GB2175247A - Manufacture of corrugated board - Google Patents
Manufacture of corrugated board Download PDFInfo
- Publication number
- GB2175247A GB2175247A GB08611152A GB8611152A GB2175247A GB 2175247 A GB2175247 A GB 2175247A GB 08611152 A GB08611152 A GB 08611152A GB 8611152 A GB8611152 A GB 8611152A GB 2175247 A GB2175247 A GB 2175247A
- Authority
- GB
- United Kingdom
- Prior art keywords
- resin
- adhesive
- mixing
- board
- mixing tank
- 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.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 239000000853 adhesive Substances 0.000 claims abstract description 53
- 230000001070 adhesive effect Effects 0.000 claims abstract description 53
- 239000011347 resin Substances 0.000 claims abstract description 50
- 229920005989 resin Polymers 0.000 claims abstract description 50
- 238000000034 method Methods 0.000 claims abstract description 24
- 238000004078 waterproofing Methods 0.000 claims abstract description 12
- 229920002472 Starch Polymers 0.000 claims abstract description 6
- 239000000203 mixture Substances 0.000 claims abstract description 6
- 235000019698 starch Nutrition 0.000 claims abstract description 6
- 239000008107 starch Substances 0.000 claims abstract description 6
- 239000000523 sample Substances 0.000 claims description 12
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical group O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 claims description 8
- 238000003860 storage Methods 0.000 claims description 7
- 239000003054 catalyst Substances 0.000 claims description 3
- 230000001276 controlling effect Effects 0.000 claims 2
- 125000002485 formyl group Chemical class [H]C(*)=O 0.000 claims 1
- 230000001105 regulatory effect Effects 0.000 claims 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 238000004132 cross linking Methods 0.000 description 2
- 239000000654 additive Substances 0.000 description 1
- 150000001299 aldehydes Chemical class 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- KVBYPTUGEKVEIJ-UHFFFAOYSA-N benzene-1,3-diol;formaldehyde Chemical compound O=C.OC1=CC=CC(O)=C1 KVBYPTUGEKVEIJ-UHFFFAOYSA-N 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 235000011121 sodium hydroxide Nutrition 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/30—Multi-ply
- D21H27/40—Multi-ply at least one of the sheets being non-planar, e.g. crêped
-
- 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
- B31F1/2809—Methods characterised by the chemical composition of the glue
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J103/00—Adhesives based on starch, amylose or amylopectin or on their derivatives or degradation products
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2666/00—Composition of polymers characterized by a further compound in the blend, being organic macromolecular compounds, natural resins, waxes or and bituminous materials, non-macromolecular organic substances, inorganic substances or characterized by their function in the composition
- C08L2666/02—Organic macromolecular compounds, natural resins, waxes or and bituminous materials
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Adhesives Or Adhesive Processes (AREA)
Abstract
A process for manufacturing corrugated board by combining a non-waterproof starch based adhesive and a waterproofing resin continuously and in small quantities without storing the mixture to ensure improved wet strength board performance.
Description
SPECIFICATION
Manufacture of corrugated board
This invention relates to a method of manufacture of corrugated board and more particularly to a method of manufacture of high wet strength adhesives for use therein.
In the existing method of manufacture of corrugated board, starch based adhesives are prepared in a batch process and stored in tanks holding quantities sufficient for several hours of consumption by corrugating machines and involves mixing substantial volumes. The adhesive is fed directly from the storagetanksto glueline stations on the corrugating machine.
Hitherto there has been no reliable method for measuring the wet strength performance of corrugated board adhesives. It has now been found that the wet strength ofthe adhesive bond in the finished board falls substantially as a function of the residence time that the mixture is stored after the waterproofing resin has been mixed with the adhesive and prior to application of the adhesive.
Thus mostwaterproofing resins used by the corrugating industry lose their effectiveness due to premature crosslinking within a couple of hours, which can resu It in poor bonding, low production speeds and poorwater resistance of the bonds produced. This is illustrated in thefollowing Table I.
TABLE Time Elapsed Wet Strength
Samples After Resin Added (Newtons/Metre)
45Min. 139 2 Hrs. 122 II 30 Min. 236
II 2 Hrs. 184
II 3Hrs. 165 lil 45 Min. 214
III 2Hrs. 126
IV 45 Min. 70
IV 2Hrs. 34
An object of the present invention is a method of manufacture of corrugating adhesives and of corrugated board which improves the uniformity of wet strength of the adhesive bond in the finished board, orwhich otherwise improves the efficiency of the corrugated process.
According to one aspect of the invention consists in a method of manufacture of corrugated board comprising the steps of, storing a waterproofing resin in a first container, storing a non-waterproof starch based adhesive in a second container, combining the resin and the adhesive in a predetermined ratio downstream of said first and second containers, mixing said resin and adhesive and feeding the mixed combination to the glue trays of a corrugated machineforapplication to board substantiallywithoutfurther storage.
