CN109311258B - 用于生成具有带改进结构的介质的多层纸板的系统及方法 - Google Patents

用于生成具有带改进结构的介质的多层纸板的系统及方法 Download PDF

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CN109311258B
CN109311258B CN201780038055.3A CN201780038055A CN109311258B CN 109311258 B CN109311258 B CN 109311258B CN 201780038055 A CN201780038055 A CN 201780038055A CN 109311258 B CN109311258 B CN 109311258B
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CN109311258A (zh
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贾尔斯·格林菲尔德
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    • 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
    • B31F1/2818—Glue application specially adapted therefor
    • 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
    • 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
    • B31F1/22—Making webs in which the channel of each corrugation is longitudinal with the web feed
    • B31F1/225—Making webs in which the channel of each corrugation is longitudinal with the web feed combined with uniting the corrugated web to flat webs; Making corrugated-web structures
    • 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
    • B31F1/289—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 from discrete sheets
    • 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
    • B31F1/2895—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 from corrugated webs having corrugations of particular shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered 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
    • B32B29/005—Layered 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/08—Corrugated paper or cardboard
    • 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
    • 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
    • B31F1/36—Moistening and heating webs to facilitate mechanical deformation and drying deformed webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y10T428/24669—Aligned or parallel nonplanarities
