AU625378B2 - Improvements relating to moulded paperboard - Google Patents

Improvements relating to moulded paperboard Download PDF

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Publication number
AU625378B2
AU625378B2 AU45732/89A AU4573289A AU625378B2 AU 625378 B2 AU625378 B2 AU 625378B2 AU 45732/89 A AU45732/89 A AU 45732/89A AU 4573289 A AU4573289 A AU 4573289A AU 625378 B2 AU625378 B2 AU 625378B2
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AU
Australia
Prior art keywords
laminate
corrugated
coated layer
contact
layer
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.)
Ceased
Application number
AU45732/89A
Other versions
AU4573289A (en
Inventor
Michael Prattley
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EMHART AUSTRALIA PTY Ltd
Original Assignee
EMHART AUSTRALIA
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by EMHART AUSTRALIA filed Critical EMHART AUSTRALIA
Publication of AU4573289A publication Critical patent/AU4573289A/en
Application granted granted Critical
Publication of AU625378B2 publication Critical patent/AU625378B2/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • B31F1/0077—Shaping by methods analogous to moulding, e.g. deep drawing techniques
    • 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
    • B31F1/2804—Methods

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Description

i L r 6 25 3 7 COMMONWEALTH OF AUSTRALIA PATENTS ACT 1952 COMPLETE SPECIFICATION (Original) Class Int. Class Application Number: PJ 1731 Lodged: 1ST DECEMBER, 1988 Complete Specification Lodged: Accepted: Published: Priority: Related Art: Name of Applicant: EMHART AUSTRALIA PTY. LTD.
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S2' Address of Applicant: P.O. BOX 50, THOMASTOWN, VICTORIA 3074,
AUSTRALIA
Actual Inventor: MICHAEL PRATLEY Address for Service: WATERMARK PATENT TRADEMARK ATTORNEYS, THE ATRIUM, 290 BURWOOD ROAD, HAWTHORN, VICTORIA 3122, AUSTRALIA S Complete Specification for the invention entitled: IMPROVEMENTS RELATING TO MOULDED PAPERBOARD
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The following statement is a full description of this invention, 4' including the best method of performing it known to us.
-iii i
'I
2 IMPROVEMENTS RELATING TO MOULDED PAPERBOARD This invention relates to a method and apparatus for manufacturing moulded paperboard panels useful in interior head lining and door linings and other furniture of motor cars.
There is considerable prior art on this subject as exemplified by Australian Patent Specification Nos. 562471 and 536688 relating to starch bonding and resin bonded boards. Also we refer to Australian Patent Nos. 484,085 (113794/76) relating to a curved paperboard process with thermoplastic resin layers treated by application of heat; 503,583 (26340/77) relating to a method of pressing a flat blank into a curved 1 0 portion which is inelasticafly compressed to eliminate creases; 492,630 (26880/77) relating to a trim panel with a substrate and a skin layer for decorative effects using S thermoplastic adhesive; 505,817 (35908/78) relating to a double sided thermoplastic to create relative displacement uilier heat and pressure conditions; 508,862 S (39754/78) relating to a method feeding a facing layer into a die to be pressed against 01 $1 paperboard; 505,213 (39873/78) relating to thermoplastic bonded paperboard S pre-heated prior to positioning in die.
Reference is also made to U.S, Patent Nos. 3,920,496 and 3,723,222.
""The present invention seeks to provide a moulded paperboard structure having the ideal combination of strength and moisture proofing at least the equal of prior art products whilst being capable of manufacture relatively cheaply.
0- There is provided according to the present invention a method of producing a mouldable paperboard structure comprising the steps of forming a non-resin bonded S corrugated board laminate, formed from a planar base sheet and a corrugated sheet, applying a layer having a heat sensitive coating thereon to the exposed corrugated surface of the corrugated board laminate to bring the heat sensitive coating into contact with I points of contact on the corrugated board laminate, placing and pressing the laminate and coated layer between a pair of heated dies to bond the coated layer to the corrugated laminate at said points of contact between the coated layer and the corrugated laminate, said coated layer forming a decorative or like surface on the paper board structure, Conveniently the non-resin bonded material is adhered by starch or the like low cost adhesive as used in lox cost box board construction.
The laminate so formed Is flexible and may be m e to jqVeRtAit ape pri to S7 Rp 992 I i 7 r TENT? ii j, r ;1 -I 1 3 application of the decorative or like outer layer to the laminate.
The invention wi!S now be described in greater detail with reference to proposed methods tf manufacture as follows: In the drawings Figure 1 is a perspective view of the base corrugated laminate and single layer; Figure 2 is a cross-sectional view of the completed lamimra.i; Figure 3 is an exploded view showing the various layers; and Figure 4 is a schematic view of a shaping die with the laminate inserted therein.
The substrate panel is made by forming a non-resin bonded single faced 1 0 corrugated sheet 11 on a base layer 10 to a desired shape and then bonding a skin of Spolyethylene coated material 12 to the open corrugated surface of the single faced S° structure. This coated material upon cooling will render the structure quite rigid in its desired shape.
Subsequently a skin 13, which may be a decorative panel material of non-woven S 1 15 fibre construction for example, is applied to the formed structure or alternatively the decorative layer may be integrally formed with the skin of the thermoplastic layer.
o*r, The polyethylene coated material may be Kraft high load bearing paper suitable for maintaining the structure in its desired shape.
Alternatively, the decorative panel material may be applicable directly to the 2 0 open corrugated surface of the non-resin bonded structure.
p S In both forms the panel material will embody a skin of polyethylene material for adhesion to the corrugated surface or to the formed structure upon application of heat.
64. In a practical arrangement of the invention, the thermoplastic layer 12 will react to heat applications in the range of 1050 to 150 0 C. The resin is preferably a thermoplastic, however, it is possible in some applications for thermosetting plastic to be S utilised. The forming dies 14 may be of any desired shape and are utilized to mould the laminate to a desired shape simultaneously with the application of the decorative or like surface layer to the laminate. The shape depicted is for a typical motor vehicle head-lining.
Accordingly, it will be appreciated that the finished corrugated laminate structure will have the twin virtue of incorporating a roi!t!vely cheap starch bonded laminate base, coupled with a waterproof therroplastic outer layer which may 2
A
Ii..
4 incorporate a decorative or high strength finish, suitable for use in interior decor of a motor vehicle or the like.
00 0 @6 9 Q 6040 0 4 91]

