3D-Formable Sheet Material Strength and Stretchability
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Solution Overview
Problem
Current 3D-formable sheet materials face limitations due to poor strength, limited stretchability, and potential separation of fillers and cellulose materials, which hinder their effectiveness in forming high-quality 3D articles.
Innovation Solution
A 3D-formable sheet material comprising a cellulose material mixture with nanofibrillated and microfibrillated cellulose, combined with a high percentage of particulate inorganic filler materials, such as calcium carbonate, to enhance strength, stretchability, and ensure homogeneous distribution, preventing filler separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If sheet material contains high filler content to reduce cost, then manufacturing cost decreases, but strength and stretchability deteriorate
Solution Approach 1:
The patent applies composite materials by combining cellulosic material with particulate inorganic filler material in a controlled composition. The cellulosic matrix provides structural integrity and binding, while the filler material (45-95 wt.%) contributes to cost reduction and stiffness. This composite structure resolves the contradiction by maintaining strength through the cellulosic network while achieving high filler content for cost efficiency.
Solution Approach 2:
The patent employs parameter changes by optimizing the composition ratios of cellulosic material and filler material, controlling particle size distribution (0.1-10 μm), and adjusting moisture content (5-20%) to achieve the desired balance between strength and filler content. These parameter optimizations enable the material to maintain adequate strength while incorporating high filler loads.
2Adaptability or versatility
If sheet material is made more stretchable for 3D-forming, then formability improves, but strength decreases
Solution Approach 1:
The patent uses parameter changes by controlling moisture content (5-20%) to enhance stretchability during 3D-forming operations. The moisture acts as a plasticizer, temporarily reducing intermolecular forces and enabling greater elongation without permanent damage. After forming, the material dries and regains strength, thus achieving both formability and strength through temporal parameter control.
Solution Approach 2:
The patent applies local quality by creating regions of different properties within the sheet material. The cellulosic material provides localized strength and structural support, while the filler material regions contribute to overall formability and stiffness. This spatial differentiation of material properties allows the sheet to exhibit both strength and stretchability in different locations during the forming process.
3Stress or pressure
If filler material is added to increase stiffness, then rigidity improves, but homogeneity deteriorates due to separation
Solution Approach 1:
The patent employs an intermediary approach by using cellulosic material as a binding matrix that mediates between the filler particles and the overall sheet structure. The cellulosic network envelops and binds the filler particles, preventing their separation and ensuring homogeneous distribution. This intermediary matrix maintains rigidity through filler content while preserving compositional homogeneity throughout the sheet.
Solution Approach 2:
The patent applies composite materials with optimized interfacial adhesion between the cellulosic matrix and filler particles. The composite structure ensures that filler particles remain uniformly distributed within the cellulosic network, preventing segregation during processing and use. This well-bonded composite maintains both rigidity from the filler and homogeneity from the integrated structure.
Data Source
AI summary
The present invention relates to a 3D-formable sheet material, a process for the preparation of a 3D-formed article, the use of a cellulose material and at least one particulate inorganic filler material for the preparation of a 3D-formable sheet material and for increasing the stretchability of a 3D-formable sheet material, the use of a 3D-formable sheet material in 3D-forming processes as well as a 3D-formed article comprising the 3D-formable sheet material according.