Lesson video

Hello, thank you for joining me for your design and technology lesson.

My name is Mrs. Conway, and I will be guiding you through your learning today.

So today's lesson outcome is, "I can explain how paper and board material properties can be enhanced." And these are our keywords.

We have properties, combine, modify, reinforce, and structural integrity.

I'll go through these as we work through the lesson.

So the first thing we're going to look at then is the combining of materials.

So materials don't always have the perfect properties for the job that we want them to do.

Sometimes they're too weak, too flexible, not hard-wearing enough, or simply just can't handle heat or moisture, for example.

So by enhancing material properties, we can make products stronger and last longer.

We can also improve their safety and their performance, and also allow for innovation in design and function.

Now, properties are words to describe how a material appears, whether that be physical or characteristic, or behaves when worked, whether again that be working or mechanical.

So there are three ways that a materials properties can be enhanced.

Combining, which is joining together, modifying, which is changing, and reinforcing, which is making stronger.

Okay, which three methods are used to enhance material properties? Is it A, compare model and reinforce, B, combine manufacture and repeat, C, combine, modify, and reinforce, or D, compare, modify, and reuse? Feel free just to pause the video, take a moment to think about your answer.

And the correct answer then, it was C.

So the three methods that are used to enhance material properties are combine, modify, and reinforce.

Well done if you got that right.

So composites are materials that are made by combining.

Now you need a matrix and also reinforcement.

A matrix is a binder and the reinforcement is used for strength.

So combining these two things, we can make a composite, and that creates a material with improved overall properties.

So, for example, a composite is a little bit like a chocolate chip cookie.

The dough is the matrix, that's the binder, and the chips are the reinforcement.

They're the added strength.

Another example to shift to give you there, it can also be a bit like a lava or a layer cake, where the reinforcement is either encapsulated, a bit like in a lava cake, or layered through the matrix, a bit like a layer cake.

Now these images show a plant pot that is paper-based, and the matrix is eco-friendly glue and the reinforcement are the paper fibres.

Now this results in a biodegradable but really sturdy material that can hold its shape really well.

Okay, quick check for understanding then.

In a composite material, what is the role of the reinforcement? Is it A, to hold the structure together, B, to give strength or other useful properties, C, to act as a decorative layer, or D, to make the material more flexible? Pause the video here, just take a moment to think about your answer.

And the correct answer then, it was B.

So in a composite material, the reinforcement, works to give strength for other useful properties.

Again, well done if you got that right.

Other examples of blended matrix reinforcement composites include paper mache.

Now, paper mache combines paper fibres, which are the reinforcement, with diluted glue, which is the matrix, and it's used for lightweight structures such as the costume masks that you can see there, and also pinatas.

Cotton paper is another example, and that's made from wood cotton fibres, which, again, is the reinforcement, combined with adhesive, which is the matrix, and it's used for painting on with watercolours to minimise bleeding.

Now, composite materials can have the matrix and the reinforcement laminated, which is meaning layered together, or encapsulated, which is a bit like the example of the lava cake.

It basically means it's enclosed.

Now, foil-lined cardboard is used widely for hot food containers, and both layer materials insulate the foil and that enhances the protection against leakage.

Board games are usually made from greyboard, paper, and a thin polymer layer, and those are laminated together.

So they're layered.

And you know may know this process as lamination in the picture that I'm just showing you there, it's actually encapsulation.

So even though we call it lamination or laminating something, actually what we're doing is encapsulating it.

The polymer pouch encloses the paper and the card within it.

Okay, another quick check for understanding then.

Which property is improved by using foil-lined cardboard for pizza boxes instead of corrugated cardboard? Is it A, moisture resistance, B, aesthetics, C, waterproofing, or D, thermal insulation? Pause the video here, just take a moment to think about your answer.

And the correct answer, it was two different elements then.

So we have moisture resistance as well as insulation.

Again, well done if you got that right.

The word, ply, means layer.

And you may have heard the word, ply, before.

