JP2015178279A - Improved method and apparatus for forming corrugated board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an improved method of, and an improved apparatus for, forming corrugated board.SOLUTION: The present invention relates to an apparatus for bonding a planar porous sheet material to a porous corrugated sheet material in a continuous process, the apparatus comprising: a linear corrugator module (300) comprising a corrugating roller (306); an endless fluted conveyor belt (301) wherein the fluted surface (302) of the conveyor belt intermeshes with the teeth on the corrugating roller; a glue applicator (308); and an endless tensioned belt assembly which holds the planar and corrugated sheets together so a bond is formed between them. The production rate (and therefore the dimensions of the corrugating roll) is governed by the formula RP=DHT/BT, where RP is the rate of production in meters/minute; DHT is the distance in meters for which the respective sheets are held together; and BT is the bond time of the adhesive in minutes.

Description

  The present invention relates to an improved method and apparatus for forming cardboard. Specifically, the present invention discloses a method and apparatus for making single-sided cardboard and / or in some embodiments, double-sided cardboard.

  For the sake of brevity of reference, the present invention will now be described with respect to the production of single-sided cardboard, which is limited because certain embodiments of the invention can be used to produce double-sided cardboard. Should not be seen as being.

  The terms corrugated and fluted and their grammatical variants as used throughout this specification are used interchangeably and refer to a series of alternating ridges (tops) and grooves (valleys).

  Single-sided corrugated paper is very well known and is widely used in industry, especially in packaging used as protective pads and packaging. It is also used as a basic component in the production of standard cardboard (ie double-sided cardboard) and many structural objects such as boxes, panels, pallets and the like.

  Single sided corrugated paper sheets are bonded together to form multilayer corrugated paper of various thicknesses and strengths. One of the reasons why corrugated paper is widely used is its relative light weight, rigidity, and strength.

  Single-sided corrugated paper is produced by fixing flute-like sheet material paper (generally recycled paper) on a liner sheet. The liner sheet is typically kraft paper, but other materials may be used.

  In conventional machines for producing single-sided (also called flute) cardboard, a flute sheet is formed by passing a sheet of paper between two corrugating rollers. Two rollers are arrange | positioned so that a tooth | gear may mesh | engage on the outer periphery of each roller. A sheet of paper is fed between the teeth of the rollers and the paper is pushed into the flute when the teeth of the rollers are engaged. The fluted sheet is typically kept in contact with the teeth on the outer periphery of one of the corrugating rollers by means of the vacuum created in the corrugating cylinder until at least the liner is added.

  A series of adhesives are applied to the top of the flute to secure the liner to the flute paper. The liner paper sheet is typically pressed onto the top by a smooth roller to secure the liner to the fluted paper, thereby forming a single-sided (or fluted) ball.

  A limiting factor in this process is the condition that the contact between the fluted sheet and the liner must be maintained for a time sufficient for the adhesive to cure and a bond to form. This time can be several seconds or more at standard room temperature and pressure. However, time has traditionally been shortened by raising the temperature during the anchoring process and applying pressure to the joint between the top and the liner.

  High pressure steam is typically used to heat the moving cylinders on which the flute and liner papers move and raise the temperature of the paper. The typical operating temperature of the corrugating roller can be about 150-200 ° C.

  Pressure can be applied to the joint between the liner and each top by means of a pressure roller arranged to press the liner against the top covered with adhesive. Due to the relatively short contact time between the pressure roller and the corrugating roller (holding the fluted sheet), high pressure is generally required to significantly accelerate the anchoring process.

  With this type of arrangement (high pressure in addition to heating), the fixing time can be reduced to a few hundredths of a second, thus enabling high-speed production of single-sided board paper. However, one of the problems with this arrangement is that the high pressure provided by the pressure roller deforms the paper, leaving an unsightly mark on the liner paper surface and reducing its value.

  There are other devices such as endless belts in some machines that press the liner and fluted sheets as they move around the corrugating rollers. This extends the time during which pressure is applied, so lower pressures can be used so as not to deform the cardboard surface.

  A typical arrangement of an apparatus for producing the single-sided cardboard generally described above is disclosed in US Pat.

  The mechanical device illustrated in US Pat. No. 6,057,059 is in contact with only one third of the circumference of the corrugated ring, as is apparent from the fluted sheet / liner combination. Has a limited contact time (and therefore a settling time). Such limited contact times require the use of quick-drying adhesives such as starchy glues typically used in industry. Unfortunately, starchy glues require the application of heat (about 150 ° C.) to activate. This leads to the disadvantages described below.

  The use of heat can reduce the time required to form a bond between the fluted sheet and the liner, thereby promoting high throughput, but for the cost and process of machinery Presents several technical issues that significantly increase the operating costs of The use of high pressure steam always requires boilers, piping and housing to ensure steam containment. Additional safety measures are required to ensure that steam is correctly generated and managed and that the heat produced does not pose a safety hazard during machine operation. Typically, a heating engineer is required to operate the boiler and maintain the heating system, adding to the cost of additional technicians and, in addition, stopping production if there are no appropriately qualified engineers. It may be necessary.

  The addition of a high-pressure steam system to the machine's key elements inevitably increases the size of the machine and thus increases the space required for machine operation. The need for wider space increases the operational costs of producing single-sided flute plates.

  Furthermore, high pressure steam is very corrosive to many materials, and parts of these machines that are exposed to steam, such as corrugated rollers, need to be made of a corrosion resistant material. Such materials, such as alloy steel 48 CrMo hardened to the HRC 58-62 standard, are generally expensive and heavy. Devices made of such materials may require substantial support structures to maintain the structural integrity of the machine.

  The problem with both methods of applying pressure (rollers and belts) is that it may cause some of the adhesive to diffuse where the applied pressure is not the contact line between the liner and the top of the fluted sheet. The surrounding paper is damp. Adhesive that diffuses away from the top (ie, contact line) is not under pressure and therefore does not dry as quickly as the adhesive along the top, typically forming a bond between two sheets of material. do not do. As a result, the extra (spread) adhesive that may cause cardboard deformation problems due to drying at a non-uniform speed will remain wet for a long time and cut or further processed until completely dry Difficult to do. A common solution is to apply additional heat to dry the paper and excess (diffused) adhesive. However, this increases production costs and may limit the speed of the process.

  Since the diffused adhesive can also be transferred to the surface of the device (eg, roller or belt) that applies the pressure, the surface needs to be continuously cleaned. In addition, some of the diffused adhesive can be transferred to the outer surface of the liner, which can cause problems during wrapping and storage because adjacent sheets can stick together and make the product unusable. There is a possibility. In addition, excess diffused adhesive can leave marks on the surface, adversely affecting the appearance and value of the cardboard.

  Further disadvantages of conventional machines are typically both feed rollers (used to feed paper onto corrugating rollers, whether fluted or used as liners) and corrugating rollers Is heated before adding the adhesive to dry the paper. This is done to reduce the water content of the paper and to shorten the fixing time. Generation of high-pressure steam for heating the corrugating roller and preheating the paper requires a huge amount of energy. All of the above factors can significantly increase the cost of single-sided cardboard made by conventional processes and machines.

Applicants have previously addressed many of these issues in their PCT application WO 2009/145642. However, when using a cooling process to manufacture corrugated sheet material,
It would also be useful if methods and formulas were provided that could be used to manipulate machine configuration and / or accurately predict production rates.

  In particular, it would be useful if an optimized manufacturing method was provided.

  Previously, in WO 2009/145642, the applicant considered that the production rate was determined by the diameter and rotational speed of the second (larger) corrugating roller. Applicant also considered the fact that an endless belt extending around three quarters of the second corrugating roller fixed the rotational speed to about 20 revolutions per minute. Applicant noted that for a second corrugating roller having a diameter of 1.6 m, the production rate was about 100 m / min for single-sided board.

  However, the above production speed is a fast estimate at best, and more accurate production to ensure that the machine meets the expected requirements before building the machine to produce single-sided boards It soon became clear that a speed equation was necessary. The need for a more accurate production rate equation was particularly apparent given the time, expense, and cost of building the corrugating device. It would be useful if a more accurate way to determine the production rate in advance was provided.

  Currently, due to the heat used in the production of corrugated sheet material, it is not possible to stick the preprinted sheet material directly to the corrugated sheet material because the heat breaks the print.

  Thus, typically flexographic rubber printing stereos are used to apply printing, but these require that pressure be applied in order to apply ink to a liner affixed to corrugated sheet material. When considered, this breaks the flute of the corrugated sheet material. This reduces the strength (ie, structural integrity) of the ball because the flute is slightly crushed by the flexographic comb printing stereo. In addition, the ink rollers only form poor quality prints on the balls, such as found in many apples or other fruit boxes.

