Waterproof Stone Paper Corrugated Packaging
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Solution Overview
Problem
Conventional corrugated cartons made from wood pulp are not suitable for refrigerated or frozen applications due to moisture absorption, leading to structural damage, mold growth, and increased water consumption, while alternatives like plastic hollow boards are environmentally harmful and inefficient.
Innovation Solution
A waterproof corrugated paper made from ground natural stone powder with a low percentage of linear polyolefin plastic for binding, which is frost-resistant, reduces water consumption, and prevents bacterial growth without additional antibacterial agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional corrugated carton made from wood pulp papers is used for packaging refrigerated or frozen products, then the packaging can provide basic structure and protection, but the carton absorbs moisture when taken out of refrigerator, causing fiber structure to break and become wet and weak
Solution Approach 1:
The patent changes the material composition parameters by replacing wood pulp with inorganic materials (calcium carbonate, silica, alumina) as the primary component. This fundamental parameter change makes the packaging material impermeable to water, preventing moisture absorption during temperature transitions and eliminating the fiber breakdown issue that plagues conventional wood pulp cartons.
Solution Approach 2:
The patent creates a composite material system combining inorganic powder (calcium carbonate, silica, alumina) with a small amount of plastic binder (3-15 parts by weight). This composite structure provides both the waterproof properties of inorganic materials and the binding capability of plastic, achieving structural integrity while resisting moisture infiltration during refrigeration and thawing cycles.
2Duration of action of stationary object
If corrugated carton made from wood pulp papers is stored in refrigerator for long time, then basic packaging function is maintained, but the absorbed moisture freezes and expands, breaking the fiber structure and causing gradual damage
Solution Approach 1:
The patent fundamentally changes the material composition from organic wood pulp fibers to inorganic materials (calcium carbonate, silica, alumina) that do not absorb water. This parameter change eliminates the mechanism of moisture-induced fiber breakdown, allowing the packaging to maintain structural integrity during extended refrigeration and freezing storage periods.
Solution Approach 2:
The patent employs a disposable inorganic-based corrugated carton designed for single-use in refrigerated applications. The material's resistance to freezing damage allows it to serve its packaging function throughout the entire product shelf life in refrigeration, after which it can be discarded without degradation from moisture absorption cycles.
3Adaptability or versatility
If corrugated carton is repeatedly frozen and unfrozen, then packaging can accommodate temperature cycles, but the carton becomes wet, soft, weak, and allows mold and bacteria growth
Solution Approach 1:
The patent changes the material composition to inorganic substances (calcium carbonate, silica, alumina) that are inherently impermeable to water. This parameter change prevents moisture absorption during thawing cycles, eliminating the wet and soft conditions that promote mold and bacteria growth, while maintaining structural strength through repeated freezing and thawing.
Solution Approach 2:
The patent converts the potential harm of moisture absorption into a benefit by using inorganic materials that naturally repel water. The material's inherent waterproof property transforms the freezing-thawing cycle from a damaging process into a non-damaging one, preventing microbial growth without requiring additional chemical treatments.
4Object-affected harmful factors
If antibacterial and antifungal agent is added to corrugated carton to prevent mold and bacteria growth, then safety risk is reduced, but the agent may dissolve into packaged food, increasing safety risk
Solution Approach 1:
The patent converts the need for chemical antibacterial agents into a benefit by using inorganic materials (calcium carbonate, silica, alumina) that naturally resist moisture absorption. This eliminates the requirement for chemical treatments, preventing both mold growth and chemical contamination of food, as the waterproof property itself prevents microbial proliferation.
Solution Approach 2:
The inorganic-based corrugated carton provides its own antibacterial protection through its inherent waterproof properties. The material structure itself prevents moisture absorption, which in turn prevents mold and bacteria growth without requiring external chemical agents, making the packaging self-protecting against microbial contamination.
5Ease of manufacture
If conventional papers are made from wood pulp, then basic paper properties are achieved, but strong acids, strong alkalis, and bleach are needed to process wood into pulp, harmful to environment
Solution Approach 1:
The patent extracts the harmful processing step from paper production by completely replacing wood pulp with inorganic materials (calcium carbonate, silica, alumina). This extraction eliminates the need for strong acids, alkalis, and bleach in the manufacturing process, as inorganic materials can be directly formed into corrugated structure without chemical pulping.
Solution Approach 2:
The patent fundamentally changes the raw material parameter from organic wood pulp to inorganic materials. This parameter change transforms the manufacturing process from a chemically intensive wood pulping operation to a simpler inorganic material formation process, eliminating the need for harmful chemical agents and reducing environmental pollution.
6Quantity of substance
If wood pulp is used to manufacture conventional papers, then paper can be produced, but large amount of water is consumed (90 tons for wood pulp, 35 tons extra for papermaking)
Solution Approach 1:
The patent changes the material composition parameter from water-intensive wood pulp to inorganic materials that require minimal water in processing. This parameter change dramatically reduces water consumption from 125 tons per ton of product to a fraction of that amount, while maintaining manufacturing feasibility through alternative processing methods suitable for inorganic materials.
Data Source
AI summary
A waterproof corrugated paper includes at least one stone paper medium and at least one stone liner paper, wherein the at least one stone paper medium includes a first fluting surface. A stone glue is utilized to adhere the at least one stone liner paper and several wave crests of the first fluting surface. The stone glue includes a linear polyolefin plastic material and an inorganic material. The linear polyolefin plastic material is 30 wt %-70 wt % based on the stone glue, and the inorganic material is 30 wt %-70 wt % based on the stone glue. The waterproof corrugated paper provided by the present invention is waterproof and frost-resistant, which is adapted to package cooled or frozen food. A manufacturing method, a manufacturing apparatus, and a usage of the waterproof corrugated paper are also provided in the present invention.