Preferred embodiments of the invention enable production of corrugated board having a higherwet strength than hitherto achievable.
The herein described invention relatesto a processfor automatically dosing waterproofing resin additives to corrugated adhesives. The dosing is controlled such that small quantities of resin treated adhesive are being produced continuously. This eliminates the historical problems associated with the short pot life of such resin treated adhesives, and enables higher levels of resin to be used to improve wet strength board performance.
A preferred embodiment of the invention will now be described by way of example only with reference to the schematic diagram of Figure 1.
In the process illustrated, a small volume of non-waterproof starch based adhesive is treated with resin at each separate singlefacter and doublebacker station. This is accomplished at each station by connecting tothe existing sump (1) via a float valve (2), a small stirred tank or in line mixing chamber (3) cpntaining a high/low level control probe (4) and measuring thefresh adhesive supply to this tank (3) via a remotely controlled valve (5). The sump pump (6) which normally recycles the adhesive to the main storagetank, is altered to supplythe adesivetrays (7,8) directly. Unless air operated pumps are used a bleed pipe and valve allowing some return to sump (1) is utilised to prevent pump burnout should the tray supply valve be closed accidentally.
Alternatively the float valve (2) can be replaced by an air activated or motorised valve, (directed by conductivity probes), to dropthetreated adhesive from Tank (3) into the sump (1 An air operated pump can be used to deliver the treated adhesive from the sump (1) to the adhesive applicatortrays where gravity returns it to the sump.
The waterproofing resin is held in either a bulkstoragetank(9) ora disposable drum and is pumped to each individual station. In the preferred embodiment of the invention the resin is pumped to small dosing tanks (10) situated above each tank (3) via remotely controlled valves (11) with each tankalso having a remote controlled valve (12) to measure the amount of resin added to tank(3).
Level control probes (13) in dosing tanks (10) allowtwovolumes of resinto be stored priorto addition. The highervolume of resin is added to the adhesive at the very start ofthe cycle to treat adhesive contained in the tanks (3), sumps (1) and trays (7,8). On subsequent cycles a lower volume of resin is added to treat onlythe fresh adhesive introduced into tank (3), since the adhesive in the sump and trays is already treated. The amountof adhesivetreated on any given cycleisthat required to provide notgreaterthan two hours running at each station and preferably is an amountwhich will be consumed within 1 hour or less, thereby ensuring that relatively fresh waterproof adhesive is always used.
An alternative method of measuring the amountof resin to be added is to use a remotely controlled valve leading directly into tank (3). This valve would open fora settimeto delivera selected volume of resin at constantflow rate. The process can be modified to add more than one resin component if so desired, our a blend of aldehyde based resins or resins and catalysts, such as formaldehyde.
Adjustment of the level control probes in the dosing tank (10) enables any level of resin to be added.
(Normally a higher resin level is used atthesinglefacerstationsthan atthe doublefacers).
With some types of corrugators, the single facer sumps may need to incorporate a waterjacketto cool the adhesive and reduce gelling in the trays.
Corrugating plants not using a "ring-main" adhesive system would need to install an air operated pumpto facilitate supply interruption or alternatively install a bypass line and valve afterthe pump leading back intothe storage tank (14).
The process described herein uses a programmable controller or relay bankto co-ordinate all the sequences involved.
It will be understood thattank (3) should be as small as possible consistentwith satisfactory mixing Tank (3) is not intended for storage after mixing ofthe adhesive with the waterproofing resin since the adhesive should be applied as soon as possible.
By way of illustrating the improvement obtainable by the method of the invention, tests were conducted in which various resins and cross-linking chemicals were added to corrugating adhesives, principally starch and samples taken at various intervals. The adhesive samples were used to prepare in the laboratory small squares of corrugated board which were subsequently tested forwetstrength.
It can be seen from the results in Table I thatthere was a marked drop in performance of the adhesive as time progresses and the resin cross-links.
In one example, water resistant corrugating adhesive (Sample A) was prepared by mixing together458g of commercially available liquid corrugating adhesive, 32g of PR-900 (a commercially available resorcinol formaldehyde resin) and 20.59 offormalin.
Test pieces of corrugated board were prepared in the laboratory 15 minutes, 1 hour, 2 hours and 3 hours after combination ofthe above ingredients. These test pieces were cured for 24 hours and tested fortheirwater resistance strength. The results were as follows: TABLE II
Sample A
Time Interval After Mixing Water Resistance Force (g/cm) 1SMins 224 1 Hour 201 2 Hours 173 3 Hours The adhesive was too thickto
use.
Another sample (Sample B) was prepared by mixing 458g of commercial corrugating adhesive, 24g of
PR-900 and 16g of formalin. Test pieces were prepared at intervals of 15 mins, 1 hour and 3 hours aftermixing.
