and Optimal Design of Corrugated Fiberboard Using Drop Testing

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Shock Absorption Characteristics and Optimal Design of Corrugated Fiberboard Using Drop Testing applied sciences Article Shock Absorption Characteristics and Optimal Design of Corrugated Fiberboard Using Drop Testing Chien-Chih Wang 1,* , Chin-Hua Chen 2 and Bernard C. Jiang 3 1 Department of Industrial Engineering and Management, Ming Chi University of Technology, New Taipei City 24303, Taiwan 2 Yuen Foong Yu Packaging Inc., Taoyuan Plant, Taoyuan City 33849, Taiwan; [email protected] 3 Department of Industrial Management, National Taiwan University of Science and Technology, Taipei City 24301, Taiwan; [email protected] * Correspondence: [email protected]; Tel.: +886-2-2908-9889 Abstract: The application of corrugated paper to buffer packaging has increased with the rise of the circular economy. The dynamic buffer curve is the key to designing the buffer packaging structure but requires multiple testing by small- and medium-sized enterprises (SMEs) without resources. In this study, we propose drop testing to perform a fractional factorial experiment and establish a regression model of impact strength through experimental data. The analysis results show that static stress, falling height, and buffer material thickness are the key variables of impact strength, and an impact strength prediction model (R2 = 94.1%) was obtained. Model verification using the buffer package design of a personal computer showed that the measured values of impact strength fell within the estimated 95% confidence interval. These results indicate that SMEs can use the proposed analysis procedure to improve the design of corrugated paper using minimal resources. Citation: Wang, C.-C.; Chen, C.-H.; Jiang, B.C. Shock Absorption Characteristics and Optimal Design Keywords: dynamic buffer curve; static stress; drop testing; cushion design; regression model of Corrugated Fiberboard Using Drop Testing. Appl. Sci. 2021, 11, 5815. https://doi.org/10.3390/app11135815 1. Introduction Academic Editors: João Carlos de Buffer packaging is essential for ensuring high-quality logistics services. Although Oliveira Matias, Carina Pimentel, the packaging is part of external quality costs, achieving an effective packaging design is Anabela Carvalho Alves and essential in the industry [1,2]. Foamed plastics are commonly used as buffer packaging Andrea Spagnoli materials. However, with the rise of environmental awareness, some countries have regulated the use of foamed plastic materials [3]. Recently, corrugated board has been Received: 24 May 2021 favored for buffer packaging [4–7]. Biancolini [6] proposed a numerical model to evaluate Accepted: 21 June 2021 the stiffness parameters of corrugated boards; the model was used for the parametric Published: 23 June 2021 investigation of the influence of local parameters on corrugated board panel stiffness. The results showed that the stiffness parameters were weakly controlled, acting on the fluting Publisher’s Note: MDPI stays neutral shape and composition. Further, design methods for corrugated board containers were with regard to jurisdictional claims in reviewed, and two numerical models were developed using finite elements to evaluate the published maps and institutional affil- iations. buckling and ultimate load predictions [7]. In practice, the six-step method of cushion packaging design and MIL-HDBK-304C form the most important basis for packaging design [8]. Product damage during delivery may occur from shock (accidental drop during handling) and vibration (bumps during transportation). Therefore, shock absorption and vibration transfer characteristics must be Copyright: © 2021 by the authors. considered in packaging design. The dynamic buffer curve can reveal the shock ab-sorption Licensee MDPI, Basel, Switzerland. characteristics of the buffer material. This curve shows the impact strength (maximum This article is an open access article acceleration) of a specific buffer material with a specific thickness and height under different distributed under the terms and conditions of the Creative Commons static stresses. The dynamic buffering curve can be used to determine the thickness and Attribution (CC BY) license (https:// area of the buffering material in the early design stage. However, because the corrugated creativecommons.org/licenses/by/ board is a composite made of multilayer Kraft paper and corrugated core paper, each layer 4.0/). may be changed owing to cost, leading to various permutations and combinations. In Appl. Sci. 2021, 11, 5815. https://doi.org/10.3390/app11135815 https://www.mdpi.com/journal/applsci Appl. Sci. 2021, 11, x FOR PEER REVIEW 2 of 15 paper, each layer may be changed owing to cost, leading to various permutations and combinations. In addition, the existing buffer material evaluation method