Application of Pulp Molding in Interior Decoration

The consumption of energy and resources during the construction, use, and demolition of residential buildings, as well as the treatment of solid waste, will result in significant greenhouse gas emissions. Reducing carbon emissions during the construction, use, and demolition processes of residential buildings, and developing low-carbon materials are the contemporary requirements for the development of the building materials industry in a low-carbon society.

The selection of recyclable and easy-to-process green environmental materials is particularly important in today’s increasing focus on sustainable development. Against this backdrop, the research on low-carbon energy-saving pulp molding interior decoration components, which involves the recycling of waste paper and the use of virgin pulp boards to produce pulp without chemical treatment for reshaping, holds unique significance. If decorative panels and sound-insulating materials made from pulp molding products need to be discarded, they can simply be returned to the manufacturer nearby, where they can be processed through conventional methods to produce paper or be remade into pulp molding products.

1. Advantages of Pulp Molding Decorative Components

The high demand for pulp molding products has made the pulp molding industry the third-largest consumer of recycled paper in the world. Currently, pulp molding products in China are mainly used in the product packaging industry. Their application in other fields has not been effectively expanded, especially in interior design, where they have not received sufficient attention. As the application fields of pulp molding products continue to expand, pulp molding technology is bound to be developed and applied in the fields of interior design and furniture design. The advantages of pulp molding decorative components used in interior design are mainly reflected in the following aspects.

1.1 Environmental Protection Advantages of Pulp Molding: Complete Biodegradability - From Nature, Back to Nature

Due to their plant fibers, paper materials are environmentally friendly, low-carbon, energy-saving, and recyclable, which has led to a broader application space in the design field. The raw materials for pulp molding mainly come from waste paper, waste cardboard, as well as inexpensive bagasse, wheat straw, and grass pulp, which are widely available. The research on indoor decorative components made from these materials aligns with the green environmental requirements of “reducing waste, recycling, and circular utilization,” holding high social value. Additionally, compared to materials like stone, pulp molding decorative components are less likely to produce dust during processing and are less prone to cracking due to their strong toughness, thereby reducing material waste. It is evident that pulp molding decorative components have significant advantages in terms of environmental protection.

1.2 Production and Processing Advantages of Pulp Molding: Malleability - Endless Variations at Will

Compared to the use of other decorative components, the production and installation of pulp molding decorative components are more convenient. The process of creating pulp molding decorative components generally follows a sequence of waste paper collection, pulping, purification, sizing, slurry preparation, pressure molding, dewatering, drying, and finally producing indoor decorative components. Whether it’s single-stage molding or subsequent manual or mechanical processing, it is simpler than the processing of other decorative materials.

In contrast to semi-finished wooden decorative components, which have mechanical properties that are “anisotropic,” pulp molding decorative components have consistent mechanical properties in all directions. This makes pulp molding decorative components easier to manipulate during processing and less likely to produce defective products. Therefore, the advantages of pulp molding decorative components in production and processing are also quite evident.

1.3 Performance Advantages of Pulp Molding Components: Affinity - Warm and Smooth as Jade, with a Green Gene

Due to the processing characteristics of pulp molding decorative components, targeted modifications can be made to the material during the manufacturing process. The resulting pulp molding decorative components can be lightweight, strong, durable, moisture-resistant, uniformly dense, isotropic, easy to reprocess, and possess properties such as waterproofing, insect resistance, corrosion resistance, mold resistance, and non-brittleness. Additionally, adjusting the processing techniques can yield components with various shapes and colors.

After special processing, pulp molding interior decorative components have advantages in sound absorption and thermal insulation compared to gypsum, brick, and other decorative materials. They can improve the soundproofing and thermal insulation properties of living spaces to a certain extent. This can reduce energy consumption for heating, cooling, and lighting, achieving a positive energy cycle within the indoor environment.

1.4 Economic Benefits Advantages of Pulp Molding: Full Cycle, Low-Carbon Recycling, Optimal Cost

When comparing the economic and technical aspects of pulp molding decorative components with current market products (such as gypsum board, fiberboard, solid wood products, etc.), it is evident that pulp molding decorative components have the lowest price among decorative components of the same volume. Moreover, product modification can be carried out during the production process, which can save on modification and processing costs.

Additionally, pulp molding decorative components can be produced in bulk, are recyclable, biodegradable, and can be recycled, which facilitates processing, transportation, and recycling. This significantly reduces economic investment, reflecting not only economic benefits but also certain social benefits.

2.Application of Pulp Molding Interior Decorative Components

Currently, the application of pulp molding products in China is concentrated in the packaging and related fields, with less application in interior decorative components. Due to the aforementioned advantages of pulp molding decorative components, these components are increasingly being used in the following three areas of interior design.

