CA2283774A1 - Process and device for making a corrugated sheet for containers - Google Patents

Process and device for making a corrugated sheet for containers Download PDF

Info

Publication number
CA2283774A1
CA2283774A1 CA002283774A CA2283774A CA2283774A1 CA 2283774 A1 CA2283774 A1 CA 2283774A1 CA 002283774 A CA002283774 A CA 002283774A CA 2283774 A CA2283774 A CA 2283774A CA 2283774 A1 CA2283774 A1 CA 2283774A1
Authority
CA
Canada
Prior art keywords
liner
paper sheet
paper
metallised
laminating apparatus
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.)
Abandoned
Application number
CA002283774A
Other languages
French (fr)
Inventor
Wayne John Harrison
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.)
INSUL-BOX (NZ) Ltd
Original Assignee
Individual
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
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=19926178&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=CA2283774(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Individual filed Critical Individual
Publication of CA2283774A1 publication Critical patent/CA2283774A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00Layered products comprising a layer of paper or cardboard
    • B32B29/08Corrugated paper or cardboard
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING 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
    • B31FMECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/20Corrugating; Corrugating combined with laminating to other layers
    • B31F1/24Making webs in which the channel of each corrugation is transverse to the web feed
    • B31F1/26Making webs in which the channel of each corrugation is transverse to the web feed by interengaging toothed cylinders cylinder constructions
    • B31F1/28Making 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/36Layered products comprising a layer of synthetic resin comprising polyesters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00Layered products comprising a layer of paper or cardboard
    • B32B29/002Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/0008Electrical discharge treatment, e.g. corona, plasma treatment; wave energy or particle radiation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/0036Heat treatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D65/00Wrappers or flexible covers; Packaging materials of special type or form
    • B65D65/38Packaging materials of special type or form
    • B65D65/40Applications of laminates for particular packaging purposes
    • B65D65/403Applications of laminates for particular packaging purposes with at least one corrugated layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514Oriented
    • B32B2307/518Oriented bi-axially
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00Containers; Receptacles
    • B32B2439/70Food packaging

Abstract

The present invention relates to a method of forming a laminated material comprising the steps of corrugating a paper sheet (1), and applying a liner (4) to one or both sides of the corrugated sheet, wherein the liner is a pre-made laminate of a paper backing and plastic film which is metallised on one side and corona treated on the other side. A laminating apparatus for use in the above method is also described herein, which includes a means for feeding out a paper sheet and a liner to a set of corrugating rollers (6), the liner being a pre-formed laminate of paper and plastics film, and means for uniting the paper sheet and liner immediately subsequently to the corrugation of the paper sheet.

Description

PROCESS AND DEVICE FOR MAKING A CORRUGATED SHEET FOR CONTAINERS
TECIiI~TICAL FIELD
This invention relates to containers and in particular containers used for transportation and storing chilled or frozen foods.
BACKGROUND ART
Chilled or frozen foods are commonly packed in insulated containers. In one example expanded foams are commonly used for providing insulation properties. The material however has low impact resistance and is not generally regarded as having sufficient structural integrity for packaging applications and as a result the foam is often protected by an outside box. In addition, expanded foams are not approved for food contact applications and food within such containers consequently needs to be bagged or wrapped.
Metal foils are also used in packaging situations to provide insulation properties.
The use of expanded foam insulation materials in packaging is not regarded as ideal because the material is bulky and in addition there are recognised disposal problems.
Metal foils present manufacturing problems, additional costs, physical properties are not compatible with machinery and standard processing techniques and consequently tend to be used only for smaller higher value items.
As an alternative packaging material, cardboard has good natural insulation qualities, which can be improved if a board is laminated, lamination also improving strength.
It is an object of the present invention to provide a method and apparatus for producing insulated containers with corrugated board as a core material.