Claims (4)

1. A method of producing a mouldable paperboard structure comprising the steps of forming a non-resin bonded corrugated board laminate formed from a planar base sheet and a corrugated sheet, applying a layer having a heat-sensitive coating thereon to the exposed corrugated surface of the corrugated board laminate to bring the heat sensitive coating into contact with points of contact on the corrugated board laminate, placing and pressing the laminate and coated layer between a pair of heated dies to bond the coated layer to the corrugated laminate at said points of contact between the coated layer and the corrugated laminate, said coated layer forming a decorative or like surface on the paper board structure. *1
2. A method as claimed in Claim 1, wherein the non-resin bonded material is adhered by starch or the like low cost adhesive as used in box board construction. o S
3. A method as claimed in Claim 1 or Claim 2, wherein the laminate is formed from flexible materials and moulded to a desired shape in a mould simultaneously with the application of said coated layer to the corrugated laminae.
4. The product of the method as claimed In any one of Claims 1 to 3. S* DATED this 2nd day of April, 1992. EMHART AUSTRALIA PTY. LTD. WATERMARK PATENT TRADEMARK ATTORNEYS THE ATRIUM 290 BURWOOD ROAD HAWTHORN, VICTORIA 3122 AUSIBAL[ LJD:BB ,T t I 9 !I a\I i
AU45732/89A 1988-12-01 1989-12-01 Improvements relating to moulded paperboard Ceased AU625378B2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPJ1731 1988-12-01
AUPJ173188 1988-12-01

Publications (2)

Publication Number Publication Date
AU4573289A AU4573289A (en) 1990-06-07
AU625378B2 true AU625378B2 (en) 1992-07-09

Family

ID=3773551

Family Applications (1)

Application Number Title Priority Date Filing Date
AU45732/89A Ceased AU625378B2 (en) 1988-12-01 1989-12-01 Improvements relating to moulded paperboard

Country Status (1)

Country Link
AU (1) AU625378B2 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995035204A1 (en) * 1994-06-20 1995-12-28 Newark Group Industries, Inc. Method for forming corrugated paper container and container made therefrom
EP1188688A1 (en) * 2000-09-15 2002-03-20 Ekco Packaging Limited A container for food

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3723222A (en) * 1970-05-01 1973-03-27 Mitsui Petrochemical Ind Process for manufacturing corrugated thermoplastic synthetic resin cardboard sheet
US3920496A (en) * 1972-02-22 1975-11-18 Michael C Wilkinson Corrugated paperboard and its method of manufacture
EP0341652A2 (en) * 1988-05-10 1989-11-15 Manville Corporation Corrugated paperboard automative liner

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3723222A (en) * 1970-05-01 1973-03-27 Mitsui Petrochemical Ind Process for manufacturing corrugated thermoplastic synthetic resin cardboard sheet
US3920496A (en) * 1972-02-22 1975-11-18 Michael C Wilkinson Corrugated paperboard and its method of manufacture
EP0341652A2 (en) * 1988-05-10 1989-11-15 Manville Corporation Corrugated paperboard automative liner

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995035204A1 (en) * 1994-06-20 1995-12-28 Newark Group Industries, Inc. Method for forming corrugated paper container and container made therefrom
EP1188688A1 (en) * 2000-09-15 2002-03-20 Ekco Packaging Limited A container for food

Also Published As

Publication number Publication date
AU4573289A (en) 1990-06-07

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