Potential materials for my design (why I chose them)

Why Is Cardboard Strong?

 Cardboard is a kind of paper, but it can be almost as strong as wood in some cases. The main reason why cardboard is strong is in the composition, construction and testing of all cardboard. All of these elements combined help to form some of the strongest paper in the world.

1. Cardboard Composition

   • Modern cardboard is usually made up of kraft paper. Kraft paper was invented by the Swedish chemist Carl F. Dahl in 1884. He found that pulping wood chips and converting them into a thick paper created a material that was hard to tear and damage. Since then, most all cardboard is made from three layers of this kraft paper, with two flat layers and a corrugated layer between them. Some cardboard is made of just one thick layer (such as in cigar boxes), but it is not as widely used.

   Construction Process

   • The kraft paper is made by pulping the wood, which is created by taking wood chips and extracting the cellulose from the wood with chemical sulfate. The pulp is then pressed into thick sheets of paper and allowed to dry. The paper is transferred to a cardboard making factory, where some of the paper is crimped to make the center of the cardboard, and the other layers of cardboard are glued on either side of the corrugated layer. Different plants make different strengths of cardboard. This multilayer function of cardboard makes it much stronger than paper alone. The crimps in the paper make it better able to withstand the weight and pressure of heavier objects.

   Cardboard Testing

   • As it is being made, cardboard withstands several tests. The Cobb test determines how much moisture the cardboard contains. Wrap tests are given to find out how well the cardboard can get formed into a box. Corrugated cardboard is also tested to find out the strength of the bond and glue between the layers of cardboard. All of this testing helps create cardboard that is almost as strong as wood.
     Cardboard made into a box is put through a few more tests. The edge crush test is a test applied to the corners of cardboard boxes. This measures the strength of the box's corners, identifying how much weight can be stacked on the box. Another common test performed on cardboard boxes is the burst test. This test measures how many pounds of weight a box can hold before the bottom of the box bursts.

   Cardboard Strength

   • Cardboard commonly comes in different strengths. Cardboard strength is measured with glue tests, bursting tests and compression tests. These measurements are recorded and the cardboard is assigned different grades depending on the score it receives. A common strength indicator looks like this: 125K/B/125T. The first number is the weight that the cardboard can withstand before it is crushed. The letter stands for the kind of corrugation between the two layers of cardboard. Common letters include E, less than 1/10-inch thick; B, less than 1/8 inch; C, about 1/6th inch; and BC, about 1/5 inch thick. The last number stands for how much weight the second layer of cardboard can hold, and the final letter stands for the kind of paper used. K stands for kraft, one of the most commonly used types of paper.

   Choosing Cardboard

   • When choosing cardboard always look for the highest number listed on the packaging. Higher numbers indicate higher strengths and grades. The higher grade numbers on cardboard indicate that the cardboard is suitable for uses where greater strength is required. When choosing cardboard boxes, look for the Box Manufacturer's Certificate (BMC) on the bottom of cardboard boxes. The certificate states that the box has passed all requirements and tests given to cardboard.

http://www.ehow.com/about_6306347_cardboard-strong_.html

 

 

Cardboard Box Types or Classes

1. Corrugated

   • Three types of corrugated cardboard are single-wall, double-wall and triple-wall. Single-wall consists of two flat outer sheets of cardboard with one sheet of fluted cardboard between. Double-wall adds one additional flat sheet and one fluted sheet, creating a five-layer cardboard. Triple-layer adds one flat sheet and one fluted middle sheet onto the double-wall construction, resulting in seven layers. The most common form of corrugated cardboard as of 2011 is single-wall, which holds up to 350 lbs. Double-wall holds up to 500 lbs., and triple-wall holds in excess of 500 lbs.

   Food Grade

   • Food-grade cardboard boxes must meet federal regulation guidelines established by the Food and Drug Administration (FDA). Food grade cardboard cannot contain or come into contact with chemicals, toxic materials or food additives that may cause human harm. The FDA defines food additive as "any substance the intended use of which results or may reasonably be expected to result, directly or indirectly, in its becoming a component or otherwise affecting the characteristics of any food (including any substance intended for use in packing, packaging or holding food)."

   Non-Food Grade

   • "Non-food-grade" is the generic term used to describe all cardboard boxes not approved for use with food. Types of non-food-grade cardboard boxes include crafting, packing and shipping boxes.