  Therefore, it would be useful if a scheme was provided to apply preprinted sheet material directly to corrugated sheet material as part of a continuous in-line process for the production of single or double sided balls. In particular, the method that allows pre-printed sheets to form a liner reduces the amount of material and manufacturing steps and time required to manufacture a box or other promotional material from cardboard, It will be beneficial.

A further problem with conventional corrugating machines is
-Applying heat to the paper, at the same time,
-A penetrating brake force applied to the paper that is peeled off the reel stand to keep its path straight;
All will produce corrugated cardboard that is not a flat sheet (observed with the naked eye), which would be a high-value end product with rounded corners and thus no loss.

  When paper is wound on a reel in pulp and paper mills, it is exposed to left and right tension, and a penetrating brake is required to deflect the paper from a straight path when it is unwound from the reel.

US Pat. No. 5,951,817 (Thomas)

  The object of the present invention is to address the aforementioned problems, or at least publicly provide a useful choice.

  All references, including any patents or patent applications cited herein are hereby incorporated by reference. Neither reference is admitted to constitute prior art. The bibliography states what the author claims and the applicant has the right to question the accuracy and validity of the cited document. Several prior art publications may be referred to herein, but this reference is not intended to refer to any of these documents, nor any general knowledge of the art in New Zealand or any other country. It will be clearly understood that it does not constitute a recognition that forms part of.

  It is recognized that the term “comprising” can include either exclusive or non-exclusive meaning in jurisdictions. For the purposes of this specification, and unless otherwise specified, the term “comprising” shall have a non-exclusive meaning, that is, not only the listed components to which it directly refers, It is taken to mean including other unspecified components or elements. This logical interpretation is also used when the terms “comprised” or “comprising” are used in reference to one or more steps of a method or process.

  Further aspects and advantages of the present invention will become apparent from the following description, given by way of example only.

  As used herein, the term “continuous process” refers to a flat sheet material so that corrugated sheet material allows the production of single-sided balls through a single continuous (ie, non-intermittent) process. Refers to a process that can be secured to a flat sheet material immediately after forming the corrugated sheet material by the engagement of large and smaller corrugating rollers that impart flutes.

In accordance with one aspect of the present invention, there is provided a method of securing a substantially planar sheet material, both porous, to a corrugated sheet material using a continuous process, the method comprising:
a) applying a controlled amount of adhesive to the apex contact portion of the corrugated sheet material;
b) at the specified pressure, holding the respective flat sheet and corrugated sheet together for a specified pressing period, thereby forming a bond between them.

  Preferably step a) and step b) are performed at ambient temperature.

  In some preferred embodiments, the adhesive is applied and cured at ambient temperature. In other embodiments, the adhesive may be heated prior to application (depending on the nature of the adhesive used), but in all such embodiments, the selected adhesive will cure at ambient temperature. Must be like that.

The term “apex contact portion” as used herein refers to the top of the top of the flute on the corrugated sheet of material that is pressed adjacent to the planar sheet in step b) of the process. The apex contact portion includes the apex of the top and its region on either side that is pressed into direct contact with the planar (liner) sheet and then secured to it by diffusion of the adhesive. The inventor has discovered that serious problems arise when the adhesive extends beyond the apex contact to the sides of the corrugated structure. Such a problem
The fixing time increases because the porosity of the liner cannot absorb the moisture of the adhesive outside the apex contact area;
-Waste of adhesive,
-The flute is depressed,
-When single-sided boards are used to produce double-sided balls, including curling the board.

  Preferably, the specified pressure is as high as possible without compromising the integrity of the paper. In preferred embodiments, the specified pressure is less than the tear strength of the selected porous sheet material. The inventor has discovered that the higher the specified pressure, the faster the fixing time.

  The porous sheet material may generally be paper, but can include other sheet materials having similar characteristics suitable for forming corrugated cardboard. The main feature of the sheet material is that the porosity is sufficient to absorb substantially the majority of the moisture of the adhesive at the specified pressure.

In accordance with another aspect of the present invention, a method is provided for securing a substantially planar porous sheet material to a corrugated porous sheet material using substantially the continuous process described above, wherein the production rate is of the formula:
RP = DHT / BT
Where RP is the production rate in meters / minute, DHT is the distance in meters that the two respective sheets are held together, and BT is in minutes This is the adhesive fixing time.

In accordance with another aspect of the present invention, an endless belt is provided that provides a method of manufacturing a device having large and small meshing corrugating rollers for the continuous production of single-sided porous sheet material to achieve a desired production rate. To determine the diameter of the large corrugating roller and the percentage of the circumference of the large corrugating roller that the assembly needs to apply pressure, the formula:
RP = DHT / BT
Where RP is the production rate in meters / minute, DHT is the distance in meters where the two respective sheets are held together, and BT is in minutes This is the adhesive fixing time.

In accordance with another aspect of the present invention, in order to produce a single-sided corrugated porous sheet material as part of a continuous process utilizing a large corrugating roller and a smaller corrugating roller and a glue applicator assembly with an endless tension belt, Providing a device for fixing a planar flat sheet material to a corrugated porous sheet material, the production rate of the device is:
RP = DHT / BT
Where RP is the production rate in meters / minute, DHT is the distance in meters that the two respective sheets are held together, and BT is in minutes This is the adhesive fixing time.

As used herein, the term “designated pressing period” refers to the formula:
BT = DHT / RP
The sticking time (BT) calculated by, where RP is the production rate in meters / minute and DHT is the distance in meters at which the two respective sheets are held together.

  If the apparatus of the present invention includes a large diameter corrugating roller that meshes with a smaller diameter corrugating roller, the value of DHT is DHT = X. Defined by (π2r), where r is the radius of the large corrugating roller and X is sufficient to ensure that the belt of the endless tension belt assembly is sufficient for the glue applicator assembly and the smaller corrugating roller. However, it is the ratio of the circumference C of a large corrugating roller to which pressure can be applied. The maximum value of X increases as the diameter of the large corrugating roller increases, as further outlined below.

  As used herein, terms such as “large roller”, “large diameter corrugating roller”, or “large diameter mesh corrugating roller” are interchangeable, “smaller diameter roller”, “smaller” "Diameter corrugating roller" or a corrugating roller having a diameter that is at least twice the diameter of a "smaller diameter mesh corrugating roller".

In accordance with another aspect of the present invention, there is provided an apparatus for securing a substantially planar porous sheet material to a corrugated porous sheet material for producing a single-sided corrugated porous sheet material via a continuous process. Is arranged to facilitate lamination of flat sheets and corrugated sheets by applying pressure on the circumferential surface of the large corrugated rollers and the large diameter corrugated rollers that mesh with the smaller diameter corrugated rollers And the circumference of the large diameter corrugating roller to which the endless belt can apply tension is the formula:
C = (RP.BT) / X
Where C is the roller circumference (ie, π2r), RP is the production rate in meters / minute, BT is the fixing time in minutes, and X is the pressure The maximum percentage of the circumference that can be applied by an endless tension belt.

  In accordance with another aspect of the present invention, there is provided an apparatus for securing a substantially planar porous sheet material to a corrugated porous sheet material for forming a single-sided corrugated porous sheet material through a continuous process. Is arranged to facilitate the lamination of flat sheets and corrugated sheets by applying pressure on the circumference of the large corrugated rollers and the large corrugated rollers that mesh with the smaller diameter corrugated rollers The circumference ratio of a large corrugating roller that does not have an endless tension belt assembly, including an endless tension belt assembly, and that applies pressure to it, is the minimum required for a smaller corrugating roller and glue applicator assembly Limited only by relative space.

The inventor currently states that the speed limiting factor is not the corrugating roller rpm, but actually the formula:
RP = DHT / BT
Where RP is the production rate in meters / minute, DHT is the distance in meters where the two respective sheets are held together, and BT is Adhesive fixing time in minutes.

  Preferably, the belt assembly is configured such that the belt can apply pressures greater than 70% to 93% of the circumference of the large corrugating roller.

In a preferred embodiment, the inventor has shown that the diameter of the large corrugating roller, which is substantially in the range of 0.4 m to 2.0 m, is the endless belt,
It has been found to determine the maximum percentage that can be stretched around the circumference of the largest corrugating roller, while ensuring space for the glue applicator including the glue roller, and the smaller corrugating roller.

  For example, in a large roller having a diameter of 0.4 m, the maximum ratio at which the endless belt can be stretched around the outer periphery of the large roller is substantially 70%. In a large roller having a diameter of 2 m, the endless belt has a large roller. The maximum percentage that can be stretched around is 93%.

