GB2166687A - Manufacture of thermoformable corrugated paper board - Google Patents

Manufacture of thermoformable corrugated paper board Download PDF

Info

Publication number
GB2166687A
GB2166687A GB08426814A GB8426814A GB2166687A GB 2166687 A GB2166687 A GB 2166687A GB 08426814 A GB08426814 A GB 08426814A GB 8426814 A GB8426814 A GB 8426814A GB 2166687 A GB2166687 A GB 2166687A
Authority
GB
United Kingdom
Prior art keywords
web
paper
corrugated
facing
coating
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.)
Withdrawn
Application number
GB08426814A
Other versions
GB8426814D0 (en
Inventor
John Charles Wareham
Stephen Richard Charlton
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.)
FIRTH FURNISHINGS Ltd
Original Assignee
FIRTH FURNISHINGS Ltd
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 FIRTH FURNISHINGS Ltd filed Critical FIRTH FURNISHINGS Ltd
Priority to GB08426814A priority Critical patent/GB2166687A/en
Publication of GB8426814D0 publication Critical patent/GB8426814D0/en
Publication of GB2166687A publication Critical patent/GB2166687A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • 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 form; Layered products 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 form; Layered products 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 form; Layered products 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
    • 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
    • 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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered 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
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/26—All layers being made of paper or paperboard
    • 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B32B2317/122—Kraft paper
    • 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B32B2317/127—Corrugated cardboard

Abstract

A method of producing thermoformable corrugated paper board comprising the steps of (a) forming corrugations in a continuous web of base paper; (b) preheating a continuous web of facing paper having a precoating of a thermoplastics material on one side of its surfaces; and (c) bonding said one surface of the facing paper web to the corrugated base web by the application of heat and pressure to cause the thermoplastic precoating of the facing web to act as an adhesive between the two webs. The method is preferably performed within a conventional machine for the production of corrugated board.

