PACKAGING DYNAMICS #4 of 5

Dynamic Cushion Testing for Shock Absorption and

Vibration Attenuation

Herb Schueneman Edmund Tang

President & CEO Laboratory Manager
Presenter Presenter
July 2015
Agenda
• Review of Webinars #1 – 3
• Cushion Systems Defined
• Vibration Dynamics of Cushion Systems
• Shock Dynamics of Cushion Systems
• Designing the Optimum Cushion System
o Selecting Cushion Thickness
o Static Loading Determination
o The Use of Ribs (non-linear cushions)
• Other Issues: (fabrication factors, nesting, corner
protection, test procedures, etc.)
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Review of Webinar #1
• History and background of Packaging Dynamics
• Terminology and Lingo
– Time domain vs. frequency domain
– Single degree of freedom spring mass system
• Common Packaging Dynamic hazards
– Vibration
– Impact (shocks and drops)
– Compression (static and dynamic)

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Review of Webinar #1 : Shock Input and Response

Input

Response

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Review of Webinar #2
Step 1
• Define the Environment

• Define Product Fragility (or Sensitivity)

Step 2

• Cushion Material Performance Evaluation

Step 3

• Package Design
Step 4

• Test the Product/Package System

Step 5

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 Review of Webinar #2
Define the Distribution Environment by QUANTIFYING all the
Hazards Capable of Causing Damage to the Product.
• Impacts: determine the anticipated drop height range, number, and
orientation of the likely impacts.
• Vibration: Determine the vibration spectrum that envelopes all the
vehicles in which the product will likely travel.
• Temperature & Humidity: Determine extreme levels and likelihood
of occurrence.
• Top Load Compression: Quantify the max stack height and duration
in distribution and storage.
• Altitude: Determine the maximum altitude exposure (minimum
pressure) for both truck and aircraft shipment.

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Review of Webinar #2
SOURCES of INFORMATION:
• Direct Measurement of the Distribution
Environment
• Literature Search and Historical Records
• Observation
• Damage Claims
Other Concerns
• Cost of Data
• Validity of Data
• Time Available to Collect Data

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Review of Webinar #3
• Define the Environment
Step 1

Step 2
• Define Product Fragility (or Sensitivity)

• Cushion Material Performance Evaluation

Step 3

• Package Design
Step 4

• Test the Product/Package System

Step 5

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 Product Fragility Assessment

In Webinar
#3, we
quantified
this bar

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 Cushion Test & Design
In this
Webinar #4,
we will
quantify this
bar

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Define the Terms
“Cushion”
“Static Loading”
“Non-linear”

Cushion: Any device or material that

will deflect in response to an applied
dynamic load resulting in a longer
duration and lower peak acceleration
response.

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Define the Terms
Static Loading: (product weight / cushion area)

Normally expressed in pounds/square inch (psi)

or
Kilograms/square meter (kg/m^2)
or
Grams/square centimeter (g/cm^2)

Most commonly used cushion materials (polymer foams) function

best in the loading range of 0.5 to 2.0 psi.

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Define the Terms

Static
Loading Cushion area = 100 sq in

Examples
B

Cushion area = 50 sq in

Static Load = Weight/area

Weight = 50 = 50 Lbs/50 sq in
Lbs. = 1.0 Lbs/sq in
= 1 psi
Cushion area = 50 sq in 13
Define the Terms
To determine cushion area from a target Static Stress level, simply
reverse the formula:

Cushion area = Mass (Product weight)/Static Loading

EXAMPLE: Product weight = 47 pounds

Desired static stress loading = 0.75 psi
Cushion area = Mass/loading
= 47 lbs / 0.75 psi
= 63 sq in

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Define the Terms
Linear cushion system: “The stress/strain characteristics
of a cushion system follow a straight line as the stress
(force) is varied.”

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Vibration Dynamics
• Cushions are essentially springs.