  The inventor found that the average circumferential distance of the large roller required to provide space for the glue roller and smaller corrugating roller of the above embodiment is substantially between about 0.45 m and 0.5 m. I found it to get.

  In a preferred embodiment, the large corrugated roller may have a diameter of substantially 0.62 m and the endless belt applies pressure to about 76% of the circumference of the large roller.

  In another embodiment, the large corrugating roller may have a diameter of 2 m and the endless belt applies pressure to about 93% around its circumference.

  In accordance with a further aspect of the present invention, a method for operating a large diameter corrugating roller meshing with a smaller diameter corrugating roller, and an endless tension belt, on a portion of the circumferential surface of the corrugating roller having a large tension belt. A pressure step, arranged to form an adhesive bond between the substantially planar porous sheet material and the corrugated porous sheet material, and the circumference of the large corrugated roller And further determining the production speed using a percentage of the total length of the surrounding belt.

  In accordance with yet a further aspect of the present invention, from a porous flat sheet material and a planar corrugated sheet material using a tension belt, a large diameter corrugated roller that mates with a smaller diameter corrugated roller, and a glue applicator assembly. A method for producing single-sided corrugated board is provided, the method comprising applying an adhesive to the corrugated sheet material at ambient temperature, and then each flat sheet and corrugated sheet via a tension belt for a specified time. Holding together.

The inventor found that the maximum production rate of a device comprising a large diameter and a smaller diameter mesh corrugating roller is the formula:
RP = X (π2r). BT
Where RP is the production rate in meters / minute, BT is the fixing time in minutes, and X is large, where pressure is applied by an endless tension belt It is the ratio of the circumference of the corrugating roller.

An apparatus for producing single-sided corrugated cardboard from a porous sheet material, wherein the apparatus has the formula:
RP = X (π2r). BT
Where RP is the production rate in meters / minute, BT is the fixing time in minutes, and X can be applied by an endless tension belt. The ratio of the circumference of the large corrugating roller.

A method using a large corrugating roller and an endless tension belt, the maximum production speed is the formula:
RP = X (π2r). BT
Where RP is the production rate in meters / minute, BT is the settling time in minutes, and X is a large corrugating roller where pressure is applied by an endless tension belt Is the ratio of the circumference of.

  By way of illustration only, the above formula for maximum production speed for meshing large and smaller diameter corrugated rollers is the roller circumference (ie, π2r), the circle in which pressure can be applied by an endless tension belt. It is calculated by multiplying by X which is the ratio of the circumference and multiplying this by BT.

  In a preferred embodiment, the RP is substantially in the range of at least 25 m / min to 200 m / min.

  In a preferred embodiment, the sheet material is kraft paper.

  Kraft paper is usually used to form single-sided cardboard. However, as noted above, other porous sheet materials may be used with the present invention, and therefore a limited interpretation is that the reference in this specification to sheet material is kraft paper. Should not do.

  A flat sheet material known as a liner may also be made from kraft paper.

  It should be understood that a reference to the term “substantially planar” refers to a sheet or web having a substantially flat surface in a single plane (at least when viewed with the naked eye).

  In contrast, a reference to the term “corrugated” should be understood to refer to a sheet or web whose surface is configured such that a series of alternating tops and troughs (ie, corrugated structures).

  The corrugated structure of the corrugated sheet used to form single-sided cardboard is usually referred to as a flute. Typically, by passing a sheet of kraft paper through a set of corrugating rolls set in relation to each other such that the teeth of the corrugating roller engage on either side of the kraft paper, Flutes are formed. The shape of the flute obtained depends on the shape and size of the teeth on the corrugating roll. For example, the flutes may be (without limitation) triangular, sinusoidal, trapezoidal, serrated, diamond, square, or any other suitable repeated undulating shape. Similarly, the size of the flute is determined by the equal size of the teeth and may vary depending on the end application of the single-sided cardboard.

  In a preferred embodiment, the corrugated sheet material has flutes having a substantially triangular cross-sectional profile.

  The advantage of having a flute with a substantially triangular cross-sectional profile is that this profile is relatively simple to form by using the teeth conventionally formed on the corrugating roller.

  Further, the triangular shaped flute may have additional strength compared to some of the other shapes, especially for compression along the length of the flute.

  When the liner and fluted sheet are formed from kraft paper, the adhesive used to secure the liner to the top contact portion of the fluted sheet is typically an aqueous glue.

  The adhesive may be a non-aqueous glue, provided that it is liquid while being applied to the apex contact portion and can be absorbed by the porous sheet material according to the present invention.

  The term “controlled amount of adhesive” refers to an adhesive that is applied to the apex contact portion so that it does not stretch beyond the apex contact portion before or during the fastening step b). Thus, a “controlled amount of adhesive” can include glue beads, glue coating, or glue droplets, along the apex contact portion of each top of the fluted sheet, Or installed on it.

  The controlled amount of adhesive may vary in form depending on the type of application.

  In some embodiments, the discrete quantities may be in the form of fine lines, smears, a fine interconnect line network, break line (s), or dash (s).

  The key to achieving adhesion between each sheet is that the adhesive first wets and penetrates the corrugated sheet and then wets and penetrates the second sheet (liner).

  By having a controlled amount, less adhesive is applied to the fluted sheet than in conventional methods. Furthermore, the controlled amount also ensures that the adhesive does not stretch beyond the apex contact, especially during step b). Thus, the controlled amount allows some diffusion of the adhesive that occurs on the dry areas of each sheet when pressure is applied to the liner and fluted sheets.

  In one preferred embodiment, the adhesive is substantially spaced apart in the manner disclosed in the applicant's previous PCT application WO 2009/145642 (when the droplets are applied to the top). And applied over the apex contact area.

  It is envisioned that the droplet is a small circular or pear-shaped amount of adhesive that adheres to the surface, but this should not be interpreted restrictively.

  The preferred size of the droplet may depend on several factors, including the nature of the fluted paper and liner and the type of adhesive used. However, in all cases, the droplet size should be small enough that the droplet substantially retains its morphology and does not collapse with its own weight. A relatively large volume relative to the surface area (compared to the adhesive strip or line) reduces the rate of evaporation of moisture from the droplets, so that the adhesive droplets are not allowed to dry before the adhesive is dry. This is important because it increases the time it takes to wet and penetrate the top of the fluted paper and the liner.

  A preferred droplet size is about 0.5 mm 3. The preferred gap between the droplets is determined by determining the desired adhesive thickness when diffusing and by placing the droplets so that they just touch each other when the diffused droplet reaches that thickness. Calculated.

  In another preferred embodiment, the adhesive is applied to the apex contact portion in the form of a thin continuous bead (ie, a line of adhesive).

  Applicants have discovered that the method of the present invention can be used to produce single-sided cardboard without applying heat acting on the bond between the fluted sheet material and the liner sheet material.

  As used herein, the term “ambient temperature” refers to the temperature of a room / building where the apparatus can operate and perform the method of the present invention. In general, the ambient temperature is a temperature substantially between 5 ° C and 60 ° C. Most preferably, the ambient temperature may be a temperature substantially between 10 ° C and 25 ° C.

  It should be understood that the choice of the adhesive of the present invention is important. As described in the art, starchy adhesives require an activation temperature of about 150 ° C. Thus, such an adhesive would not be desirable for use in the present invention unless it was activated prior to application (eg, by heating in a storage tank). Suitable adhesives that cure rapidly at room temperature and have the required bond strength are described later herein.

  The ability to produce corrugated board without applying heat to the porous material to be fixed is a significant advantage of the present invention. As further described herein, this eliminates the need for expensive machinery and significantly reduces energy requirements. It should be understood that by applying a controlled amount of adhesive at a sufficient pressure to the apex contact portion of a porous corrugated sheet, it is perceived that significant benefits can be achieved at ambient temperatures and with shorter fastening times. It is.

  In the second step of the method according to the invention, a bond can be formed by pressing the liner against the fluted sheet for a specified time at a specified pressure. This can be achieved by various means.

  In a preferred embodiment, a tensioned endless belt assembly presses a flat (liner) sheet against a corrugated (flute-like) sheet.

  The application of pressure on the liner to press it against the fluted sheet by the use of a tension endless belt is well known in the art, and the equipment for doing this need not be detailed.

  As used herein, the term “designated pressure” is set at or slightly below the maximum pressure that can be applied by a belt without deforming the paper (liner and flute paper). It refers to the pressure applied to the large surface of the corrugating roller. Excessive pressure can cause paper wrinkling and / or tearing. The maximum pressure varies depending on the material used for the liner and fluted paper.

  In a preferred embodiment, the sheet material is held together for a period of 2 seconds or longer.

