紙材料與環氧樹脂複合材料之數位製造與構築

台灣的造紙業年生產量達到448萬公噸，其中紙板的產量大約占了80%以上，其種類包括瓦楞箱用紙與各類紙板，此外也生產環保衛生紙、再生印刷書寫用紙、與宗教供奉燃燒用紙等，這些產品全部都使用回收紙作為原料，而國內回收紙的總量在2021年達到289萬公噸，相當於5座木柵焚化爐一年的處理量。即使如此還是有159萬公噸的廢紙產生，所以如何能夠有效的利用或處理這些大量的廢紙，將是本研究所要探討之主題。本研究主要分為三個部分，分別是紙材料與環氧樹脂的三種型態實驗測試、層積報紙板材的小尺度設計與製造、層積報紙板材的1:1大型構築設計與製作。本研究藉由嘗試製作出3種不同型號的環氧樹脂與10-50張的報紙層積後，共搭配出來15種不同特性的板材。還有以環氧樹脂與碎報紙混合攪拌後的碎報紙板材與碎報紙磚，以及同樣層積但是使用卷報紙的方式所製造的報紙圓柱，測試並探討此複合材料的結構穩定性與材料特性。基於材料實驗測試結果，選擇使用層積板材來進行接下來的設計，分別製作了厚度達到9.2MM的兩種不同造型與曲面的滑板板身，與使用5層報紙厚度0.5MM製作的20面體燈具，以及使用15層報紙厚度1.2MM製作的格柵型曲面雨傘架，主要在於展現相同的材料可以製作出不同型態與特性的小尺度工業設計產品。在生產製作裡，材料在硬化乾燥的過程中，可以針對材料的特性給予不同的形狀塑造，與傳統的材料加工與製造不同。最後在大尺度的構築設計與操作上，因為結構的不穩定下，在第一次組裝時失敗了，後續加強了結構補強，在第二次組裝時成功了，但是部份節點的強度還是不足夠的，所以無法維持長時間的矗立，因此也整理了在過程中所面臨的問題，並提出由設計到製造端的後續研究與建議。作為一種新型態的複合材料，本研究做了初步的探討與嘗試，而材料的在製作上還是有許多待解決的問題以及尺度上的限制，如何增加結構強度並利用材料特性，需要更多不同的測試，強化設計與製作過程中的完成度。

關鍵字

報紙；環氧樹脂；複合材料；構築；數位製造

並列摘要

The annual production of Taiwan’s paper industry has reached 4.48 million tons, of which the output of paperboard accounts for more than 80%. The types of paperboard include corrugated cardboard and various types of paperboard. In addition, it also produces environmentally friendly sanitary paper, recycled printing and writing paper, and religious burning paper, all using recycled paper as raw materials. The total amount of domestic recycled paper reached 2.89 million tons in 2021, equivalent to the processing capacity of five Mu-Zha incinerators in one year. However, there are still 1.59 million tons of waste paper produced. Therefore, effectively using or processing these large amounts of waste paper will be the main topic of this study. This study is mainly divided into three parts: three types of experimental tests on paper materials and epoxy resin, small-scale design, and 1:1 large-scale pavilion design and fabrication of laminated newspaper boards. This study tried to produce 15 different boards using three different types of epoxy resin and 10-50 layers of newspapers. There are also shredded newspaper boards and shredded newspaper bricks mixed with epoxy resin and shredded newspaper cylinders made by the same lamination method but using rolled newspapers. The structural stability and material properties of this composite material were tested and studied. Based on the results of material experimental tests, laminated boards were selected for the next stage of design. Two different shapes and curved skateboard decks with a thickness of up to 9.2mm were made, as well as a 20-sided polyhedron lamp made of 5 layers of newspaper with a thickness of 0.5mm and a lattice-type curved umbrella stand made of 15 layers of newspaper with a thickness of 1.2mm. The main purpose is to show that the same material can be used to make small-scale industrial design products with different shapes and characteristics. In the production process, different shapes can be given to the material during the curing and drying process according to its characteristics, which is different from traditional material processing and fabrication. Finally, in the large-scale pavilion design and fabrication, due to the instability of the structure, it failed in the first assembly. After strengthening the structural reinforcement, it succeeded in the second assembly. However, the strength of some joints is still insufficient to maintain long-term standing. Therefore, the problems faced during the process are summarized, and suggestions for subsequent research and development from design to fabrication are proposed. As a new type of composite material, this study has made preliminary explorations. There are still many problems to be solved in the production process of materials and limitations in scale. Increasing structural strength and using material characteristics requires more tests to strengthen the completion of the design and fabrication process.