Gradient Molten Rate Web Structural Body for Wrinkle-Free Deep Drawing
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Solution Overview
Problem
Existing cellulose fiber-based containers lack sufficient strength and rigidity, particularly when forming three-dimensional shapes, as they are prone to wrinkles and breakages due to the structure of laminate sheets with thermoplastic resin layers.
Innovation Solution
A web structural body composed of cellulose fibers bound by a binding material with a higher molten rate at the surface than at the center, ensuring sufficient strength and rigidity, achieved through a manufacturing process involving mixing, depositing, and heating the fibers and binding material to specific thickness and density specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a thermoplastic resin layer is provided on the surface of a base paper layer to maintain shape, then shape maintenance is improved, but sufficient strength and rigidity cannot be obtained
Solution Approach 1:
The patent applies local quality by creating a gradient structure where the binding material content varies through the thickness of the web structural body. The surface region contains a higher concentration of binding material compared to the center, providing localized strength and rigidity enhancement at the surface while maintaining overall shape stability throughout the structure.
2Strength
If high density paper is used as base material to improve strength, then strength is improved, but wrinkles and breakages occur during deep drawing molding
Solution Approach 1:
The patent applies parameter changes by controlling the density distribution and binding material content through the thickness of the web structural body. The optimized density range (0.02 to 0.20 g/cm³) and gradient binding material distribution allow the material to have sufficient strength while maintaining flexibility and deformability during deep drawing molding, preventing wrinkles and breakages.
3Strength
If binding material content is increased to improve strength, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by incorporating the binding material uniformly throughout the web structural body during the manufacturing process, rather than adding it later as a separate surface treatment. This preliminary incorporation simplifies the overall manufacturing process while ensuring adequate strength distribution throughout the material structure.
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 web structural body achieves enhanced strength and rigidity, allowing for the formation of complex shapes without wrinkles or breakages, and can be used to create containers like food trays with improved structural integrity.
Implementation Method 1
the heating portion heats the deposit at a temperature of 70.0° C. to 220.0° C. so that a molten rate of the binding material at a surface of the web structural body is higher than a molten rate of the binding material at a center in a thickness direction of the web structural body
Implementation Method 2
a molten rate of the binding material at a surface of the web structural body is higher than a molten rate of the binding material at a center in a thickness direction of the web structural body
Implementation Method 3
the heating portion may include a pair of heating rollers, and the heating rollers each may have a rotation rate of 30.0 to 350.0 rpm
Data Source
AI summary
A web structural body includes cellulose fibers and a binding material binding the cellulose fibers, and in the web structural body described above, a molten rate of the binding material at a surface of the web structural body is higher than a molten rate of the binding material at a center in a thickness direction of the web structural body.