  Applicant has good liner and fluted board when using an endless belt (tensioned to hold the liner firmly against the top without damaging the liner) in combination with a suitable commercially available adhesive It has been discovered that the liner and fluted sheet need to be pressed together at room temperature for a period longer than about 2 seconds (pressing time) to ensure that a good bond is formed.

  Typically, single sided cardboard is not completely or properly formed if the pressing time is less than about 2 seconds, or if the pressure between the sheets is too low. In this case, since the tension in the corrugated sheet is sufficient to break the sticking, the liner will move away from the flute sheet.

  For practical purposes, a holding time of 2 to 4 seconds is desirable at room temperature, and a pressing time of about 3 seconds is preferred. A pressing time of more than 4 seconds may be used, but such a time is not preferred because it can significantly reduce the production rate of single-sided cardboard unless the corrugating roller size is increased.

  However, the discovery of the formula that defines the inventor's specified processing time is that one skilled in the art can configure the equipment to achieve faster production rates within the physical property limits of the paper and adhesive used. Enable operation.

  A pressing time of about 2 or 3 seconds is significantly slower than that achieved with some prior art machines that use a combination of high temperature and high pressure. However, an advantage of the present invention is that many single-sided cardboards can be produced at an acceptable rate at room temperature. This provides the advantages of a process and apparatus that can produce single-sided cardboard in a lower cost, safe and environmentally friendly manner.

The inventor
-Use a controlled amount of adhesive,
-Applying an adhesive to the apex contact of the corrugated sheet;
-Consider the combination of using a specified pressing time, holding the corrugated sheet and the flat sheet together, and-using an adhesive that cures at ambient temperature to form a bond,
Enables commercial production of single-sided cardboard through a cooling process.

  In a preferred embodiment, the adhesive is an aqueous glue that is suitable for securing a porous material such as paper. In a preferred embodiment, the adhesive may be a dispersion containing a vinyl acetate copolymer.

  Aqueous adhesives containing dispersed vinyl acetate copolymers may be preferred because they are harmless materials in normal use and can therefore be used safely as long as normal ventilation is provided.

  Vinyl acetate copolymer dispersions can cure relatively rapidly at room temperature and do not require high activation temperatures, unlike starchy glues. They have low viscosity, good adhesion, and long air drying times. A relatively low viscosity is required to allow the adhesive to flow easily (eg when transferred from an applicator to a fluted sheet), while good adhesion forces rapidly adhere to the surface. Provide the function to do.

  Air drying time is a period of time during which the adhesive can have an exposed surface under normal temperature and pressure before wetting the opposing surface and losing its ability to penetrate the opposing surface fibers. This wetting and penetration is necessary to form an effective bond between the fluted paper and the liner. Since the adhesive may be exposed to the atmosphere for some time before application to the flute, an adhesive having a relatively long air drying time is preferred.

  Preferably, the adhesive is Adhesin ™ Z9129W, a vinyl acetate copolymer supplied by Henkel New Zealand Limited. Applicants have found that Adhesin ™ Z9129W has the required viscosity and the long air drying time required for use in the present invention. For example, Adhesin (trademark) Z9129W is 2100-2200 m. Pa. It has a viscosity in the range of S and an air drying time of 0.5 to 1 minute. However, it is envisioned that other adhesives having similar properties may be used.

  Apply an adhesive in droplet form (Adhesin (such as Z9129W) to the top of the fluted sheet and press the liner against the top for about 3 seconds to form a bond between the fluted sheet and the liner This provides several significant advantages over the prior art, in particular, this method can be used to produce single-sided corrugated paper at ambient temperatures, thereby heating corrugated rolls or drying single-sided cardboard. This will result in a significant reduction in energy usage and thus reduce cardboard manufacturing costs.

  In some preferred embodiments, the glue applicator for applying a controlled amount of adhesive includes a roller having an undulating surface on the outer surface of the roller.

  Another adhesive that has been found to be suitable is Adhesin ™ Z9040, which takes about 2 seconds to form a bond between the fluted sheet and the liner.

  The relief surface can be in several forms, and in one embodiment it can be a depression or an irregular surface. In some embodiments, the relief surface may be in the form of a U-shaped groove. The roller may also be similar to an anilox roller in some further embodiments.

  Preferably, however, the relief surface is in the form of a fine corrugated structure reminiscent of a square wave.

  In a preferred embodiment, the relief surface may be a corrugated surface. It should be understood that a corrugated surface refers to a surface formed at a series of peaks and troughs.

  In a preferred embodiment, the tops (and valleys) are substantially parallel and extend around the circumference of the roller.

  In a preferred embodiment, the top forms a helix.

  In other embodiments, the tops may form concentric circles.

  Preferably, the top and the valley may be formed by cutting (or forming) a groove of a “V” shape or a square shape on the surface of the glue roller. Although the actual shape of the groove is not critical, a “V” shaped groove is preferred because it is relatively easy to cut into a smooth cylindrical surface.

  In use, the adhesive may be supplied to the glue roller by a smooth surface pickup roller.

  Alternatively, an air blade that passes through a spray nozzle or trough may be used.

  In embodiments having a pick-up roller, the pick-up roller is preferably placed adjacent to the adhesive bath so that the outer surface is coated with the adhesive as the pick-up roller rotates.

  The glue roller is placed against the pickup roller so that the top of the glue roller is in firm contact with the surface of the pickup roller. In this way, the adhesive is transferred from the surface of the pick-up roller into the groove on the surface of the glue roller with little or no application to the top of the applicator roller.

  The gap between the pick-up roller and the glue roller determines the amount of glue applied.

  Preferably, the glue roller is also placed so that the top of the applicator roller is in firm contact with the top of the fluted sheet on the corrugating roller. In this arrangement, as the glue roller rotates, it picks up the adhesive in the grooves on its surface in contact with the pick-up roller, and then deposits the adhesive as droplets on top of the fluted sheet .

  The amount of adhesive in each droplet can be determined by the size (width and depth) of each groove, while the separation of the droplets can be determined by the separation of adjacent grooves.

  It should be understood that the grooves should be shallow enough to avoid excessive glue depositing on the corrugated sheet material. In other words, the groove should be sized so that the glue is only volumed on the apex contact portion. In a preferred embodiment, the groove depth is 0.5 mm and the groove width is about 1 mm.

  In preferred embodiments, the top may take the form of an acute angle.

  Preferably, the “V” shaped grooves on the roller are arranged such that each groove contacts an adjacent groove so as to form an acute angle, and the cross-section across the series of grooves forms a continuous zigzag pattern. . This arrangement can provide minimal separation between adjacent droplets (with a given width for each groove).

  In some other embodiments, the top may have a flat cross-section, in which case the droplet separation may be correspondingly increased.

  The glue roller is rotatably mounted so that the outer surface (top) of the applicator is pressed against the top of the flute-like paper held on the second corrugating roller.

In accordance with another aspect of the present invention, there is provided a method of securing a substantially planar sheet material, both porous, to a corrugated sheet material using a continuous process, the method comprising:
a) Adhesive is applied to the corrugated sheet material using a GA roller with lateral grooves from left to right around the circumference of the glue application (GA) roller that engages teeth on the corrugating roller A step wherein the groove of the GA roller retains a set amount of glue therein;
b) a step in which a sticking is formed between them by holding each flat sheet and corrugated sheet together for a specified time at a specified pressure.

The size of the groove on the GA roller is
-A series of adhesives are held therein-the teeth on the corrugating roller and the apex contact portion of the corrugated sheet can be received therein;
A series of adhesives can be applied to the apex contact portion of the corrugated sheet.

In accordance with another aspect of the present invention, there is provided an apparatus for making single-sided cardboard by affixing a corrugated sheet material having one or more tops on a substantially planar sheet, both porous. The device is
An applicator configured to apply an adhesive to each top of the corrugated sheet material;
A pressing mechanism for pressing the flat sheet against the top of the corrugated material,
The applicator is configured to apply a controlled amount of adhesive to the apex contact portion on each top of the corrugated sheet material, and the pressing mechanism is specified so that a bond is formed between them. It is configured to press the flat sheet material against the corrugated sheet material at a specified pressure for a period of time.

  Thus, the apparatus for making single-sided cardboard according to the present invention has many features in common with some prior art machines. In particular, a flute-like sheet is formed by passing sheet material between the meshed teeth of the first and second corrugating rollers. The flute-like sheet is held against a second corrugating roller having a larger diameter than the first corrugating roller due to the vacuum formed in the second corrugating roller.

  As the second corrugating roller rotates, the fluted paper passes through an applicator where the adhesive is applied to the top contact portion of the fluted sheet. In a preferred embodiment, the applicator includes a roller having a corrugated surface, substantially as described above.

