NZ715533A - Corrugated board and a process - Google Patents

Abstract

The present disclosure relates to a corrugated board and a process for manufacturing corrugated board. The corrugated board may including a corrugated medium, an inner layer applied to the corrugated medium, the inner layer having a metallised appearance; and an outer polymeric layer through which light can pass, the outer polymeric layer being joined to the inner layer to allow the metallized appearance of the inner layer to be seen through the outer polymeric layer. The corrugated board may also include a liner sheet that on one side is attached to crests of the corrugated board, and the inner layer having a metallised appearance may be applied to the other side of the liner sheet. (Figure 1). light can pass, the outer polymeric layer being joined to the inner layer to allow the metallized appearance of the inner layer to be seen through the outer polymeric layer. The corrugated board may also include a liner sheet that on one side is attached to crests of the corrugated board, and the inner layer having a metallised appearance may be applied to the other side of the liner sheet. (Figure 1).

Description

CORRUGATED BOARD AND A PROCESS FIELD OF THE PRESENT INVENTION The present invention relates to corrugated board and a process for making the corrugated board.

BACKGROUND OF THE INVENTION Corrugated board can be used in a range of different applications with one of the most common uses being the manufacture of boxes for transporting and handling food.

Niche food products including fruit and seafood such as trout, salmon, and crustaceans are often sold both locally and internationally as premium products in boxes made from corrugated board. It is desirable that the corrugated board used for packaging premium products reflect the value of the products, and one means for creating the perception that the packaging is for high value products is to metallised the corrugated board used to make the packaging.

Another means for creating the perception that the product is for high value goods is to use high resolution printing on the packaging. However, a problem with this approach is that the printing on the outer surface of the corrugated board can be easily damaged. This can be particularly problematic during the manufacture of corrugated board, for example, using a dual arch corrugating machine in which a linerboard is adhered to a corrugated medium using glue, heat and mechanical pressure.

One approach for combining metallisation of the packaging with high resolution printing has been to apply metallised stickers, some having high quality print, to the corrugated board post manufacture. For example, stickers may be applied to the corrugated board immediately after manufacture or after being used to make a packaging.

It is an object of the present invention to provide a corrugated board having a metallised appearance and a process for making the corrugated board.

SUMMARY OF THE PRESENT INVENTION The present invention relates to a corrugated board including: a corrugated medium; an inner layer applied to the corrugated medium, the inner layer having a metallised appearance; and an outer polymeric layer through which light can pass, the outer polymeric layer 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/12/15 being joined to the inner layer to allow the metallized appearance of the inner layer to be seen through the outer polymeric layer.

One of the benefits of the present invention is that the outer polymeric layer can protect the metallized appearance of the inner sheet, for example, during manufacture of the corrugated sheet.

Throughout this specification, unless the context requires otherwise, the term “layer” in the context of the inner and outer layer embraces a foil, a coating, or a film including pre-manufactured films or films formed by extrusion onto the liner. Coatings may be applied using any suitable means including spraying or printed, for example, by means of gravure printing or nip printing which can apply coatings to one side of the liner.

The corrugated board may include a liner sheet that is joined to the corrugated medium and the inner layer is joined to the liner sheet.

The inner layer and the outer polymeric layer may be joined to the liner sheet prior to the liner being joined to the corrugated medium. In other words, the inner layer may be pre-applied to the liner sheet before the liner is applied to the corrugated medium.

The inner layer may be metallised, and may for example be a metallised polymer layer or a metallic foil. In one embodiment, it is possible that only a portion of the inner layer may be metallised. Suitably metallisation of the inner layer may be applied over the entire surface of the inner layer.

It is also possible that the inner portion may be applied to only part of the liner. For example, there may be no need to apply the inner layer to parts of the liner that do not form part of an external surface of a carton made from the corrugated board.

In one embodiment, the inner layer may be applied to the liner by means of the inner layer being extruded onto the inner layer.

