CA1304663C - Manufacturing corrugated board - Google Patents
Manufacturing corrugated boardInfo
- Publication number
- CA1304663C CA1304663C CA000558970A CA558970A CA1304663C CA 1304663 C CA1304663 C CA 1304663C CA 000558970 A CA000558970 A CA 000558970A CA 558970 A CA558970 A CA 558970A CA 1304663 C CA1304663 C CA 1304663C
- Authority
- CA
- Canada
- Prior art keywords
- flute
- mediums
- liner
- roll
- fluted
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
- B31F1/20—Corrugating; Corrugating combined with laminating to other layers
- B31F1/24—Making webs in which the channel of each corrugation is transverse to the web feed
- B31F1/26—Making webs in which the channel of each corrugation is transverse to the web feed by interengaging toothed cylinders cylinder constructions
- B31F1/28—Making webs in which the channel of each corrugation is transverse to the web feed by interengaging toothed cylinders cylinder constructions combined with uniting the corrugated webs to flat webs ; Making double-faced corrugated cardboard
- B31F1/2813—Making corrugated cardboard of composite structure, e.g. comprising two or more corrugated layers
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Machines For Manufacturing Corrugated Board In Mechanical Paper-Making Processes (AREA)
- Laminated Bodies (AREA)
- Table Devices Or Equipment (AREA)
- Breeding Of Plants And Reproduction By Means Of Culturing (AREA)
- Paper (AREA)
- Materials For Medical Uses (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Abstract
ABSTRACT
A conventional single faced corrugated board manufacturing plant is modified to produce corrugated board having two fluted mediums bonded at their flute tips. In addition to the existing corrugating rolls a further pair of corrugating rolls synchronized with the existing pair are provided so that the corrugated mediums are contacted at their flute tips. An additional mill roll stand is provided for the second fluted medium. A carrier roll is provided adjacent to the pairs of corrugating rolls to take off the bonded fluted mediums and provide support and prevent uncontrolled movement of the flute to flute structure during the development of the adhesion bond. Adhesive applicators are provided to apply adhesive to one of the mediums prior to the flute tip to flute tip bonding and to coat the flute tips of the bonded fluted structure on the carrier roll for bonding to the liner. An additional guide roll is provided to allow tangential approach for the liner onto the flute to flute structure carried by the carrier roll. Radiant energy is used to assist in bonding the liner to the flute to flute tip structure enabling a low pressure bonding technique to be used.
A conventional single faced corrugated board manufacturing plant is modified to produce corrugated board having two fluted mediums bonded at their flute tips. In addition to the existing corrugating rolls a further pair of corrugating rolls synchronized with the existing pair are provided so that the corrugated mediums are contacted at their flute tips. An additional mill roll stand is provided for the second fluted medium. A carrier roll is provided adjacent to the pairs of corrugating rolls to take off the bonded fluted mediums and provide support and prevent uncontrolled movement of the flute to flute structure during the development of the adhesion bond. Adhesive applicators are provided to apply adhesive to one of the mediums prior to the flute tip to flute tip bonding and to coat the flute tips of the bonded fluted structure on the carrier roll for bonding to the liner. An additional guide roll is provided to allow tangential approach for the liner onto the flute to flute structure carried by the carrier roll. Radiant energy is used to assist in bonding the liner to the flute to flute tip structure enabling a low pressure bonding technique to be used.
Description
~3046~3 This invention relates -to a method o forming sandwich structures, comprising one or more non-corrugated sheet elements (liners) to which are bon~ed two or more corruyated (fluted) sheet elements (mediums) which are themselves bonded together.
~ pplicant's copending Canadian 517,430, filed September 3, 1986 discloses an improved corrugated paper board structure in which two or more layers of corrugated medium (flutes) are bonded together at the peaks of the flutes, and are sandwiched between two outer liners.
The above-identified paten-t application also discloses a method of forming the structural paper in which two or more separate layers of corrugating medium are corrugated and then brought into flute tip to flute tip contact on synchronised corrugating rollers.
That method does not address the problem of capital cost in constructing a new corrugating plant for the flute to flute paper board and the likely under utilization of existing corrugating machinery, making conventional flute to liner corrugated boards.
It is an object of this invention to provide a modification to existing corrugating machinery to enable conventional corrugated board, as well as the new flute to flute corrugated board, to be made. The modification can also be incorporated into the manufacture of new corrugating machinery to enable conventional corrugated board with improved printing properties and visual appearance to be also made.
Conventional machinery for forming corrugated board incorporates a unit for making single faced corrugated board, that is a liner adhered to a single fluted layer. More complex board constructions can be formed by bonding the exposed flutes to another liner and, if desired, subsequently bonding that to another single faced corrugated board.
~ .
~41~;3 A "slngle facer" plant normally include~ a~ lt6 essential components:
a) Mill roll stands for liner and corrugatlng medium.
b) A pair of corrugating roller6 for corrugating the medium into a fluted medium.
c) A pair o~ heated smooth (non corrugated) guide rolls for the liner board.
d) A non corrugated pres~ure roll for bringing the liner into contact with the second corrugating roller to form the single ~acsd board.
e) An idler roll to guide the formed single faced board to subsequent processing unltfi.