  The corrugated surface of the glue roller and the grooved surface of the GA roller (as described above) are each configured to apply a drop or line of adhesive across the apex contact portion on the top of the fluted sheet. This differs from conventional machines where the applicator typically has a knurled surface so that a relatively wide strip or line of adhesive is spread over the top of the flute. Thus, conventional machines tend to apply more adhesive than necessary, and therefore no adhesive is contained within the apex contact area.

  In a preferred embodiment, the pressing mechanism is a tension endless belt assembly.

  The endless belt may be configured to move around a plurality of rollers, such that the belt makes contact with the liner as the liner and fluted sheet move around the outer periphery of the second corrugating roller. Arranged to hold.

  This arrangement may be achieved by placing a two-end guide roller spaced around the circumference of the second corrugating roller, this spacing defining the distance that the belt contacts the liner. The two-end guide provides pressure (via the belt) on the liner again upon first contact with the fluted sheet and just before the single-sided fluted sheet is removed from the second corrugating roller. It may be placed.

  The belt may be tensioned by adjustment of one or more of the remaining rollers so that the belt applies pressure to the liner and presses against the fluted sheet.

  Because no heating is required, standard rubber belts can be used rather than the expensive materials used in heated rollers. The use of a standard rubber belt reduces damage to the liner surface and can therefore be an excellent product.

  In other embodiments, the endless belt may be made of plastic or synthetic material.

  The advantage of the method of the invention is that when applied at ambient temperature, the endless belt uses heat-sensitive materials such as plastics, synthetics and some rubbers that are not suitable for conventional heating processes. It can be formed.

  In a preferred embodiment, the endless belt is configured to press the sheet material together for at least 2 seconds.

  In a preferred embodiment, the endless belt is configured to press the sheet material together for about 2 seconds to about 4 seconds, as described above.

  In other words, the present invention allows for the efficient production of single-sided cardboard without the need to apply further heating to the process.

  This feature applies a controlled amount of adhesive to the apex contact and then presses the liner against the fluted sheet at a specified pressure for a specified pressing time until a bond is formed. Achieved by combination.

  In accordance with a further aspect, an apparatus is provided for securing a substantially planar porous sheet material to a corrugated sheet material via a continuous process, the apparatus comprising a large corrugating roller that meshes with a smaller corrugating roller, and more The diameter of the small roller is at least substantially 0.16 m to 0.2 m in diameter, and the large corrugated roller has a diameter of at least substantially 0.4 m to 2.0 m.

The ability to form single-sided cardboard at ambient temperature provides one or more of the following advantages over the prior art.
Reduced energy costs and lower carbon dioxide emissions than conventional methods by eliminating the need to heat the corrugating rolls and dry the paper. This eliminates the need for high-pressure steam that consumes a large amount of energy.
・ Reduce the cost of machinery. Since heating is not required, a significant reduction can be achieved in that it does not require the storage of boilers, piping, and high-pressure steam. In addition, since the machine operates at room temperature, it can be constructed of simpler and less expensive materials such as (without limitation) ceramic, plastic, or wood. Because such materials are generally easier to form and lighter than materials used in conventional machines that use steam (generally hardened steel), the machine is cheaper to make and lighter It can be supported by a frame, which again can reduce material costs.
・ Reduce space. The removal of the device associated with heating can result in a device that requires less space than a conventional heating machine.
・ Improved safety. Since the machine operates at room temperature, there are no longer any risks associated with the generation and use of high pressure steam.
・ Reduce operating costs. In addition to reducing energy usage, the method of the present invention can significantly reduce the consumption of adhesive.

  Importantly, an apparatus according to the present invention can be of a size and cost suitable for on-site production of single-sided cardboard. Conventional heating machines are typically large, consume large amounts of energy, and are expensive to build and operate. For this reason, such machines are typically operated in a centralized location, and single-sided cardboard or products made from it are transported towards the consumer.

  Mainly, since no heating device is required, the size of the machine according to the invention can be scaled. For this reason, the device according to the invention can be of a size suitable for installation and operation in the consumer market, for example for carrying out local packaging. This may provide a reduction to the consumer because the supply is controlled by the consumer and there are no shipping and handling costs from outside the local manufacturing.

In accordance with another aspect of the present invention, in building a single-sided corrugated paper production facility, the rules:
RP = DHT / BT
Where RP is the production rate in meters / minute, DHT is the distance in meters where the two respective sheets are held together, and BT is in minutes This is the adhesive fixing time.

  In accordance with a further aspect of the present invention, there is provided the use of an aqueous adhesive in the manufacture of single-sided cardboard.

  In accordance with yet a further aspect of the present invention, there is provided the use of an adhesive that can be a dispersion containing a vinyl acetate copolymer.

In accordance with yet another aspect of the present invention, there is provided an apparatus for producing a corrugated sheet of material from a porous planar material via an automated process, the apparatus comprising:
A corrugating roller;
An endless fluted conveyor belt assembly having an endless fluted conveyor surface including a plurality of adjacent flutes, wherein the flutes are configured to correspond to teeth on the corrugating rollers.

According to a further aspect of the present invention, there is provided an apparatus for producing a single-sided corrugated sheet of porous material via an automated process, the apparatus comprising:
A corrugating roller;
An endless fluted conveyor belt assembly having an endless fluted conveyor surface comprising a plurality of adjacent flutes, wherein the flutes are configured to correspond to teeth on the corrugating rollers;
A pressure mechanism configured to hold the freshly corrugated sheet material against the fluted conveyor surface while the adhesive is applied by the glue applicator;
An endless tension belt assembly in which a flat sheet material and a corrugated sheet material are held together so that a bond is formed between them.

  Apart from the endless fluted conveyor belt assembly, most if not all of the above-mentioned features and aspects relating to the present invention are equally applicable to this linear endless slatted conveyor instead of a large corrugated roller. It should be understood by those skilled in the art. Of course, there are exceptions associated with aspects specific to large corrugating rollers. For example, production speed, specified pressing time, adhesive, and suitable porous sheet material are all applied to the linear assembly.

  The endless flute-like conveyor surface may be in a variety of different forms without departing from the scope of the present invention.

  In a preferred embodiment, the endless fluted conveyor surface may be formed from a plurality of pivotally connected strips of rigid material having fluted (corrugated) edges or surfaces.

  In some preferred embodiments, the strip may be in the form of a slat.

  In some further preferred embodiments, the strip may be in the form of a bar having a rectangular cross section.

  Each bar or slat has a connecting portion at its opposite end (relative to the intended direction of movement along the conveyor), pivotally attached to adjacent strips to form, and a fluted conveyor Enable the surface.

  In another preferred embodiment, the endless flute conveyor surface may be in the form of an endless belt. In some such embodiments, the belt may include a flexible base layer and a flute-like rigid outer layer, the outer layer configured to move around the rollers and part of the conveyor belt assembly. Form.

  Endless fluted conveyor surfaces can be made of a variety of different materials without departing from the scope of the present invention.

  In a preferred embodiment, the rod / slat is made of steel.

  In other embodiments, the rod / slat can be made of plastic, wood, or composite material.

  In another preferred embodiment, the rod / slat can be made from a perspex.

  The corrugating machine on the endless conveyor and the teeth on the flute can have several different profiles without departing from the scope of the present invention, provided that the flute shape differs from the teeth on the corrugating roller. It shall be able to mesh. For example, the teeth on the roller may have any one of A, B, C, D, E, F, or G-shaped profiles.

  In a preferred embodiment, the teeth / flutes can be formed via V-shaped grooves.

  In some preferred embodiments, the endless conveyor surface may include a number of openings located from the top surface to the bottom surface and substantially along the length of the endless conveyor surface. The purpose of the opening is to allow the application of a vacuum to the corrugated sheet material to hold it against the flute on the endless conveyor surface.

  In a preferred embodiment, the openings may be in the form of slots that form a zigzag pattern along the length of the endless conveyor surface.

  The pressure mechanism may take a variety of forms without departing from the scope of the present invention.

  In embodiments where the slats do not include the aforementioned openings, the pressure mechanism may be in the form of two or more elongated fingers that pass through the radial grooves of the corrugating roller and glue roller. Alternatively, the corrugating roller and the glue roller can be constructed in a part with a gap between the parts where the fingers can be located. The fingers are attached to a biasing device that allows the fingers to hold the corrugated sheet material against the slatted conveyor.

  In a preferred embodiment, the pressure mechanism is in the form of a vacuum box located in a conveyor with slats and may be configured to apply a vacuum condition to the slats as they pass through the vacuum box.

