Modern corrugated board packaging faces increasing demands across the supply chain, where impacts regularly exceed 50G during handling and temperature variations of -20°C to 45°C are common during transit. Traditional designs using linear fluting patterns and uniform material densities struggle to provide consistent protection across these extreme conditions while meeting sustainability requirements.

The fundamental challenge lies in achieving enhanced cushioning and thermal performance without increasing material usage or compromising the recyclability of cellulose-based structures.

This page brings together solutions from recent research—including embossed ridge patterns for targeted impact absorption, overlapping uneven-surfaced designs for thermal isolation, paper-based deformation techniques that eliminate the need for adhesives, and integrated securing features that maintain protection during dynamic loading. These and other approaches focus on practical implementations that can be manufactured at scale while meeting both protection and sustainability goals.

1. Corrugated Interior Packaging Material with Zigzag Folding and Grooved Plates for Spherical Item Stabilization

TANA-X CO LTD, 2024

Interior material for packaging boxes that can cushion and protect spherical items like eggs or fruits. The interior material is folded zigzag to create a corrugated structure with mountains, valleys, and inclined sides. The folded corrugated plate is fixed at the ends by plates to prevent deformation. The corrugated plate has receiving grooves for the lower ends of the items, and the fixed plates have corresponding grooves for the upper ends. This allows stacking multiple interior layers with handles for gripping. The upper layer has complementary grooves to engage with the lower layer. The corrugated folding provides cushioning while preventing item movement. The fixed plates prevent deformation during stacking.

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2. Embossed Paper Shipping Packaging with Integrated Cushioning Structure

CIE EUROPEENNE DE PAPETERIE, 2024

Shipping packaging with improved impact protection and reduced environmental impact compared to traditional foam-filled envelopes. The packaging has walls with embossed ridges on one side that correspond to depressions on the other side. The ridges join to a smooth sheet, holding them together. This creates a cushioning effect when objects inside impact the walls. The embossing and joining avoids using foam or plastic. The embossed paper provides impact protection while the smooth sheet covers the embossed side during shipping.

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3. Paper-Based Packaging Formation Method with Continuous Kraft Paper Deformation for Structured Cushioning Layers

MONDI AG, 2024

A sustainable packaging method that replaces plastic bubble wrap with paper-based packaging articles that have similar cushioning properties. The method involves continuously supplying Kraft paper with a minimum machine direction stretch of 5% at temperatures between 10-40°C. The paper is plastically deformed to form a structured layer with embossments or flutes. This layer is then joined with a flat cover layer to create a compound layer that forms the packaging article. The paper-based packaging has a similar cushioning effect as bubble wrap but without requiring high temperatures or moisture for deformation. The packaging can be formed into envelopes, boxes, etc.

4. Cold Forming Method for Producing Corrugated Packaging Materials Using Kraft Paper

MONDI AG, 2024

A method for producing corrugated packaging materials using a cold forming process without steam or heat. The method involves starting with a base material like kraft paper, plastically forming it between corrugated rollers to create the corrugated structure, and then using the formed structural layer in packaging. The cold forming allows creating corrugated paper without energy-intensive steam or heat. The kraft paper's elasticity is crucial for successful cold forming.

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5. Paper Packaging Material with Direct Wave Structure Formation via Corrugating Rollers

MONDI AG, 2024

Producing paper packaging material with reduced energy consumption compared to conventional corrugated cardboard. The method involves forming a wave structure directly in the paper without using heat or steam. It involves deforming a paper base material between corrugating rollers to create a structural layer with parallel waves. This eliminates the need for energy-intensive corrugating processes. The paper used has specific properties like elongation of at least 5% in the machine direction. The resulting packaging material has comparable properties like strength and tear resistance compared to corrugated cardboard.

6. Flexible Sheet Packaging with Adjustable Corrugated Voids and Insular Members for Customized Stiffness and Protection

SIMMONS GREGORY, 2023

Highly flexible sheet packaging with customizable stiffness and protection properties by adjusting the position and size of corrugated voids and insular members. The packaging consists of corrugated layers bonded to a backing layer with wavy corrugations forming parallel waves. The voids and insular members within the corrugated layers can be positioned and sized to tailor the stiffness, cushioning, and flexibility of the packaging for specific applications.