2.1 Pulp Molding Furniture and Components

Given that wood, a traditional furniture production material, holds an unshakable position in furniture manufacturing, pulp molding furniture, as a new type of furniture, can be described with the phrase “replacing wood with paper.” Scholars generally believe that the manufacturing process of pulp molding furniture has unique properties and a promising future for development and research. Pulp molding furniture can be roughly divided into two categories: directly molded furniture and assembled furniture made from molded components. Researching pulp molding furniture plays a significant role in meeting consumers’ diverse furniture needs, green design requirements, and achieving furniture standardization without compromising on humanization.

2.2 Pulp Molding Decorative Panels

Pulp molding decorative panels are a type of decorative panel produced by using pulp slurry as the basic raw material, adding appropriate waterproof and fire-resistant additives or colorants as needed, and using molds to create panels with certain shapes and decorative effects through compression molding. The performance and characteristics of pulp molding decorative panels are largely similar to those of pulp molding furniture, with differences mainly arising in the application methods and the process of installation and removal. Pulp molding decorative panels focus more on the combination of structure, shape, and material.

They can be categorized by function into molded decorative cardboard, molded sound-absorbing cardboard, etc. By processing method, they can be divided into molded embossed cardboard, molded carved cardboard, etc.

2.3 Pulp Molding Display Items

Pulp molding displays are often also referred to as “paper plastics.” Pulp molding display items made without colorants are usually in a milky white or gray color. Pulp molding display items play a unique role in interior decoration; they are aesthetically pleasing, lightweight, not easily breakable, and have a low cost. Mr. Ji Shengjiu, acclaimed as the “first person in Chinese paper plastic art,” has created many pulp molding display items in his spare time, and these items can be considered art treasures.

3. Production Process of Pulp Molding Interior Decorative Components

The application of pulp molding decorative components in interior design is still in its initial stage. Academic research on the surface treatment, design principles, and processing methods of pulp molding products is quite rare, and relevant national standards and technical specifications are yet to be established.

3.1 Principle of Shaping for Pulp Molding Decorative Components

The shaping process of pulp molding products involves the pulp slurry beginning to dehydrate and adhere to the surface of the mold until the tissue structure of the paper mold is set. At this point, the fiber organization morphology, the directionality of fiber arrangement, and the fiber distribution are all established and will not significantly change during the subsequent dehydration process. When the moisture content of the paper mold is around 75%, the mobility of the fibers in the paper mold essentially disappears, meaning the positions and arrangement of the fibers within the mold are largely no longer subject to change. When dehydrated to a moisture content of about 65%, the physical dehydration process is basically complete, forming a wet embryo, which is then dried and set into shape.

3.2 Laboratory Mold Design Requirements

Based on the principle of shaping, we can understand that the quality of the mold design directly affects the quality of the pulp molding decorative components. Therefore, during mold design, it is essential to consider various factors as much as possible, such as improving the precision of the mold, considering the functional requirements of the parts, and considering the requirements for mass production. With the advancement of technology, mold design is increasingly being completed with the aid of computer-aided design.

3.3 Key Production Techniques

The production of pulp molding decorative components generally follows this process: collection and sorting of waste paper → hydraulic pulping → pulp purification → ingredient mixing (including gluing based on functional requirements) → pulp preparation → pressure molding → dehydration → drying → indoor decorative components. This process is typically carried out using common molding methods, precision molding methods, compressed air forming, or pressure drying techniques to shape the pulp.

Common methods for the drying process of pulp molding indoor decorative components include: natural air drying, heat drying, microwave drying, and kiln drying.

During processing, attention must be paid to the waterproof and moisture-proof treatment of the pulp molding decorative components, as well as their surface decorative qualities, load-bearing capabilities, environmental friendliness, functionality, and aesthetic appeal.

4. Trends in Pulp Molding Decorative Components

The application of pulp molding decorative components is extensive, ranging from various forms of furniture products to indoor decorative panels and interior display items, all of which can be produced using pulp molding techniques. As the technology continues to advance, pulp molding decorative components are increasingly becoming a part of everyday life for the general public. In the future, a variety of pulp molding products such as furniture, door panels, partition boards, ribbed lining panels, corner guards, sound-absorbing wall panels, decorative trims, decorative panels, and embossed panels will be produced in a mass, factory-based, and customized manner.

5. Conclusion

The application and promotion of pulp molding interior decorative components align with the concepts of sustainable development and environmental protection. They possess advantages such as social significance, economy, artistry, non-pollution, and simple craftsmanship. In the future, they are certain to play a role in protecting the natural environment and improving living conditions.