    • Y10T428/24694—Parallel corrugations
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y10T428/24669—Aligned or parallel nonplanarities
    • Y10T428/24694—Parallel corrugations
    • Y10T428/24702—Parallel corrugations with locally deformed crests or intersecting series of corrugations
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y10T428/24669—Aligned or parallel nonplanarities
    • Y10T428/24694—Parallel corrugations
    • Y10T428/24711—Plural corrugated components

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Machines For Manufacturing Corrugated Board In Mechanical Paper-Making Processes (AREA)
  • Laminated Bodies (AREA)
  • Paper (AREA)
  • Making Paper Articles (AREA)

Abstract

本发明涉及用于生成由具有凸印介质的纸张产品制成的纸板产品的系统及方法，该凸印介质具有改进结构轮廓。该改进结构轮廓可包含三角形凹槽图样，其中各凹槽可展现各支撑中心顶点结构的第一线性腿部支撑件及第二线性腿部支撑件。该顶点可具有经配置以接合面层的大致扁平部分。因此，该纸板产品可进一步包含黏接至该凸印介质的一个或多个面层。进一步地，各“三角形”的顶点也可具有用于以连续且均匀的方式接收黏合剂的沟槽或通道。

Description

用于生成具有带改进结构的介质的多层纸板的系统及方法
技术领域
本发明涉及纸制品生产技术，更具体涉及一种纸板产品、一种纸板制作方法以及一种纸板制作机。
背景技术
现代造纸技术在造纸厂使用造纸机生成纸卷，而此纸卷继而可由纸板制造商用于生成纸板产品(即波纹状纸板)。结果，纸卷可由连续操作的机器生成。现代造纸机通常借由许多物质生成纸张，包含包括木纤维的木浆(尽管也可使用其他纤维)。此纤维倾向于伸长且适于彼此相邻地对齐。纤维以可从造纸机的调浆箱进给至移动筛网上的浆料形式开始。在现代造纸机中，纤维倾向于彼此对齐并与筛网在其中移动的方向对齐。下层纤维的此对齐方向称为纸张的主要方向，并与机器方向一致。因此，主要方向通常简称为机器方向(MD)，并且生成的纸张具有相关联的MD值。
当纸张用于制作纸板产品时，纸板产品的部分或层可为波纹状。传统波纹机将在纸张的交叉方向(CD)上使下层纸张产品波纹化，从而无法利用纸张在机器方向上的自然强度偏差。进一步地，纸张在机器方向上的较大自然强度质量在纸板制作解决方案中无法被交叉波纹技术所利用。又进一步地，传统波纹状介质包含由于传统波纹化辊对中的突起的形状而呈现正弦曲线形状的凹槽。结果，生产传统纸板产品的公司仍深陷限制纸板产品强度的陈旧生产程序中。
发明内容
本发明的目的是生成具有带改进结构轮廓的凸印介质的纸张产品所制成的纸板产品。
一方面，根据本发明的纸板产品包括：具有多个凹槽的纸张介质，其中多个凹槽的至少一组各包括第一线性腿部支撑结构、第二线性腿部支撑结构以及顶点结构；以及纸张面层，其耦接至尖端支撑结构。
另一方面，根据本发明的纸板制作方法包括：将纸张产品凸印成包含多个凹槽，其中多个凹槽的至少第二多个各包括第一线性腿部支撑结构、第二线性腿部支撑结构以及顶点结构；以及将纸张面层耦接至第二多个凹槽的至少第三多个顶点结构。
再一方面，根据本发明的纸板制作机包括：凸印器，其经配置以将纸张产品凸印成包含多个凹槽，其中多个凹槽的至少第二多个各包括第一线性腿部支撑结构、第二线性腿部支撑结构以及顶点结构；以及组合器，其经配置以将纸张面层耦接至第二多个凹槽的至少第三多个线性尖端支撑结构。
附图说明
当结合附图参考以下详细描述时，权利要求的各方面及诸多随附优点将变得更加容易明白且同样变得更好理解，其中：