7. Cardboard-Based Thermal Insulating Material with Parallel Corrugated and Flat Layer Structure

GOGGLEBOXES LTD, 2023

Thermal insulating material for packaging made of cardboard with corrugated layers sandwiched between flat layers. The corrugated layers are parallel and the flat layers are between them. This provides thermal insulation for packaging applications using recyclable and biodegradable cardboard. The insulating material can be made by laminating corrugated cardboard sheets with flat cardboard sheets. The corrugated layers provide the insulation while the flat layers maintain the structure.

8. Corrugated Cardboard Engine Packing Member with Foldable Table, Partitions, and Reinforced Base Body

NABIACE CO LTD, 2022

Engine packing member using corrugated cardboard for transporting engines in a stable and cost-effective manner. The packing member has a table made of corrugated cardboard with partitions and notches to securely hold the engine. The cardboard table folds into a compact shape for storage. The engine sits partially inside the cardboard housing. The cardboard table is combined with a grid of plates forming the base body. This allows multiple engines to be packed together. The cardboard table and base body are reinforced with wooden frames. This reduces weight compared to composite materials. The foldable cardboard table simplifies packing and reduces costs compared to fixed wooden boxes. The cardboard housing absorbs vibrations and prevents engine movement during transport. The compact foldable design saves space.

9. Corrugated Packaging Material with Fluted Wick Layer and Wood Substitute Pulp

Kimberly-Clark Worldwide, Inc., 2022

Corrugated packaging material that provides strength and structural strength for corrugated packaging applications. The material includes a corrugated paper layer, a fluted wick layer, and a wood substitute pulp material.

10. Ink Cartridge with Corrugated Cardboard Reinforcement for Impact Resistance

KYOCERA DOCUMENT SOLUTIONS INC, 2020

Ink cartridge design and packaging to prevent deformation and damage of the cartridge case when dropped. The cartridge has an inner reinforcing sheet made of corrugated cardboard. The corrugated sheet is sandwiched between the cartridge and the inner wall of the storage case. The corrugations in the cardboard absorb impact forces and prevent the cartridge from deforming if dropped. The corrugations extend in the direction of the cartridge's longitudinal axis.

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11. Rectangular Cushioning Material with Adjustable Bends and Corrugated Cardboard Structure

BROTHER INDUSTRIES LTD, 2018

Cushioning material for packing that can be easily customized to fit varying item shapes and sizes. The packing material is a rectangular sheet with bends that allow it to compress and expand in one direction. The sheet has two flat plates connected by bends inside and outside the perimeter. The bends can be adjusted to change the compression range. This allows the plates to move closer together for thicker packing or farther apart for thinner packing. The bends also provide springiness for impact resistance. The material is made of a corrugated cardboard with wavy cores parallel to the end edges. This adds rigidity in the compression direction.

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12. Corrugated Cardboard Bucket Transport Package with Integrated Support Structures

WELLKISTENFABRIK FRITZ PETERS GMBH & CO KG, 2017

A corrugated cardboard bucket transport package that provides a cost-effective and recyclable alternative to plastic molded inserts. The package consists of a sleeve made of double-sided corrugated cardboard with a bottom and lid. Inside, it has support structures to hold the bucket in place. The sleeve and support structures are all made from corrugated cardboard. Additional layers can be added as buffers against the bucket bottom and lid surfaces to provide a custom fit. This eliminates the need for expensive molded inserts and allows recycling of the entire package.

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13. Double-Wall Corrugated Fiberboard with B Flute Corrugations for Enhanced Impact Absorption

MITSUBISHI ELECTRIC CORP, 2017

Shock absorbing material for packing that provides improved impact protection for wrapped objects during drops and falls. The material has a unique configuration that allows it to effectively absorb impacts from both vertical and angled drops. It achieves this by using double-wall corrugated fiberboard with B flute corrugations. The B flute corrugations increase the material's flexural rigidity, which raises impact absorption capacity for both vertical and angled falls. The rigidity also allows thinner walls to provide sufficient protection compared to conventional materials. This reduces material requirements while maintaining protection.

