Corrugated Cardboard 3D Molding via Liquid Hardening Agent

Solution Overview

Problem

Existing methods for producing three-dimensional construction elements, such as sound protection elements, from corrugated cardboard are time-consuming, material-intensive, and lead to significant wear and tear on equipment.

Innovation Solution

A manufacturing process involving the application of a liquid hardening agent to corrugated cardboard, followed by deformation in a press form under controlled pressure and duration, allowing the cardboard to maintain its structural integrity and desired shape without material loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional machining methods (milling) are used to create three-dimensional shapes from corrugated cardboard, then design options can be increased, but processing time is extended and material loss occurs

Engineering Contradiction:

Improvedesign optionsVSAvoidprocessing time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent replaces mechanical machining (milling) with a chemical process. A liquid agent is applied to the corrugated cardboard, causing localized softening that allows the material to be molded into three-dimensional shapes. This chemical approach eliminates the time-consuming mechanical removal of material while achieving complex geometries.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical-chemical parameters of the corrugated cardboard by applying a liquid agent that modifies the material's properties locally. The liquid causes the cardboard to soften and become pliable, enabling it to be deformed into three-dimensional shapes. After molding, the liquid evaporates or hardens, leaving the desired shape without material loss.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If traditional machining methods (milling) are used to create three-dimensional shapes from corrugated cardboard, then design options can be increased, but material loss and contamination occur

Engineering Contradiction:

Improvedesign optionsVSAvoidmaterial loss

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent replaces mechanical machining (milling) with a chemical process. A liquid agent is applied to the corrugated cardboard, causing localized softening that allows the material to be molded into three-dimensional shapes. This chemical approach eliminates the time-consuming mechanical removal of material while achieving complex geometries.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical-chemical parameters of the corrugated cardboard by applying a liquid agent that modifies the material's properties locally. The liquid causes the cardboard to soften and become pliable, enabling it to be deformed into three-dimensional shapes. After molding, the liquid evaporates or hardens, leaving the desired shape without material loss.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If multi-sided machining is performed to form complex three-dimensional shapes, then design complexity increases, but processing time and material wear increase significantly

Engineering Contradiction:

Improvedesign complexityVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent replaces mechanical machining (milling) with a chemical process. A liquid agent is applied to the corrugated cardboard, causing localized softening that allows the material to be molded into three-dimensional shapes. This chemical approach eliminates the time-consuming mechanical removal of material while achieving complex geometries.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies the liquid softening agent to the corrugated cardboard before molding, preparing the material in advance for shape formation. This preliminary chemical treatment enables the cardboard to be easily deformed into complex three-dimensional shapes without requiring subsequent mechanical machining, significantly reducing total processing time.

Inventive Principle:

Principle #10Preliminary action

4Stability of the object's composition

If corrugated cardboard is deformed to create three-dimensional shapes, then structural stability may be improved, but the webs and channels may be impaired

Engineering Contradiction:

Improvestructural stabilityVSAvoidweb integrity

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The patent applies the liquid softening agent to the corrugated cardboard before molding, preparing the material in advance for shape formation. This preliminary chemical treatment enables the cardboard to be easily deformed into complex three-dimensional shapes without requiring subsequent mechanical machining, significantly reducing total processing time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the physical-chemical parameters of the corrugated cardboard by applying a liquid agent that modifies the material's properties locally. The liquid causes the cardboard to soften and become pliable, enabling it to be deformed into three-dimensional shapes. After molding, the liquid evaporates or hardens, leaving the desired shape without material loss.

Inventive Principle:

Principle #35Parameter changes

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

This process enables rapid, cost-effective, and material-efficient production of three-dimensional corrugated cardboard elements with high stability and design versatility, reducing processing time and equipment wear compared to traditional methods.

Implementation Method 1

the corrugated cardboard part is softened with a liquid medium before the pressing process

Methodology Applied

Scientific EffectSoftening:

Implementation Method 2

The liquid medium for softening the corrugated cardboard hardens under the influence of air or through chemical processes

Methodology Applied

Scientific EffectHardening:

Data Source

PatentEP4541574A1Method for producing a three-dimensional construction element and three-dimensional construction element

Publication Date: 2025.04.23 SOUNDCOMB GMBH

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Figure 2~3
Figure 4

AI summary

The invention relates to a method for manufacturing a three-dimensional structural element (1), in particular a soundproofing element, from a substantially flat corrugated cardboard part (2) with a predetermined thickness (dW) and ribs (3) arranged substantially perpendicular to the longitudinal extent of the corrugated cardboard part (2) and channels (4) formed between the ribs (3), as well as such a three-dimensional structural element (1). The following manufacturing steps are provided for the suitable and rapid formation of a three-dimensional structural element: - Application of a liquid hardening agent (5) to the corrugated cardboard part (2); - Placement of the corrugated cardboard part (2) treated with the liquid hardening agent (5) into a mold (6); - Closing of the mold (6) and application of a predetermined pressing pressure (pP) to the corrugated cardboard part (2); - Hardening of the corrugated cardboard part (2) for a predetermined pressing time (tP); - Opening of the mold (6); and - removal of the deformed corrugated cardboard part (2).