Flame-Proof Corrugated Paperboard Coating Structure
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Solution Overview
Problem
Existing methods for producing flame-proof corrugated paperboard face challenges such as high production costs, complex processes, and inadequate flame-proof performance due to the use of large amounts of flammable resins and inorganic layers, as well as issues with the separation of flame-proofing agents under heat or friction.
Innovation Solution
A flame-proof corrugated paperboard is created using a linerboard with a flame-proof layer containing a polymer of molecular weight between 8,000 and 10,000,000, and an overcoat layer, which reduces the penetration of the flame-proofing agent and enhances the strength of the coating film, allowing for high flame-proof performance with a small coating amount and simplified production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flame-proofing agent is applied to the surface of the linerboard to form a coating film, then flame retardancy is improved, but the coating film layer separates under heat or friction due to weak strength
Solution Approach 1:
The patent uses a composite coating film made of acrylic resin and flame-proofing agent. The acrylic resin forms a strong polymer matrix that binds the flame-proofing agent particles together, creating a composite material that maintains both flame retardancy and mechanical strength, preventing separation under heat or friction.
Solution Approach 2:
The acrylic resin acts as an intermediary substance between the flame-proofing agent and the linerboard surface. It provides adhesion to prevent the flame-proofing agent from separating while also forming a protective coating layer that maintains flame retardancy.
2Strength
If a large amount of acrylic resin is used to prevent flame-proofing agent penetration, then coating film strength is improved, but flame-proof performance deteriorates due to high flammability
Solution Approach 1:
The patent optimizes the concentration ratio of flame-proofing agent to acrylic resin in the coating film. By controlling this parameter, the formulation achieves sufficient film strength while maintaining effective flame retardancy, avoiding the use of excessive flammable resin.
Solution Approach 2:
The composite structure allows the flame-proofing agent particles to be distributed within the acrylic resin matrix, where the resin provides structural integrity while the dispersed flame-proofing agent maintains flame retardancy through synergistic effects.
3Reliability
If an inorganic layer is formed on the paper surface to prevent flame retardant infiltration, then flame-proof performance is improved, but production process complexity and cost increase
Solution Approach 1:
The patent extracts the flame-proofing agent application step from the paper production process, allowing it to be applied separately as a coating layer on the linerboard surface. This separates the flame-proofing function from the base paper manufacturing, simplifying the overall production process while maintaining effectiveness.
Solution Approach 2:
The patent changes the physical state and application method of the flame-proofing agent from being mixed into pulp (solid/liquid suspension) to being applied as a coating film (liquid solution), enabling better control over the coating amount and reducing production complexity.
4Reliability
If flame-proofing agent is contained in pulp to make paper, then flame retardancy is achieved, but production is not suitable for small lots due to large paper manufacturing requirements
Solution Approach 1:
The patent segments the flame-proofing treatment from the base paper production. The linerboard is manufactured first as a separate component, then the flame-proofing coating is applied as a separate subsequent step. This segmentation allows flexible production of small batches without requiring large-scale paper manufacturing.
Solution Approach 2:
The linerboard is prepared in advance as a separate component with its flame-proof coating applied before final assembly into the corrugated container. This preliminary action enables on-demand production of small batches while maintaining flame retardancy.
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 approach results in a cost-effective, high-performance flame-proof corrugated paperboard that maintains its flame-proof integrity even under heat or friction, without the need for extensive inorganic layers or large amounts of flammable resins, thus addressing the limitations of previous methods.
Implementation Method 1
a flame-proof layer containing a flame-proofing agent and a polymer having a molecular weight of 8,000 or more and 10,000,000 or less
Implementation Method 2
an overcoat layer for protecting the flame-proof layer, the overcoat layer being disposed closer to a surface of the flame-proof corrugated paperboard than the flame-proof layer is
Data Source
AI summary
Provided are a flame-proof linerboard and a flame-proof corrugated paperboard in which with a small coating amount, a flame-proof layer is formed on the surface of a general linerboard so as to reduce penetration of the flame-proofing agent, and which are thus low in cost and exhibit high flame-proof performance. A flame-proof corrugated paperboard (21) is produced which includes, as a linerboard (15), a flame-proof paper including a paper layer (11), a flame-proof layer (12) containing a flame-proofing agent and a polymer having a molecular weight of 8,000 or more and 10,000,000 or less, and an overcoat layer (13) for protecting the flame-proof layer (12), the overcoat layer (13) being disposed closer to the surface of the corrugated paperboard than the flame-proof layer (12) is.