With conventional single faced board a degree of pressure is applied to ensure secure bonding between the liner and the corrugated medium. This application of pressure create6 pressure lines on the outer face of the liner corresponding to the position of the flute tlps. The need to apply pressure can adversely affect the strength of the single faced structure and adverse~y affect6 the appearance of the board and its suitability for printing.
It is also an object of this invention to overcome these deficiencies in the conventional product.
To this end the present invention provides a method for bonding a liner to a corrugated medium or mediums in which adhesive is applied to the flute tips of the corrugated medium. The liner is then brought into contact with the corrugated medium or mediums and the assembled liner and corrugated medium or mediums may be subjected to heat, or other energy or chemical process to initiate or assist in completion of the bonding. This low pressure method of bonding gives superior bond strength (pin adhesion) than is achieved in conventional single-faced board.
In another aspect this invention provides a modified single face corrugated board making apparatus capable of forming corrugated boards having two fluted mediums bonded together at the flute tips comprising ~lL3(~ i6;~
a) Mill roll stands for two medium~ and one liner.
b) Two pairs of corrugating rolls synchroniæed so that the two fluted mediums are oriented for precise flute tip to flute tip bonding and which may include pressure bonding.
c) A carrier roll juxtaposed to one of the corrugating rolls and adapted to support and constrain continuously the bonded fluted mediums during the development of the adhesive bond. This juxtaposition assists in achieving the required constraint for the joined mediums after bonding of flute tips and before bonding of the first liner.
d) A first adhesive application station adapted to apply adhesive to one of said fluted mediums prior to the flute tips of the said fluted mediums coming into contact.
e) A second adhesive applicator station to apply adhesive to the exposed flute tips of the bonded mediums or to a liner board.
f) A liner applicator roll located adjacent to said carrier roll downstream o said second adhesive applicator adapted to apply a liner board to said bonded fluted mediums.
This invention also provides the following 25 modification to enable the modified conventional single facer machine-to make both conventional single faced board and flute to flute board.
The modification comprises:
i) Substituting or installing in addition to existing rolls, corrugating rolls synchronised with the existing pair of corrugating rolls (b) in place of the heated guide rolls (c) and pressure roll (d). These new corrugating rolls may substitute for the heated guide and pressure rolls or be installed in addition to existing rolls. One or both heated guide rolls may be used to preheat the second fluting medium.
.
, ~, .
46~3 ii) Providing a mill roll stand for a ~econd fluting medium to be fed through the new corrugating rolls (i), if an exis~ing mill roll stand is not available.
iii) Providing an adhesive applicator to apply adhesive to either a liner or the exposed tips on one side of the flute to flute structure prior to bonding with a liner.
iv) Providing a new guide roll to allow tangential approach of the liner prior to bonding to the flute to flute structure.
(v) Providing very similar treatment of each medium prior to corrugating. This includes the provision of tension control, ; 15 preheater/preconditioners, heated S wrap drive rolls, and steam box conditioners incorporating a new carrier roll which operates as a take off roll and supports the flute to flute structure holding it in a configuration which (a) provides an accurately registered support during glue application, and (b) prohibits uncontrolled movement of the flute to flute structure during development of the glue bond with the liner.
This modification enables two fluting mediums to be precisely bonded ~lute tip to flute tip maintained in that orientation and then to be bonded to a liner as a first :
stage in preparing a flute to flute corrugated board. Where a conventional single faced board is to be formed one fluting medium is simply omitted and the one pair of corrugating rolls the preferred pair being the upper pair, (b), are not utilized. Also the first adhesive applicator is preferably not used.
In forminy the bonded fluted mediums it is necessary to constrain the mediums to maintain the flute orie~ntation of each fluted layer and to maintain the : :; : ` :
.
: , , , , ~;31046~
orientation and symmetry of the flute tip to flute tip bonds. This may be achieved by using a grooved carrier roll to take up the bonded mediums and support them until the bond is set. Alternatively a smooth carrier surface can be used in association with vacuum to provide the necessary constraint. Other means for constraining the mediums can also be used such as strings or straps to maintain the flute tips in correct orientation.
The improved strength characteristics of the double flute construction enable lighter weight board to be made having strengths equivalent to those found in heavier boards of conventional structure. Thus savings in material costs are possible using the flute to flute construction.
It has been found that boxes formed from flute to lS flute board-exhibit superior durability and strength. The creasing and folding characteristics of board having flute to flute bonding are such that the corner and edge folds of boxes provide added strength to the construction. The flute to flute structure creases in a well defined manner to produce a hinged joint which is superior in strength, flexibility and visual appearance compared with creases in conventional board.
Bonded fluted mediums according to this invention can be subsequently bonded to any suitable liner material to form light weight structural laminates. The mediums can be manufactured from 100% cellulose fibre or ligno-cellulose fibre or combinations of cellulose, ligno-cellulose and synthetic fibres, or they may be laminated structures.
The liners or sheet elements may be of any material and structure of varing thickness including, but not limited to, paper board made of cellulose fibres, ligno-cellulose fibres; cellulose, ligno-cellulose and/or synthetic fibre mixtures; natural or synthetic polymers, wood, or metal; or laminates made of bonded layers of any combinations of these materials. Strips or strings nf any material may also be fed interm;ttently, between the mediums across the flutes and thus be bonded at the flute tip to flute tip junction.