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only DISCLOSURE OF INVENTION
According to the present invention there is provided a method of forming a laminated material comprising the steps of corrugating a paper sheet and applying liner being a pre-made laminate of a paper backing and plastics f lm which is metallised on one side and corona treated on the other side.
The liner can include a bi-axially orientated polyester film which is metallised on one side and corona treated on the other side.
The liner can be preheated prior to its application to the paper sheet.
The liner can be heated by heating rollers and adhered to the paper sheet using a PVA
adhesive with the metallised film of the liner outermost.
The liner can be heated by heating rollers and adhered to the paper sheet using a PVA
adhesive with the metallised film of the liner innermost.
According to a further aspect of the invention there is provided a laminating apparatus including means for feeding out a paper sheet and a liner to a set of corrugating rollers, the liner being a pre-formed paper laminate of paper and plastic film, and means for uniting the paper sheet and liner subsequent to the corrugation of the paper sheet.
The apparatus can include means for pre-heating the paper sheet and liner prior to same being fed to the corrugating rollers.
The apparatus may include means for feeding a second liner for lamination with the paper sheet.
The lamination of the paper sheet and liner with the second liner can be subsequent to the lamination of the paper sheet with the liner.
The lamination of the paper sheet and the liner with the second liner can be achieved with the assistance of a cluster of in-line pressure rollers.
The second liner can be a laminate of a plastics film and paper The paper used to form the laminate can be of various thicknesses and grades and within the definition of paper it is intended to include thicker semi-rigid paper sheets (cardboard) and recycled and composite sheet materials including cellulose fibres derived from a variety of materials.
BRIEF DESCRIPTION OF DRAWINGS
Aspects of the present invention will be described in relation to the accompanying drawing which is a schematic side view of apparatus in accordance with the present invention set up to produce a two or three ply laminate.
BEST MODES FOR CARRYING OUT THE INVENTION
With respect to the drawing a roll of paper 1 is threaded over a heating roller 2 and fed to corrugating rollers 6. Simultaneously a liner material is fed from a roll 4 over a pre-heating roller 5 to the corrugating rollers 6 and laminated to one side of corrugated laminar 7 with the laminar being fed via rollers 8, 9 to nip rollers 10, where (optionally) a liner 11 from a roll 12 is fed via pre-heating roller 13 to the nip rollers 10 to provide a lining to the other side of the laminar. A cluster of crushing and heating rollers 14 are positioned downstream of the nip rollers 10 through which the completed laminar is fed. Downstream of the lamination apparatus the completed laminate is stored and cured prior to cutting into box blanks. Containers can be erected from the box blanks.
WO 98/41400 PCT/I~IZ98/00036 The paper 1 can be selected from a range of kraft and recycled papers. The liner film has high gas barrier properties, high reflectivity to light and radiant heat, low permeability to gases and water vapour, it is attractive and decorative, exhibits good abrasion resistance and can be characterised or specified as:
1. Thickness, 12 Micron 2. Tensile strength, 29800 kg/mm2 3. Tear strength 7 MD
4. Coefficient of friction 0.6 (film to film) 5. WVTR g/m2/24hr = 2.0 The process of laminating the polyester laminate to any of the kraft liners is a reel to reel process using PVA adhesive, applied at normal room temperature at approximately 70 metres per minute.
Three reels of paper are delivered to the corrugator for loading one or two liners and one laminar.
The metallised side of the kraft liner can be threaded over the pre-heaters with the metallised side facing outwards or inwards (this avoids any likelihood of scuffing the metallised surface). Care must be taken to avoid scuffing if the inwards method is used.
An ideal corrugating speed is between 90 and 120 metres per minute.
At normal corrugating temperature (130 - 160°C) the board, because of the metallised exterior retains heat for some time, during which time care must be taken when handling the product.
The converting process (making of a finished box) cannot take place until 24 hours after cornzgating. This time is necessary for the curing process i.e. cooling of the board and the moisture balance to finalise.
Whilst it has been known to laminate sheet material such as cardboard with plastics film in the past, this has never been done using a corrugator. Despite advice to the contrary our process has made this possible, the key factor we believe being the pre-made liner material, a laminate of polyester metallised film and a light paper backing.
The paper backing resists stretching and minimises the distribution of heat during the laminating process.
Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof as defined in the appended claims.

Claims (15)