In one embodiment, the outer polymeric layer may have no decorative feature or image. In another embodiment, the outer polymeric layer may have an image or decorative feature that has been applied thereto. For example, the image or decorative feature may be printed on an inner surface of the outer polymeric layer. 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/12/15 It is also possible that an image or decorative feature may be printed on an outer surface of the outer polymeric layer. The image applied to the outer surface of the outer polymeric layer may be applied instead of, or in addition to, the image being applied to an inner surface of the outer polymeric layer.

The inner layer may also have an image applied thereto, such as a printed image. The image may be applied, for example, by means of applying stickers to the inner layer.

An advantage provided by this aspect is that the corrugated board will have a metallised appearance and may have an image that can be seen through the outer polymeric layer. Moreover, the metallised appearance of the inner layer and the image applied to the outer polymeric layer can be protected during manufacture of the corrugated board by the image being located on the inner face of the outer polymeric layer and outer polymeric layer being located over the inner layer to protect the inner layer. Another advantage of the present invention is that the image applied to the inner face of the outer polymeric layer may be a high quality printed image which is protected during manufacture of the corrugated board.

The inner layer may be a polymeric layer having a metallised appearance. The inner layer may be any polymeric material including at least one of metallised nylon, metallised PET (polyethylene terephthalate), metallised polypropylene including oriented polypropylene (OPP) and bi-oriented polypropylene (BOPP). The metallised appearance may have a lustre which is a characteristic of a metallised appearance.

The lustre may be of any colour including yellow, gold, silver, aluminium, tin or grey steel colours.

The inner layer may include a metallic foil layer such as an aluminium foil or a tin foil layer.

The outer polymeric layer may be clear, and may be a transparent polymeric layer and/or translucent polymeric layer. The outer polymeric layer may be a pre-formed film, an extruded film, or coating applied to the inner layer.

The outer polymeric layer may be any suitable polymeric material including nylon, PET (polyethylene terephthalate), polypropylene including oriented polypropylene (OPP) and bi-oriented polypropylene (BOPP) 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/12/15 Either one or both of the inner layer or the outer polymeric layer may have been subjected to a surface energy modification treatment. For example, the inner layer may be subjected to a corona treatment or some other form of plasma treatment to change the inherent surface energy of the inner layer or the outer polymeric layer.

Altering the surface energy of a surface of the inner layer, or the outer layer, may increase the bond strength between the inner layer and the liner sheet, or the bond strength between the inner layer and the outer layer.

The corrugated medium may have flutes of any shape and size. The corrugated medium may also include a plurality of sheets of flutes.

According to the present invention there is also provided a process of manufacturing a corrugated board, the process including: providing a corrugated medium; applying an inner metallised layer to the corrugated medium; and applying an outer polymeric layer through which light can pass to the inner metalliosed.

According to the present invention there is also provided a process of manufacturing a corrugated board, the process including: applying an inner metallised layer to a liner sheet; applying an outer polymeric layer through which light can pass to the inner layer; providing a corrugated medium; and joining the liner to crests of the corrugated medium to help maintain the corrugated medium in the corrugated form and so that the inner metalized layer can be seen through the outer layer.

In one embodiment, the steps of the process described herein may occur simultaneously or consecutively, that is with little or no period therebetween, and without intervening steps. In another embodiment, the steps of the process described herein may also occur disjunctively, that is with one or more intervening steps between at least two of the steps described herein.

The process may include a step of applying the image to the inner face of the outer polymeric layer. Applying the image may include printing the image on the inner face of the outer polymeric layer. 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/12/15 The outer polymeric layer and the inner layer may be joined together prior to being joined to the paper sheet. Ideally, the outer polymeric layer is preformed prior to being applied to the corrugated board. Moreover, the decorative image that is applied to the inner face of the outer polymeric layer may be a reverse printed image. When the outer layer is applied to the inner layer, the image can be observed through the outer polymeric layer.

The outer polymeric layer may be a coating that may, for example, be sprayed or printed onto the inner layer. Printing the outer polymeric layer may, for example, include gravure printing, or nip printing/application including single sided nip application.

The outer coating may be a film.

The step of applying the inner layer to the liner may include joining a film having a metallised appearance of the inner layer to the liner.