to obtain Appl. Sci. 2021, 11, 5815 dynamic buffer curve does not provide the final packaging solution 2and, of 15 thus, causes excessive packaging. The dynamic buffer curve is usually U-shaped (Figure 1). Zone A refers to the weight ofaddition, the heavy the existinghammer buffer being material relatively evaluation light. method When to an obtain impact dynamic is applied buffer curve to the cushioning does not provide the final packaging solution and, thus, causes excessive packaging. material, the impact force fails to deform the cushioning material but generates a high The dynamic buffer curve is usually U-shaped (Figure1). Zone A refers to the weight acceleration.of the heavy hammer Zone B being refers relatively to the light. heavier When weight an impact of is the applied heavy to the hammer. cushioning The cushioning materialmaterial, is the deformed impact force upon fails the to deform application the cushioning of the impact, material prolonging but generates the a high impact time and greatlyacceleration. reducing Zone Bthe refers acceleration. to the heavier Zone weight B ofis thethe heavy most hammer. suitable The area cushioning for cushion design. Zonematerial C refers is deformed to the upon fact the that application the heavy of the hammer impact, prolonging is too heavy the impact to bear time the and impact, and a greatly reducing the acceleration. Zone B is the most suitable area for cushion design. cushionZone C refersbottom to theout fact occurs that the when heavy the hammer hammer is too fall heavys. Currently, to bear the the impact, cushion and material a has no bufferingcushion bottom effect. out A occurs dynamic when cushion the hammer curve falls. can Currently, be used the to cushion determine material the has thickness no and area ofbuffering the cushioning effect. A dynamic material cushion to avoid curve cost can beincr usedeases to determine or product the thicknessdamage and caused area by excessive orof insufficient the cushioning packaging. material to avoid However, cost increases this curve or product is obtained damage caused by the by excessiveASTM D1596 [9] test or insufficient packaging. However, this curve is obtained by the ASTM D1596 [9] test underunder a specificspecific combination combination of buffer of buffer material material type, thickness, type, thickness, and drop height and anddrop can height and can onlyonly be usedused to to describe describe the shockthe shock absorption absorption characteristics characteristics of the buffer of material the buffer under material under thatthat specific specific combination. combination. When When conditions conditions change, change, time-consuming time-consuming experiments experiments must be must be repeatedrepeated toto obtain obtain the the curve. curve. Figure 1. Dynamic buffer curve under a specific combination of buffer material type, thickness, and Figuredrop height 1. Dynamic by the ASTM buffer D1596 curve test. under a specific combination of buffer material type, thickness, and drop height by the ASTM D1596 test. Thus far, Taiwanese buffer material manufacturers have not provided dynamic buffer curveThus data, far, although Taiwanese they have buffer been widelymaterial used ma innufacturers other countries. have The not cost ofprovided test dynamic equipment is high, and only large institutions such as the Industrial Research Institute have buffersuch equipment. curve data, Generally, although the industrythey have or design been unitswidely do notused have in suchother equipment, countries. and The cost of test equipmentobtaining the is required high, informationand only bylarge self-testing institutions is challenging. such as Since the a seriesIndustrial of tests Research have Institute haveto be performed,such equipment. it is costly andGenerally, time-consuming the industry for small- andor medium-sizeddesign units enterprises do not have such equipment,(SMEs) to obtain and the obtaining required dynamicthe required buffer information curve data. Therefore, by self-testing cushion packagingis challenging. Since a designs often rely on the experience of the designer. seriesIn of practice, tests thehave methods to be for performed, establishing dynamicit is costly buffer and curves time-consuming are ASTM D1596 for for small- and medium-sizedthick plate materials enterprises and ASTM D4168(SMEs) [10 ]to for obtain foam-in-place the required materials. Theredynamic are relevant buffer curve data. Therefore,method applications cushion topackaging evaluate the designs dynamic often cushioning rely on performances the experience of packaging of the ma- designer. terialsIn [practice,11–13]. However, the methods no dynamic for establishing buffering curve dynamic test method buffer exists curves for laminated are ASTM D1596 for thickcorrugated plate bufferingmaterials materials.
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