The inclusion of such strips or strings will constrain the ~3~ 3 bonded mediums and prohibit expanslon of the flute tip to flute tlp structure until one or more llners are added and may additionally confer added strength to the board.
Bol~ding ma~ be achieved by use of adhe~ives or by other means such as, but not limited to, soldering, brazing and fusion welding.
Where a light weight structural panel for building such as celling panels or for use ln furnlture i6 required the liners can be wood veneer. In other applications such as air~frame skin6 for aircraft, the ].iners may be metal foil or synthetic polymers.
The modification of a single flute station according to this invention enables in a conventional corrugator, the elimination of the need for pressure application to secure the bond between the liner and the corrugated medium. The use of the heat or other means to complete the bonding process of the first liner to corrugated medium or mediums at the single facer is an innovation and has the advantage of not adversely affecting the 6trength of the board and of not adversely affecting the appearance of the board by reduclng the normal pressure lines.
A preferred embodiment of this invention will now be described with reference to the drawings in which figure 1 represents a schematic view of a conventional single facer unit; figure 2 shows a schematic view of the unit as modified by this invention for forming a flute to flute structure; figure 3 shows a detailed view of figure 2 and figure 4 shows the modified unit of this invention when used to make conventional single faced corrugated board.
A conventional single facer unit comprises mill roll stands 4 and 5, a preheater roll 6, a single facer station 7 and a mill roll 8 stand for fluting medium 23.
The single facer station 7 comprises the corrugating rolls 10 and 11, adhesive applicator 12, pressure roll 13 for pressing the liner against the corrugated medium 23 on roll 11. The liner board 21 is fed from stand 5 over preheater roll 6 to the heated smooth guide rolls 14 and 15.
q~he ~ormed singl~ faced board 2~ i8 tran~ferred to ldler roll 16 and then to conveyor 17 which transport6 the single faced board 24 for further processing.
In the modified unlt of thls lnvention one of the a mill roll stands 5 is used for a second corrugating medium 22 while an other mill roll stand is used for liner 21. A
new guide roll 31 is used to guide the liner onto preheater roll 6 and then under a new guide roll 32, to the S wrap rolls and onto the carrier roll 36.
l~ For medium 22, a second preheater roll 42 is inserted under preheater roll 6. A new roll guide 43 16 used to guide the medium onto the preheater roll 42 and then under a new guide roll 44.
For medium 23, a further preheater roll 45 i~ used.
This will require a roll guide 46 and a roll guide 47 to guide the medium into the single facer S wrap heated rolls.
Steam sprays may be mounted on preheater rolls to precondition the sheet.
Steam boxes may be located before rolls 10 and 34 2t) to condition the mediums prior to corrugating.
An automatic spllcer may be utlllzed with each medium coming from roll stands 5 and 9 with the liner coming from roll stand 4.
The guide roll 14 and pressure roll 13 shown in figure 1 are replaced by corrugating rolls 34 and 35. The heated smooth guide roll 15 is used to preheat the corrugating medium 22. The two corrugated mediums 22 and 23 are adhered together between rolls 35 and 11 which are driven synchronously to ensure precise flute tip to flute 33 tip bonding. This can be achieved by installing a direct drive, meshed gear drive or toothed belt drive between the driven lower corrugating roll 35 and the corrugating roll 11 .
A carrier roll 36 is installed to operate as a 3~ take-off roll and to provide support and constraint for the bonded mediums.
The carrier roll 36 may be constructed as a shell with appropriate drilling for vacuum application to hold the flute to flute structure in position on the carrier roll.
Fingers or guides may also be provided to achieve ~he positioning of the flute to flute structure on the carrier roll and the corrugating rolls.
As an alternative, the corrugating rolls 11 and 35 can be arranged with a vacuum facility to hold the fluted product in the roll flutes. The area providing the vacuum on roll 35, can be extended to hold the flute to flute structure in -the roll flutes and present them in such a way as to ach,ieve a correctly aligned transfer to the carrier roll 36.
The carrier roll 36 may be a plain or grooved cylindrical surface or may also be provided with spaced bars of metallic or non-metallic materials to carry the flute to flute structure.
Holding of the flute to flute structure to the carrier roll 36 may also be achieved by use of vacuum, applied from within the carrier roll inner cavity.
A new adhesive applicator station 37 is located adjacent to the carrier roll 36 to apply adhesive to the flute tips on the exposed face of the flute to flute structure. The ~0 surface of the carrier roll may be arranged to provide a positive air pressure at point 49, causing the flute to flute structure to " ~ out" ensuring a good transfer of the adhesive to the exposed tips of the structure. The roll 38 guides the liner 21 to join with the flute to flute structure to form one particular example of the structures which are the subject of the invention disclosed in Canadian Patent Application No. 517,430.
The top liner 21 is assisted in bonding to the flute to flute structure after the glue application by an input of energy in the~form of radiant or convected heat, microwave or other energy by the units 39.