   Recycled

   • Dry cardboard boxes free from grease and other food stains are recycled into paper, paperboard and new cardboard boxes. Companies label recycled cardboard boxes based on the percentage of old cardboard used in the production process. For instance, companies using post-consumer cardboard used to manufacture new cardboard boxes list the percentage of post-consumer material. The label reads, "Recycled from 50 percent post-consumer waste."

http://www.ehow.com/info_8527110_cardboard-box-types-classes.html

Types of Cardboard Boxes

Consumers may take boxes for granted but product manufacturers and retailers don’t. The box a product comes in identifies a brand, represents the company, and presents an image to rival competitors. Packaging designers spend hours to select the right photograph, write copy, and present pricing information to compel the consumer to put the box in her shopping cart. Even the boxes we use when moving are selected to carefully house our personal belongings. Companies are also increasingly offering boxes made of recycled materials in an effort to protect the environment and satisfy desires to go “green.”

Shipping

• Shipping boxes are typically made of unprinted brown corrugated cardboard. They vary in size and durability. Shipping boxes are used by consumers to send packages through delivery services like United Parcel Service and the United States Postal Service. Package delivery companies also have shipping boxes in various rectangular and tube shapes manufactured and printed with their logos to sell to customers for sending items ranging from documents to household items.

Packing and Moving

• Companies in the moving and storage business have cardboard boxes manufactured to sell to customers. The cardboard boxes they use are constructed from heavyweight cardboard. The boxes are used to pack household goods like dishes, lamps and decorative items. Large-size boxes are made to pack clothing and have a metal rod that can be inserted so that packers can keep clothes on hangers. A packing box also includes an area on the side to list the contents inside and route the box to the proper room.

Gift

• Gift boxes are sold in greeting card stores, gift and stationery stores, discount stores, and a variety of other retail outlets. Department stores have customized gift boxes imprinted with their logo. Perhaps one of the most famous gift boxes of all is that of Tiffany, the prestigious jewelry store. The shade of blue used on the box is so recognizable that people even refer to it as “Tiffany Blue.”

Customized Product Packaging Boxes

• Manufacturers create customized cardboard boxes to contain their products. For example, electronics manufacturers develop product-specific boxes, printed in full color with attractive photographs of the products contained inside. They also print important information for shoppers including product features, the model number, the size of the item, itemized box contents, and brief operating instructions. Shoppers can use the photographs and descriptions on the box to make sure that they are purchasing the right item, by comparing what’s described on the box to the actual product on the store shelf.

Retail Display Boxes

• Display boxes are used by companies to hold merchandise. They are often seen inside of grocery, drug, and other retail stores. They are referred to as “set-up” boxes. They are shipped flat, with printed instructions on how to set the box up. Once completed, they are ready to hold products. Some set-up display boxes even hold shelves made of cardboard or lightweight plastic so that merchandise can be attractively displayed. Display boxes might also include holes for retail merchandisers to include signage, pricing, posters and other sales promotion information.
  
  http://www.ehow.com/list_6722092_types-cardboard-boxes.html
  
  

  Cardboard Box Ideas

   Cardboard boxes are a great source for craft supplies. After using a cardboard box for packaging items, save it for fun children projects and even for home storage ideas. With a few supplies and tools there are several ways to make great cardboard box ideas.

   

  1. Lacing and Braiding Board

     • This is a fun project for young children. Cut the cardboard box into 8-inch squares or other sizes and shapes, then punch holes to thread yarn through. The holes can be punched in a variety of patterns and for a variety of purposes, such as two vertical rows of evenly spaced holes to teach shoe lacing, or several holes punched around the perimeter to teach braiding. Simply use colorful yarn to thread through the holes for many hours of fun and motor skill development.

     Wall Décor

     • Cardboard boxes make a very durable solution for fabric-covered wall art. Cut the cardboard to the desired width and length. Cut out as many pieces as you need for your wall design. Use coordinating decorating fabric with either solid colors or vibrant patterns that accentuate your room's style. You may even want to embellish this artwork further with images, lettering or accents, or batting to give the artwork more dimension.
       Lay your cardboard piece onto the fabric and cut the fabric, leaving enough around the edges to fold over to the back. Secure with strong tape to the back of the cardboard, then use paper to cover and tape into place over the fabric edges. Attach picture hanging hooks to the back of your artwork and hang on the wall.