The water resistant results were as follows:
TABLE Ill
Sample B
Time interval After Mixing Water Resistance Force (g/cm) 15Mins 170 1Hour 100 3 Hours 79
These effects are even more pronounced with modern corrugating adhesives because high speed machines require low gel points which are obtained by increasing caustic soda levels in the formulation. Unfortunately mostwaterproofing resins are alkaline cured which further aggravates the pot life problem described above.
Waterproofed adhesive which is kept overnight, ortheweekend, often has to be dumped because if used, production speeds and bond quality deteriorate to an unacceptable level.
The method and apparatus hereindescribed may be varied to an extent which will be apparent to those skilled in the artfrom the teaching hereof without departing from the scope ofthe invention herein described.
Claims (13)
1. A method of manufacture of corrugated board comprising the steps of: (a) storing a waterproofing resin in a first container; (b) storing a non-waterproof starch based adhesive in a second container; (c) combining the resin and the adhesive in a predetermined ratio downstream ofthefirst and second containers, (d) mixing the resin and adhesive and (e)feeding the mixed combination to the gluetrays ofa corrugated machineforapplicationto board substantially without further storage.
2. A method according to claim 1 wherein the mixed combination is applied to board within 1 hourof mixing.
3. A method to claim 1 wherein the mixed combination is applied to board within 15 minutes of mixing.
4. A method according to any preceding claim wherein the waterproofing resin is an aldehyde based resin.
5. A method according to any one of claims 1 to 3 wherein the waterproofing resin is a blend ofaldehyde based resins.
6. A method according to anyone of claims 1 to 3 wherein the waterproofing resin is a blend ofaldehyde resins and catalysts.
7. A method according to claim 6wherein a catalyst is formaldehyde.
8. A method according to any preceding claim wherein a predetermined amountofthe non-waterproof adhesive is added to a mixing tank;
a waterproofing resin is added to the mixing tankfrom a dosing tank;
the resin is combined into the non-waterproof adhesive in the mixing tank;
the combination is transferred from the mixing tank or a sumptothe gluetrays of a corrugated machine;
a portion ofthe combination is applied to the board;
the unused portion of the mixed combination is returned to the mixing tank or sump; and
further controlled quantities of non-waterproof adhesive and of resin are added to the mixing tank via probe controlled valves to maintain a predetermined proportion of resin to non-waterproof adhesive.
9. Apparatus for applying a mixed combination of non-waterproof adhesive and waterproofing resin to corrugated board comprising: (a) an adhesive storage tank; (b) a resin storage tank; (c) a mixing tank; (d) a sump; (e) a high/low level probe in the mixing tank controlling a valveforregulating the quantity of adhesive from the adhesive storage tank into the mixing tank;; (f) a second high/low level probe in the resin storagetankcontrolling a valvefor regulating the quantity of resin from the resin storagetank into the mixing tankwhereby a predetermined quantity of resin is initially added to the mixing tank and a smaller quantity is continuously added thereafter and (g) means to deliver a portion of combined adhesive and resin to corrugated board and (h) means to return any unused portion thereof to the mixing tankorthesump.
10. Apparatus according to claim 9 wherein the meansto deliver and means to return comprises a sump pump, an automatic valve controlling thevolume of combined adhesive and resin in thesump and a bleed valve in parallel with a line from the pump to board.
11. A method of manufacture of corrugated board substantially as described herein with reference to the accompanying drawing.
12. Apparatus as described herein with reference to the accompanying drawing.
13. Corrugated board manufactured bythe method claimed in any one of claims 1 to 8 and 11.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AUPH045985 | 1985-05-07 | ||
| AU57034/86A AU582848B2 (en) | 1985-05-07 | 1986-05-01 | Apparatus for applying a mixed combination of adhesive and resin to corrugated board |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB8611152D0 GB8611152D0 (en) | 1986-06-11 |
| GB2175247A true GB2175247A (en) | 1986-11-26 |
| GB2175247B GB2175247B (en) | 1989-06-28 |
Family
ID=25631512
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8611152A Expired GB2175247B (en) | 1985-05-07 | 1986-05-07 | Manufacture of corrugated board |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2175247B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0356219A2 (en) * | 1988-08-23 | 1990-02-28 | George Weston Foods Limited | High compression strength corrugated board |
-
1986
- 1986-05-07 GB GB8611152A patent/GB2175247B/en not_active Expired
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0356219A2 (en) * | 1988-08-23 | 1990-02-28 | George Weston Foods Limited | High compression strength corrugated board |
| EP0356219A3 (en) * | 1988-08-23 | 1990-11-07 | George Weston Foods Limited | High compression strength corrugated board |
Also Published As
| Publication number | Publication date |
|---|---|
| GB8611152D0 (en) | 1986-06-11 |
| GB2175247B (en) | 1989-06-28 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 19950507 |