  The endless belt assembly may be configured to move around a plurality of rollers that are well known in the art. The rollers are arranged such that the belt retains contact with the liner as the liner and fluted sheet move around the outer periphery of the endless fluted conveyor belt assembly that effectively functions as a second corrugating roller. .

  An endless flute-like conveyor belt assembly formed from a plurality of adjacent slats can be configured in a number of different ways without departing from the scope of the present invention.

  In a preferred embodiment, the slatted conveyor belt assembly can include one or more flexible belts to which the slats are attached. The belt moves around the roller and is driven by a drive mechanism known in the art.

  The glue applicator can take several different forms.

  Preferably, the glue applicator may be a grooved glue roller that engages (engages) teeth on the slats. The glue roller receives glue from the glue pick-up roller and the accompanying glue tray.

  However, the glue applicator can also be configured in substantially other ways as described above.

In accordance with another aspect of the present invention, there is provided an apparatus for producing double-sided cardboard via a continuous in-line automation process, the apparatus comprising:
i) a single-sided corrugated module,
A corrugating roller;
An endless fluted conveyor belt assembly having an endless fluted conveyor surface comprising a plurality of adjacent flutes, wherein the flutes are configured to correspond to teeth on a corrugating roller; and With
The module is configured so that the sheet material passing between each meshing tooth on the corrugating roller and the endless flute conveyor belt assembly is corrugated and contacted with the glue applicator before contacting the flat sheet material. Subject to one pressure mechanism and to a second pressure mechanism in the form of an endless tension belt assembly that holds the respective planar and corrugated sheets together so that a bond is formed therebetween. A single-sided corrugated module,
ii) a laminate module,
-Two vertically opposed endless linear tension belt assemblies,
a) a flat sheet material;
b) a single-sided corrugated sheet material from the corrugated module comprising an assembly therebetween,
Before the glue applicator enters the opposing endless tension belt assembly that holds the flat sheet material and the single-sided cardboard together, an adhesive is applied to the single-sided cardboard and / or the flat sheet material so that a bond is formed between them. A laminate module.

  In accordance with yet another aspect of the present invention, at least one endless liner tension belt assembly and one endless flute shape such that an anchorage is formed therebetween by holding the corrugated sheet material together with the planar sheet material. An anchoring method is provided for use in the manufacture of single-sided or double-sided corrugated cardboard, both of which are porous, characterized by the step of using a conveyor assembly arrangement.

In accordance with another aspect of the present invention, the corrugated sheet material and the planar sheet material have the formula:
BT = DHT / RP
Provides the method substantially as described above, held together for a specified pressing time calculated by: where RP is the production rate in meters / minute and DHT is the two respective sheets Is the distance in meters that is held together, and BT is the fixing time in minutes of the adhesive used, which determines the pressing period.

  In accordance with another aspect of the present invention, there is provided a single-sided ball produced substantially by the method described above.

  In accordance with yet another aspect of the present invention, there is provided a double-sided ball produced substantially by the method described above.

  In accordance with an additional aspect of the present invention, there is provided a double-sided ball substantially produced from the single-sided ball described above.

  In accordance with a further aspect of the present invention, there is provided a single-sided ball produced from a preprinted flat sheet that is directly adhered to corrugated sheet material at ambient temperature.

  In accordance with a further aspect of the present invention, there is provided a pre-printed double-sided ball produced from a pre-printed flat sheet that is secured directly to a corrugated sheet of material that forms part of the single-sided ball produced at ambient temperature.

  Preferably, the preprinted flat sheet is applied to a single-sided ball immediately after being formed as part of an automated continuous in-line process.

  In accordance with a further aspect of the present invention, there is provided a double-sided ball produced from two pre-printed flat sheets that are bonded directly to the top and bottom surfaces of corrugated sheet material at ambient temperature.

  It is understood that the pre-printed flat sheet is affixed to the corrugated sheet material so that the printing surface (s) is the exposed surface (s) of the single / double-sided ball.

The advantages achieved by the preferred embodiment of the endless liner tension belt assembly and the endless slatted conveyor belt assembly include:
Formula: RP = DHT / BT, where RP is the production rate in meters / minute, DHT is the distance in meters at which the two respective sheets are held together, and BT is the minute Providing a method for increasing the production rate according to
In particular, the production rate is the formula C = (RP.BT) / X, where C is the circumference of the larger roller (ie π2r) and RP is the production rate in meters / minute , BT is the fixing time in minutes and X is the percentage of the circumference where pressure is applied by the endless tension belt) (ie, large and small corrugating rollers meshing) Is not limited by X. This equation is due to the fact that DHT is equal to X (π2r). Since the diameter of the large corrugating roller makes it very heavy and cannot be increased significantly beyond 2 meters, the maximum value of X for the large corrugating roller constitutes a rate-limiting step. In contrast, the length of the linear corrugator is desirable because it can be easily increased almost without limitation.
-Can include providing the aforementioned advantages of the cooling process over the prior art for producing double-sided cardboard as well as single-sided.

For both linear and non-linear wave shapers, the advantages provided by preferred embodiments of the present invention are:
-The ability to apply pre-printed paper directly to cardboard as part of an inline continuous automation process;
Due to the fact that it was produced with a passive brake system that is flat with the naked eye, does not apply heat, and the paper is peeled from the reel, it also includes the ability to produce single or double sided cardboard that does not tend to curl.

  Further aspects of the invention will become apparent by reference to the following description, given by way of example only, and the accompanying drawings in which:

Figure 3 shows the apex contact portion in schematic side view both before and after anchoring the flute sheet to the liner. Figure 3 shows the apex contact portion in schematic side view both before and after anchoring the flute sheet to the liner. FIG. 3 shows a schematic perspective view of a portion of a single-sided machine device, in accordance with a preferred embodiment of the present invention. The perspective view of the single-sided machine apparatus shown by FIG. 2 is shown. FIG. 4 shows a schematic perspective view of a single-sided machine apparatus according to a further preferred embodiment of the present invention. FIG. 3 shows a schematic perspective view of a linear corrugating machine for producing single-sided corrugated board according to a preferred embodiment of a further aspect of the present invention. FIG. 7 shows a schematic perspective view of an apparatus for producing double-sided corrugated board according to a preferred embodiment of a further aspect of the present invention utilizing a linear corrugating machine substantially as shown in FIG. Fig. 3 shows a plan view of a cylindrical rod detailed in the embodiment shown in Fig. 2; FIG. 3 shows a top view of the alignment bar detailed in the embodiment shown in FIG. 2. FIG. 3 shows a plan view of a convex roller detailed in the endless tension belt assembly of the embodiment shown in FIG. 2. FIG. 7 shows a schematic perspective view of an apparatus for producing double-sided corrugated board according to a preferred embodiment of a further aspect of the present invention utilizing a modified linear corrugating machine as shown in FIG. Fig. 2 shows a part of an endless conveyor surface in the form of a conveyor belt made of a plurality of strips in the form of fluted bars. FIG. 12 shows a side view of a flute-like rod forming part of the conveyor belt of FIG. 11. FIG. 13 shows a cross-sectional view of the flute bar of FIG. 12. FIG. 13 shows a perspective view of the flute-like bar of FIG. 12.

  1A and 1B show schematic views of a corrugated (flute-like) sheet of paper (100) illustrating the apex contact portion (101).

  The apex contact portion includes the apex (102) of the apex (103) and the region on either side that contacts by diffusing the adhesive (104) into the liner sheet (105).

  FIGS. 2 and 3 show a portion of an apparatus for forming a single-sided cardboard, commonly known as a single-sided machine indicated by an arrow (200). The single-sided machine (200) has a first smaller corrugating roller (201) and a second larger corrugating roller (202). For clarity, the rollers (201, 202) illustrated in this figure are not shown in their entirety, but a series of roller components are assembled and shafts (not shown) until the desired roller width is achieved. Understand that they are built by placing them side by side on top.

  In operation, a porous sheet material in the form of kraft paper (250) is fed to the corrugating rollers (201) and (202). After passing through the rollers (201, 202), the kraft paper (250) becomes a corrugated (flute-like) sheet material (251).

  The second roller (202) has teeth (203) that engage with lateral grooves (204) on the surface of the glue applicator (GA) roller (205). The glue applicator roller (205) surface is picked up from the glue tank (not shown) in the form of Adhesin (TM) Z9040 and the excess glue is glued so that only the glue remains in the groove (204). Remove from surface via scraper (206). In use, the freshly corrugated sheet material (251) that is held against the second roller (202) through a vacuum condition is such that the apex contact portion (not shown) of the corrugated sheet material is bonded to the adhesive. Pass between the second roller (202) and glue roller (205) to be received in a groove (204) along the teeth (203) to achieve transfer to the apex contact portion.

