Biobased Resin Sheet Assembly for Durable Recyclable Cards
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Solution Overview
Problem
Biodegradable cards made from paper layers with biodegradable polymers are not durable and prone to delamination, while metal-inclusive cards are difficult to recycle.
Innovation Solution
A multi-layer sheet assembly using resin-impregnated paper with biobased resins and high-density particles, which can be cut into cards that mimic metal weight and durability without conductive layers, ensuring durability and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If biodegradable polymers are used to make cards from paper layers, then environmental friendliness is improved, but durability and resistance to delamination deteriorate
Solution Approach 1:
The patent uses composite materials by combining biodegradable polymer layers with reinforcement elements (such as woven fabrics, mesh, or grid structures) to create a multi-layer composite card structure. This combination maintains the biodegradable nature of the polymer while the reinforcement elements provide structural strength and prevent delamination, resolving the contradiction between environmental friendliness and durability.
Solution Approach 2:
The patent employs flexible shells and thin films by using biodegradable polymer films as the base material and incorporating protective outer layers or coatings that enhance durability. These thin film structures provide both the desired biodegradability and improved resistance to delamination and environmental degradation.
2Weight of moving object
If metal is included in cards to provide heavier weight, then customer desirability is improved, but recyclability deteriorates
Solution Approach 1:
The patent applies parameter changes by modifying the weight and density parameters of the card material without using metal. It achieves increased weight and metal-like feel through the use of dense biodegradable polymers, compressed paper structures, or natural minerals embedded in the card material, thereby maintaining recyclability while satisfying customer preferences for heavier weight.
Solution Approach 2:
The patent uses copying by creating a card structure that mimics the properties of metal (weight, durability, feel) without actually using metal material. The card replicates the appearance and tactile characteristics of metal cards through sophisticated layering and material selection, achieving the desired aesthetic and functional properties while maintaining environmental sustainability and recyclability.
3Object-generated harmful factors
If biodegradable cards are made from paper layers, then environmental friendliness is improved, but ability to withstand humid environments deteriorates
Solution Approach 1:
The patent uses composite materials by combining biodegradable polymer layers with moisture-resistant reinforcement elements and protective coatings. This multi-layer composite structure maintains the biodegradable nature of the core material while the additional layers provide resistance to humid environments and water exposure.
Solution Approach 2:
The patent employs flexible shells and thin films by incorporating protective outer film layers or coatings over the biodegradable paper layers. These thin film barriers prevent direct exposure of the biodegradable material to humidity and moisture while allowing the card to maintain its environmental-friendly properties.
Data Source
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AI summary
Sheet assembly (100) can be cut into cards (102), includes upper layer (124) configured to receive a first printing (122), core (126) coupled with the upper layer and lower layer (128) configured to receive a second printing (130) and coupled with the core with the core disposed between the upper sheet and the lower sheet. One or more of the upper layer, the core, or the lower layer is formed from paper impregnated with a resin that includes a biobased resin. The biobased resin can include one or more of the following: plants, petroleum-based or not, cellulosics, lignocellulosics, natural fibers, starches, polysaccharides, fats and oils, protein, and/or alginates, kenaf, sisal, jute, hemp, flax, corn, potato, tapioca, pectin, chitin, levan, pullalan, soybeans, lesquerella, rapeseed, casein, zein, soy protein, PLA, PHA, PBAT, PBS, PE, PP, PET, PUR, EPDM, PVC, PMMA, PEF, PTF, PTT, SBR, PBT, ABS, PA, APC, CA.