US3290205A - Method of making corrugated fibre board and products obtained thereby - Google Patents

Method of making corrugated fibre board and products obtained thereby Download PDF

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Publication number
US3290205A
US3290205A US188508A US18850862A US3290205A US 3290205 A US3290205 A US 3290205A US 188508 A US188508 A US 188508A US 18850862 A US18850862 A US 18850862A US 3290205 A US3290205 A US 3290205A
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Prior art keywords
adhesive
liners
board
mediums
medium
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US188508A
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English (en)
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Goldstein Abraham
Wolf Murray
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Tri Wall Containers Inc
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Tri Wall Containers Inc
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Priority to US188508A priority Critical patent/US3290205A/en
Priority to GB15271/62A priority patent/GB1018241A/en
Priority to LU42142D priority patent/LU42142A1/xx
Priority to ES279700A priority patent/ES279700A1/es
Priority to DE19621411875 priority patent/DE1411875A1/de
Priority to SE10719/62A priority patent/SE310592B/xx
Application granted granted Critical
Publication of US3290205A publication Critical patent/US3290205A/en
Priority to JP48137466A priority patent/JPS5220917B1/ja
Priority to NL7414025A priority patent/NL7414025A/xx
Anticipated expiration legal-status Critical
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/20—Corrugating; Corrugating combined with laminating to other layers
    • B31F1/24—Making webs in which the channel of each corrugation is transverse to the web feed
    • B31F1/26—Making webs in which the channel of each corrugation is transverse to the web feed by interengaging toothed cylinders cylinder constructions
    • B31F1/28—Making webs in which the channel of each corrugation is transverse to the web feed by interengaging toothed cylinders cylinder constructions combined with uniting the corrugated webs to flat webs ; Making double-faced corrugated cardboard
    • B31F1/2813—Making corrugated cardboard of composite structure, e.g. comprising two or more corrugated layers
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard
    • D21J1/16—Special fibreboard
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1007—Running or continuous length work
    • Y10T156/1016—Transverse corrugating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y10T428/24669—Aligned or parallel nonplanarities
    • Y10T428/24694—Parallel corrugations
    • Y10T428/24711—Plural corrugated components
    • Y10T428/24727—Plural corrugated components with planar component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/27—Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]

Definitions

  • This invention essentially relates to a method of making multiple wall corrugated fibre (or paper) board of the thick and very thick kind comprising at least two and preferably three layers or plies of corrugated mediums and three of four liners and to the products obtained thereby.
  • the corrugated mediums are thus interposed or sandwiched between, these spaced liners which are flat sheets adhesively secured to the tips of the corrugated medium to form an integrated product.
  • the triple wall product has the advantage over other fibre board materials when made into boxes, of having great column strength and therefore permitting a number of the boxes to be piled one on top of another when containing heavy objects, without causing excessive buckling or complete collapse of the vertical walls of the boxes near the bottom.
  • Another advantage is that this product has great resistance against the tearing penetration occasioned by sharp objects striking against it, such as might occur when boxes are transported and subjected to careless treatment.
  • one flat liner sheet is adhesively bonded to one web of corrugated medium by adhesive or glue applied to the tips or crests of the corrugations or flutes across the entire width of the latter which are parallel to each other, so as to form a layer known as a single face corrugated board. This is done twice or three times according as a double wall or a triple wall corrugated board is contemplated.
  • the single face boards are preheated to condition the sheets for the reception of adhesive and the exposed ridges of the corrugations on the unlined side of the corrugated medium of each of the two or three layers have adhesive applied to them across their entire Width and the two or three layers are superimposed and pressed together with a third or fourth outermost liner whereby said ridges of said corrugation are .adhesively secured to the liner of an adjacent ply and to said outer third or fourth liner. While pressure is continuously applied to the composite board thus obtained, the latter is heated to partially dry it for bonding the several sheets together whereby the sheets are incompletely set. For triple wall corrugated board this heating may be effected preferably at a tempera- 3 90,205 Patented Dec.