The step of applying the inner layer to the liner may include extruding the inner layer onto the liner sheet.

The inner layer may be a metallised polymeric material, and the step of applying the inner layer may include extruding the metallised polymeric material onto a film so that the inner layer joins onto the liner.

In another example, the inner layer may be a pre-manufactured sheet or film that is bonded to the liner.

Irrespective of whether the inner layer is a film extruded onto the liner, a pre- manufactured sheet or a coating applied to the liner, the bond between the inner layer and the liner may be a chemical bond or a physical bond. In one example, it is possible that an adhesive, such as polyvinyl acetate (PVA) may assist in bonding the inner layer to the liner.

The inner layer may include metallized foils or metal-like elements such as ink having a metal-like appearance. Suitably however, the inner layer is in the form of a polymeric film having a metallised appearance or is metallised. 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/12/15 The process described herein may include any one or a combination of the features of the corrugated board described herein. In addition, the corrugated board described herein may include any one or a combination of the features of the process described herein.

According to the present invention there is also provided a process of manufacturing a corrugated board, the process including: applying an inner layer having a metallised appearance to a liner sheet; applying an image to an inner face of an outer polymeric layer, wherein light can pass through the outer polymeric layer; joining the inner face of the outer polymeric layer to the inner layer; providing a corrugated medium; and joining the liner to crests of the corrugated medium to help maintain the corrugated medium in the corrugated form so that the metallised appearance of the inner layer and the decorative image of the outer layer to be seen through the outer layer.

The present invention also relates to a corrugated board including: a corrugated medium; a liner sheet that is joined to the corrugated medium; an inner layer applied to the liner sheet, the inner layer having a metallised appearance; and an outer polymeric layer through which light can pass, the outer polymeric layer having an imaged on the inner face of the outer polymeric layer and being joined to the inner layer to allow the metallized appearance and the image to be seen through the outer polymeric layer.

According to the present invention there is provided packaging having a lid and bottom portion that can be separated, the bottom portion having a base and a first side wall extending from the base, and the lid having a top wall and a second side wall extending from the top wall, the side wall of the lid being sized to fit around the first side wall, wherein the top and the second side wall of the lid are formed from the corrugated board described herein.

Suitably, the second side wall fits can cover the height and length of the first side wall when the lid is fitted to the bottom portion. 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/12/15 BRIEF DESCRIPTION OF THE DRAWINGS An embodiment of the present invention will now be described with reference to the accompanying drawings, of which: Figure 1 is schematic cross-section of part of a corrugated board according to a preferred embodiment; Figure 2 is a schematic cross-section of part of a corrugated board according to an alternative embodiment; Figure 3 is a perspective view of corrugated board according to Figure 1; Figure 4 is a schematic diagram illustrating a process and apparatus for making corrugated board such as, but by no means limited to, the corrugated board illustrated in Figure 1; and Figure 5 is a schematic diagram of an embodiment of a packaging having a lid and bottom that separated, in which the lid is made of a corrugated board as described herein.

DETAILED DESCRIPTION Various embodiments of the present invention will now be described with reference to the accompanying figures which have been included by means of non-limiting examples. Some features of the embodiments have been identified by reference numerals, and where possible, the same reference numerals have been used to identify the same or similar features of the different embodiments.

With reference to the figures, the corrugated board 10 includes a corrugated medium 11 and a linear liner sheet 12 that is attached to the crests of the corrugated medium 11 using any suitable means such as starch, adhesives, steam, pressure and so forth.

The liner sheet 12 and corrugated medium 11 may for example, be attached together using conventional dual arch processing equipment. The corrugated medium 11 may also include a single corrugated sheet or multiple corrugated sheets having flutes of any suitable spacing and size.

Prior to attaching the liner sheet 12 to the corrugated medium 11, ideally the 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/12/15 appearance of the liner sheet 12 is enhanced so as to having a metallic appearance.

Boxes and cartons made from the corrugated board have a metallised appearance and are often associated with high value products.