图1是根据本文公开的主题的一个或多个实施例可为一个或多个纸板产品的部分的凸印介质的等距剖视图。
图2是根据本文公开的主题的一个或多个实施例可为一个或多个纸板产品的部分且具有施加至介质支撑结构的尖端的黏合剂的凸印介质的等距剖视图。
图3A-C是根据本文公开的主题的实施例具有改进结构的介质的各种凹槽轮廓的轮廓图。
图4是根据本文公开的主题的实施例具有图1的凸印介质的纸板产品的等距剖视图。
图5是根据本文公开的主题的实施例经配置以生成图4的纸板产品的机器的各方面的图。
具体实施方式
呈现以下讨论以使得本领域技术人员可制作且使用本文公开的主题。在不脱离本详细描述的精神及范畴的情况下，本文所述的一般原理可应用于除了上文详述实施例及应用之外的实施例及应用。本公开无意受限于所示实施例，而是与符合本文公开或建议的原理及特征的最宽广范畴相一致。
作为概述，本文公开的主题可涉及一种用于生成由具有凸印介质(有时称为凸印开槽)的纸张产品制成的纸板产品的系统及方法，该凸印介质具有改进的结构轮廓。改进结构轮廓可包含三角形凹槽图样，其中各凹槽可展现各支撑中心顶点结构的第一线性腿部支撑件及第二线性腿部支撑件。顶点可具有经配置以接合面层的大致扁平部分。因此，纸板产品进一步可包含黏接至凸印介质的一个或多个面层(有时称为衬垫或壁)。进一步地，各“三角形”顶点也可具有用于以连续且均匀的方式接收黏合剂的沟槽或信道。
当生产纸板产品使得凸印介质包含线性腿部结构侧接大致扁平顶点的凹槽轮廓时，所得纸板产品及整体结构相对于具有波纹状介质的传统生成纸板有所改进。进一步地，凸印介质可使用利用纸张产品机器方向的自然强度的线性凸印程序生成。在相同纸板产品中具有交叉波纹状介质及线性凸印介质的基本概念的额外排列是可行的，包含在波纹状介质与凸印介质之间安置面层并在纸板产品的外壁一者或两者上具有面层。下文参考图1-5讨论本文公开的主题的各种实施例的此优点及附加方面。
在讨论各种实施例之前，提出了关于交叉波纹化及线性凸印的简要讨论。如上文已有简述，传统纸板产品包含传统生产的波纹状介质(有时称为波纹状开槽)，例如交叉波纹状介质。交叉波纹状介质具有垂直于纸张产品的最下层纤维形成的凹槽。这会导致凹槽不与大多数下层纤维对齐，且因此不会利用纸张的MD值的自然强度(当与CD值比较时)。当要实现特定板强度时，无法利用纸张的MD值会导致在制造纸板产品时失去机会。也就是说，必须花费更多纸张(较重的纸张、较大的凹槽等)来实现所需的纸板强度。
线性凸印介质与交叉波纹状介质的不同之处在于产生的凹槽与纸张产品的MD值对齐。这导致凹槽与大部分下层纤维对齐，且因此利用纸张MD值的自然强度(与CD值相比)。当要实现特定纸板强度时，利用纸张MD值可以提高纸板产品的制造效率。也就是说，必须花费较少的纸张(较轻的纸张、较小的凹槽等)来实现所需的纸板强度。在2016年3月22日提交的题为“用于借由相对于机器方凸印而在纸张产品中进行开槽的系统及方法(SYSTEM ANDMETHOD FOR INDUCING FLUTING IN A PAPER PRODUCT BY EMBOSSING WITH RESPECT TOMACHINE DIRECTION)”的美国专利申请案第15/077,250号中更详细讨论制作、生成及使用线性凸印介质的方面，该案全部内容为了所有目的以引用的方式并入本文。因此，出于简洁，不再赘述线性凸印介质的各方面，现在转而参考图1-5进行讨论。
图1是根据本文公开的主题的一个或多个实施例可为一个或多个纸板产品的部分的凸印介质130的等距剖视图。此图展示可由凸印程序形成的凸印介质130的一部分的等距视图。也就是说，借由使用线性凸印技术使初始纸张产品通过凸印辊而形成凹槽131，使得凹槽131形成为与纸张的大部分下层纤维125一致。凹槽131也形成为与机器方向122一致。线性凸印介质130在纸张的机器方向122上形成凹槽131(例如，与大部分底层纤维125一致)时会利用纸张在机器方向122上的自然强度。因此，线性凸印介质130利用纸张在机器方向122上的自然强度。此凸印介质130可为如下文参考图4所讨论的纸板产品的组件/层。
进一步地，如图1所示，当从剖视角度观察时，凹槽131可形成三角形图样。具有三角形重复形状的此凹槽图样在下文中被称为凹槽轮廓。在剩余图式中讨论的实施例中，当与展现曲线或正弦曲线凹槽轮廓的凹槽轮廓相比，该凹槽轮廓在凸印介质的结构完整性上提供改进。这种曲线或正弦曲线的凹槽轮廓在传统交叉波纹介质中是普遍的。因此，如图1所示的三角形凹槽轮廓在介质强度及结构完整性上也优于波纹状介质。下文参考图2-3呈现为何此凹槽轮廓及其他类似凹槽轮廓展现出优异的强度及结构完整性的各种原因。
