Multi-layer cardboard with coconut peat fine particles
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Solution Overview
Problem
Existing multi-ply cardboard materials require a high proportion of fresh wood fibers, leading to increased costs and resource consumption, particularly in producing high-quality cardboard.
Innovation Solution
Incorporating coconut peat as fine particles with a particle size of less than 0.5 mm into the fibrous layers, which expands upon moisture absorption, increasing the material's strength and rigidity, and reducing the need for mechanical pulp, thereby reducing costs and resource usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a high proportion of fresh wood fibers is used in multi-ply cardboard materials, then the strength and quality of the cardboard is improved, but the resource consumption and production costs increase
Solution Approach 1:
The patent changes the physical-chemical parameters of the substitute material by specifying fine particles with particle size d0.5 < 0.5 mm and aspect ratio a/b between 0.7:1 and 1:0.7. These parameter specifications enable the substitute material to achieve comparable reinforcement effects to wood fibers while using alternative sources like coconut peat, thereby reducing wood fiber consumption without sacrificing cardboard strength
Solution Approach 2:
The patent creates a composite fibrous layer combining cellulose-containing material with fine particles having specific size and shape parameters. This composite structure allows the fine particles to effectively replace a portion of wood fibers (up to 80 wt% substitution) while maintaining the mechanical strength requirements, thus resolving the contradiction between strength and resource consumption
2Quantity of substance
If coconut fibers are used to replace wood fibers in cardboard production, then resource consumption is reduced, but production costs increase significantly
Solution Approach 1:
The patent specifies precise particle size parameters (d0.5 < 0.5 mm) and aspect ratio parameters (a/b between 0.7:1 and 1:0.7) for the fine particles. By optimizing these parameters, the patent achieves effective reinforcement with smaller, more efficiently processed particles from alternative sources like coconut peat, reducing both material costs and processing costs compared to using whole coconut fibers
Solution Approach 2:
The patent employs inexpensive alternative materials such as coconut peat and agricultural waste as substitutes for expensive wood fibers. By processing these abundant, low-cost materials into fine particles with optimized parameters, the patent achieves cost-effective cardboard production that reduces dependency on costly wood resources
3Strength
If fine particles with optimized size and shape are used in the fibrous layer, then the rigidity and volume of the cardboard material increase, but the manufacturing complexity increases
Solution Approach 1:
The patent defines specific parameter ranges for fine particles (particle size d0.5 < 0.5 mm, aspect ratio a/b between 0.7:1 and 1:0.7) that balance reinforcement effectiveness with processing feasibility. These parameter specifications enable effective rigidity enhancement while avoiding excessively complex processing requirements that would arise from more stringent particle control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The use of coconut peat allows for the production of cost-effective, resource-saving multi-ply cardboard with enhanced strength and rigidity, achieved by adjusting the proportion of fine particles in the fibrous layers.
Implementation Method 1
the fine particles have a particle size d0.5 < 0.5 mm and expand upon moisture absorption
Data Source
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AI summary
The present invention relates to a multilayer cardboard material (10) comprising at least a first fiber layer (12) having a cellulose-containing base material, and at least a second fiber layer (14) comprising a mixture of cellulose-containing material and fine particles, wherein a source material for the fine particles is coconut peat and the fine particles have a particle size of < 0.5 mm, in particular < 0.3 mm. The invention further relates to a method for producing a multilayer cardboard material (10), in particular a multilayer cardboard web, comprising at least a first and a second fiber layer (12, 14), and the use of a fiber layer comprising a mixture of cellulose-containing material and fine particles.