Products such as toilet paper and napkins are made up of multiple thin layers or plies.

You may have also heard the word, ply, when we are using the word, plywood, as well, which is a manufactured board.

Now those layers or plies for things like toilet paper and napkins are bonded together to improve the strength, the softness, and the absorbency of those products.

Now, of course, the more plies toilet paper has, the more expensive it is.

And you may have heard the word, ply, being used in maybe an advert for toilet paper or even maybe on the packaging to explain how many plies it actually has, or how many layers that toilet roll is made up out of.

Okay, it's over to you now to complete some tasks.

You've got three tasks to do.

The first one is I'd like you to explain what a paper or board-based composite is, referring to the terms matrix and reinforcement in your answer.

So matrix and reinforcement are your keywords there, your key vocabulary that you do wanna make sure are in that answer.

The second task I'd like you to do then is to describe two benefits of using composite materials.

I'd like you to use examples in that answer.

And lastly then, I'd like you to answer this question, what is the difference between laminating and encapsulating paper? Now, use labelled diagrams to support your answer.

Okay, it's gonna be over to you then, so good luck with this task.

Pause the video here to have a go.

Okay, hope you got an okay.

We'll look at some example answers then for each of these tasks.

The first one was explain what a paper or board-based composite is, referring to the terms, matrix and reinforcement, in your answer.

So an example answer to this then, "A paper or board-based composite is made by combining two or more materials to improve its properties.

The matrix is the main material that holds everything together, such as an adhesive.

The reinforcement is added to give extra strength or function like paper fibres." Just compare your answer to the example that I've given you there.

Do you think you've included enough details? Have you made sure that you've included those terms of matrix and reinforcement in your answer? The second question then was to describe two benefits of using paper or board-based composite materials.

And I wanted you to use examples in your answer.

Again, I'm just gonna go through an example answer for you for you to compare your answer to.

So one benefit of paper-based composites is that they can be made stronger and more rigid by combining materials.

So, for example, paper mache uses laser paper, reinforcement, and diluted glue, the matrix, to create a tough, moldable surface suitable for model making.

Another benefit is that composites can protect paper from damage.

So, for example, encapsulated paper is sealed between two layers of polymer, which makes it waterproof and tear-resistant, ideal for menus or signage used in public places.

Again, just compare your answer to that one.

Have you described the benefits in enough detail and have you remembered to use examples in your answer as well? And the last task then, what is the difference between laminating and encapsulating paper? And I ask you to use labelled diagrams to support your answer.

Again, if we just look at an example for you to compare yours to then.

So laminating covers just one or both flat surfaces of the paper with a thin polymer layer, leaving the edges exposed.

Now this improves durability and water resistance, but the edges can still get damaged.

And I've used a diagram there just to kind of explain that.

Encapsulating, however, completely seals the paper inside two polymer layers, including the edges, offering full protection from water and tearing.

And again, there's little diagram to help explain that.

So again, just compare your answer to the one given.

So next then, we're going to look at modifying materials.

Now, modifying a material means changing its structure or its composition, and that is what it is made from, to improve how it performs. And the changes usually take place at a molecular level, and they include things such as additives, heat treatments, and chemical treatments.

Now papers and boards can have additives mixed with paper pulp during production, and pigments can be added to give different colour.

Brighteners are another example of additives as well.

So brighteners can be added to copy paper to improve its opacity.

Now, coatings can prove the surface properties of papers, making it suitable for specific applications.

So an example of a coating would be that printed photographs can have different coatings to give a gloss or a matte finish to them.

Baking paper is another example.

And our baking paper is coated with silicon to provide a non-stick coating.

So that's another example of a coating to improve a surface property.

Quick check for understanding on that then.

What is the purpose of adding silicon to paper? Is it A, to make it heat proof, B, to change its colour, C, to make it crease-resistant, or D, to make it non-stick? Think about the purpose of this in the example that I just showed you.

Okay, pause the video here just to take a moment to think about your answer.

And the correct answer then was to make it non-stick.