图2是根据本文公开的主题的一个或多个实施例可为一个或多个纸板产品的部分且具有施加至介质支撑结构的顶点结构的黏合剂201的凸印介质130的等距剖视图。在图2中，仔细观察凸印介质展示形成等腰三角形凹槽轮廓的一系列凹槽。凹槽轮廓可包括各包含三个部分的一系列支撑结构。在此实例中，该三个部分为第一腿部支撑结构211、第二腿部支撑结构212及顶点结构210。如所示，顶点结构210被安置在第一腿部支撑解耦股211与第二腿部支撑结构212之间。然后，在此实例支撑结构中，各支撑结构可具有面向上的顶点(虽然向上是根据图式简单展示的任意方向)。
出于同样的原因，第二系列支撑结构也可各包含三个部分，但是是从面向下的角度而言。在此方面，腿部支撑结构212也形成用于面向下的三角形的腿部支撑结构。因此，三个部分为第一腿部支撑结构214、第二腿部支撑结构212以及安置在第一腿部支撑结构214与第二腿部支撑结构212之间的顶点结构213。应注意，第二腿部结构212相对于向上顶点210及向下面层顶点213是相同的第二腿部支撑结构。然后，凹槽轮廓可被认为是向上面层顶点210及向下面层顶点213的系列交替，其中交替的线性腿部支撑结构(例如，211、212及214)被安置在其间。
各顶点210及213可形成为大致扁平，以便提供均匀表面以从用于定位顶点的机器接收黏合剂201并且向各顶点施加连续的黏合剂线。然后，凸印介质130可在黏合剂201就绪的顶点处固定到面层140。在其他实施例中，各顶点210及213可具有沟槽，以便于接收黏合剂。利用沟槽，当凸印介质130正移动通过纸板制作机时，黏合剂将倾向于保持在适当位置。下文参考第3C图讨论此带沟槽顶点实施例。
如参考图1-2所讨论的实施例具有凸印介质130，其展现具有优异强度及改进支撑结构的等腰三角形凹槽轮廓。此实施例提供优异强度的一个原因在于腿部支撑结构211、212及214是线性的。也就是说，腿部支撑结构不是弯曲的，且因此当从各个方向施加各种力时，腿部支撑结构倾向于保持固定和刚性。在正弦曲线波纹介质中，“腿部”更像是正弦曲线图样的连续曲线。因此，各凹槽的“顶点”可为正弦曲线中展现弯曲、平滑过渡到介质的最终形成准平顶点的任何部分的顶侧。由于在传统波纹状介质的顶点的任一侧上的弯曲、平滑过渡，顶点可能会以不期望的方式向前与向后平移。利用线性腿部支撑结构211、212及214，得以提供抵抗不可预测的移动及故障点的更加限定的结构。
进一步地，众所周知，谚语有云，两点之间的最短距离是直线。如本文所应用，各面向顶侧的顶点与面向底侧的顶点之间的最短距离是线性腿部支撑结构。因此，具有三角形凹槽轮廓必然使用较少的整体纸张来生成凸印介质(与正弦曲线波纹状介质相比)。其他实施例可包含用于凹槽轮廓的不同形状，包括锯齿形、梯形或任何方式的几何形状，该形状展现侧接交替顶侧顶点与底侧顶点的线性腿部支撑结构。接下来，在图3A-C中展示且讨论三个此类实施例。
图3A-C是根据本文公开的主题的实施例具有改进结构的介质的各种凹槽轮廓的轮廓图。在第3A图中，展示第一等腰三角形凹槽轮廓300。此凹槽轮廓300也在图1及图2中展示，但是此图提供了实际凹槽轮廓的横截面视图。在此实施例中，各凹槽包含各耦接至安置在其间的一个顶点303的第一线性腿部支撑结构301及第二线性腿部支撑结构302。顶点303被安置成大致扁平且处于与可耦接至最终面层(经由黏合剂或其他装置-未展示)平行的平面中。进一步地，此实施例中的顶点303的宽度约为各线性腿部支撑结构301及302的长度的十分之一。因此，此实施例可被称为窄顶点凹槽轮廓300。
在此实施例中，各腿部301及302相对于各顶点303的角度可为约60度。然而，可实现任何数量的腿部角度。因此，第一线性腿结构301及第二线性腿部结构302可相对于顶点303平面以约30度及60度之间的角度固定。
在图3B中，展示第二等腰三角形凹槽轮廓320。凹槽轮廓320视图提供了实际凹槽轮廓的横截面视图，其展现了各耦接至安置在其间的一个顶点323的第一线性腿部支撑结构321及第二线性腿部支撑结构322。进一步地，顶点323被安置成大致扁平且处于与可耦接至最终面层平行的平面中。与图3A不同，此实施例中的顶点323的宽度约为各线性腿部支撑结构321及322的长度的五分之一。因此，此实施例可被称为宽顶点凹槽轮廓320。
