Packaging is a requirement for almost all industries because it provides the protection for products during handling, shipment and storage. Reliability of packaging is very critical so that industries have to make a careful choice for appropriate materials that are not only lightweight but cost effective so as not to impact heavily on shipping costs. Recently, major innovations have been introduced in clear product packaging to satisfy the requirements of end users in terms of protection, shock absorption, aesthetics and cost effectiveness.

Polyurethane for clear product packaging

The physical characteristics of polyurethane foam make it ideal for clear product packaging. Polyurethane foam is a popular cushioning material for many industrial applications but its ability to absorb shock makes it highly desirable for the electronics industry. By shock absorber, it means the ability to protect a product from damage by absorbing impact efficiently and recovering its shape quickly and repeatedly. Another important characteristic of polyurethane foam is its flexibility which allows the packaging material to be cut and shaped easily for bracing, support and for wrapping electronic items.

While firmness is important for clear product packaging, density allows the material to absorb repeated shocks without compromising its cushioning characteristic. High density foam with high energy absorbing qualities can be customized from a soft and conforming surface or a firm and not so conforming surface. If greater shocks are expected from shipping conditions, higher density foam with increased thickness may be more appropriate.

Properties of foam appropriate for clear product packaging

A proper packaging solution can be achieved by providing the right information to the foam packaging manufacturer. It is critical to convey to the manufacturer the level of fragility of the product that has to be protected. G factor fragility index is the measurement used for the fragility of a product. It is used by design engineers to properly select the cushioning material so that the product will not sustain damage when dropped from a certain height. The maximum drop height of a packaged product is also measured because it is common for handlers to accidentally drop the product during transport. Once the maximum drop height has been determined, the design engineer will create dynamic cushioning curves to design the protective package.

Different foam properties can affect the cushioning curve including the specifications of packaging. Aside from foam thickness, firmness and density, it is also important to consider foam porosity because it affects how well cushioning can absorb shock and decelerate for a fragile electronic product. Foam porosity or the relative degree that air passes through a foam sample is largely affected by its structure. Foams with greater porosity are more suitable for clear product packaging of lightweight and delicate objects whose fragility is quite high from lower maximum drop height. On the other hand, foams with less porosity are more appropriate for electronics products that are quite heavy but require greater energy absorption. Tight foam that has the lowest airflow values is prefect for clear product packaging of objects with moderate fragility and drop height.