Allicomponents may be pre-heated, moistened or pre-treated to accelerate bonding of the component to component interfaces.
The carrier roll, assisted by positive air pressure from the blow box 40 inside the carrier roll 36, or vacuum from the liner side, will discharge the combined liner and ~04~3 flute to flute structure 25 to ~ransport ~ection 41 preceding the next processing st~tion.
The trAnsport section 41 may be straight or curved in shape, and i~ curved, the curve will be arranged to S utilise tension forces in the liner to apply gentle pressure to the glue bond. A change in radius will achieve further beneficial bond development.
The transport section ~1 may be provided with a driven carrier belt or belts to transfer the combined liner and flute to flute structure to the next section or next processing unit.
The carrier roll 36 is driven by a separate synchronised drive, a meshed gear drive or a toothed belt drive from the lower corrugating roll 35 or primary driven roll 11 to ensure it is synchronised with the corrugating roll 35. Precision, of flute tip to flute tip bonding and in the control of transfer from corrugating roll 35 to the carrier roll 36 and in the positional restraint of the flute to flute structure prior to the addition of liner 21 form key elements of this invention.
As shown in figure 4 the modified unit of this invention can also be used to make an improved form of conventional single faced corrugated board.
An improved single-faced corrugated board may be produced by ceasing to feed the corrugating medium 23 to the corrugating rolls 10 and 11 and also ceasing to apply glue to glue station 12 while continuing application at glue station 37 to corrugated medium 22. In this case the glue station 37 is moved towards the carrier roll 36 to contact the thinner conventional corrugated sheet and the carrier roll 36 is rotated through one half flute pitch to bring corrugated medium 22 into mesh with carrier roll 36, after leaving corrugating roll 35.
From the above it can be seen that the production of board structures with flute tip to flute tip bonding can be achieved with modification of existing machinery or construction of new machinery.
Also from the above it can be seen that the production of conventional board structures with improved appearance can be achieved.
g _
~ pplicant's copending Canadian 517,430, filed September 3, 1986 discloses an improved corrugated paper board structure in which two or more layers of corrugated medium (flutes) are bonded together at the peaks of the flutes, and are sandwiched between two outer liners.
The above-identified paten-t application also discloses a method of forming the structural paper in which two or more separate layers of corrugating medium are corrugated and then brought into flute tip to flute tip contact on synchronised corrugating rollers.
That method does not address the problem of capital cost in constructing a new corrugating plant for the flute to flute paper board and the likely under utilization of existing corrugating machinery, making conventional flute to liner corrugated boards.
It is an object of this invention to provide a modification to existing corrugating machinery to enable conventional corrugated board, as well as the new flute to flute corrugated board, to be made. The modification can also be incorporated into the manufacture of new corrugating machinery to enable conventional corrugated board with improved printing properties and visual appearance to be also made.
Conventional machinery for forming corrugated board incorporates a unit for making single faced corrugated board, that is a liner adhered to a single fluted layer. More complex board constructions can be formed by bonding the exposed flutes to another liner and, if desired, subsequently bonding that to another single faced corrugated board.
~ .
~41~;3 A "slngle facer" plant normally include~ a~ lt6 essential components:
a) Mill roll stands for liner and corrugatlng medium.
b) A pair of corrugating roller6 for corrugating the medium into a fluted medium.
c) A pair o~ heated smooth (non corrugated) guide rolls for the liner board.
d) A non corrugated pres~ure roll for bringing the liner into contact with the second corrugating roller to form the single ~acsd board.
e) An idler roll to guide the formed single faced board to subsequent processing unltfi.
With conventional single faced board a degree of pressure is applied to ensure secure bonding between the liner and the corrugated medium. This application of pressure create6 pressure lines on the outer face of the liner corresponding to the position of the flute tlps. The need to apply pressure can adversely affect the strength of the single faced structure and adverse~y affect6 the appearance of the board and its suitability for printing.
It is also an object of this invention to overcome these deficiencies in the conventional product.
To this end the present invention provides a method for bonding a liner to a corrugated medium or mediums in which adhesive is applied to the flute tips of the corrugated medium. The liner is then brought into contact with the corrugated medium or mediums and the assembled liner and corrugated medium or mediums may be subjected to heat, or other energy or chemical process to initiate or assist in completion of the bonding. This low pressure method of bonding gives superior bond strength (pin adhesion) than is achieved in conventional single-faced board.
In another aspect this invention provides a modified single face corrugated board making apparatus capable of forming corrugated boards having two fluted mediums bonded together at the flute tips comprising ~lL3(~ i6;~
a) Mill roll stands for two medium~ and one liner.
b) Two pairs of corrugating rolls synchroniæed so that the two fluted mediums are oriented for precise flute tip to flute tip bonding and which may include pressure bonding.
c) A carrier roll juxtaposed to one of the corrugating rolls and adapted to support and constrain continuously the bonded fluted mediums during the development of the adhesive bond. This juxtaposition assists in achieving the required constraint for the joined mediums after bonding of flute tips and before bonding of the first liner.
d) A first adhesive application station adapted to apply adhesive to one of said fluted mediums prior to the flute tips of the said fluted mediums coming into contact.
e) A second adhesive applicator station to apply adhesive to the exposed flute tips of the bonded mediums or to a liner board.
f) A liner applicator roll located adjacent to said carrier roll downstream o said second adhesive applicator adapted to apply a liner board to said bonded fluted mediums.