Applied to the liner sheet 12 is an inner layer 13 having a metallised appearance. The inner layer 13 may have several different forms, for instance, figure 1 illustrates the inner layer 13 in the form of metallised polymeric film laminated to the liner sheet 12.

Figure 2 illustrates a metallised coating 13, such as an ink printed onto the liner sheet 12. It is within the scope of the present invention that the inner layer 13 may be applied to only a portion to the liner 12 or entirely over the liner 12. The corrugated board 10 also includes an outer clear layer 15 through which light can pass so that the inner layer 13, and optionally the liner sheet 12, can be seen through the outer layer.

An advantage provided by the outer layer 15 is that it can protect the inner layer 13 from being damaged, for instance during the dual arch process. The outer layer 15 is therefore a protective layer and is preferably transparent or translucent so that the metallic appearance of the inner layer 13 can be seen.

Figure 1 illustrates the outer layer 15 in the form of a polymeric film that is applied over the inner layer 12. For example, the polymeric film may be joined or laminated to the inner layer 13 and liner 12. In order to further enhance the appearance of the corrugated board and to provide product labelling, descriptions and so forth, an additional layer 14 including decoration and images may be applied to the inner layer 13 or the liner 12 prior to the outer layer 15 being applied.

In addition, or alternatively, the additional layer 14 may be applied to the outer layer 15 prior to the outer layer 15 being bonded to the layer 14. Figure 1 illustrates the additional layer 14 in the form of information applied and, ideally printed on, an inner face of the outer layer 15 that faces toward to inner layer 13. The addition layer 14 applied to the inner face of the outer layer 15 will be a reverse of the image that can be observed through the outer layer 15 when the outer layer 15 has been applied to the corrugated board 10.

The additional layer 14 may be in the form of a reverse printed high quality image. An advantage of this configuration is that the printed image will be protected during down stream manufacturing processes. 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/12/15 Figure 2 illustrates the situation in which the additional layer 14 is applied directly to the inner layer 13, for example by being printed onto the inner layer 13, and the outer layer is laid over, and ideally laminated to the inner and outer layers 13, 14 of the liner 12.

The assembly of layers 13, 14 and 15 form the outer cladding layer 16.

Figure 3 is a schematic illustration of a corrugated board 10 having the enhanced cladding of figure 1. Although the corrugated board 10 has liners on opposite sides, it is envisaged that only one of the liners, namely the cladding 16 that would form the outer face of box would have the metallised appearance as described above in relation to figures 1 and 2. The inside/opposite liner 17 may be conventional liner board.

Figure 4 is a process and apparatus diagram illustrating one possible sequence of steps or equipment items for making the corrugated board 10 illustrated in Figure 1.

Ideally, the process is a continuous process including conveying the liner sheet 12 through a first station 20 where the inner layer 13 is applied, and suitably extruded, onto the liner 12. The liner 12 may be any suitable material including paper based materials, or laminates including polymeric materials, paper based materials and so forth. The inner layer 13 is suitably a metallised polymeric material, such as metallised nylon, metallised oriented and bi-oriented polypropylene including metallised medium density polypropylene that is laminated to the liner 12. The liner 12 and inner layer 13 are then conveyed to a second station 21 where the outer polymeric layer 15 is applied. An image 14 may also be printed onto an inner face of the polymeric layer in the second station 2, or in any event, prior to being to the liner 12 being applied to the inner layer 13.

The image 14 applied to the outer layer 15, may for example, be printed onto the inner surface of the outer layer 15 and may undergo suitable drying, for example, by an air blower prior to the outer layer 15 being applied, and suitably laminated to the liner 12 (and the inner layer 13). It is also possible that the image 14 may be applied or printed onto an inner surface of the outer layer 15, dried and then stored prior to being applied to the liner 12. In the situation in which the outer layer is a coil of film, the film may be unwound and rewound from roll to roll with printing and drying therebetween.

It is possible that the outer layer 15 may have a structure or properties that allows an image to be formed on or within the outer layer 15 without applying an image to the outer layer 15 or to the inner layer 13. For example, the outer layer 15 or the inner 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/12/15 layer may have thermal printing properties.