  At this point, a flat (liner) sheet material (260) in the form of kraft paper is fed between the endless tension belt assembly (270) and the second corrugating roller (202) to corrugate sheet material (251). Contact with the apex contact part. The endless tension belt assembly has an endless belt (271) that applies a specified pressure to the flat sheet (260) to hold against the corrugated sheet (251). The endless belt (271) applies a specified pressure to 76% of the circumference (20) of the large roller indicated by the arrow X. It will be appreciated that the sheet material (260) may be pre-printed with high quality graphic images and / or text in some embodiments.

  The endless tension belt assembly has a series of rollers (290-294) in which tension is applied by radially adjusting the tension roller (292) relative to the axis of the second higher corrugating roller (202). In operation, the tension of the belt (271) is first adjusted where breakage usually occurs in the form of wrinkles or tears in the liner and / or flute paper. The tension is then reduced by gradually adjusting the tension roller (292) until the liner / fluted paper no longer breaks (ie, the tension roller is adjusted back to the specified pressure). ).

Each sheet (260, 251) has the formula:
BT = DHT / RP
Held together for a specified time determined by where RP is the production rate in meters / minute and DHT is the distance in meters where the two respective sheets are held together Yes, BT is the adhesive fixing time in minutes. Thus, as shown, the 360 ° rate indicated by the double arrow X where the endless tension belt contacts the roller circumference (20) is the distance held together, and thus to determine the production rate is important.

The circumference (202) of the second corrugating roller is given by the formula:
C = (RP.BT) / X
Where C is the roller circumference (ie, π2r), RP is the production rate in meters / minute, BT is the fixing time in minutes, and X is the pressure The ratio of the circumference that can be applied by the endless tension belt.

  Therefore, when a production speed of 44 m / min is required and the adhesive fixing time is 2 seconds (that is, 0.0333 minutes), the circumference of the second roller is 44 × 0.0333, 1 .4666, which is equal to 1.93 m when divided by 76%. This is equivalent to a diameter of 0.62 m. In other words, the DHT in this example is equal to 2πr multiplied by 0.76%.

  The kraft paper used may be recycled or unused paper, ideally about 90-150 gsm.

  The second corrugating roller (202) causes a vacuum pump (not shown) to pass through the surface of the roller (not shown), so that an incomplete vacuum state is generated via the vacuum pump. It has a conduit network (not shown) so that it can be made inside. This incomplete vacuum inside the second corrugating roller (202) holds the fluted sheet (260) in place against the teeth (203) of the second corrugating roller (203). .

  As also shown in FIG. 2, the apparatus (200) generally has first and second alignment systems indicated by arrows (500) and (502).

  The first alignment system (500) has a cylindrical bar (510-512) that defines a zigzag path to paper (250) that is peeled from a reel (not shown). The alignment system keeps the path of the paper (250) straight when the paper is peeled from the reel and inserted into the device (200). Cylindrical rods (510-512) do not rotate, but instead provide a frictional force that allows the rods to keep the paper path straight and prevent any left-right movement of the paper when peeled off the reel To do. To further assist in paper alignment, the cylindrical rod (510-512) prevents the paper from coming out of the cylindrical rod and out of alignment with the device (200) (513) (see FIG. 7).

  The second alignment system (502) has a flared end (525) (see FIG. 8) that tapers out from a cylindrical central portion that is the width of the paper (260) to be peeled from a reel (not shown). It has a first alignment bar (520). The flare end extends about 50 mm out from the edge of the paper (260) passing through the bar (520). The paper (260) then passes around a cylindrical rod (521) having a flange end (see FIG. 7). The paper (260) then moves to a second alignment bar (522) having a flared end (see FIG. 8). Similarly, the bars (520, 521 and 522) are fixed, similar to the first alignment system (500).

  Prior to being inserted into the device (200), the paper (260) passes through the rollers (290) of the endless tension belt assembly (270). The roller (290) has a convex outer surface (see FIG. 9). The inventor has discovered that the convex outer surface of this roller minimizes the risk of wrinkling and wrinkling the paper before it is inserted into the device (200). This gathering occurs as a result of the paper turning toward the center through a second alignment bar (522) where the flare end prevents any left-right deflection of the paper relative to the bar (522).

  The relative position of the rods relative to each other and the respective reels of the first and second alignment systems (500) and (502) may be adjustable so that a precise pressure is applied to the paper, Those skilled in the art will appreciate that it can remain aligned with the device (200).

  In operation, the endless tension belt assembly (270) is 76% of the roller circumference (203) indicated by arrow X, respectively, until the single-sided cardboard (280) is made and exits the device (200). When moving around, pressure is applied to the liner (260) and fluted paper (251) (previous kraft paper 250) via a belt (271).

  Those skilled in the art should understand that the embodiments with large and smaller meshing rollers shown in FIGS. 2, 3 and 4 can also be used to form double-sided cardboard. To do so, the apparatus also includes a double-sided machine (not shown), which is well known in the art.

  Although not shown, it will be appreciated that a paper alignment system that peels from the reel may also be utilized in the embodiments illustrated in FIGS. The alignment system may be substantially the same as shown and detailed in FIG.

  FIG. 4 shows a device similar to that shown in FIGS. 2 and 3, and thus similar reference numerals have been used to indicate similar elements. An important difference in the embodiment shown in FIG. 4 is that the radius of the large corrugating roller (202) is 1 m, while in FIGS. 2 and 3, the large corrugating roller (202) is 2 m in diameter, The fact is that the endless belt (271) applies pressure to about 93% of the circumference of the large roller (202) indicated by arrow X.

  FIG. 5 shows an apparatus for producing a single-sided corrugated sheet material, generally in the form of a liner corrugating machine indicated by arrow (300). The apparatus (300) includes a plurality of adjacent flutes attached to a set of flexible endless belts (not shown) driven by a drive mechanism having a motor (not shown) and a pair of drive sprockets (303). An endless fluted conveyor surface in the form of an endless slatted conveyor belt assembly (301) having a slat (302). The endless conveyor belt assembly includes a number of false rollers (304) that maintain an endless belt (not shown) and slats (302) on the bottom surface at a fixed height relative to the endless tension belt assembly (350). Have. The drive mechanism and rollers of the endless tension belt assembly (350) are not shown assuming that such an arrangement is well known in the art.

  The endless slatted conveyor belt assembly (301) has just been corrugated in the form of kraft paper (not shown) that has just passed between the corrugating roller (306) and the endless slatted conveyor belt assembly (301). A vacuum pump (305) that can apply a vacuum state to the sheet material is included. An opening in the form of a slot (307) in the slat (302) allows a vacuum condition to be applied on the corrugated kraft paper.

  After exiting the corrugating roller (306), the corrugated kraft paper is applied to the apex contact portion (not shown) of the top (not shown) via a glue roller having a grooved surface (not shown). With a controlled amount of adhesive (not shown). It should be understood that this glue roller (308) is described as being suitable in the embodiment shown in FIGS. 2, 3, and 4 and in addition may be the same as actually illustrated. . The adhesive is taken from a glue tray (not shown) and transferred to the glue roller (308) via the glue pick-up roller (309).

  The glue roller (308) may preferably be configured to be able to move laterally relative to the tension belt assembly (310) so that it can be prepared to accommodate smaller width paper. A flat sheet of material in the form of a kraft paper liner (not shown) is introduced between the slatted conveyor belt assembly (301) and the endless tension belt assembly (350) at the point indicated by arrow (310). The The overlapping length (ie, expansion) of the slatted conveyor belt assembly (301) and the endless tension belt assembly (350) represents DHT.

  As will be appreciated, the length of the slatted conveyor belt assembly (301) and the endless tension belt assembly (350) can both be stretched to increase the production rate according to the formula: RP = DHT / BT. .

  FIG. 6 shows a portion of an apparatus for producing a double-sided corrugated sheet material generally indicated by arrow (400). The apparatus (400) has a single-sided corrugating module substantially in the form of a linear corrugating machine (401) described above with respect to FIG. Thus, the kraft paper (402) to be corrugated is inserted into the linear corrugating machine (401) as shown, and the kraft paper (403) forming the liner is shown as glue roller (407) as shown. Is inserted into the linear corrugating machine. The laminated module is placed on the linear corrugating machine (401) in the form of a double-sided machine (404). The double-sided machine (404) includes two endless opposing tension belt assemblies (405, 406), a glue applicator, and a nip roller assembly (407) through which the single-sided cardboard passes before being inserted into the double-sided machine (404). Have The glue roller assembly (407) is substantially the same as described with respect to FIG. Kraft paper (408) forming a double-sided liner is inserted into the device (400) and linear corrugated before being inserted into the double-sided machine (404) along with single-sided cardboard at the point indicated by arrow (409). It moves along the top of the conveyor (410) with endless slats in the machine (401).

