AN EVALUAUGK CF THE
CU‘SHEQNENG ?§O?ERNES O?
CQRRQGA'EEG FAPEMCARBE
Tfiests for 1530 Degree of M. S.
EMCEHGAN S'E‘A'E‘Ei ‘UXE‘IERS‘E‘E‘Y
Gerald L Faimreuter
2968
LIBRARY
Michigan State
University ’
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3 1293 10422 0573
ABSTRACT
AN EVALUATION OF THE CUSHIONING PROPERTIES
‘ OF CORRUGATED PAPERBOARD
by Gerald L. Palmreuter
This study was undertaken in order to determine the
shock absorbing characteristics of built up corrugated mate-
rial. Test cushions varying in thickness, basis weight, and
flute size were evaluated with a Vertical Dynamic Drop Test-
er. The data obtained was used in evaluating cushioning
prOpertics and predicting the shock experienced by an article
packaged in corrugated.
0n the basis of the data, the following conclusions were
drawn:
1) Unstressed corrugated is a very inconsistent mate-
rial and its performance inside a package cannot be steadily
predicted after the initial drop.
2) Prestressed corrugated cushioning is a relatively
consistent cushioning material and it performs quite
well inside a package. However, its cushioning ability
cannot be predicted with the use of cushion curves.
3) The basis weight of the corrugated medium is a
more important factor in determining cushion effective-
ness than the basis weight of the liner.
h) As the flute size increases, the first impact ef-
fectiveness increases but the multidrop effectiveness
decreases.
AN EVALUATION OF THE CUSHIONING PROPERTIES
OF CORRUGATED PAPERBOARD
By
Gerald L: Palmreuter
A THESIS
Submitted to
Michigan State University
in partial fulfillment of the requirements
for the degree of
f MASTER OF SCIENCE
School of Packaging
1968
ACKNOWLEDGEMENTS
The author wishes to thank Dr. James w. Goff, Professor
and Director, Michigan State University School of Packaging,
for his guidance throughout the course of this study and
Stephen R. Pierce, Instructor, School of Packaging, for his
suggestions and assistance on technical problems.
He would also like to thank Roger W. Esker, former Pack-
aging Technologist, West Virginia Pulp and Paper, for both his
ideas and his help in obtaining the test samples needed for
this study and Mrs. Elizabeth Anderson for her assistance in
preparing this paper.
11
TABLE OF CONTENTS
ACKNONLEDGENENTS ..................................
TABLE OF CONTENTS .................................
LIST OF TABLES ....................................
LIST OF FIGURES ...................................
LIST OF APPENDICES ................................
INTRODUCTION ......................................
BACKGROUND ........................................
TEST EQUIPMENT & INSTRUMENTATION ..................
EXPERIMENTAL PROCEDURE ............................
RESULTS ...........................................
DISCUSSION OF RESULTS .............................
CONCLUSIONS .......................................
BIBLIOGRAPHY ......................................
APPENDIX I ........................................
APPENDIX II ........................................
APPENDIX III ......................................
APPENDIX Iv .......................................
iii
' Page
ii
iii
iv{
vii
10
17
22
80
86
87
88
89
91+
99
LIST OF TABLES
Table Page
' I. Shock Predicted Via Corrugated Cushion
Curves Vs. Shock Actually EXperienced
By An Article Packaged In.Corrugated
cushioning .0....0.0000000000000000000COO 75
II. Dynamic DrOp Test Data .................. 100
. iv
Figures
(hm-rum
Q)\"
9-12
13-16
17-22
23-26
27-30
31-36
37-h0
HI-Hé
#7252
53f56
LIST OF FIGURES
Unstressed, 2h", ZZ-A Flute Cushion Curve ...
Hypothetical Cushion Curve ..................
Hypothetical Cushion Curve ..................
Vertical Dynamic DrOp Tester ................
Dummy-Load For The Package DrOp Test ........
L.A.B. Model 5D~lOO Package Drop Tester .....
Baldwin-Emery SR—h Compression Tester .......
A Typical Package Ready For The Package
DrOp Test ...................................
Unstressed, 2h", ZR-A Flute Cushion Curves ..
Unstressed, 2h", AV-A Flute Cushion Curves ..
Unstressed, 2h", RRHA Flute Cushion Curves ..
Unstressed, 2h", FR-Q Flute Cushion Curves ..
Unstressed, 2h", AR—Q Flute Cushion Curves ..
Unstressed, 2h", AR—A Flute Cushion Curves ..
Unstressed, 2h", ZZ-A Flute Cushion Curves ..
Unstressed, 2%", AS-A Flute Cushion Curves ..
UnstresSed, 2h", PLY PAC-A Flute Cushion
Curves ......................................
Unstressed, 2h", PLY PAC-Q Flute Cushion
Cllrves .0......OOOOOOOOOOOOOOOOOO0.00.0000...
Page
12
1h
16
2o
23
27
31
37
#1
#5
55
61
67
Figures ' Page
57 Prestressed, 2%", ZRmA Flute Cushion Curve .. 71
58 Prestressed, 2h”, AV-A Flute Cushion Curve .. 72
59 Unstressed, 18", PLY PAC-A Flute Cushion
. Curve ....................................... 73
60 Unstressed, 30", PLY PAC—A Flute Cushion
Cul‘Vre ...O0."...00.0.0.0.........OOCOQOOOOOOO 71+
61 Cushion Curve Comparing Cushioning PrOperties
Of Corrugated ind Foamed Polyethylene ....... 82
62 Cushion Curve Used To Determine Effects Of
Flute Size .................................. 83
63 Cushion Curve Used To Determine Effects Of
Varying The Basis Height Of The Corrugated
Liner ....................................... 8%
6h Cushion Curve Used To Determine Effects Of
Varying The Basis Height Of The Corrugated
Medium ...................................... 85
65 Foamed Polyethylene Cushion Curves .......... 92
66-68 Photographs Of Selected OscillOSCOpe Traces . 96
LIST OF APPENDICES
Appendix Page
I. A Key To West Virginia Pulp & Paper's
Letter Designations ......................... 88.
