Analytical Determination of the Bending Stiffness of a Five-Layer Corrugated Cardboard with Imperfections

Bending stiffness (BS) is one of the two most important mechanical parameters of corrugated board. The second is edge crush resistance (ECT). Both are used in many analytical formulas to assess the load capacity of corrugated cardboard packaging. Therefore, the correct determination of bending stiffness is crucial in the design of corrugated board structures. This paper focuses on the analytical determination of BS based on the known parameters of the constituent papers and the geometry of the corrugated layers. The work analyzes in detail the dependence of the bending stiffness of an asymmetric, five-layer corrugated cardboard on the sample arrangement. A specimen bent so that the layers on the lower wave side are compressed has approximately 10% higher stiffness value. This is due to imperfections, which are particularly important in the case of compression of very thin liners. The study showed that imperfection at the level of a few microns causes noticeable drops in bending stiffness. The method has also been validated by means of experimental data from the literature and simple numerical finite element model (FEM). The obtained compliance of the computational model with the experimental model is very satisfactory. The work also included a critical discussion of the already published data and observations of other scientists in the field.

Influence of the surface characteristics of corrugated cardboard on the quality of inkjet printing

This paper investigates the quality of inkjet printing on corrugated cardboard with various characteristics such as the presence of surface coating, the type of cardboard structure, the corrugated layer profile, and the corrugated cardboard height. The color characteristics of the corrugated board surface of studied samples were analyzed in the CIE Lab system; the value of the discrepancy in the shade of white was established when compared with the reference values of the ISO 12647 standard. During the study, the main criteria for assessing the quality of color reproduction of inkjet imprints were analyzed: an indicator of the general contrast level (K), the value of color differences for the basic tone shades (ΔE), and the volume of the body color coverage (ΔE2). It was found that when printing on various types of corrugated cardboard, there is a general decrease in the overall contrast value. The actual level of color differences is ΔE=10...45 and exceeds the permissible standards for the color reproduction quality. This adversely affects the reproduction of different color tones in the printed image. In general, the quality of color reproduction differs for the test samples of corrugated cardboard in terms of the magnitude of the spread in the values of color distortions on the tone shades. The influence of the main characteristics of the investigated samples of corrugated cardboard on the quality indicators of inkjet printing has been analyzed. In particular, a significant influence of the index of color characteristics of the surface of corrugated cardboard L* and the type of corrugated board structure on the quality of color reproduction has been established. The study results reported here could make it possible to reasonably approach the selection of the corrugated board structure that is optimal in composition, increase the productivity of the technological process for manufacturing containers, and stabilize the quality of printing on corrugated cardboard

Evaluation of Coatings to Improve the Durability and Water-Barrier Properties of Corrugated Cardboard

Recently, corrugated cardboard furniture gained interest from the market, yet is limited to indoor application. With an aim toward outdoor usage, water-barrier improvement of such products must be achieved. In this work, three commercially available coating grades (i.e., polymeric, mineral-filled polymeric, and hybrid silica sol-gel products) were spray-coated on corrugated cardboard using a facile, yet readily transferable, process. The investigation assessed the coating performance from the different drying conditions and natural UV-vis weathering effects, characterising their water absorption, hydrophobicity, coating morphology, and colour change. Results show a reduction in water absorption values (up to −98%) for both the polymeric coatings; instead, the hybrid sol-gel coating showed contact angles up to almost 150°. Generally, the SEM micrographs displayed some surface defects as well as good thickness homogeneity. A perceivable colour change occurred for each sample (CIEDE2000 up to 6.41), mainly occurring in the 0–100 h time range. This work provides promising results for the outdoor application of corrugated cardboard furniture.

Efficient Design of Thin Wall Seating Made of a Single Piece of Heavy-Duty Corrugated Cardboard

Corrugated cardboard has waved cores with small flutes that prevent the use of detailed numerical models of whole structures. Many homogenization methods in the literature overcome this drawback by defining equivalent homogeneous plates with the same mechanical behaviour at a macro-mechanical scale. However, few homogenization works have considered complete structures, focusing mainly on beams or plates. For the first time, this study explores the application of homogenization approaches to larger structures as an aid in their design process. We also considered triple-wall boards rather than single- and double-wall configurations commonly addressed in the literature. To this end, we adapted the homogenization methods proposed by Talbi and Duong to analyze thin-walled stools made of triple-wall corrugated cardboard. Using a progressive design process, we performed an efficient stool design by removing material zones with lower stresses, with 35% less material, 35% lower vertical deflections, and 66% lower stresses than the initial design. Unlike other corrugated cardboard stools, this design comprises just one folded piece instead of three, thus saving storage space. These results demonstrate the utility of homogenization techniques as an aid in the design process of whole structures made of corrugated cardboard. Further research will consider buckling analysis.

