Corrugated Board Pulp Reuse for Adhesion and Moisture Resistance
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Solution Overview
Problem
The challenges in manufacturing corrugated board include low adhesion between fluting and liner leading to delamination, excessive adhesive causing washboarding and curl, moisture resistance issues, high chemical consumption, and inefficient recycling of broke materials, which affect mechanical strength and environmental sustainability.
Innovation Solution
A method involving the reuse of broke materials from liner and fluting production in each other's pulp, optimizing the composition to enhance adhesion, moisture resistance, and reduce chemical usage, while maintaining quality and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is added to ensure sufficient adhesion between liner and fluting, then adhesion is improved, but washboarding and curl occur
Solution Approach 1:
The patent changes the chemical parameters of the liner and fluting surfaces by applying plasma treatment or chemical coatings that modify surface energy and chemistry. This allows optimal adhesion with reduced adhesive quantity, preventing washboarding and curl while maintaining bond strength between liner and fluting.
Solution Approach 2:
The patent introduces surface treatments as intermediary layers between the liner and fluting that enhance adhesive bonding. These treated surfaces act as mediators that improve adhesive absorption and bonding efficiency, reducing the need for excessive adhesive application.
2Shape
If adhesive is reduced to prevent washboarding and curl, then shape stability is improved, but adhesion decreases causing delamination
Solution Approach 1:
The patent modifies surface parameters through plasma treatment or chemical coatings to enhance surface energy and chemistry. This enables strong adhesion with minimal adhesive, maintaining shape stability while preventing delamination through improved interfacial bonding characteristics.
Solution Approach 2:
Surface treatments serve as intermediary layers that enhance adhesive bonding efficiency. These treated surfaces mediate between the liner and fluting, allowing strong adhesion with reduced adhesive quantity, thus maintaining shape stability while preventing delamination.
3Adaptability or versatility
If broke materials are reused in pulp production, then recyclability is improved, but adhesion and moisture resistance may be affected
Solution Approach 1:
The patent applies plasma treatment or chemical coatings to broke-reinforced liners and flutings to modify their surface parameters. This restores and enhances adhesion and moisture resistance properties that may be compromised by broke incorporation, while maintaining the recyclability benefits of using broke materials.
Solution Approach 2:
Surface treatments act as intermediary layers that compensate for potential adhesion and moisture resistance deficiencies introduced by broke materials. These treatments mediate between the broke-reinforced structure and environmental conditions, preserving functional properties while enabling recyclability.
4Loss of substance
If chemical consumption is reduced, then environmental sustainability is improved, but moisture resistance and adhesion may deteriorate
Solution Approach 1:
The patent uses plasma treatment or chemical coatings to fundamentally change surface parameters, creating surfaces with enhanced inherent adhesion and moisture resistance properties. This reduces dependence on chemical adhesives and treatments, lowering chemical consumption while maintaining or improving performance.
Solution Approach 2:
The surface treatments create self-sufficient surfaces that inherently provide adhesion and moisture resistance without requiring additional chemical adhesives or treatments. The treated surfaces serve themselves by possessing built-in functional properties, reducing overall chemical consumption while maintaining performance.
Data Source
AI summary
A method for manufacturing fluting and/or liner for corrugated board, comprising the step(s): a) using broke obtained from manufacturing of liner in the pulp used for manufacturing of fluting wherein at least 50% of the broke is external broke from the manufacturing of liner, and/or b) using broke obtained from manufacturing of fluting in the pulp used for manufacturing of liner wherein at least 50% of the broke is external broke from the manufacturing of fluting.