This invention also provides the following 25 modification to enable the modified conventional single facer machine-to make both conventional single faced board and flute to flute board.
The modification comprises:
i) Substituting or installing in addition to existing rolls, corrugating rolls synchronised with the existing pair of corrugating rolls (b) in place of the heated guide rolls (c) and pressure roll (d). These new corrugating rolls may substitute for the heated guide and pressure rolls or be installed in addition to existing rolls. One or both heated guide rolls may be used to preheat the second fluting medium.
.
, ~, .
46~3 ii) Providing a mill roll stand for a ~econd fluting medium to be fed through the new corrugating rolls (i), if an exis~ing mill roll stand is not available.
iii) Providing an adhesive applicator to apply adhesive to either a liner or the exposed tips on one side of the flute to flute structure prior to bonding with a liner.
iv) Providing a new guide roll to allow tangential approach of the liner prior to bonding to the flute to flute structure.
(v) Providing very similar treatment of each medium prior to corrugating. This includes the provision of tension control, ; 15 preheater/preconditioners, heated S wrap drive rolls, and steam box conditioners incorporating a new carrier roll which operates as a take off roll and supports the flute to flute structure holding it in a configuration which (a) provides an accurately registered support during glue application, and (b) prohibits uncontrolled movement of the flute to flute structure during development of the glue bond with the liner.
This modification enables two fluting mediums to be precisely bonded ~lute tip to flute tip maintained in that orientation and then to be bonded to a liner as a first :
stage in preparing a flute to flute corrugated board. Where a conventional single faced board is to be formed one fluting medium is simply omitted and the one pair of corrugating rolls the preferred pair being the upper pair, (b), are not utilized. Also the first adhesive applicator is preferably not used.
In forminy the bonded fluted mediums it is necessary to constrain the mediums to maintain the flute orie~ntation of each fluted layer and to maintain the : :; : ` :
.
: , , , , ~;31046~
orientation and symmetry of the flute tip to flute tip bonds. This may be achieved by using a grooved carrier roll to take up the bonded mediums and support them until the bond is set. Alternatively a smooth carrier surface can be used in association with vacuum to provide the necessary constraint. Other means for constraining the mediums can also be used such as strings or straps to maintain the flute tips in correct orientation.
The improved strength characteristics of the double flute construction enable lighter weight board to be made having strengths equivalent to those found in heavier boards of conventional structure. Thus savings in material costs are possible using the flute to flute construction.
It has been found that boxes formed from flute to lS flute board-exhibit superior durability and strength. The creasing and folding characteristics of board having flute to flute bonding are such that the corner and edge folds of boxes provide added strength to the construction. The flute to flute structure creases in a well defined manner to produce a hinged joint which is superior in strength, flexibility and visual appearance compared with creases in conventional board.
Bonded fluted mediums according to this invention can be subsequently bonded to any suitable liner material to form light weight structural laminates. The mediums can be manufactured from 100% cellulose fibre or ligno-cellulose fibre or combinations of cellulose, ligno-cellulose and synthetic fibres, or they may be laminated structures.
The liners or sheet elements may be of any material and structure of varing thickness including, but not limited to, paper board made of cellulose fibres, ligno-cellulose fibres; cellulose, ligno-cellulose and/or synthetic fibre mixtures; natural or synthetic polymers, wood, or metal; or laminates made of bonded layers of any combinations of these materials. Strips or strings nf any material may also be fed interm;ttently, between the mediums across the flutes and thus be bonded at the flute tip to flute tip junction.
The inclusion of such strips or strings will constrain the ~3~ 3 bonded mediums and prohibit expanslon of the flute tip to flute tlp structure until one or more llners are added and may additionally confer added strength to the board.
Bol~ding ma~ be achieved by use of adhe~ives or by other means such as, but not limited to, soldering, brazing and fusion welding.
Where a light weight structural panel for building such as celling panels or for use ln furnlture i6 required the liners can be wood veneer. In other applications such as air~frame skin6 for aircraft, the ].iners may be metal foil or synthetic polymers.
The modification of a single flute station according to this invention enables in a conventional corrugator, the elimination of the need for pressure application to secure the bond between the liner and the corrugated medium. The use of the heat or other means to complete the bonding process of the first liner to corrugated medium or mediums at the single facer is an innovation and has the advantage of not adversely affecting the 6trength of the board and of not adversely affecting the appearance of the board by reduclng the normal pressure lines.
A preferred embodiment of this invention will now be described with reference to the drawings in which figure 1 represents a schematic view of a conventional single facer unit; figure 2 shows a schematic view of the unit as modified by this invention for forming a flute to flute structure; figure 3 shows a detailed view of figure 2 and figure 4 shows the modified unit of this invention when used to make conventional single faced corrugated board.
A conventional single facer unit comprises mill roll stands 4 and 5, a preheater roll 6, a single facer station 7 and a mill roll 8 stand for fluting medium 23.