  • the composite board is then cooled to allow handling thereof and possibly subsequently scored or creased transversely to the corrugations to permit folding or bending the material to a packaging shape and possibly crushed locally and trimmed and cut to finished size. All of said operations may be effected manually but they are generally more conveniently carried out while the material is continuously moving with the corrugations transverse to the path of travel in a single pass through an automatic corrugated fibre board machine comprising two or three corrugating and single facer sections followed by a combining double backer device incorporating a laminating, heating and cooling section and a scoring and shearing section.
  • the temperature-speed relationship is varied with the humidity, the thickness, and porosity of the sheets to provide a residence time in the heating section to set or harden said adhesive.
  • the web of triple wall corrugated board may be heated for not less than 14 seconds and not more than 24 seconds (otherwise the product is scorched).
  • the medium which is relatively cheap may have any furnish and may even be glassine paper.
  • this sheet is generally composed of paper made by the kraft pulping process, paper made by the semi-chemical pulping process, paper made from waste papers or paper made from the pulping of straw.
  • the liner which is relatively expensive can again have any furnish but is generally a sheet of all kraft furnish or a sheet with waste paper furnish.
  • the purpose of the adhesive is to adhere the mediums to the liners. rugated board operate at relatively high speed, the adhesive must bond or at least set immediately. When an adhesive is set, it has undergone either a physical or chemical change to an extent such that the materials between which it lies are sufficiently adhered so that they cannot be separated easily. Further physical or chemical changes only serve to help develop maximum bond strength in the adhesive. This latter period is a curing or a bonding period.
  • This method is remarkable notably in that among other operations known per se it comprises the step of tensioning said liners end to end by stretching same to positively maintain their flatness throughout the manufacturing process, the step of assembling the component layers in their freshly made and slightly damp state with all of the adhesive incompletely set by simultaneously and continuously pressing them firmly together while the liners are held taut and the component parts are prevented from any slippage relative to each other, the moisture but not all of it then being progressively driven off substantially uniformly by heating, the step of cooling the resulting composite board while still tensioned and immediately thereafter possibly scoring said board as required by folding, while some moisture still remains therein, and possibly the step of stacking the finished product cut to size for a curing time to allow the remaining moisture to evaporate i and the board components to eventually acquire a stabi- Since the machines used to produce cor-- lized moisture content with respect to the humidity of the surrounding atmosphere
  • the finished product is to 'be scored to permit the folding of flaps and the like, this should be done immediately after the cooling stop because at that time the product still retains some of its moisture and although its glue is set, it is still slightly flexible, thereby facilitating the crushing which forms the score lines or strips without substantial harm to any of the layers or to the glue connections.
  • the result is a product that is structurally balanced and firmly interconnected.
  • the triple wall product resulting from the above procedure is tremendously stronger in every way than is the double wall product even though the weight of the liners of both is substantially the same.
  • the triple wall product may be made with relatively thinner or lighter weight paper liners.
  • the adhesives used comprise essentially starch and water which must be heated to a high enough temperature to cause the starch to gel, or a silicate type adhesive such as sodium silicate and water which must be heated to evaporate the water to set the adhesive. Thus heat is require-d in both instances.
  • both outermost liners are of greater weight than the inner liners to attain the greatest possible moment of inertia.
  • Thicker liners soak up more water when the adhesive is applied and their very thickness reduces their ability to conduct heat.
  • Higher corrugations contain more air which reduces the flow of heat and in addition spaces the liners and adhesive farther from the heat which can only be applied to one side of the combined pieces when any convenient manufacturing method is used.
  • the production of multiple wall corrugated fibre board especially of the triple wall type whose minimum strength is better than similar known board made with the same overall weight of liners or flat sheets incorporated in only three flat sheets or liners and only two webs of corrugated medium between them and whose maximum strength is considerably greater than this is made possible in a practical way.
  • This is done by making the outermost liners or fiat sheets of paper not only of greater weight but according to another feature of the invention also by employing liners of very great density obtained by using highly calendered paper.