     Storage Boxes

     • Cover cardboard boxes

       Cardboard boxes provide an easy base for storage solutions. If you have a few coordinating boxes, consider making a set.
       Paint the inside and outside of the boxes with colors that will go with your style. Use acrylic paint or regular latex paints to cover all of the surfaces. You may have to add a second coat for a uniform look. The paint will also seal the cardboard, making it last longer. Use your painted box set for your home office, to store toys or even to store clothes or other household items.
       Another option is to use fabric to cover your boxes. Measure the perimeter of your box, then measure the height of your box with the flaps folded into the box. Double the height measurement so that the fabric can fold over and into the box for a neater appearance. Cut the fabric, leaving a little extra for the seam, and sew a narrow hem at the top and bottom edges. Next, stitch the side of the fabric closed, then slip over the box, folding the fabric into the box. You may want to line the bottom of the box before use.

     Playhouse

     • Very large boxes, the size that fits lawn mowers and refrigerators, make very nice playhouses for children. Children can help decorate the walls to mimic a house or a store. If you have several large boxes, the children can even make a mini town for hours of fun.

  
  

  http://www.ehow.com/way_5184454_cardboard-box-ideas.html

  
  

  
  

  Corrugated Cardboard Types

  It is very important to know the type of cardboard that you will require when ordering your boxes. There are two factors to consider when choosing the type of cardboard – the flute and the wall construction.

  Flutes

  When dealing with differing types and styles of cardboard, we often refer to its flute, or flutes. What is a flute? Well, it simply means the type of corrugation that is sandwiched between the two outer layers of cardboard. The larger the flute, the stronger the box. Below is a small break down of the three types of flute that we offer at Instabox and their respective strengths and weaknesses.

  

  “C” Flute Thickness = 11 / 64″ Flutes per foot = 41 “C” flute cardboard has a very high stacking strength and a higher resistance to being crushed. It is one of the most commonly used flutes for shipping boxes and tends to perform the best when holding materials such as glass, furniture and food products.

  “B” Flute Thickness = 1 / 8″ Flutes per foot = 49 “B” Flute cardboard is the perfect combination of strength and style. It has a higher resistance to punctures than the other flutes and usually consumes less space than the regular “C” Flute. It is most often used for boxes that have to be durable but also need to have some style. Generally used for stand up displays or ballot boxes.

  “E” Flute Thickness = 1 / 16″ Flutes per foot = 95 “E” Flute is the most lightweight of all the types of corrugated cardboard we carry. It is a stronger alternative to paperboard and performs great when used for die cut designs. “E” Flute has a superior printing surface and works best when used as software packaging or point of purchase boxes.

  Cardboard Wall Construction

  Although most people think that cardboard boxes have only one type of structure there are actually two different styles of wall structure that we offer to our customers. Depending on which characteristics and qualities you would like to have in your box, you can choose from single or double wall structure.

  

  Single Wall Corrugated Cardboard This is the most popular corrugation material used in the boxes we manufacture, it consists of only one layer of whichever type of flute you pick. It is available in a wide range of board strengths, from 23 ECT right throough to 44 ECT. Generally, depending on what type of flute you have chosen, this type of wall structure is not the best choice for shipping heavy objects.

  

  Double Wall Corrugated Cardboard This wall structure is made of one layer of “B” Flute and one layer of “C” Flute. Stronger than a single wall structure, double wall enables heavier objects to be shipped and should be used when a stronger box or extra padding is needed. Double wall is available in 48 ECT to 71 ECT and is excellent for stacking heavier items.

  
  

  
  

  http://www.instabox.com/boxes/box-guide/corrugated-materials/

  Corrugated Card Advantages

  1. • Corrugated card offers a number of advantages. angled corrugated cardboard image by leafy from Fotolia.com

       Corrugated card (or corrugated cardboard) has a number of different advantages over other materials. This is especially true when corrugated card is being compared to other types of paper material used for storage (such as multi-layer paper or thin plastic), since corrugated card is most commonly used for making boxes.

     Recyclable

     • In this age of green materials and concerns about the environment, corrugated cardboard offers a major advantage in that it's completely recyclable. Made out of paper (which may also be recycled) corrugated card can be made even more ecologically friendly if it's made without any bleaches or dyes so that the color remains natural. Of course, corrugated card can be used again and again because it can be remade time and again, and from a variety of different kinds of paper pulp.