The single facer station 7 comprises the corrugating rolls 10 and 11, adhesive applicator 12, pressure roll 13 for pressing the liner against the corrugated medium 23 on roll 11. The liner board 21 is fed from stand 5 over preheater roll 6 to the heated smooth guide rolls 14 and 15.
q~he ~ormed singl~ faced board 2~ i8 tran~ferred to ldler roll 16 and then to conveyor 17 which transport6 the single faced board 24 for further processing.
In the modified unlt of thls lnvention one of the a mill roll stands 5 is used for a second corrugating medium 22 while an other mill roll stand is used for liner 21. A
new guide roll 31 is used to guide the liner onto preheater roll 6 and then under a new guide roll 32, to the S wrap rolls and onto the carrier roll 36.
l~ For medium 22, a second preheater roll 42 is inserted under preheater roll 6. A new roll guide 43 16 used to guide the medium onto the preheater roll 42 and then under a new guide roll 44.
For medium 23, a further preheater roll 45 i~ used.
This will require a roll guide 46 and a roll guide 47 to guide the medium into the single facer S wrap heated rolls.
Steam sprays may be mounted on preheater rolls to precondition the sheet.
Steam boxes may be located before rolls 10 and 34 2t) to condition the mediums prior to corrugating.
An automatic spllcer may be utlllzed with each medium coming from roll stands 5 and 9 with the liner coming from roll stand 4.
The guide roll 14 and pressure roll 13 shown in figure 1 are replaced by corrugating rolls 34 and 35. The heated smooth guide roll 15 is used to preheat the corrugating medium 22. The two corrugated mediums 22 and 23 are adhered together between rolls 35 and 11 which are driven synchronously to ensure precise flute tip to flute 33 tip bonding. This can be achieved by installing a direct drive, meshed gear drive or toothed belt drive between the driven lower corrugating roll 35 and the corrugating roll 11 .
A carrier roll 36 is installed to operate as a 3~ take-off roll and to provide support and constraint for the bonded mediums.
The carrier roll 36 may be constructed as a shell with appropriate drilling for vacuum application to hold the flute to flute structure in position on the carrier roll.
Fingers or guides may also be provided to achieve ~he positioning of the flute to flute structure on the carrier roll and the corrugating rolls.
As an alternative, the corrugating rolls 11 and 35 can be arranged with a vacuum facility to hold the fluted product in the roll flutes. The area providing the vacuum on roll 35, can be extended to hold the flute to flute structure in -the roll flutes and present them in such a way as to ach,ieve a correctly aligned transfer to the carrier roll 36.
The carrier roll 36 may be a plain or grooved cylindrical surface or may also be provided with spaced bars of metallic or non-metallic materials to carry the flute to flute structure.
Holding of the flute to flute structure to the carrier roll 36 may also be achieved by use of vacuum, applied from within the carrier roll inner cavity.
A new adhesive applicator station 37 is located adjacent to the carrier roll 36 to apply adhesive to the flute tips on the exposed face of the flute to flute structure. The ~0 surface of the carrier roll may be arranged to provide a positive air pressure at point 49, causing the flute to flute structure to " ~ out" ensuring a good transfer of the adhesive to the exposed tips of the structure. The roll 38 guides the liner 21 to join with the flute to flute structure to form one particular example of the structures which are the subject of the invention disclosed in Canadian Patent Application No. 517,430.
The top liner 21 is assisted in bonding to the flute to flute structure after the glue application by an input of energy in the~form of radiant or convected heat, microwave or other energy by the units 39.
Allicomponents may be pre-heated, moistened or pre-treated to accelerate bonding of the component to component interfaces.
The carrier roll, assisted by positive air pressure from the blow box 40 inside the carrier roll 36, or vacuum from the liner side, will discharge the combined liner and ~04~3 flute to flute structure 25 to ~ransport ~ection 41 preceding the next processing st~tion.
The trAnsport section 41 may be straight or curved in shape, and i~ curved, the curve will be arranged to S utilise tension forces in the liner to apply gentle pressure to the glue bond. A change in radius will achieve further beneficial bond development.
The transport section ~1 may be provided with a driven carrier belt or belts to transfer the combined liner and flute to flute structure to the next section or next processing unit.
The carrier roll 36 is driven by a separate synchronised drive, a meshed gear drive or a toothed belt drive from the lower corrugating roll 35 or primary driven roll 11 to ensure it is synchronised with the corrugating roll 35. Precision, of flute tip to flute tip bonding and in the control of transfer from corrugating roll 35 to the carrier roll 36 and in the positional restraint of the flute to flute structure prior to the addition of liner 21 form key elements of this invention.
As shown in figure 4 the modified unit of this invention can also be used to make an improved form of conventional single faced corrugated board.
An improved single-faced corrugated board may be produced by ceasing to feed the corrugating medium 23 to the corrugating rolls 10 and 11 and also ceasing to apply glue to glue station 12 while continuing application at glue station 37 to corrugated medium 22. In this case the glue station 37 is moved towards the carrier roll 36 to contact the thinner conventional corrugated sheet and the carrier roll 36 is rotated through one half flute pitch to bring corrugated medium 22 into mesh with carrier roll 36, after leaving corrugating roll 35.