Description

SPECIFICATION Manufacture of thermoformable corrugated paper board The present invention relates to the manufacture of thermoformable corrugated paper board.
Thermoformable corrugated paper board which can be shaped, using traditional press-forming or moulding techniques, has been used successfully as a building material, for example in the interiors of buildings and vehicles e.g. vehicle head liners.
One method of manufacture of thermoformable corrugated paper board is described in G.B. Patent Specification No. 1 481 050 published on 27th July, 1977. This method consists essentially of a specially designed corrugating machine which incorporates extrusion coating heads capable of interposing films of molten thermoplastics polymer between the face board and fluting material. Such a process is undoubtedly an efficient method for large scale production. However, it requires considerable capital investment in the form of purpose-designed corrugating machinery especially for this type of product.
The transportation costs of traditional types of corrugated board products (using starch-based adhesives) are a significant element in the total cost to the user and for this reason the Corrugated Board Industry has grown and adapted itself to meet the needs of its market by building corrugating manufacturing plants within reasonable distance from the customers. Thus there is a wide availability of board corrugating machinery already in existence.
It is an object of the present invention to enable the manufacture of thermoformable corrugated paper board using traditional/existing corrugation machinery without any fundamental modifications thereto.
In accordance with the present invention, there is provided a method of producing thermoformable corrugated paper board comprising: (a) forming corrugations in a continuous web of base paper; (b) pre-heating a continuous web of facing paper having a pre-coating of a thermoplastics material on one of its surfaces; and (c) bonding said one surface of the facing paper web to the corrugated base web by the application of heat pressure to cause the thermoplastic precoating of the facing web to act as an adhesive between the two webs.
The method is preferably performed within a conventional machine for the production of corrugated board as described hereinafter.
The invention is described further hereinafter, by way of example only, with reference to the accompanying drawing which is a diagrammatic side elevation of one embodiment of a thermoformable corrugated paper board producing apparatus in accordance with the present invention.
The illustrated apparatus is essentially a conventional corrugated board producing apparatus with certain modifications as described hereinafter. In the conventional machine, a base fluting material 10 is unwound from a reel and passed between a plurality of toothed corrugated rolls 12. A liner material, normally plain paper, is unwound from a reel 14 and fed to a plurality of steam-heated rolls 16 via a pre-heater 18. During or after passage around the heated rolls 16, the liner material is supplied with a coating of starch and is then brought into contact with the corrugated base material whereby the liner material is adhered to the base material at the apex of each corrugation by the starch. A second sheet of liner material can, if required, be adhered to the other side of the corrugated base material to form double-faced board.
To perform the present method of production of thermoformable corrugated board, the principal differences are that the starch applicator is not used and that the plain liner material is replaced by a material which itself already carries a facing of a thermoplastic material. A preferred example of such a material is conventional Kraft paper.
In detail, the preferred method in accordance with the present invention comprises the following steps: (1) The core sheet of fluting material 10 is preheated to about 130 - 1500C. and is then fed to the corrugating rolls 12 at a ratio to the peripheral speed of the corrugating rolls, corresponding to the corrugation ratio. This is defined as the length of the core sheet prior to shaping, divided by the length of the core sheet after shaping.
(2) Shaping the core sheet using the corrugating rolls 12.
(3) Feeding the shaped core sheet while retaining the shaped core sheet on the surface of one of the corrugating rolls (12).
(4) Pre-heating a face sheet 20, which has a precoating of a thermoplastics material, to a temperature of about 60 - 160"C. in the pre-heater 18.
(5) Feeding the face sheet 20 under controlled tension to the corrugated core sheet 10, while continuing to heat the face sheet 20 to a temperature of about 130 - 180"C. by means of the steamheated rolls 16.
(6) Bonding the face sheet 20 to the apices of the corrugations in the core sheet 10 by the application of heat and pressure, causing the thermoplastic pre-coating of the face sheet to act as an adhesive between the two sheets.
(7) Removing the thus formed single-faced board under controlled tension, for either winding onto a roll 22, cutting into sheets, or feeding into a double backing section (not shown) for the application of a second face sheet in like manner.
The papers used for the face sheets and core sheets can be selected from papers such as Kraft paper, water-repelling paper, water proofing paper, imitation Kraft paper, semi-chemical pulp paper, chemical pulp paper, ground pulp paper, straw pulp paper, jute paper and ordinary paper.
The substance of the papers used is preferably in the range 180 - 400 gm/m2 for the face sheets and 125 - 250 gm/m2 for the core sheets.
The thermoplastic pre-coating of the face sheet may be of any thermoplastic material, but is pref erably of L.D. (low density) polyethylene, H.D.
(high density) polyethylene or polypropylene.
Kraft and other paper products are readily available, already pre-coated with various thermoplastics resins according to end use.
Boards can be produced using A, B or E fluting configurations as required for particular end uses.
By means of the aforegoing process, thermoplastic corrugated boards can be produced by tra- ditional corrugating machines so that local markets can be serviced efficiently as the demand arises.
This enables supplies of board to be produced and users serviced locally. Also since the machine is not dedicated to this one type of product range, the effective machine utilisation is not at risk due to dependence on this particular type of product.

Claims (8)

1. A method of producing thermoformable corrugated paper board comprising: (a) forming corrugations in a continuous web of base paper; (b) pre-heating a continuous web of facing paper having a pre-coating of a thermoplastics material on one of its surfaces; and (c) bonding said one surface of the facing paper web to the corrugated base web by the application of heat and pressure to cause the thermoplastic pre-coating of the facing web to act as an adhesive between the two webs.
2. A method as claimed in claim 1, wherein the corrugations are formed in the base paper using a conventional machine for the production of corrugated board.
3. A method as claimed in claim 1 or 2, wherein the web of base paper is pre-heated to a tempera ture within the range 130 - 1500C prior to being formed with corrugations.
4. A method as claimed in claim 1, 2 or 3, wherein the facing paper having the pre-coating of thermoplastics material is preheated to a temperature within the range 60 - 160"C in a pre-heater prior to being brought into contact with the corrugated base paper.
5. A method as claimed in any of claims 1 to 4, wherein the facing paper is made of Kraft paper.
6. A method as claimed in any of claims 1 to 4, wherein the thermoplastic pre-coating on the facing web is low density polyethylene, high density polyethylene or polypropylene.
7. A method as claimed in any of claims 1 to 6, wherein a second, pre-heated continuous web of facing material, having a pre-coating of a thermoplastics material on one of its surfaces, is bonded to the other side of the corrugated web to that bonded said first-mentioned web of facing paper, by the application of heat and pressure to cause the thermoplastic pre-coating of the second facing web to act as an adhesive between the latter facing web and the corrugated web.
8. A method of producing thermoformable corrugated paper board, substantially as hereinbefore described with reference to the accompanying drawing.
GB08426814A 1984-10-23 1984-10-23 Manufacture of thermoformable corrugated paper board Withdrawn GB2166687A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB08426814A GB2166687A (en) 1984-10-23 1984-10-23 Manufacture of thermoformable corrugated paper board