So silicon is added to things such as baking paper to make it non-stick.

Now, heat treatment is another way that we can modify materials, and heat treatment is used to alter molecular structure of papers and boards to change their properties.

And this can change the strength and also the rigidity of that material.

Now a common method to heat treat paper is calendering.

Now paper and board are strengthened by passing them through heated rollers, and this is calendering, and where the heat softens the fibres and the pressure compresses them.

This makes the material denser, stronger, and often smoother or glossier as well.

And this process is common in making glossy papers like magazine pages, for example, and also high-density paperboard, like luxury packaging or gift boxes.

Now here's a diagram of the calendering, and you can see those big rollers and those are the heated rollers, and the material then passes through those.

So the paper or board are fed through the rollers, the heated rollers compress the material, and then the material is then turned out to be either denser and smoother.

Okay, quick check for understanding on that then.

Why is heat used to improve paper and board properties? A, to make it lightweight, B, to improve strength and rigidity, C, to improve its opacity, or D, to make it flexible.

Pause the video, just take a moment to think about your answer.

And the correct answer was B.

So heat is used to improve strength and rigidity.

Now paper and board-based materials can have chemical treatments as well, and those can also be used to enhance the properties.

Thermal paper has a heat-sensitive chemical layer added, and it's used to print till receipts without using ink.

Museums also use special paper which has been treated with an alkaline substance to protect archived items. Okay, it's gonna be over to you now to complete a couple more tasks.

The first task I'd like you to do them is this, paper and board can be strengthened during manufacture using heat and pressure.

I'd like you to name this process.

The second task then.

I'd like you to draw a label diagram to show how this process that you've just named in the first task, how this process works.

And your diagram should include the sheet of paper or board, the rollers, arrows showing movement, and the labels that show where the heat and the pressure are being applied.

Pause the video here to crack on with this task, and good luck.

Okay, let's go through the answers to this then.

So the first task was to name the process where paper and board can be strengthened during manufacture using heat and pressure.

Now that process was calendering.

The second task then was to draw a label diagram to show how this process works.

So just look at your diagram and compare it to the one that you can see in front of you now.

You should have included where that paper and board is being fed through, you should have also included those rollers, and you should be labelling that heat and pressure are applied at that point.

And the last thing then is when the paper comes out, it is then smooth and dense paper comes out.

So just compare yours to the example.

Lastly then, we're going to look at these words, structural integrity.

Now materials can be reinforced to enhance their properties, and we've already looked at that, and reinforcement involves adding an element or altering the structure of a material to improve its performance under stress.

Reinforcement techniques can be applied to a variety of materials, including things such as timbers, polymers, papers and boards, textiles, and metals.

So a range of materials can be and have the ability to be reinforced.

Okay, quick check for understanding on reinforcement then.

Why might materials need to be reinforced? A, it improves aesthetics, B, to make them stronger and last longer, C, to reduce costs for the consumer, or D, it makes them more environmentally friendly? Pause the video here, just to take a moment to think about your answer And the correct answer, it was to make them stronger and last longer.

So materials are reinforced to make them stronger and last longer.

Well done if you got that right.

Now, reinforcing materials improves their structural integrity, and structural integrity refers to how well something stays together and holds up without breaking.

For papers and boards, the techniques used to ensure structural integrity are particularly prevalent in things such as packaging and also models.

And you can imagine why structural integrity is important for those kind of products.

Okay, quick check for understanding on those words, and those are structural integrity.

What does structural integrity refer to in materials and structures? A, the ability of a structure to maintain its shape under normal conditions without breaking, B, the aesthetic appearance of a structure, C, the ability of a structure to resist environmental changes like temperature and moisture, or D, the cost-effectiveness of building a structure.

Okay, pause the video here, just to take a moment to think about your answer.

That's right, it was A.

So structural integrity refers to the ability of a structure to maintain its shape under normal conditions without breaking.

Now mechanical methods of providing structural integrity focus on physically altering the material during its manufacture.

