Method and system for forming domed paper and structures
A method and system for forming domes or protruded structures in a flat material such as paper is disclosed. The method includes cutting one or more sheets; applying an adhesive between the one or more sheets, joining the one or more sheets together in a registered manner to form a substrate, and pressing the adhesive under pressure to shape the substrate into a desired shape may include the domes or protruded structures.
1 . A method for forming domes or protruded structures in a flat material such as paper comprising:
cutting one or more sheets;
applying an adhesive between the one or more sheets;
joining the one or more sheets together in a registered manner to form a substrate; and
pressing the adhesive under pressure to shape the substrate into a desired shape comprising the domes or protruded structures,
wherein the pressing is performed after a duration greater than a curing time in ambient conditions of the adhesive has elapsed since the applying of the adhesive.
2 . The method of claim 1 further comprising winding and rolling one or more of the sheets together.
3 . The method of claim 1 wherein each of the one or more sheets is less than 0.01″ in thickness.
4 . The method of claim 1 wherein each of the one or more sheets comprises Kraft paper.
5 . The method of claim 1 wherein the adhesive is activated prior to the pressing by applying one or more of a polar solvent, a non-polar solvent, a UV light exposure, heat, or pressure.
6 . The method of claim 1 , wherein the pressing heats the substrate when the substrate is under pressure.
7 . The method of claim 1 wherein the applying applies the adhesive in a selective area of the one or more sheets, and the pressing presses the substrate in the selective area.
8 . The method of claim 1 wherein, after the pressing, the substrate is used to package an item to be shipped.
9 . The method of claim 1 wherein the desired shape comprises a shape of a phone or a computer.
10 . The method of claim 1 wherein the adhesive comprises a starch.
11 . The method of claim 1 wherein the adhesive has a viscosity between 1000-2000 centipoise (cp).
12 . The method of claim 1 wherein the adhesive has a viscosity greater than 2000 cp.
13 . The method of claim 1 further comprising applying an ancillary structural component to form an attached structure.
14 . The method of claim 13 wherein the attached structure comprises an envelope.
15 . The method of claim 13 wherein the ancillary structural component comprises one or more of a snap, an adhesive pull strip, a tag, a grommet, a hook and loop, a handle, or a valving.
16 . The method of claim 1 wherein the cutting comprises partially cutting one of the one or more sheets.
17 . The method of claim 1 wherein the cutting cuts one of the one or more sheets less than 50%, less than 75% or less than 100% of a thickness of the one of the one or more sheets.
18 . The method of claim 1 further comprising forming registration marks on one of the one or more sheets in synchronicity with a location of the cutting by one or more of printing, burning, cutting, or pressing.
19 . A method for forming domes or protruded structures in a flat material such as paper comprising:
cutting one or more sheets;
applying an adhesive between the one or more sheets;
joining the one or more sheets together in a registered manner to form a substrate;
pressing the adhesive under pressure to shape the substrate into a desired shape comprising the domes or protruded structures; and
encapsulating the one or more sheets in a container to prevent curing of the adhesive, wherein the pressing is performed remote from the encapsulating.