Abstract: Presently, with the rising cost of packaging materials, the profit of the household appliances is reduced. The optimization of the cushioning package structure is one of the effective ways to improve the competitiveness of the household appliance enterprises. In this paper, the CAE simulation technology is used to simulate and calculate a packaged of inner air-conditioner with over protection. The compression deformation of the foams and the parts of high failure risk of the product are found in the different falling conditions. The over protection parts and the unreasonable buffer structure parts of the foam are found. The structure of the foam are pertinence optimized and improved. Which is compared with the original scheme by simulation analysis and physical verification comparative analysis. The simulation results show that the optimization scheme is better protection and better product quality. Also, the optimization scheme reduces the overall size of the original scheme, reduces the material consumption by 23.7%, and reduces the cost of one unit by about 1.6 yuan.

Key words: CAE, Ls-Dyna, Simulation, Dropping, Cushion, Packaging