14. Cardboard Packaging Structure with Integrally Formed Non-linear Support Portions

NATIONAL TSING HUA UNIVERSITY, 2015

A packaging structure for protecting a product that is simple, cost-effective, and provides good support. The packaging uses a cardboard sheet that is integrally formed into a structure with at least one first support portion. This first support portion is formed by using the non-linear paper side of the cardboard on one side. This provides horizontal support for the product. The cardboard structure can also have a second support portion on the opposite side to provide vertical support. The non-linear paper side on the first support portion allows cost savings compared to complex folded structures while still providing good protection by leveraging the paper's strength.

15. Packaging Box with Interlocking Corrugated Paper Structure and Integrated Corner Inserts

CHOICE 3H COMPANY LTD, 2015

Improved packaging box structure that has higher strength and is more convenient and environmentally friendly compared to traditional wooden boxes. The improved box uses corrugated paper instead of wood for the bottom, sides, and lid. It also has interlocking corrugated plates with inserts that lock together and pass through the corners of the bottom and lid to secure the box. The corrugated paper provides comparable strength to wood but is lighter, more sustainable, and eliminates assembly issues.

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16. Accordion-Folded Rigid Packaging Structure with Wrapped Compression

ILLINOIS TOOL WORKS, 2014

A shaped rigid packaging structure that provides improved strength and prevents delamination compared to traditional layered paper boards like Angleboard. The new board structure is made by accordion folding multiple sheets of material, compressing them together, and wrapping the folded sheets. The accordion fold pattern with equal width legs on each side flute prevents delamination and provides uniform strength across the board. The wrapped compression reduces weight compared to layered boards.

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17. Flexible Wrapping Material with Single-Sided Corrugated Cardboard and Expandable Inner Sheet

TANA-X:KK, 2013

A flexible wrapping material made of a single-sided corrugated cardboard with an expandable inner sheet that allows wrapping articles of any shape. The wrapping paper consists of a single-sided corrugated cardboard formed by laminating a corrugated board onto a flat plate. An elastic inner sheet, such as crepe paper, expands and contracts in the direction perpendicular to the corrugated wave. This allows the paper to conform to objects of various shapes by expanding and contracting around them. The corrugated cardboard provides cushioning protection while the expandable inner sheet allows custom fitting.

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18. Corrugated Cardboard Packing Material with Deformable Sections and Integrated Object Securing Mechanism

TANA-X CO LTD, 2013

A packing material using corrugated cardboard that reliably holds hard or fragile objects during transportation without the need for separate wrapping materials like bubble wrap or padded envelopes. The packing material is made by sandwiching the object between two corrugated cardboard plates, with cutting lines in the center plate to deform the corrugated sections when pressed. This allows the plates to securely grip the object between the deformed sections and the undeformed sections around it. The plates can be pressed together, folded, or adhesive-bonded to hold the object. Using softer corrugated material on the inner plates can prevent damage to fragile objects. The deformable corrugated construction allows reliable holding of a wide range of objects without damage.

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19. Corrugated Cardboard Partition with Double Corrugation and End-Securing Flaps for Stabilizing Electric Component Units

TEGA SANYO INDUSTRY CO LTD, 2013

Packaging device for electric component units like control boards that uses a main partition made of corrugated cardboard to stably house and support the component unit in compartments inside a larger corrugated cardboard box. The main partition has walls with double corrugation on the inside to accommodate the component's thickness. Flaps facing the component's ends are formed to insert and secure the ends in contact. This prevents movement and provides stable storage. The component's long rectangular shape fits horizontally in the compartments.

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20. Micro-Corrugated Cardboard Packaging with Columnar Vertical Walls and Enhanced Stackability

IGLESIAS CARBONELL PABLO CARLOS JOSE, 2012

Micro-corrugated cardboard pizza box and empanadas packaging with improved strength and stackability compared to conventional pizza boxes. The new design has a base with micro-corrugations and vertical walls that act as columns when the lid is closed. This prevents the lid from collapsing under external pressure like stacking force. It provides better protection for the pizza or empanadas inside. The micro-corrugations also improve resistance and prevent denting.

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