Process for manufacturing packaging box by using calcium carbonate

Abstract

The invention provides a manufacturing process of a novel packaging box containing calcium carbonate and a high polymer material, relates to the technical field of packaging materials, and aims to solve the limitation of an existing carton material in the aspects of strength, durability and moisture resistance. The process is realized through the following steps: 1) preparing materials, namely mixing calcium carbonate powder with the purity of 98% with polyethylene (PE), polypropylene (PP) and an additive; (2) mixing and plastifying to ensure that the two materials are fully mixed and dispersed; 3) performing hot pressing to form a stable plate; 4) cutting and post-processing to meet actual packaging requirements; and 5) finally, carrying out performance inspection to ensure that various application requirements are met. According to the manufacturing process, the light and high-strength packaging box can be produced, the packaging box is suitable for severe environments, and meanwhile environmental protection and recoverability are considered.

Description

Technical fields:

[0001] This invention relates to the field of packaging materials technology, and in particular to a novel packaging box manufacturing process that integrates calcium carbonate and polymer materials. Background technology:

[0002] In the modern packaging industry, the performance of packaging materials directly affects product protection, transportation, and sales. Traditional cardboard boxes have limitations in strength, durability, and moisture resistance due to material constraints, making them unsuitable for long-distance transportation and storage in harsh environments.

[0003] Calcium carbonate, as a widely used inorganic filler, is extensively applied in plastics, rubber, building materials, and other fields due to its excellent physical and chemical properties, improving product properties and reducing costs. In recent years, combining calcium carbonate with polymer materials has led to the development of composite packaging materials with high strength, lightweight, environmental friendliness, and cost-effectiveness, attracting widespread attention in the industrial sector.

[0004] However, in practical applications, the composite of calcium carbonate and polymer materials presents certain challenges. The compatibility and dispersibility of the two materials, as well as the process parameters of the composite, must be considered to achieve optimal performance. Polypropylene (PP), due to its good chemical stability, corrosion resistance, lightweight, and low cost, is considered an ideal choice for composite with calcium carbonate. However, precisely controlling the composite ratio of calcium carbonate and PP, and the process conditions, to ensure that the final product possesses superior mechanical properties and cost-effectiveness remains a technical challenge facing the industry.

[0005] Furthermore, increasingly stringent environmental regulations have placed higher demands on the production of packaging materials. Existing packaging boxes are often difficult to degrade, causing long-term environmental impacts. Therefore, developing packaging materials that can improve physical properties while also being environmentally friendly and recyclable has become a key research focus in the industry. Summary of the Invention:

[0006] In the current packaging technology field, most packaging boxes are mainly made of paper and plastic materials. However, these materials often cannot balance the requirements of lightweight and high strength, and also pose certain challenges in terms of environmental protection and easy recycling. Therefore, this invention addresses the defects or deficiencies of existing packaging materials by proposing a novel manufacturing technology for calcium carbonate composite materials to prepare high-performance packaging boxes. This technology introduces calcium carbonate as a key component of the cardboard board material, aiming not only to reduce the weight of the material but also to improve its structural strength and durability, while possessing good environmental adaptability, such as sound insulation, heat insulation, and moisture resistance.

[0007] The core technical solution of this invention involves mixing calcium carbonate powder with synthetic polymers such as polyethylene (PE) and polypropylene (PP) in a specific ratio, followed by a plasticizing and hot-pressing process to obtain a composite cardboard material. During the plasticizing process, process parameters such as temperature, pressure, and time are optimized to ensure that calcium carbonate particles are uniformly dispersed in the polymer matrix, enhancing the overall mechanical properties of the material through microscopic interfacial interactions. Furthermore, the temperature and pressure of the hot-pressing process are precisely controlled to ensure the production of boards with consistent texture and ideal shape.

[0008] Cardboard made from calcium carbonate composite materials exhibits significantly improved overall performance compared to existing technologies. Firstly, the addition of calcium carbonate improves the cardboard's hardness and compressive strength, while its unique crystal structure and low density reduce material weight. Secondly, optimization of interfacial interactions and dispersion properties enhances the cardboard's toughness, thereby improving its stability and durability under impact loads. Finally, the addition of calcium carbonate provides better thermal and sound insulation, as well as moisture resistance, offering additional protection for the transportation and storage of packaging boxes.

[0009] Compared with existing technologies, the present invention has the following beneficial effects. First, the cardboard material of the present invention, while maintaining its lightweight characteristics, achieves a significant improvement in strength and durability, effectively reducing the possibility of damage during logistics and transportation. Second, the improved sound insulation, heat insulation, and moisture-proof capabilities can more effectively protect the contents from environmental factors. Finally, calcium carbonate, as an inorganic substance widely found in nature, has excellent biocompatibility and environmental friendliness; therefore, the cardboard material of the present invention is also more convenient to recycle and process, which helps to reduce the environmental burden. These advantages make the cardboard material of the present invention a novel packaging material with broad application prospects. Detailed implementation method:

[0010] Example 1

[0011] A process for manufacturing packaging boxes using calcium carbonate is disclosed. This process involves introducing calcium carbonate powder with synthetic polymer materials to prepare a composite material, which is then used to create high-performance packaging box panels. In this embodiment, we will describe the manufacturing steps and necessary details in detail.