Influence of Cardboard Pretreatment on the Determination of Starch Content by the Enzymatic Method

We determined the amount of starch by the enzymatic method in different samples of corrugated cardboard, including the sample produced of primary semi-finished products and corrugated cardboard made of 100 % waste paper. For starch enzymatic degradation, it is necessary to extract it from the corrugated board structure, since the processes of compression and keratinization of pulp fibers reduce the availability of starch for extraction. Enzymatic treatment requires the use of a complex amylolytic preparation for complete hydrolysis of starch to glucose. We were able to determine, respectively, 70 and 84 % of starch obtained from primary semi-finished products by mechanical methods, such as defibrillation in water and degradation in a liquid nitrogen medium, and added at the production stage of corrugated cardboard. It was shown that extraction with alkaline agents was necessary for more complete extraction of starch from corrugated cardboard. The influence of alkaline treatment on the characteristics of fibers of waste paper fractions obtained at the Sukhonsky Cardboard and Paper Mill has been analyzed. The fibers swell in alkali, resulting in an increase in fiber width and its shortening, as well as a decrease in crystallinity, which can be a positive opportunity for more complete starch extraction. Fiber swelling and crystallinity reduction are more intensive for the short fiber fraction compared to the long fiber fraction. When determining starch in corrugated cardboard using the standard method SCAN-P 91:09 SСAN-W 13:09 it was not possible to detect all the starch added at the production stage of corrugated cardboard from primary semi-finished products. Also the processing conditions of this methodology lead to degradation of the partially hydrolyzed starch. The most complete extraction of starch from corrugated cardboard was achieved by two stages of alkaline extraction under the following conditions: 5 % NaOH, temperature of 20 °C, the duration of each extraction – 2 h. Under these processing conditions it was possible to determine all the starch (22.8 kg/t) in the corrugated cardboard produced of primary semi-finished products with known consumption of starch; the starch content in the corrugated cardboard produced of 100 % waste paper was 48.2 kg/t. For citation: Khadyko I.A., Novozhilov E.V., Chukhchin D.G. Influence of Cardboard Pretreatment on the Determination of Starch Content by the Enzymatic Method. Lesnoy Zhurnal [Russian Forestry Journal], 2021, no. 5, pp. 150–162. DOI: 10.37482/0536-1036-2021-5-150-162

New Edge Crush Test Configuration Enhanced with Full-Field Strain Measurements

The standard edge crush test (ECT) allows the determination of the crushing strength of the corrugated cardboard. Unfortunately, this test cannot be used to estimate the compressive stiffness, which is an equally important parameter. This is because any attempt to determine this parameter using current lab equipment quickly ends in a fiasco. The biggest obstacle is obtaining a reliable measurement of displacements and strains in the corrugated cardboard sample. In this paper, we present a method that not only allows for the reliable identification of the stiffness in the loaded direction of orthotropy in the corrugated board sample, but also the full orthotropic material stiffness matrix. The proposed method uses two samples: (a) traditional, cut crosswise to the wave direction of the corrugated core, and (b) cut at an angle of 45°. Additionally, in both cases, an optical system with digital image correlation (DIC) was used to measure the displacements and strains on the outer surfaces of samples. The use of a non-contact measuring system allowed us to avoid using the measurement of displacements from the crosshead, which is burdened with a large error. Apart from the new experimental configuration, the article also proposes a simple algorithm to quickly characterize all sought stiffness parameters. The obtained results are finally compared with the results obtained in the homogenization procedure of the cross-section of the corrugated board. The results were consistent in both cases.

Structural Application of Lightweight Panels Made of Waste Cardboard and Beech Veneer

In recent years, the furniture design trends include ensuring ergonomic standards, development of new environmentally friendly materials, optimised use of natural resources, and sustainably increased conversion of waste into value-added products. The circular economy principles require the reuse, recycling or upcycling of materials. The potential of reusing waste corrugated cardboard to produce new lightweight boards suitable for furniture and interior applications was investigated in this work. Two types of multi-layered panels were manufactured in the laboratory from corrugated cardboard and beech veneer, bonded with urea-formaldehyde (UF) resin. Seven types of end corner joints of the created lightweight furniture panels and three conventional honeycomb panels were tested. Bending moments and stiffness coefficients in the compression test were evaluated. The bending strength values of the joints made of waste cardboard and beech veneer exhibited the required strength for application in furniture constructions or as interior elements. The joints made of multi-layer panels with a thickness of 51 mm, joined by dowels, demonstrated the highest bending strength and stiffness values (33.22 N∙m). The joints made of 21 mm thick multi-layer panels and connected with Confirmat had satisfactory bending strength values (10.53 N∙m) and Minifix had the lowest strength values (6.15 N∙m). The highest stiffness values (327 N∙m/rad) were determined for the 50 mm thick cardboard honeycomb panels connected by plastic corner connector and special screw Varianta, and the lowest values for the joints made of 21 mm thick multi-layer panels connected by Confirmat (40 N∙m/rad) and Minifix (43 N∙m/rad), respectively. The application of waste corrugated cardboard as a structural material for furniture and interiors can be improved by further investigations.

New Edge Crush Test Configuration Enhanced with Full-Field Strain Measurements

The standard edge crush test (ECT) allows to determine the crushing strength of the corrugated cardboard. Unfortunately, this test cannot be used to estimate the compressive stiffness, which is an equally important parameter. It is because, any attempt to determine this parameter using current lab equipment quickly ends in a fiasco. The biggest obstacle is obtaining a reliable measurement of displacements and strains in the corrugated cardboard sample. In this paper, we present a method that not only allows to reliably identify the stiffness in the loaded direction of orthotropy in the corrugated board sample, but also the full orthotropic material stiffness matrix. The proposed method uses two samples: (a) traditional, cut crosswise to the wave direction of the corrugated core, and (b) cut at an angle of 45 degrees. Additionally, in both cases, an optical system with digital image correlation (DIC) is used to measure the displacements and strains on the outer surface of samples. The use of a non-contact measuring system allows to avoid using the measurement of displacements from the crosshead, which is burdened with a large error. Apart from the new experimental configuration, the article also proposes a simple algorithm to quickly characterize all sought stiffness parameters. The obtained results are finally compared with the results obtained in the homogenization procedure of the cross-section of the corrugated board. The results were consistent in both cases.