     Strength

     • Corrugated card is also quite strong. This strength comes from the arch that's in the middle of the layers of corrugated card. There are three layers of paper, and the middle layer looks a lot like a sine wave. This arched shape, which is so often used in other types of construction like bridges or doorways, lends a great deal of support to corrugated card. This means that it can hold a great deal more than it would be able to if it was made of just three, flat layers.

     Shaping

     • Corrugated card can be easily joined with a variety of different adhesives and fasteners. Staples are difficult to put through corrugated card (unless they're industrial staples), but glue can easily bind corrugated card together. Additionally, corrugated card can be cut fairly easily, even if it stands up to pressure well from all six principle directions. The ease with which corrugated card can be bound together is a major advantage because it means that a variety of shapes and structures can be made out of this simple material.

  
  

  http://www.ehow.com/list_6547670_corrugated-card-advantages.html

  
  

  Corrugated Board: Advantages & Disadvantages

  
  

  
  

  

  Corrugated board is a multiuse product also known as cardboard.

  Corrugated board is a common but often overlooked material with several uses. Also called cardboard, the material is found in individual and commercial settings. However, this very versatile board is not without its faults. For example, water destroys corrugated board. As with any other multiuse material, corrugated board has its advantages and disadvantages.

  
  

  1. Flexibility

     • Corrugated board can be cut, folded, glued, stapled and taped to assume a number of different shapes and sizes. One sheet can be shaped to hold large or small items. The flexibility does come at a price, however. The points where the cuts are made into the corrugated board are weak spots prone to breakage under heavy pressure. The flexible material can only make polygon shapes with few curves. It does not conform easily to the size of many products, requiring the need for packing materials prior to shipping.

     Composition

     • According to I. Waterman Box Makers Ltd., corrugated board is composed of paper made from cellulose. Glue is used to connect a ridged piece of corrugated board between two straight pieces. The composition creates the strength the corrugated board containers are known for. Despite the strength in composition, corrugated board is still made from paper, which is easily destroyed by liquids. Any liquid shipped in corrugated board without support and proper sealing can create a mess during shipping.

     Uses

     • The board is used primarily in shipment of goods. However, corrugated board is used in everything from display boards to bracing for picture frames. Corrugated board can be found in cheap furniture as well. Although it is used in a number of ways, the corrugated board is limited in the amount of weight that the containers made from the material can handle. This is especially true for containers that come specially made, using multiple pieces and lots of glue and/or tape. The material cannot transport liquids and hazardous chemicals without stringent approval.

     Recycling Corrugated Board

     • Corrugated board is biodegradable and often contains recycled paper. It can also be recycled. However, problems arise when trying to store corrugated board for recycling. Many companies incur additional costs and individuals end up using space within the home or forgoing recycling altogether. Recycling the board can be seen as less than convenient. Corrugated board is no longer recyclable when it has been laminated, and some recycling centers require metal parts, such as staples, to be removed before they will accept corrugated board.

  
  

  
  

  http://www.ehow.com/info_8568047_corrugated-board-advantages-disadvantages.html

  
  

  Liquid packaging board

  Liquid packaging board is a multi-ply paperboard with high stiffness, strong wet sizing and a high barrier coating. Only virgin paper fibers are used. The barrier coating must hold the liquid and prevent migration of air and flavors through the paperboard.

  A liquid packaging board might be up to five plies and is formed on a multi-ply paper machine with online coating. The most common is to use three plies with a basis weight of about 300 g/m².^[2] The base or middle ply is normally made of pulp from bleached or unbleached chemical pulp, CTMP or broke (waste paper from a paper machine). CTMP gives more bulk and stiffness. The top ply (inside) is made of bleached chemical pulp. The barrier coating depend of the application and might be applied on both sides. The back side of the board is the printing side and might have an extra ply made from chemical pulp of quality that is suitable for the printing applications. Liquid packages are normally heat sealed.
  Cartons filled with short shelf life diary products use board that are barrier coated on both sides with one layer of low density polyethylene. For long shelf life products is is common to use aluminium foil as barrier coating together with polyethylene. Commonly the plastic coating on the top side is 12 - 20 g/m² and on the reverse side 15 - 60 g/m².^[2]
  Liquid packaging board are used for two package types: brick and gable top cartons.

  Packaging for beverages. The most common applications are milk and juicebox packaging.

  
  

  I also found a company that is designing with this type of material and is giving a lot of information about how and for what it can be used. It also talks about sustainability. More details on their website.

  http://www.weyerhaeuser.com/Businesses/LiquidPackaging