• With a product (mass) on them, the result can be

analyzed as a “spring/mass system.”

mass mp

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Vibration Dynamics
• Vibration DAMPING is a primary cushion
function
• What is the DYNAMIC SPRING RATE of the
cushion?
• In the last Webinar, we demonstrated how
to determine the PRODUCT vibration
sensitivity.
• Now we need to determine the CUSHION
vibration characteristics for optimum
package system design.

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Vibration Dynamics
• “Vibration Cushion Curves” (called
“Amplification/Attenuation Plots”) are developed by
weighting a cushion, shaking it, and measuring the
response.

Guided Test
Block Method

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 Vibration Dynamics
T-C MODEL
M ETHOD A C-C
M MODEL
ETHOD B

Alternate
Method CUSHION
RESPONSE
ACCELEROM ETER M ASS
M ASS INPUT
CUSHION ACCELEROM ETER CUSHION
V IBRATION TABLE V IBRATION TABLE

M ASS ADHERED TO FOAM M ASS ISOLATED BETWEEN

InSO
this model, the mass is
THAT THE "SPRING"
In this model, the mass is
2 "SPRINGS" (CUSHIONS)
adhered toWORKS
(CUSHION) the cushion so
IN BOTH isolated
THAT WORKbetween
ONLY 2
that the “spring”
TENSION AND COM(cushion)
PRESSION “springs” (cushions) so
IN COM PRESSION.
works in both tension and that the cushions work in
compression. compression only.

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Vibration Dynamics
Westpak’s cushion test fixture mounted to a vibration test system (right)

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Vibration Dynamics
For either method, the Spring/Mass system is excited
(random or sine vibration) and the response/input ratio
is plotted as a function of frequency.

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Remember from the last Webinar?
What is “Resonance?”
Resonance is that characteristic of all structures (analyzed as
spring/mass systems) wherein the response to a vibration input is
greater than the input itself.

Response>Input

This is what we’re looking for

Image Source
http://www.edn.com/electronics-blogs/signal-integrity/4369617/Whang-that-ruler
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Vibration Dynamics – Important Regions

1:1 Coupling Amplification Attenuation

• Response = Input • Response > Input • Response < Input
• Q=1 • Q>1 • Q<1
• Damage occurs • Vibration protection

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Vibration Dynamics
• How do we build an Amplification / Attenuation
(A/A) plot to design a package?
– Load your cushion at a specific loading utilizing the
fixture previously described
– Excite your cushion with vibration
– Identify your three important regions from the
Transmissibility Plot
• 1:1 Coupling
• Amplification
• Attenuation
– Repeat for all static loadings
• Typically minimum of 5 loadings

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Vibration Dynamics – T Plots

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Vibration Dynamics
Amplification / Attenuation Plot
• Point pick the three important regions in the
Transmissibility Plots to build an A/A Plot.

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 Vibration Dynamics - Example
• Now if your product is a futuristic robot that has a fragile component
with a resonant frequency of 70 Hz – How do you use this data?
1) Draw a horizontal line at
the resonant frequency
2) Look at the “usable”
range of the cushion,
this is where your line
falls into the attenuation
zone
3) Design accordingly 

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QUESTIONS??

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Impact (shock) Dynamics
• This characteristic is measured using
instrumented impacts resulting in a cushion
curve.
• Typical procedures include:
– ASTM D1596
– ASTM D4168
– MIL STD 26514E

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Impact (shock) Dynamics
• How do we build a cushion curve plot to design a
package?
– Load your cushion at a specific loading
– Impact (shock) your cushion and record peak
decelerations (G’s)
• Throw out first value
• Average next four values
– Repeat for the other static loadings
• Typically minimum of 5 loadings
– Repeat for other thicknesses
• (if desired [optional])

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Impact (shock) Dynamics
This is what the ASTM D1596 test looks like:

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Impact (shock) Dynamics
This curve describes the amount of acceleration (or, more correctly, deceleration)
transmitted through a given thickness of material as a function of static stress
(loading) on the cushion and the drop height.