在图3C中，展示第三等腰三角形凹槽轮廓340。此凹槽轮廓340视图提供了凹槽轮廓的横截面视图，其展现了各耦接至安置在其间的一个顶点343的第一线性腿部支撑结构341及第二线性腿部支撑结构342。如前所述，顶点343被安置成大致扁平且处于与可耦接至最终面层平行的平面中。与图3A及图3B不同，顶点343包含用于在耦接至面层(未展示)之前接收黏合剂的沟槽或通道。在此实施例中，顶点343的宽度约为各线性腿部支撑结构321及342的长度的五分之一。因此，此实施例可被称为宽沟槽顶点凹槽轮廓340。预期有其他凹槽轮廓，但是为了简洁起见，不再赘述。
图4是根据本文公开的主题的实施例具有带改进凹槽结构的压印介质130的纸板产品400的等距剖视图。在此实施例中，纸板产品包含四层：第一面层110、波纹状介质120、凸印介质130以及第二面层140。如所示，第一面层110可形成耦接至第一波纹状介质120的一侧的顶侧外壁(虽然与纸板产品100的对齐的顶部/底部方向参考是任意的)。耦接可通过施加至波纹状介质120的顶侧上的各凹槽的顶点的黏合剂，使得面层110被胶合至在其中施加黏合剂的波纹状介质120。在其他实施例中，可在耦接至波纹状介质120之前将胶施加至整个面层110。
同样地，第二面层140可形成耦接至凸印介质130的一侧的底侧外壁(再次，顶部/底部方向参考是任意的)。耦接可通过施加至介质130的底侧上的各凹槽的顶点的黏合剂，使得面层140被胶合至在其中施加黏合剂的凸印介质140。在其他实施例中，可在耦接至凸印介质130之前将胶施加至整个面层140。
进一步地，波纹状介质120及凸印介质130也可使用黏合剂彼此黏合。因为波纹状介质120的凹槽在交叉方向上对齐并且凸印介质130的凹槽在机器方向上对齐，所以此两种介质之间的接触点将位于相应凹槽的顶点的交叉处。以此方式，波纹状介质120及凸印介质130相对于彼此固定，因为黏合剂将一种介质直接固定在另一种介质上。
当装配且固定所有四种介质时，所得纸板产品400比传统纸板产品更坚固，因为线性凸印介质130包含由于各凹槽的线性腿部结构而展现优异强度的凹槽轮廓。进一步地，黏合剂可较精确地以可预测且可重复的方式连续且均匀地施加至各顶点，因为黏合剂的部分不会如不具有扁平接收区域的正弦曲线顶点的情况般溢出至腿部。如图4所示，纸板产品400包含波纹状介质120。在其他实施例中，可能未呈现波纹状介质120，使得顶侧面层110被胶合至凸印介质的各顶侧顶点且顶侧面层140被胶合至凸印介质130的各底侧顶点。接下来，参考图5的机器讨论图4的纸板产品400的附加方面。
图5是根据本文公开的主题的实施例经配置以生成图4的纸板产品的机器500的各方面的图。在此实施例中，机器包含用于生成纸板产品的四个纸张进给辊510、520、530及540。此进给辊包含第一面层进给辊510、波纹状介质进给辊520、凸印介质进给辊530以及第二面层进给辊540。应注意，被缠绕在波纹介质进给辊520上的纸张系在波纹化之前且被缠绕在凸印介质进给辊530上的纸张是在凸印之前。各相应进给辊的纸张的重量及组成可不同并且专门针对相应目的而设计。
来自各卷的纸张可从各相应卷展开并且朝向经配置以将各层纸张组合在一起以形成所得纸板产品的组合器550进给。在进入组合器550之前，来自进给辊的纸张的至少一些可通过用于将纸张形成为介质的台。如本文及本行业中所使用，介质可指已形成为具有凹槽的纸张的纸张产品。因此，波纹状介质进给辊520可将纸张进给至相对于彼此对齐的第一波纹化辊521a及第二波纹化辊521b中。当纸张离开波纹化台(例如，波纹化辊521a及521b)时，其变成波纹状介质120。然后波纹状介质120被进给至组合器550中以与其他材料组合。类似地，凸印介质进给辊530可将纸张进给至彼此对齐的第一凸印辊531a及第二凸印辊531b中。当纸张离开凸印台(例如，凸印辊531a及531b)时，其变成如上文参考图1所讨论的凸印介质130。然后凸印介质130被进给至组合器550中以与其他材料组合。
进一步地，可首先将凸印介质进纸张530进给至可在凸印之前调节纸张的调节器560中。此调节可包含润湿纸张、加热纸张、冷却纸张、将化学品施加至纸张以及改变纸张之基本状态的各种其他形式以更好地准备凸印。在此意义上，可将调节阶段视为“松弛”纸张的下层纤维，使得纸张可处于更柔顺的状态以便更容易操纵，以免撕裂和撕开。此条件可以移除或修改纸张中的固有刚度，并降低在凸印期间将在拉伸程序中发生的可能纤维损坏的程度。在一个实施例中，调节器可(完全或部分地)将处理中的纸幅浸入液体(例如水、可回收溶剂等)中。可加热或不加热液体，以便实现所需纸张顺应性/可塑性的条件。