From the above it can be seen that the production of board structures with flute tip to flute tip bonding can be achieved with modification of existing machinery or construction of new machinery.
Also from the above it can be seen that the production of conventional board structures with improved appearance can be achieved.
g _
Claims (4)
EXCLUSIVE PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS
FOLLOWS:
1. A single face corrugated board making apparatus capable of forming corrugated boards having two fluted mediums bonded precisely together at the flute tips and one liner comprising:
(a) a mill rod stand for two mediums and one liner;
(b) two pairs of corrugating rolls;
(c) a first adhesive application station adapted to apply adhesive to one of said fluted mediums;
(d) a corrugated roll from each of said pairs being synchronized with each other and arranged for causing the tips of the fluted mediums to contact and adhere to each other to form a fluted mediums structure, having precise flute tip orientation;
(e) a carrier roll juxtaposed to one of the corrugating rolls so as to support and continuously constrain the adhered fluted mediums structure to prevent uncontrolled movement of the flute tip to flute tip structure whereby the adhered fluted mediums are supported continuously first by one of the corrugating rolls and then by said carrier roll and to maintain alignment during the development of the adhesive bond;
(f) a second adhesive applicator station to apply adhesive to the exposed flute tips of the bonded mediums or to a liner board;
(g) a liner applicator roll located adjacent to said carrier roll downstream of said second adhesive applicator adapted to apply a liner board to said bonded fluted mediums at low pressure, whereby undesirable pressure lines are avoided.
(a) a mill rod stand for two mediums and one liner;
(b) two pairs of corrugating rolls;
(c) a first adhesive application station adapted to apply adhesive to one of said fluted mediums;
(d) a corrugated roll from each of said pairs being synchronized with each other and arranged for causing the tips of the fluted mediums to contact and adhere to each other to form a fluted mediums structure, having precise flute tip orientation;
(e) a carrier roll juxtaposed to one of the corrugating rolls so as to support and continuously constrain the adhered fluted mediums structure to prevent uncontrolled movement of the flute tip to flute tip structure whereby the adhered fluted mediums are supported continuously first by one of the corrugating rolls and then by said carrier roll and to maintain alignment during the development of the adhesive bond;
(f) a second adhesive applicator station to apply adhesive to the exposed flute tips of the bonded mediums or to a liner board;
(g) a liner applicator roll located adjacent to said carrier roll downstream of said second adhesive applicator adapted to apply a liner board to said bonded fluted mediums at low pressure, whereby undesirable pressure lines are avoided.
2. Apparatus as claimed in claim 1 in which the liner applicator roll is positioned to enable a tangential approach of the liner prior to bonding to the bonded fluted mediums.
3. Apparatus as claimed in claim 1 wherein (a) the second adhesive applicator is located adjacent the carrier roll and applies adhesive to the exposed flute tips of the bonded fluted mediums;
(b) an energy applicator is located adjacent to said carrier roll downstream of the liner applicator roll to promote bonding of the liner to the bonded fluted mediums.
(b) an energy applicator is located adjacent to said carrier roll downstream of the liner applicator roll to promote bonding of the liner to the bonded fluted mediums.
4. Apparatus as claimed in claim 1, 2 or 3 including means for providing positive air pressure in the carrier roll adjacent the second adhesive applicator to fluff out the mediums to ensure adequate application of adhesive to the exposed tips of the fluted medium.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AUPI042187 | 1987-02-18 | ||
| AUPI0421 | 1987-02-18 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1304663C true CA1304663C (en) | 1992-07-07 |
Family
ID=3772024
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000558970A Expired - Lifetime CA1304663C (en) | 1987-02-18 | 1988-02-16 | Manufacturing corrugated board |
Country Status (14)
| Country | Link |
|---|---|
| EP (1) | EP0279609B1 (en) |
| JP (1) | JPH07110525B2 (en) |
| AT (1) | ATE84464T1 (en) |
| BR (1) | BR8800608A (en) |
| CA (1) | CA1304663C (en) |
| DE (1) | DE3877375T2 (en) |
| DK (1) | DK171173B1 (en) |
| ES (1) | ES2037209T3 (en) |