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Impact (shock) Dynamics
A cushion curve shows peak acceleration on the vertical axis and static stress on
the horizontal axis (static stress = weight/bearing area). Each curve is drawn from a
minimum of 5 test points (static stress levels) and each test point is the average of
the last 4 of 5 acceleration readings (impacts) of the cushion material.

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Underloaded
• On the left side of the curve, the object does not
have sufficient force (mass) to deflect the cushion
and therefore resembles dropping a product onto a
rigid surface
– Underloaded cushion
– Short pulse duration with high deceleration levels

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Properly Loaded
• In the center of the curve, the object has
sufficient force to deflect the cushion.
– Optimally loaded cushion
– Longer pulse with deceleration levels relatively
low

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Overloaded
• On the right side of the curve, the object has too much force
(mass) and results in continuing right through the cushion and
therefore bottoming out and can’t deflect anymore. At that
point, it is the same as dropping the product onto a rigid
surface
– Overloaded cushion
– Longer pulse with sudden deceleration due to cushion
gradually stiffening and not being able to deflect anymore.

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 Impact (shock) Dynamics
It is desirable to use cushions in the lower portion ("belly") of the curve
where performance is optimum. When the product critical acceleration,
weight and design drop height are known, the usable static stress range of
cushion area can be determined for a given material and thickness.

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 Impact (shock) Dynamics - Example
• Now if your product is a futuristic laser that has a fragile
component with a critical acceleration (Ac) of 70 G’s – How do
you use this data?
1) Draw a horizontal line at
the Critical Acceleration
2) Look at the “usable”
range of the cushion,
this is where your line is
UNDER 70 G’s
3) Design accordingly 

3”
4” 4”
Range

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 Designing the Optimum Cushion System

Selecting Cushion Thickness

Assume the cushion material behaves as a linear spring and look
solely at the total deflection necessary to achieve the required
deceleration from the design drop height. This deflection is
estimated by:

∆x = 2h / (A - 2)
where:
∆x = cushion deflection in cm (or inches)
h = drop height in cm (or inches)
A = the required deceleration level (G's)

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 Designing the Optimum Cushion System

• ∆x = theoretical deflection necessary, not

the overall cushion thickness.

• Most foam cushions will compress 40 to

60% before "bottoming out".

• More flexible materials such as

polyurethane foam will compress up to
80% before it bottoms out.

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 Designing the Optimum Cushion System
DESIGN EXAMPLE:
A product has a fragility of 50 G's and a design drop height of 90 cm. (35 inches).

The theoretical deflection is calculated from the formula:

∆x = (2 x 90) / (50-2) = 3.75

The resulting theoretical deflection is 3.75 cm

Total cushion thickness necessary for the individual materials is:

MATERIAL OPTIMUM STRAIN % TOTAL THICKNESS

cm inches
EPS foam 40% 9.4 (3.75/.4) 3.7
PE foam 50% 7.5 (3.75/.5) 3.0
Polyurethane foam 70% 5.4 (3.75/.7) 2.1

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 Designing the Optimum Cushion System

Static Loading Determination

• The optimum static stress loading is determined from a Cushion
Curve and the Amplification/Attenuation Plot for that material.

• Any portion of the cushion curve that lies below the product
fragility level will define a static stress loading capable of
transmitting less than the critical acceleration to the product.

• For optimum material usage, it is normally desirable to load the

cushion to the highest static stress allowed by the curves.

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 Designing the Optimum Cushion System
Static Loading
Determination
Vibration
Fn = 70 Hz
Range: Range > 0.80 Hz

Impact (Shock)
Ac = 70 G’s
Range:
0.66 psi < Range < 1.33 psi Combined Range
0.80 psi < RANGE < 1.33 psi
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 Designing the Optimum Cushion System
Points to remember!!!
• Don’t ignore vibration. It’s 100% certain and
can be very destructive.
• Sometimes the Vibe & Impact loadings don’t
overlap. In this case, rely on the Vibe loading
value.
• The procedure used for running cushion curves
may have a significant effect on the usefulness
of the data.
• The use of ribs in the cushion design can have a
very positive result on the design effectiveness.
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 Designing the Optimum Cushion System
The Use of Ribs (non-linear cushions)

Ribbed (non-linear) Rectangular (linear)

design design
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 Designing the Optimum Cushion System
The Use of Ribs (non-linear cushions)
1. In general, the depth of a rib should be approximately 1/2 to 2/3
total cushion thickness.