一旦通过凸印辊531a及531b，凸印介质130便可行进到施加器570，以将黏合剂施加至新形成的顶点。施加器可包含用于识别各顶点的位置且然后将一系列黏合剂施配器与所识别顶点对齐的装置。在其他实施例中，黏合剂可用纸张在其中接触胶膜并黏合到凹槽尖端的(多个)胶辊转移到凹槽尖端。以此方式，可以连续且均匀的方式精确地施加黏合剂。然后，使用诸如黏合、固化、润湿、干燥、加热及化学处理等各种技术在组合器中组合第一面层110、波纹状介质120、凸印介质130以及第二面层140。所得纸张产品400具有至少一个交叉波纹状介质120及至少一个线性凸印介质130，其中线性凸印介质包含带改进结构的凹槽轮廓。
虽然本文讨论的主题易于进行各种修改及替代构造，但是其某些绘示的实施例在图式中展示并且已在上文有详细描述。然而，应理解，无意将权利要求限制于所公开的具体形式，正相反，旨在覆盖落入权利要求的精神及范畴内的所有修改、替代构造及等效物。

Claims (20)

1.一种纸板产品，其包括：
具有多个凹槽的纸张介质，其中所述多个凹槽的至少一组各包括具有第一长度的第一线性腿部支撑结构、具有第一长度的第二线性腿部支撑结构以及具有第二长度的顶点结构，所述第二长度为所述第一长度的十分之一；及
纸张面层，其耦接至所述顶点结构。
2.根据权利要求1所述的纸板产品，其进一步包括相对于所述纸张介质固定的第二面层。
3.根据权利要求1所述的纸板产品，其进一步包括相对于所述纸张面层固定的第二纸张介质。
4.根据权利要求1所述的纸板产品，其中所述第一线性腿部结构及所述第二线性腿部结构相对于所述纸张面层以30度与60度之间的角度固定。
5.根据权利要求1所述的纸板产品，其中各顶点结构包括与所述纸张面层平行的扁平部分。
6.根据权利要求1所述的纸板产品，其中各顶点结构进一步包括扁平部分，所述扁平部分具有经配置以引导黏合剂来将各顶点结构耦接至所述纸张面层的沟槽。
7.根据权利要求1所述的纸板产品，其进一步包括耦接在各顶点结构与所述纸张面层之间的连续黏合剂线。
8.根据权利要求1所述的纸板产品，其中所述多个凹槽进一步包括：
第一多个凹槽，其各具有耦接至所述纸张面层的顶点结构，使得所述纸张面层在第一侧上被固定至所述纸张介质；及
第二多个凹槽，其各具有耦接至第二纸张面层的顶点结构，使得所述第二纸张面层在与所述第一侧相对的一侧上被固定至所述纸张介质。
9.一种纸板制作方法，其包括：
将纸张介质凸印成包含多个凹槽，其中所述多个凹槽的至少第二多个各包括具有第一长度的第一线性腿部支撑结构、具有第一长度的第二线性腿部支撑结构以及具有第二长度的顶点结构，所述第二长度为所述第一长度的十分之一；及
将纸张面层耦接至所述第二多个凹槽的至少第三多个顶点结构。
10.根据权利要求9所述的纸板制作方法，其进一步包括在各顶点结构中凸印沟槽。
11.根据权利要求9所述的纸板制作方法，其进一步包括在凸印之前加热所述纸张介质。
12.根据权利要求9所述的纸板制作方法，其进一步包括在凸印之前润湿所述纸张介质。
13.根据权利要求12所述的纸板制作方法，其进一步包括在凸印之后干燥所述纸张介质。
14.根据权利要求9所述的纸板制作方法，其进一步包括在凸印之后固化所述纸张介质。
15.根据权利要求9所述的纸板制作方法，其进一步包括将所述纸张介质胶合至所述纸张面层。
16.根据权利要求9所述的纸板制作方法，其进一步包括相对于所述纸张介质固定第二面层。
17.根据权利要求9所述的纸板制作方法，其中所述凸印进一步包括面向第一方向凸印第一组顶点结构且面向与所述第一方向相反的第二方向凸印第二组顶点结构。
18.一种纸板制作机，其包括：
凸印器，其经配置以将纸张介质凸印成包含多个凹槽，其中所述多个凹槽的至少第二多个各包括具有第一长度的第一线性腿部支撑结构、具有第一长度的第二线性腿部支撑结构以及具有第二长度的顶点结构，所述第二长度为所述第一长度的十分之一；及
组合器，其经配置以将纸张面层耦接至所述第二多个凹槽的至少第三多个线性顶点结构。
19.根据权利要求18所述的纸板制作机，其进一步包括调节器，所述调节器经配置以在凸印之前调节所述纸张介质。
20.根据权利要求18所述的纸板制作机，其中所述组合器进一步包括黏合剂施加器，所述黏合剂施加器经配置以定位各顶点结构并将黏合剂的连续线施加至各顶点结构。
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US20190232599A1 (en) 2019-08-01
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