| FI (1) | FI90641C (en) |
| GR (1) | GR3007159T3 (en) |
| MY (1) | MY102285A (en) |
| NO (1) | NO173642C (en) |
| NZ (1) | NZ223556A (en) |
| ZA (1) | ZA881100B (en) |
Families Citing this family (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE68910122T2 (en) * | 1988-03-31 | 1994-04-28 | Amcor Ltd | PRODUCTION OF CARDBOARD. |
| US5306384A (en) * | 1988-10-27 | 1994-04-26 | Amcor Limited | Machine for making corrugated board including a vacuum/positive pressure transfer roll |
| GB8825145D0 (en) * | 1988-10-27 | 1988-11-30 | Langston Machine | Improvements in corrugating machines |
| US5693167A (en) * | 1990-05-15 | 1997-12-02 | Molins Plc | Corrugated board manufacture |
| JP3385021B2 (en) * | 1991-08-19 | 2003-03-10 | アムコー・リミテッド | Cardboard manufacturing |
| MY107173A (en) * | 1991-09-17 | 1995-09-30 | Amcor Ltd | Corrugated paperboard production and apparatus therefor |
| ES2053377B1 (en) * | 1992-03-02 | 1996-01-16 | Torres Martinez M | SYSTEM FOR THE MANUFACTURE OF CORRUGATED CARDBOARD. |
| FR2708011B1 (en) * | 1993-07-20 | 1995-10-13 | Otor Sa | Machine and method for manufacturing a sheet of single-sided corrugated cardboard. |
| FR2719521B1 (en) * | 1994-05-06 | 1996-07-19 | Otor Sa | Machine and method for manufacturing a single-sided corrugated sheet by gluing under tension. |
| GB2303385A (en) * | 1995-07-14 | 1997-02-19 | Scm Container Mach Ltd | Apparatus for producing corrugated paperboard |
| WO1998018614A1 (en) * | 1996-10-30 | 1998-05-07 | Best Carton, Ltd. | Production of corrugated board structures |
| DE19716706A1 (en) * | 1997-04-21 | 1998-10-29 | Bhs Corr Masch & Anlagenbau | Machine for producing corrugated cardboard length coated on one side |
| PT2734360T (en) * | 2011-07-20 | 2017-02-28 | Sca Forest Prod Ab | Smoothly bendable board |
| DE102012201279A1 (en) * | 2012-01-30 | 2013-08-01 | Hauni Maschinenbau Ag | Method and apparatus for processing a wrapping material strip |
| CN109334130B (en) * | 2018-11-26 | 2024-06-14 | 天津津永诚包装技术有限公司 | Corrugated board assembly line |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR12081E (en) * | 1910-07-05 | Societe L. Sutre Et J. Tardieu | Packaging and material to make it | |
| DE473855C (en) * | 1926-11-18 | 1929-03-22 | Albert Marcel Arbin | Process for the production of corrugated cardboard with compressed corrugations as an intermediate layer and one or two cover sheets |
| JPS555418A (en) * | 1978-06-22 | 1980-01-16 | Kuromi Ezeru | Solarrenergyyoperated engine |
| DE3232774C2 (en) * | 1982-09-03 | 1986-06-19 | Werner H.K. Peters Maschinenfabrik Gmbh, 2000 Hamburg | Single sided corrugator |
| ZA866491B (en) * | 1985-09-04 | 1987-05-27 | Amcor Ltd | Corrugated board |
-
1988
- 1988-02-12 BR BR8800608A patent/BR8800608A/en not_active IP Right Cessation
- 1988-02-13 MY MYPI88000150A patent/MY102285A/en unknown
- 1988-02-15 EP EP88301228A patent/EP0279609B1/en not_active Expired - Lifetime
- 1988-02-15 DE DE8888301228T patent/DE3877375T2/en not_active Expired - Fee Related
- 1988-02-15 AT AT88301228T patent/ATE84464T1/en not_active IP Right Cessation
- 1988-02-15 ES ES198888301228T patent/ES2037209T3/en not_active Expired - Lifetime
- 1988-02-16 CA CA000558970A patent/CA1304663C/en not_active Expired - Lifetime
- 1988-02-17 ZA ZA881100A patent/ZA881100B/en unknown
- 1988-02-17 DK DK081488A patent/DK171173B1/en not_active IP Right Cessation
- 1988-02-17 FI FI880743A patent/FI90641C/en not_active IP Right Cessation
- 1988-02-17 NO NO880696A patent/NO173642C/en unknown
- 1988-02-18 NZ NZ223556A patent/NZ223556A/en unknown
- 1988-02-18 JP JP63034118A patent/JPH07110525B2/en not_active Expired - Fee Related
-
1993
- 1993-02-25 GR GR930400395T patent/GR3007159T3/el unknown
Also Published As
| Publication number | Publication date |
|---|---|
| BR8800608A (en) | 1988-09-27 |
| EP0279609A2 (en) | 1988-08-24 |
| FI880743A0 (en) | 1988-02-17 |
| ZA881100B (en) | 1988-08-12 |
| EP0279609B1 (en) | 1993-01-13 |
| JPH07110525B2 (en) | 1995-11-29 |
| FI90641C (en) | 1994-03-10 |
| EP0279609A3 (en) | 1988-09-28 |
| ATE84464T1 (en) | 1993-01-15 |
| NO880696L (en) | 1988-08-19 |
| ES2037209T3 (en) | 1993-06-16 |
| FI880743A (en) | 1988-08-19 |
| DK81488D0 (en) | 1988-02-17 |
| NO880696D0 (en) | 1988-02-17 |
| GR3007159T3 (en) | 1993-07-30 |
| DE3877375T2 (en) | 1993-05-06 |
| DK81488A (en) | 1988-08-19 |
| DE3877375D1 (en) | 1993-02-25 |
| NO173642B (en) | 1993-10-04 |
| JPS63203325A (en) | 1988-08-23 |
| DK171173B1 (en) | 1996-07-15 |
| FI90641B (en) | 1993-11-30 |
| NO173642C (en) | 1994-01-12 |
| MY102285A (en) | 1992-05-15 |
| NZ223556A (en) | 1990-09-26 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKLA | Lapsed |