2. The cross sectional area of material at zero deflection should

yield a static loading of 2 or more times the optimum static
stress obtained from a cushion curve for that material, thickness
and drop height.

3. The cross sectional area of a rib at 25% total deflection should be

approximately equal to that which would give the optimum
loading for that material from a representative cushion curve.
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 Designing the Optimum Cushion System

4. The cross sectional rib area at 50% total cushion compression

should equal a static loading approximately 2/3 that called for by the
applicable cushion curve.
RIB COMPRESSION
RIB COMPRESSION
0%

25%
T .6T
50%

PYRAMIDAL TRAPEZOIDAL HEMISPHERICAL

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 Designing the Optimum Cushion System

The Use of Ribs (non-linear cushions)

• Most rib designs are trapezoidal in cross section.

• From a theoretical standpoint the best rib design is a

pyramidal cross section.

• A hemispherical cross section also is a good

theoretical design.

• Vibration response of a cushion material can be

substantially improved through the use of ribs.
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 Designing the Optimum Cushion System
The Use of Ribs (non-linear cushions)
• High static loading at the peak of the rib will result in a lower
natural frequency for the cushion system.

• The force levels associated with environmental vibration are

relatively small and therefore the deflection of the cushion is
correspondingly small.

• Deflection will occur at the point of maximum stress and if

this is the peak of the rib, that area will strongly influence
the vibration characteristics of the entire package system.

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 Other Issues:
FABRICATION FACTORS
• Sustainability: don’t glue foam to corrugated, etc.
• Highest yield = lowest cost
• Package suppliers have the best ideas for this.

NESTING
• Cushions are bulky. Nesting is vital for shipping & storage.

CORNER PROTECTION
• Most impacts in distribution are on the corners of shipping
containers.
• “Void corners” are a big source of damage during shipment for
otherwise well designed product/package systems.
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 Other Issues:
TEST PROCEDURES
• Different cushion test procedures will result in different design
data. Learn to use the data best suited for your purpose.
• Different finished package test procedures will likewise give
potentially different test results.

OTHER ISSUES
• Deformable cushion systems are harder to evaluate than (nearly)
100% rebounding systems.
• However, similar design and evaluation techniques can be used.

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LAST SESSION: Package Design And Evaluation

Step 1
• Define the Environment

Step 2
• Define Product Fragility (or Sensitivity)

Step 3
• Cushion Material Performance Evaluation

Step 4
• Package Design

Step 5
• Test the Product/Package System

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QUESTIONS??

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Next Webinar: Packaging Dynamics Series
#1: Overview and Definition of Terms – Jan 2015 DONE !
#2: Defining & Quantifying the Distribution Environment Through
Which All Products Must Travel – March 2015 DONE !
#3: Determining the Vibration Sensitivity & Shock Fragility of
Products; Test Methods, End Results, and Significant Insights DONE !
#4: Dynamic Cushion Testing for Shock Absorption & Vibration
Attenuation – July 2015 DONE !
#5: Design and Testing of the Protective Package System; How We
Know When the Job Was Done Correctly – September 2015

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 About WESTPAK, INC.

Two Locations

San Jose Laboratory San Diego Laboratory

83 Great Oaks Boulevard 10326 Roselle Street
San Jose, CA 95119 San Diego, CA 92121
408-224-1300 858-623-8100
www.westpak.com

Contact Us

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 THANK YOU !

Please feel free to Contact Us with any questions or

assistance with your testing needs.

Herb Schueneman Edmund Tang

President & CEO Laboratory Manager

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