Abstract: Facing the global transition to green and low-carbon practices alongside environmental packaging regulations, the traditional foam cushioning packaging in the air conditioning industry is increasingly revealing issues related to resource consumption, recycling, and pollution. To adhere to green packaging principles and focus on packaging solutions for high-end cabinet air conditioners, a comprehensive application of material performance testing and simulation technology has been achieved, realizing the dual goals of enhancing foam cushioning performance and achieving green, lightweight materials. First, the key mechanical and energy absorption properties of expanded polystyrene (EPS) were systematically investigated, and its stress-strain constitutive model was established. Subsequently, a comprehensive simulation model encompassing the complete unit, foam cushioning structure, and corrugated carton was developed based on complex logistics scenarios. The model’s accuracy was validated through experiments, and evaluation criteria for drop simulation were established. The results demonstrate strong consistency between the drop/clamp simulation outcomes and experimental data, with simulations effectively identifying potential weak points in advance and enabling structural optimization during the design phase. Furthermore, material reduction was implemented in non-load-bearing paths. The optimized foam structure achieved a 27 g reduction in material usage while maintaining transportation performance, alongside a 35% improvement in clamping energy absorption and an 8% increase in drop impact energy absorption. This approach significantly reduces carbon emissions and minimizes mold modification cycles. So validating the critical role of simulation technology in green cushioning packaging design and providing a feasible pathway for innovative packaging upgrades in the air conditioning industry.

Key words: EPS foam, Green packaging, Explicit dynamics, Drop simulation, Clamping simulation, Air conditioner packaging