[0012] Material preparation: By weight percentage, obtain 70 parts of calcium carbonate powder with a purity of 98%, 10 parts of polyethylene (PE), 10 parts of polypropylene (PP), and 10 parts of necessary additives (such as stabilizers, plasticizers, etc.).

[0013] Mixing: First, mix polyethylene, polypropylene and additives evenly according to the ratio, then slowly add calcium carbonate powder and stir continuously to ensure that the polymer materials and calcium carbonate particles are fully mixed.

[0014] Plasticizing: The mixed raw materials are fed into a twin-screw extruder for plasticizing. The control conditions for the plasticizing process are generally 180-200℃ temperature, 3-5MPa pressure, and 5-10 minutes to ensure good plasticity of the material and uniform dispersion of calcium carbonate particles.

[0015] Hot pressing: The plasticized composite material is formed by hot pressing. In this step, the pressure is adjusted to 10-20 MPa, the temperature is maintained at 150-170℃, and the duration is 5-10 minutes to ensure the stability of the internal structure of the composite material and its regular shape.

[0016] Cutting and Finished Product Processing: After hot pressing, the sheet material is cooled and cured. Once the temperature drops to room temperature, it is cut to the required dimensions and shape for the packaging boxes. Subsequently, after deburring, surface polishing, and other follow-up processes, the finished packaging box sheet material is obtained.

[0017] Performance testing: To ensure product quality, a series of performance tests are conducted on the obtained packaging box materials, including strength testing, abrasion resistance testing, thermal insulation performance testing, and environmental performance testing, to ensure that the product meets the expected application requirements.

[0018] Example 2

[0019] In another embodiment, a portion of the calcium carbonate in Example 1 was replaced with light calcium powder (by weight percentage, 35 parts of light calcium powder, and 45 parts of polyethylene (PE) and polypropylene (PP), with the other synthesis steps being the same as in Example 1.

[0020] Material adjustment: Lightweight calcium powder can further reduce the weight of the material and optimize the heat insulation and sound insulation properties of the board, making it suitable for occasions with higher requirements for the heat insulation and sound insulation performance of packaging boxes.

[0021] Performance testing: Similarly, the same performance testing process is performed on the adjusted packaging box material to verify whether its overall performance meets the specific application requirements.

[0022] The above embodiments illustrate the manufacturing process of the calcium carbonate composite material packaging box of the present invention, and describe in detail the key aspects such as material proportioning, process steps, and performance testing. According to the technical solution provided by the present invention, packaging box panels that simultaneously possess lightweight, high strength, and good environmental adaptability can be produced, demonstrating their broad application prospects in the modern packaging field.

Claims

1. A novel packaging box manufacturing process integrating calcium carbonate and polymer materials, characterized in that: The process includes a material preparation stage, a mixing stage, a plasticizing stage, a hot pressing stage, and a cutting and finished product processing stage. The material preparation stage involves obtaining calcium carbonate powder with a purity of 98%, polyethylene (PE), polypropylene (PP), and necessary additives by weight percentage. Calcium carbonate powder accounts for 70 parts, polyethylene (PE) and polypropylene (PP) each account for 10 parts, and additives account for 10 parts.

2. The manufacturing process according to claim 1, characterized in that: In the mixing stage, polyethylene, polypropylene and additives are first mixed evenly in proportion, and then calcium carbonate powder is added and stirred to ensure that the polymer materials and calcium carbonate particles are fully mixed.

3. The manufacturing process according to claim 2, characterized in that: The plasticizing stage is controlled under the following conditions: temperature 180-200℃, pressure 3-5MPa, and time 5-10 minutes, so that the material has good plasticity and the calcium carbonate particles are evenly dispersed.

4. The manufacturing process according to claim 3, characterized in that: During the hot pressing stage, the pressure is adjusted to 10-20 MPa, the temperature is maintained at 150-170℃, and the duration is 5-10 minutes to ensure the stability of the internal structure and the regularity of the shape of the composite material.

5. The manufacturing process according to claim 4, characterized in that: The cutting and finished product processing stage includes cooling and solidifying the hot-pressed sheet material, cutting it after the temperature drops to room temperature, and then deburring and polishing the surface to obtain the finished packaging box sheet material.

6. The manufacturing process according to claim 1, characterized in that: Further, the process includes a performance testing phase for the obtained packaging box materials, including strength testing, abrasion resistance testing, heat insulation performance testing, and environmental performance testing, to ensure that the product meets the expected application requirements.

7. A packaging box board manufactured using the manufacturing process described in claims 1-6.

8. The manufacturing process according to claim 1, characterized in that: In the material preparation stage, a portion of the calcium carbonate powder is replaced with light calcium powder by weight percentage, with light calcium powder accounting for 35 parts and polyethylene (PE) and polypropylene (PP) accounting for 45 parts.

9. The manufacturing process according to claim 9, characterized in that: Packaging box panels comprising a lightweight calcium powder mixed composite material manufactured according to the material adjustment steps described in claim 9.

10. The manufacturing process according to claim 10, characterized in that: Similarly, the performance of packaging box panels made of lightweight calcium powder composite material was tested to verify whether their overall performance met the specific application requirements.