Multilayer Fiber Substrate for Press Molding
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Solution Overview
Problem
Existing fiber products face issues with strength, recyclability, and efficiency in press molding due to material properties, leading to complications in handling, feeding, and recycling, particularly when not produced in direct proximity to the forming process.
Innovation Solution
A multilayer substrate with one layer providing tensile strength and another with internal strength suitable for press forming, combined with high pressure and temperature treatment, resulting in a product with enhanced mechanical properties and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the material is delivered flat on rolls or sheets, then the volume efficiency is high, but the material lacks sufficient strength for handling and feeding operations
Solution Approach 1:
The material is divided into multiple layers with different functional properties. The first layer provides tensile strength for handling, while the second layer provides compressive strength for press forming. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The invention uses a composite structure combining natural fibers (wood pulp) and synthetic fibers (polyolefin) in specific layers. The composite material achieves both high volume efficiency when delivered flat and sufficient strength for handling operations, resolving the contradiction between compact storage and operational strength.
2Strength
If the material is made stronger to withstand handling operations, then the handling strength is improved, but the material becomes difficult to separate during recycling
Solution Approach 1:
The material structure is segmented into distinct layers that can be easily separated during recycling. The first layer (natural fibers) and second layer (synthetic fibers) have different physical and chemical properties that facilitate their separation, allowing the material to maintain handling strength during use while enabling efficient recycling by separating the layers for different processing paths.
3Volume of stationary object
If the material is delivered as blanks or sheets, then the volume efficiency is high, but the feeding system complexity increases
Solution Approach 1:
The material is delivered dynamically as a continuous roll that can be fed through the press forming process without requiring complex blanking and sheeting operations. The roll configuration allows for continuous processing, reducing the complexity of the feeding system while maintaining high volume efficiency through compact rolling storage.
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 multilayer product achieves high tensile and surface strength, efficient delivery, and high recyclability, enabling high-volume packaging production with minimized additives and reduced complexity in handling and recycling processes.
Implementation Method 1
subjecting said substrate to high pressure, and subjecting said substrate to high temperature
Implementation Method 2
subjecting said substrate to high pressure
Data Source
AI summary
The present invention relates to a multi-layer material for press molding, a delivery system and a resulting fiber product. Also, a method for recovery is disclosed.