THE CLAIMS DEFINING THE INVENTION ARE:
1. A method of forming a laminated material comprising the steps of corrugating a paper sheet and applying a liner to one or both sides of the corrugated sheet said liner being a pre-made laminate of a paper backing and polyester film which is metallised on one side and corona treated on the other side.
2. A method as claimed in claim 1 wherein the plastics film is bi-axially oriented metallised polyester film.
3. The method of claim 1 or claim 2 wherein the liner is preheated prior to its application to the paper sheet.
4. The method of claims 1 to claim 3 wherein the liner is heated by heating rollers and adhered to the paper sheet using a PVA adhesive with the metallised film of the liner outermost.
5. The method of any one of claims 1 to 3 wherein the liner is heated by heating rollers and adhered to the paper sheet using a PVA adhesive with the metallised film of the liner innermost.
6. A method as claimed in any one of claims 1 to 5 wherein the plastics metallised liner is laminated to one side of the paper sheet as the paper laminar is fed firm the corrugating rollers.
7. Laminating apparatus including means for feeding out a paper sheet and a liner to a set of corrugating rollers, the liner being a pre-formed laminate of paper and matallised polyester film, and means for uniting the paper sheet and liner immediately subsequently to the corrugation of the paper sheet.
8. Laminating apparatus as claimed in claim 7 including means for pre-heating the paper sheet and liner prior to them being united.
9. Laminating apparatus as claimed in claim 7 or claim 8 including means for feeding a second liner for lamination with the first paper sheet.
10. Laminating apparatus as claimed in claim 9 wherein the lamination of the paper sheet and liner with the second liner is subsequent to the lamination of the paper sheet with the liner.
11. Laminating apparatus of 9 or claim 10 wherein the lamination of the paper sheet and the liner with the second liner is achieved with the assistance of a cluster of in-line pressure rollers.
12. Laminating apparatus as claimed in any one of claims 9 to 11 wherein the second liner is a laminate of a metallised plastics film and paper.
13. A container formed from a laminate manufactured in accordance with the method of any one of claims 1 to 6.
14. A method of forming a laminated sheet material substantially as herein described with reference to the accompanying drawings.
15. Laminating apparatus substantially as herein described with reference to the accompanying drawings.
CA002283774A 1997-03-17 1998-03-16 Process and device for making a corrugated sheet for containers Abandoned CA2283774A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
NZ314427 1997-03-17
NZ314427A NZ314427A (en) 1997-03-17 1997-03-17 Laminated sheet comprising corrugated paper and liner laminate of a paper backing and plastics film
PCT/NZ1998/000036 WO1998041400A1 (en) 1997-03-17 1998-03-16 Process and device for making a corrugated sheet for containers

Publications (1)

Publication Number Publication Date
CA2283774A1 true CA2283774A1 (en) 1998-09-24

Family

ID=19926178

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002283774A Abandoned CA2283774A1 (en) 1997-03-17 1998-03-16 Process and device for making a corrugated sheet for containers

Country Status (8)

Country Link
EP (1) EP0968085A1 (en)
JP (1) JP2001515419A (en)
AU (2) AU2351897A (en)
BR (1) BR9815896A (en)
CA (1) CA2283774A1 (en)
NO (1) NO313665B1 (en)
NZ (1) NZ314427A (en)
WO (1) WO1998041400A1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10479550B2 (en) 2012-03-26 2019-11-19 Kraft Foods R & D, Inc. Packaging and method of opening
US10507970B2 (en) 2013-03-07 2019-12-17 Mondelez Uk R&D Limited Confectionery packaging and method of opening
US10513388B2 (en) 2013-03-07 2019-12-24 Mondelez Uk R&D Limited Packaging and method of opening

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NZ335961A (en) 1999-05-26 2001-11-30 Carter Holt Harvey Ltd Container/ wall surround assembly with surround interengaging with container at walls to provide for uplifting
ATE277749T1 (en) * 2000-03-27 2004-10-15 Arnold B Finestone CARDBOARD CONTAINER
NZ568698A (en) 2008-05-27 2010-12-24 Corcel Ip Ltd Method and machine for forming single face corrugated board

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4286006A (en) * 1977-01-26 1981-08-25 Boelter Industries, Inc. Corrugated material
US4544597A (en) * 1982-11-12 1985-10-01 Adolph Coors Company Corrugated paper board and its method of manufacture
US4474293A (en) * 1983-05-10 1984-10-02 Westvaco Corporation Multi-product merchandising package
FR2558107B3 (en) * 1984-01-12 1987-03-20 Dechaume Geoffroy SANDWICH MATERIAL WITH INTERNAL PAPER RIPPING AND EXTERIOR PROTECTION BY PLASTIC FILM AND METHODS OF MAKING SUCH MATERIAL
NZ237467A (en) * 1987-11-29 1991-08-27 Brown Gables Holdings Ltd Graphic laminating machine to bond metallised plastics film to corrugated card
WO1990006222A1 (en) * 1988-12-09 1990-06-14 Michael Wayne Olvey Composites of paper and plastic film, corrugated paperboard incorporating said composites, and methods of making

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10479550B2 (en) 2012-03-26 2019-11-19 Kraft Foods R & D, Inc. Packaging and method of opening
US10507970B2 (en) 2013-03-07 2019-12-17 Mondelez Uk R&D Limited Confectionery packaging and method of opening
US10513388B2 (en) 2013-03-07 2019-12-24 Mondelez Uk R&D Limited Packaging and method of opening

Also Published As

Publication number Publication date
BR9815896A (en) 2001-01-16
NO313665B1 (en) 2002-11-11
EP0968085A1 (en) 2000-01-05
AU2351897A (en) 1998-09-24
WO1998041400A1 (en) 1998-09-24
NO994497D0 (en) 1999-09-16
NO994497L (en) 1999-09-16
JP2001515419A (en) 2001-09-18
NZ314427A (en) 1998-06-26
AU6528898A (en) 1998-10-12

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EEER Examination request
FZDE Dead

Effective date: 20180316