Figure 4 also illustrates a roll of paper based material being fed through a pair of mating corrugating rollers to impart a corrugated or fluted profile and form the corrugated medium 11, and the liner/cladding 16 having an enhanced metallised face being attached to the crests of the corrugated medium 11. A second liner 17, not having the metallised characteristics may be applied to the opposite face of the corrugated medium 11. Finally, the corrugated board 10 can be converted in downstream steps into suitable packaging, including cutting into blanks for making boxes and cartons.

Figure 5 is a schematic illustration of packaging 22 having a lid 24 and bottom portion 23 that can be separated. The bottom portion 23 has a base 27 and a first side wall 28 extending from the base 27. The lid 24 has a top wall 25 and a second side wall 26 extending from the top wall 25 that forms a skirt about the top wall 25. The second side wall 26 of the lid 24 is sized to fit around the first side wall 28 when the lid 24 is fitted to the bottom portion 23. In particular, the height and width of the second side walls 26 is sized to allow the bottom portion 23 to be essentially received within the lid In addition ideally the lid, including the top and the second side wall are formed from the corrugated board described herein so that the packaging 22 has a metallised exterior appearance.

It will be appreciated that the packaging may also have any other suitable form.

It will be understood by those skilled in the art of the present that may variations and modifications may be made to the preferred embodiment described herein without departing from the spirit and scope of the invention.

For instance, the inside or opposite liner 17 may be a non-corrugated board as shown, but it may also be a corrugated board.

In other examples, the opposite liner 17 may also have a metallised appearance and have the structure of liner 16. In yet other examples, the liner 17 may be coloured.

Although not shown in the Figures, the inner layer 13 and the outer layer 15 may be subjected to a surface energy modification such as a plasma treatment and a corona 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/12/15 treatment. Surface energy treatments may be applied to either one of the surfaces of the inner layer. For example, the treatment may be applied to a surface of the inner layer facing the liner sheet, and/or applied to the surface of the inner layer facing the outer sheet. The treatment may be applied to a surface of the outer layer that faces the inner layer. The treatment may improve the strength of the bond between the inner and outer layers, or the strength of the bond of the inner layer to liner sheet.

Although not shown in the drawings, it is also possible that the liner 12 may be omitted and that the inner layer may be applied directly to the corrugated medium 11. For example, the inner layer 13 may be a paper based layer have metallised finish is incorporated in the layer 13. 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/12/15

Claims (9)

1. A corrugated board including: a corrugated medium; 5 an inner layer applied to the corrugated medium, the inner layer having a metallised appearance; and an outer polymeric layer through which light can pass, the outer polymeric layer being joined to the inner layer to allow the metallized appearance of the inner layer to be seen through the outer polymeric layer.

2. The corrugated board according to claim 1, further including a liner sheet in which one side of the liner sheet is joined to the corrugated medium, and another side of the liner sheet is joined to the inner layer. 15

3. The corrugated board according to claim 2, wherein the inner layer is joined to the liner sheet by being extruded onto the inner layer.

4. The corrugated board according to any one of claims 1 to 3, wherein the inner layer and the outer polymeric layer are joined to the liner sheet prior to the liner 20 sheet being joined to the corrugated medium.

5. The corrugated board according to any one of claims 1 to 4, wherein the inner layer is a metallised polymer film or a metallic foil. 25

6. The corrugated board according to any one of claims 1 to 5, wherein the outer polymeric layer has an image or decorative feature.

7. The corrugated board according to claim 6, wherein the image or decorative feature has been applied to an inner surface of the outer polymeric layer that 30 faces toward the inner layer.

8. The corrugated board according to any one of claims 1 to 7, wherein the inner layer is a polymeric material including at least one of metallised nylon, metallised PET (polyethylene terephthalate), metallised polypropylene including 35 oriented polypropylene (OPP) and bi-oriented polypropylene (BOPP).

9. The corrugated board according to any one of claims 1 to 8, wherein the outer polymeric layer is a transparent polymeric layer or translucent polymeric layer 7260445_1 (GHMatters) P97621.NZ NIOUSHAA 23/