II. The Cushion Design Method And in Example .... 89-
III. A Justification For The Electric Filter
Setting ...................................... 9%
IV. Dynamic Drop Test Data ...................... 99
. - D '
. -
vii
INTRODUCTION
In our competitive society, the search for potential areas
of cost reduction is a never ending battle. Consequently, many
companies which previously regarded packaging as a "liability"
are being forced into realizing that packaging is a frontier .
which, if conquered, could give them the edge on their compet-
itor. With this increased interest, a movement is beginning
which is aimed at changing packaging from an-art into a science.
In this respect, the cushion curve-gpggk.g_vs static stress
curve--has been a very useful tool. with_the help of such
curves it is possible to compare the merits of various cush-
ioning materials for a certain given application. The School
of Packaging at Michigan State University has derived such
curves for many materials. However, prior to the time of this
study, no cushion curve work had been done with corrugated
material.
This study then is designed to use cushion curves to in-
vestigate the effects of various variables associated with cor-
rugated board--basis weight of liners, basis weight of corrugat-
ed medium, flute size, cushion thickness, etc.--upon cushioning
properties. In addition, a comparison between corrugated and
other commercially available materials will also be included.
BACKGROUND
Until werld war II there was little interest in package
cushion testing. However, during the war the Forest Products
Laboratory in Madison, Wisconsin, began studies on cushions
used in packages. These early studies were based on static
tests and they were aimed at finding some way of predicting
a cushion's performance inside a package. The static method
involves placing a series of weights on the cushioning material
and measuring the amount of compression of the material as
each weight is added. The greatest drawback to this method
lies in the fact that the forces are not applied to the cush-
ioning material at the same rate as they are when the cushioned
article is dropped. Because of this, dynamic testing, which
more closely simulates the action of a cushion in an actual
drop, became the accepted method for evaluating cushion per-
formance.1
All dynamic tests in package cushioning operate on the
same basic principle. A cushion of known thickness and area
is impacted by a mass of known weight. The deceleration of
the falling body as well as the deflection of the cushion and
the drOp distance-~based on impact velocity-~can then be measur-
ed. 'Several methods have been tried. Of these, the one making
use of the Vertical Dynamic DrOp Tester is most common because,
of the ease with which impact velocity is controlled. This
method makes use of a variable weight platen that is dropped
2
on a sample cushion.2
The main purpose in using a dynamic tester is to derive a
cushion curve. All such curves are of the basic form shown in
Figure 1. They have g's deceleration plotted against static
stress and are used to evaluate the merits of a particular pack-
age cushioning material for certain given applications. Figure l
is a first drOp -2h" free fall cushion curve for 2" ZZ-A Flute.
The ZZ_indicates that the basis weight of both the corrugated
medium and the liner is 17 lbs/1000 sq ft. (Appendix 1)
The way in which a drop tester is used to derive the curves
is the static stress, which is measured in lbs/sq", is varied
by changing weights on the dynamic drOpping head which impacts
a cushion 8 inches square. The g's experienced in the drOp for
a certain static stress are measured by an accelerometer and
' recorded on an oscillOSCOpe. From Figure 1 it is easy to see
that: .
1) Under a load of .19 lbs/sq" a shock of 50 g's was
experienced. -
2) Under a load of .MO lbs/sq" a shock of 30 g's was
eXperienced. V .
3) Under a load of .50 lbs/sq" a shock of 50 g's was
eXperienced.
Knowing that the area impacted wasi6h sq" and that static stress
(53) = pounds loading of the drOp platen (lbs)/square inches
impacted by the platen (sq"), it id easy to determine the num-
ber of pounds which impacted the cushion-at each of the above
static stresses.
2“” Free Fall Drop (First 07°F)“
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board. They had inside dimensions of 8 X.8 X 11 inches. 'All
were regular slotted containers with the manufacturers' joint,
the top, and bottom sealed with glass reinforced asphalt_
laminated kraft backed tape.
The dummy load consisted of an 11% pound wooden block.
Figure 5 illustrates the block. This block was constructed
of maple dieboard. The layers were glued together. Addition-
al rigidity was added by the use of 3/8" bolts running from
the top to the bottom at all four corners. Steel plates
were bolted to the t0p and bottom to increase the weight of
the block to 13% pounds. A Kistler Model 818 accelerometer
was mounted in the center of the block (see Figure 5). The
output of this accelerometer was fed into a Tektronix Type
56% storage oscillosc0pe through a Kistler Model 5&8 B piezo-
tron coupler.
The package drOp tester used was a L.A.B. Model SD-lOO
drOp tester. The base plate which held the drOp tester and
which the packages impacted was one-half inch steel plate
grouted onto an eight-inch concrete floor resting on tamped
earth.' The package drOp tester is shown in Figure 6.
Compression Tester
A Baldwin-Emery SR-h compression testing machine was used
to prestress the corrugated samples. This compression tester
has a capacity of 50,000 lbs. It is shown in Figure 7.
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107
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108
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109
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111
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noun g95 m sum a»: mum mum and . oauapm
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gmH
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