This study optimizes the packaging design of dryers using AI-TRIZ innovation system to address the issue of insufficient container loading due to packaging width limitations. Through functional and causal chain analysis of dryer packaging components using the AI-TRIZ innovation system, it was identified that the main problem in the packaging system lies in the inadequate support and fixation of the top and bottom foam. To address these issues, innovative solutions such as the application of high-density polyethylene materials, reinforcement of bottom Expanded polypropylene (EPP) blocks, elastic bottom edge reinforcement, and multi-layer composite cushioning structures were proposed. The new design underwent drop, clamp, random vibration, and tipping tests for validation. Results indicate that the new packaging structure meets the functional requirements for product protection while effectively reducing packaging width, achieving a 12% increase in loading capacity. The study demonstrates the significant advantages of combining AI with TRIZ innovation tools in enhancing problem-solving efficiency and generating reliable solutions, providing new insights for product design optimization in the manufacturing industry.