  One skilled in the art will appreciate that the planar sheet material used in the embodiments shown in FIGS. 5 and 6 is pre-printed with high quality graphic images and / or text in some embodiments. . For example, in FIG. 6, flat sheet materials (403) and (408) can be pre-printed.

  FIG. 10 generally shows a portion of an apparatus for producing a double-sided corrugated sheet material indicated by arrows (1000). The apparatus (1000) has a single-sided corrugating module substantially in the form of a linear corrugating machine (1001) described above with respect to FIG. The laminated module is placed on the linear corrugating machine (1001) in the form of a double-sided machine (1004). The double sided machine (1004) is produced by two endless opposing tension belt assemblies (1005, 1006), glue applicator, and linear corrugating machine (1001) before being inserted into the double sided machine (1004). And a nip roller assembly (1007) through which a single-sided cardboard (not shown) passes. The glue roller assembly (1007) is substantially the same as described with respect to FIG. Kraft paper (not shown) forming a double-sided liner is inserted into the apparatus (1000) and linearly corrugated before being inserted into the double-sided machine (1004) along with single-sided cardboard at the point indicated by arrow (1009). It moves along the top of the endless flute-like conveyor surface (1010) of the molding machine (1001).

  One significant difference from the apparatus shown in FIG. 10 over what is shown and described in FIGS. 5 and 6 relates to the form of the conveyor assembly of the linear corrugating machine (1001). The endless conveyor surface (1010) is from the fluted bar (1011) as shown in FIG. 11, as opposed to the fluted slat shown in FIG. 5, which is also arranged to form an endless belt. It is formed. A flute-like rod (1011) is connected at either end to which a pin (not shown) can be received so that adjacent rods (1011) are interconnected to form a belt (1010). , Having a connecting portion in the form of a pair of openings (1012). The fluted bar (1011), in particular the fluted upper surface (1012) of the bar (1011) is shown in more detail in FIGS.

  The linear corrugating machine (1001) moves the motor (not shown) so that the teeth of the roller (1021) engage the flute (1012) of the rod (1011) and move the belt (1010). With a belt (1010) driven via rotation of the corrugating roller (1020). In addition, further operations allow teeth (1016) to engage pins that connect rods (1011) through gaps (1017) between laterally adjacent rods (1011) of belt (1010). In addition, it can be applied to the belt via a toothed drive wheel (1015) driven by another motor (not shown). The gap (1017) also facilitates the application of vacuum conditions through the conveyor in a manner similar to that already described above with respect to FIG.

[Example 1]
In order to calculate the production speed of a second corrugated (ie, large) roller with a diameter of 1.6 m with an endless belt extending 76% around the second roller, the new formula RP = DHT / When BT is applied, this is equal to 0.76 (π1.6) /0.05 RP (production rate), equal to 76 m / min production rate, where 0.05 min is 3 seconds sticking It's time. This production rate is much slower than that calculated by the applicant in WO 2009/000085.

[Example 2]
If the manufacturer requires a production speed of 143 m / min, use an adhesive with a BT of 0.033333 min (ie 2 seconds) and the diameter of the second corrugated (ie larger) roller , The DHT can be expressed as 0.93 × (π2r) and the diameter is DHT = RP. It can be calculated from the BT and becomes (143 × 0.033333). Then, to obtain the diameter we reorganized the equation 0.93 × (π2r) = (143 × 0.033333) and 2r (ie, diameter) = ((143 × 0.033333) / 0. 76) / π, which is equal to a diameter of 2 m.

[Example 3]
If we want to calculate the production speed of a 2m diameter roller with a BT of 0.05 minutes (ie 3 seconds). Applying the formula RP = DHT / BT gives 0.93 (π2) /0.05, which is equal to 116 m / min.

  In practice, as described in this specification as shown in FIG. 2, or as described in the applicant's previous PCT application WO 2009/145642, a diameter of 2 m is a set of corrugated corrugated cardboard. It is at or near the limit that can be made via a meshing corrugating roller. In practice, one of the reasons why it is impossible to have a large corrugating roller with a diameter much larger than 2 m (eg 2.5 m, 3 m or more diameter roller) is particularly so large Due to the increased weight of such a roller, which is difficult to lift and move during construction and maintenance and repair of the roller. Furthermore, an increase in weight with a diameter of more than 2 m requires very large energy to rotate the roller, thus increasing production costs. In addition, there is a problem of maintaining a vacuum in such a large roller, as well as doing this requires more energy. For these reasons, it has been found by the applicant that any increase in production speed achieved by large corrugations with a diameter of more than 2 m is virtually denied by the aforementioned problems.

[Example 4]
A non-linear corrugating machine similar to that shown in FIG. 4 can produce single-sided corrugated cardboard at a faster rate than that outlined in the above examples, even with the same adhesive fixing time. For example, having a speed of 200 m / min with a BT of 0.033333 min would require the endless slatted conveyor to overlap the endless tension belt assembly with a length of 6.6 m. According to the formula RP = DHT / BT.

  It should be understood that aspects of the present invention have been described by way of example only and modifications and additions may be made thereto without departing from the scope of the invention.

100 Paper 101 Vertex contact portion 102 Vertex 103 Top 104 Adhesive 105 Liner sheet 200 Single-sided machine 201 Corrugated roller 202 Corrugated roller 203 Teeth 204 Groove 205 Adhesive applicator (GA) roller 206 Adhesive scraper 250 Kraft paper 251 Corrugated (flute-shaped) ) Sheet material 260 Flat (liner) sheet material 270 Endless tension belt assembly 271 Endless belt 280 Single-sided cardboard 290 Roller 292 Tension roller 500 First alignment system 510-512 Bar 513 Flange end 520-522 Bar 525 Flare end

Claims (5)

An apparatus for producing a corrugated sheet of porous material via an automated process, the apparatus comprising:
A corrugating roller;
An undulating roller for applying individual droplets of glue to the top of the freshly corrugated sheet material;
An endless fluted conveyor belt assembly having an endless fluted conveyor surface comprising a plurality of adjacent flutes, wherein the flutes are configured to correspond to teeth on the corrugating rollers; A belt assembly;
A pressure mechanism configured to hold the freshly corrugated sheet material against the fluted conveyor surface while the adhesive is applied by the glue applicator;
An endless tension belt assembly in which a flat sheet material and the corrugated sheet material are held together to form a bond therebetween, wherein the pressure mechanism is in the form of a vacuum pump and the vacuum A device wherein the pump is located only at the front of the endless flute conveyor assembly. An apparatus for producing double-sided cardboard via a continuous in-line automation process, the apparatus comprising:
i) a single-sided corrugated module,
A corrugating roller;
An endless fluted conveyor belt assembly having an endless fluted conveyor surface comprising a plurality of adjacent flutes, wherein the flutes are configured to correspond to teeth on the corrugating rollers; A belt assembly;
A pressure mechanism configured to hold the freshly corrugated sheet material against the fluted conveyor surface while the adhesive is applied by the glue applicator, the pressure mechanism comprising: In the form of a vacuum pump, the vacuum pump being positioned only at the front of the endless flute conveyor assembly;
The module is in contact with a glue applicator in the form of a corrugated roller, with the sheet material passing between the respective meshing teeth on the corrugating roller and the endless flute conveyor belt assembly. Subject to a first pressure mechanism prior to contact with the planar sheet material and to a second pressure mechanism in the form of an endless tension belt assembly that holds the respective planar sheet and corrugated sheet together A single-sided corrugated module configured to be formed between them;
ii) a laminate module,
-Two vertically opposed endless linear tension belt assemblies,
a) a flat sheet material;
b) a single-sided corrugated sheet material from said corrugated module comprising an assembly therebetween,
An adhesive is applied to the single-sided cardboard and / or flat sheet material before the glue applicator in the form of a undulating roller enters the opposing endless tension belt assembly that holds the flat sheet material and single-sided cardboard together And a laminate module in which a bond is formed between them.   Using an arrangement of at least one endless linear tension belt assembly and one endless slatted conveyor assembly to hold the corrugated sheet material together with the flat sheet material, thereby forming a bond therebetween. A fixing method for use in the manufacture of a single-sided or double-sided cardboard, both of which are porous. The corrugated sheet material and the planar sheet material have the formula:
BT = DHT / RP
Held together for a specified pressing time calculated by where RP is the production rate in meters / minute and DHT is the two respective sheets held together in meters The method of claim 3, wherein the distance is BT is the fixing time in minutes of the adhesive used, which determines the pressing period.   Corrugated sheet material produced by any one of the method or machine of claims 1-4.

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