Now, lamination bonds paper and boards with another material.

So, for example, a polymer or foil.

A cereal box often uses a laminated paperboard to add that rigidity.

So I mentioned before that this kind of structural integrity is really important for packaging.

Calendering applies high pressure and heat during manufacture to compress the fibres more tightly.

And high-quality print paper is calendered for increased tear resistance.

So that improves its structural integrity.

Mechanical methods of providing structural integrity focus on physically altering the material during its manufacture.

Corrugation is a fluted or a wavy paper layer sandwich between two flat sheets to increase its strength and stiffness without adding much weight.

Now it's mostly seen in materials like cardboard, such as corrugated cardboard, like the picture there.

Now those flutes create air pockets that help absorb impact and add strength, and the liners are then the flat layers that are glued to either side of the flutes to provide that smooth surface for printing.

Okay, what is the main purpose of corrugation in materials like cardboard? A, it improves aesthetics, B, to make the material waterproof, C, to reduce the cost of manufacturing, or D, to increase strength and stiffness without adding much weight.

Pause the video here, just take a moment to think about your answer.

And the correct answer then was to increase strength and stiffness without adding much weight.

Well done if you got that right.

Now structural design techniques use geometry and form to distribute loads more evenly and resist deformation.

Folding and scoring uses strategically placed cuts and folds to reinforce structure.

Now this method can be used in packaging inserts, and you may have seen these examples before.

Gussets are additional folded sections that allow expansion and improve load distribution, and side gussets in paper and card bags, such as like gift bags, can carry more weight than flat ones.

And again, you may have seen these before in your everyday life.

Other examples then, interlocking tabs.

Now interlocking tabs lock into slots for flat packages to hold their shape without the need for adhesives.

And again, if you have a look at the picture, you may have come across some of these before and never really paid much attention to them, but now just being more aware of what they actually are.

And ribbing is found on the inside of boxes such as egg boxes.

Its walls are designed to provide extra support to the items inside by reducing movement and adding strength.

Okay, last few tasks for you then for today's lesson.

The first thing I'd like you to do then is draw a label diagram to explain the structure of corrugated cardboard and how it provides strength.

The second task, I'd like you to explain how interlocking tabs improve the structural integrity of paper-based materials.

And lastly, I'd like you to explain how the use of gussets in paper-based materials can improve their structural integrity.

So think about those examples that I've shown you, and also the diagrams that I've shown you to help you with each one of those questions.

Okay, pause the video here to have a go at this task, and good luck.

Okay, let's look at some example answers then.

So the first question, I asked you to draw a label diagram to explain the structure of corrugated cardboard and how it provides strength.

So here's an example for you just to compare yours to.

So in this example, I've shown the outer flat layers at the top and the bottom of it and the fluted or the wavy middle layer.

Bit like a sandwich, I suppose.

The fluted layer between the flat sheets provides strength and rigidity.

Just compare yours to mine.

Have you missed anything? Did you include all the important bits of detail? The second question then, I asked you to explain how inter looking tabs improve the structural integrity of paper-based materials.

So the example answer says, "Interlocking tabs involve cutting shapes that slot together to form rigid connections.

This design helps distribute stress more evenly across the structure, reducing the need for adhesives." So just compare your answer to that one.

And lastly, I asked you to explain how the use of gussets in paper-based products can improve their structural integrity.

And the example answer says, "Gussets are folded sections added to paper-based products such as gift bags.

They allow the material to expand, increasing volume capacity while distributing weight more evenly." Okay, again, just compare your answer to mine.

Have you missed anything? Did you include enough detail? Okay, let's summarise today's lesson then.

Today we've been looking at enhancing the properties of papers and boards.

Now, combining materials creates improved properties compared to the individual materials alone.

So that is why we combine materials to always be looking at improving the properties.

Material properties can be modified with the use of things such as heat and additives.

And reinforcing techniques can improve a material's structural integrity.

Well done for all of your hard work today.

Thank you very much for joining me, and I will see you soon.