MANUFACTURING METHOD FOR WASTEPAPER SHOCK ABSORBING MATERIALS USING VACUUM FORMING PRINCIPLE AND WASTEPAPER SHOCK ABSORBING MATERIALS USING THE METHOD

Abstract

A method for manufacturing shock absorbing materials using wastepaper using vacuum forming principle and wastepaper shock absorbing materials using the method are disclosed, wherein the method comprises: disintegrating wastepaper selected from at least one or more of Korea Old Corrugated Container (KOCC), Korea Old Newspaper (KONP) and milk carton, using a blender; diluting the disintegrated wastepaper to manufacture pulp suspension; mixing the pulp suspension with cationic starch; vacuum-dehydrating the pulp cationic starch mixed with the pulp suspension to a dual direction using a vacuum forming capable of dual vacuuming to manufacture a shock absorbing material; drying the shock absorbing material; and performing a surface sizing process on a surface of the dried shock absorbing material, such that a shock absorbing material having a remarkably low elastic modulus and density can be effectively manufactured without recourse to the conventional press performed by a press plate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a photograph illustrating an egg case made by a pulp mold according to prior art.

FIG. 2 is a cross-sectional view illustrating a pulp mold manufacturing apparatus according to the prior art.

FIG. 3 shows a perspective view and an inner structural view of a pulp mold according to the prior art.

FIG. 4 is a flowchart illustrating a manufacturing method of wastepaper shock absorbing materials using a vacuum forming principle according to one embodiment of the present invention.

FIG. 5 is a mimetic diagram illustrating KOCC, KONP used as wastepaper and wastepaper fibers of milk carton, and dry-disintegrated states thereof.

FIG. 6 is a cross-sectional view illustrating a vacuum former operated by a vacuum dehydrating principle to a dual direction according to the present invention.

FIG. 7 shows a perspective view of wastepaper shock absorbing material and an inner structural view thereof according to the present invention.

FIG. 8 is a mimetic diagram illustrating a cubic change between pulp suspension used for the present invention and a wastepaper shock absorbing material following the vacuum forming process according to the present invention.

FIG. 9 is a front view of a vacuum former capable of dual vacuuming according to the embodiment of the present invention.

FIG. 10 shows lateral view of the vacuum former of FIG. 9.

FIG. 11 is a perspective view illustrating a rectangular shock absorbing material forming box of a vacuum former and a circular forming tube of a circular former in FIG. 9.

FIGS. 12 a and 12b are photographs illustrating a dyed thin specimen of a shock absorbing material and a thin specimen binary-processed according to the present invention.

FIG. 13 is a cross-sectional photograph of a pulp mold according to the prior art and a shock absorbing material according to the present invention.

FIG. 14 is a mimetic diagram and photograph illustrating a pulp mold according to the prior art and a state of a shock absorbing material applied with an external force, the force being absorbed and removed according to the present invention.

FIG. 15 is a graph illustrating changes in density in relation to suction time of shock absorbing materials according to the present invention.

FIG. 16 is a photograph (×1000) of an electron microscope illustrating interfiber bonds by microfibrils comprising a shock absorbing material according to the present invention.

FIG. 17 is a graph illustrating changes in elastic modulus in shock absorbing materials in relation to suction time of a vacuum former according to the present invention.

FIGS. 18 a and 18b are graphs illustrating changes of apparent density in shock absorbing materials in relation to mixed rates of milk cartons and suction time according to the present invention.

FIGS. 19 a and 19b are graphs illustrating changes of elastic modulus in shock absorbing materials in relation to mixed rates of milk cartons and suction time of a vacuum former according to the present invention.

FIGS. 20 a and 20b are graphs illustrating changes of apparent density in shock absorbing materials in response to addition ratio of cationic starch and recycling of the shock absorbing materials according to the present invention.

FIGS. 21 a and 21b are graphs illustrating changes of elastic modulus in shock absorbing materials in response to addition ratio of cationic starch and recycling frequency of the shock absorbing materials in relation to KOCC and KONP.

FIGS. 22 a and 22b are surface photographs of shock absorbing materials manufactured in KOCC and KONP according to the present invention.

FIGS. 23 a and 23b are cross-sectional photographs (×40) of shock absorbing materials according to the present invention.

FIG. 24 is a graph illustrating changes of porosity in shock absorbing materials in relation to addition ratio of starch according to the present invention.

FIGS. 25 a, 25 b and 25c are cross-sectional photographs (×40) of a pulp mold and shock absorbing materials manufactured of KOCC and KONP according to the present invention.

FIG. 26 is a graph illustrating changes of moisture contents in shock absorbing materials in relation to suction time according to the present invention.

FIG. 27 is a graph illustrating changes of moisture contents in shock absorbing materials in relation to recycling frequency of wastepaper according to the present invention.

Claims

1. A method for manufacturing a wastepaper shock absorbing material using a vacuum forming principle comprising the steps of: disintegrating wastepaper selected from at least one or more of Korea Old Corrugated Containers (KOCC), Korea Old Newspaper (KONP) and milk cartons, using a blender; diluting the disintegrated wastepaper to manufacture a pulp suspension; mixing the pulp suspension with cationic starch; vacuum-dehydrating the pulp suspension mixed with the cationic starch to a dual direction using a vacuum former capable of dual vacuuming to manufacture a shock absorbing material; drying the shock absorbing material; and performing a surface sizing process on a surface of the dried shock absorbing material.

2. The method as defined in claim 1, wherein the cationic starch is the one gelatinized within a temperature range of 80° C. to 85° C. and diluted by 1%.

3. The method as defined in claim 1, wherein the vacuum former comprises a rectangular shock absorbing material forming box, a circular shock absorbing material forming tube, a vacuum pump for drainage, a control box and a drainage apparatus.

4. The method as defined in claim 1, wherein the vacuum dehydration is performed within a time frame of 10 to 60 seconds.

5. The method as defined in claim 1, wherein the wastepaper is added by milk carton specimen within a scope of 20% to 80%.

6. The method as defined in claim 1, wherein the cationic starch is added to or mixed with the wastepaper within 4% to 5% of a total dry weight of the wastepaper.

7. The method as defined in claim 1, wherein the KOCC or KONP is recycled one or more times.

8. A wastepaper shock absorbing material manufactured by the method for manufacturing a wastepaper shock absorbing material using a vacuum forming principle of any one claim 1-4, wherein the wastepaper shock absorbing material is the one having an elastic modulus in the range of 150 kPa to 700 kPa, a density in the range of 0.12 g/cm3 to 0.17 g/cm3.