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB08426814A GB2166687A (en) 1984-10-23 1984-10-23 Manufacture of thermoformable corrugated paper board

Publications (2)

Publication Number Publication Date
GB8426814D0 GB8426814D0 (en) 1984-11-28
GB2166687A true GB2166687A (en) 1986-05-14

Family

ID=10568635

Family Applications (1)

Application Number Title Priority Date Filing Date
GB08426814A Withdrawn GB2166687A (en) 1984-10-23 1984-10-23 Manufacture of thermoformable corrugated paper board

Country Status (1)

Country Link
GB (1) GB2166687A (en)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1099273A (en) * 1965-02-27 1968-01-17 Regal Packaging Ltd Improvements in or relating to corrugated board and method for its manufacture
GB1194708A (en) * 1966-06-20 1970-06-10 Palson Corp A B Improvements in or relating to methods and apparatus for manufacturing Corrugated Board
GB1215149A (en) * 1967-12-14 1970-12-09 Int Paper Co Improvements in or relating to manufacture of corrugated paperboard
GB1293882A (en) * 1969-02-24 1972-10-25 Cons Paper Bahamas Ltd Method and apparatus for bonding thermoplastic materials and products thereof
GB1324862A (en) * 1969-08-29 1973-07-25 Edkvist A E Methods and apparatus for the manufacture of corrugated board

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1099273A (en) * 1965-02-27 1968-01-17 Regal Packaging Ltd Improvements in or relating to corrugated board and method for its manufacture
GB1194708A (en) * 1966-06-20 1970-06-10 Palson Corp A B Improvements in or relating to methods and apparatus for manufacturing Corrugated Board
GB1215149A (en) * 1967-12-14 1970-12-09 Int Paper Co Improvements in or relating to manufacture of corrugated paperboard
GB1293882A (en) * 1969-02-24 1972-10-25 Cons Paper Bahamas Ltd Method and apparatus for bonding thermoplastic materials and products thereof
GB1324862A (en) * 1969-08-29 1973-07-25 Edkvist A E Methods and apparatus for the manufacture of corrugated board

Also Published As

Publication number Publication date
GB8426814D0 (en) 1984-11-28

Similar Documents

Publication Publication Date Title
US6139938A (en) High flute density, printable, corrugated paperboard
US4086116A (en) Corrugated cardboard sheet and method for producing same
US4204016A (en) Reinforced paper products
RU2262444C2 (en) Method and device for producing cardboard
US5098757A (en) Tear tape opening system
US4871406A (en) Process for on-line lamination of plastic
US4765855A (en) Method of making a sandwich material with internal undulations and protective layers
US3811987A (en) Apparatus for bonding thermoplastic materials and products thereof
US5324383A (en) Apparatus for forming laminated corrugated materials
US3920496A (en) Corrugated paperboard and its method of manufacture
EP0109257A2 (en) Corrugated paper board and its method of manufacture
US4220490A (en) Method of making a laminate with removable scored paper backing
US4544436A (en) Apparatus for producing composite corrugating media for the manufacture of corrugated fiberboard and method of making same
US4339292A (en) Method for producing a reinforced, double-faced corrugated board
CN109311258B (en) System and method for producing multi-ply paperboard with improved structured media
US5362346A (en) Method of making reinforced corrugated board
US4140566A (en) Reinforced sheet-type wallcovering
US4203790A (en) Method of forming wire reinforced corrugated board
US4311746A (en) Corrugated paper board
FI90747B (en) Apparatus for making single-sided corrugated cardboard and process for making corrugated cardboard
GB2166687A (en) Manufacture of thermoformable corrugated paper board
WO1990011887A1 (en) Procedure for the manufacturing of corrugated board or the like
US4274905A (en) Apparatus for making reinforced, double faced corrugated board
AU615053B2 (en) Manufacturing corrugated board
EP0044617B1 (en) Process for the preparation of cardboard of the corrugated type

Legal Events

Date Code Title Description
WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)