Packing structures and associated methods of assembly

A packing structure comprising:

• a first base structure comprising a first section comprising a first plurality of grooves and a second section comprising a second plurality of grooves, wherein the first section is a folded section;
• a second base structure comprising a third section comprising a third plurality of grooves and a fourth section comprising a fourth plurality of grooves, wherein the third section is a folded section;
• one or more expansion base structures placed between the first base structure and the second base structure, each of the one or more expansion base structures comprising a plurality of grooves;
• and
• a plurality of cross structures, wherein each of the plurality of cross structures comprises a folded section comprising a plurality of grooves, and wherein the plurality of cross structures are inserted into the first base structure, the second base structure, and the one or more expansion base structures wherein the plurality of grooves in each cross structure are cojoined with one of the first plurality of grooves, one of the second plurality of grooves, one of the third plurality of grooves, and one of the fourth plurality of grooves and two grooves in each of the one or more expansion base structures, thereby forming one or more enclosed cells and a plurality of crush zones, wherein each of the one or more enclosed cells comprises four sides each adjacent to one of the plurality of crush zones or another enclosed cell.

A method of assembling a packing structure comprising:

• forming a base structure by:
• folding a first section along a first axis to abut a second section to form a first folded section;
• folding a third section along a second axis to abut a fourth section to form a second folded section;
• folding the first folded section to be perpendicular to a bottom section;
• and
• folding the second folded section to be perpendicular to the bottom section;
• forming a plurality of cross structures by:
• for each of the plurality of cross structures, folding a section along an axis to abut another section;
• and
• inserting the plurality of cross structures into the base structure to form one or more enclosed cells and a plurality of crush zones, where each of the one or more enclosed cells comprises four sides each adjacent to one of the plurality of crush zones or another enclosed cell.

A method of assembling a packing structure comprising:

• forming a first base structure by:
• folding a first section along a first axis to abut a second section to form a first folded section;
• folding the first folded section along a second axis so that the first folded section is perpendicular to a first bottom section;
• and
• folding a third section along a third axis so that the third section is perpendicular to the first bottom section;
• forming a second base structure by:
• folding a fourth section along a fourth axis to abut a fifth section to form a second folded section;
• folding the second folded section along a fifth axis so that the second folded section is perpendicular to a second bottom section;
• and
• folding a sixth section along a sixth axis so that the sixth section is perpendicular to the second bottom section;
• forming one or more expansion base structures by, for each of the one or more expansion base structures:
• folding a seventh section along a seventh axis so that the seventh section is perpendicular to a third bottom section;
• and
• folding an eighth section along an eighth axis so that the eighth section is perpendicular to the third bottom section;
• forming a plurality of cross structures by:
• for each of the plurality of cross structures, folding a section along an axis to abut another section;
• and
• inserting the plurality of cross structures into the first base structure, the second base structure, and the one or more expansion base structures to form one or more enclosed cells and a plurality of crush zones, wherein each of the one or more enclosed cells comprises four sides each adjacent to one of the plurality of crush zones or another enclosed cell.