  • the manufacturing of the separate single face layers comprises the step of gluing the ridges of the flutes of the corrugated medium which are to be adhered to the liner with an adhesive compounded to set at relatively high temperatures; thus when securing the single layers of liner an adhesive is used, whether of the starch or silicate kind, which requires a large amount of heat to set it properly and which therefore can later withstand satisfactorily higher temperatures.
  • an adhesive is used, whether of the starch or silicate kind, which requires a large amount of heat to set it properly and which therefore can later withstand satisfactorily higher temperatures.
  • the use of this kind of adhesive is practical because at this time there is no great problem in getting heat to the adhesive.
  • an adhesive is used, and again it may be either of the starch or silicate type, which is compounded to set at lower temperatures.
  • the liner is of heavy weight and great strength, being highly calendered, its high density and relative thinness permits the heat to pass through it more readily. Furthermore, when the final combining step is carried out a large amount of heat can be passed through the product to set the adhesive requiring the lower temperature to set this adhesive satisfactorily without hurting the previously applied adhesive having the higher temperature setting characteristic.
  • a well-established principle of mechanical engineering is that the greatest strength and rigidity in a structural member having a given amount of material is realized by disposing the surfaces subjected to stress so that they are as far apart as possible to provide the greatest moment of inertia. Therefore it is known to spread the liners or fiat sheets as far apart as possible, and in the case of triple wall board for example to use corrugated mediums two of which are made with corrugations that are quite high while the third is made with a corrugation of lesser height. Then according to a further feature of the invention, the parts are combined so that the corrugations of lesser height are closest to the heat source used to set the adhesive required to inter-connect the various layers of the final product.
  • the heat does not have to travel a great distance before reaching the first zone of adhesive used in the second or overall combining step.
  • all of the layers are spread rather widely apart from the neutral axis of the material of the product.
  • cartons made from the board described are easier to fabricate and use.
  • the adhesives applied during the combining step also differ from each other in characteristics. Those applied to the corrugation tips closest to the heat source may be compounded to set at somewhat higher temperatures than the adhesive used to affix the latter furthest from the heat source. Thus the greater heat that reaches the adhesive closest to the heat source has even less tendency to hurt that adhesive while the heat reaching the farthest adhesive is adequate to set this adhesive.
  • the liners are made from highly calendered pure kraft paper which are of high density but which are of different weights for the outermost two layers may be made of very heavy weight while the two liners in between may be made of lighter weight paper.
  • This has the great advantage that the one thicker layer closest to the heat receives its heat directly, the adhesive on the inside of the liner farthest from the heat receives heat without it passing through this liner, and the two liners in between are both of the lighter and therefore thinner paper that does not resist the passage of heat to so great a degree.
  • a further feature of the invention is to use an adhesive of a type that may be heated to high temperatures before it is applied to the tips of the corrugations of the corrugated medium in the case of the combining of all of the parts to produce the triple wall construction.
  • Such adhesive may be a formula consisting largely of silicate of soda, starch, clay, water and other additive.
  • the starch acts as a sort of desiccating or dehydrating agent, in that in conversion or gelatinization wit-h heat it absorbs the water available from the silicate of soda.
  • the silicate of soda of course sets when a certain percentage of water (e.g. between 13.5% and 15%) is removed from it.
  • the present invention permits the rapid and effective production of triple wall corrugated paper board of great strength even when the outer liners or fiat sheets are made of so called water-proof or moisture-proof pure kraft paper, and even though the corrugated medium is made of heavier than usual paper for the purpose of even further increasing the strength of the final product as will be ascertained hereinafter.
  • Another object of the present invention is to provide a scoring device for multiple wall corrugated fibre board.
  • Scoring devices which comprise at least one pair of registering rotatable score wheels between which the finished board is pulled and constituting the one a male die having in cross-section a projecting forming part and the other a female die having in cross-section a corresponding depression.
  • the scoring device according to the invention is remarkable notably in that said male die overlies said female die so as to engage from above the top surface of said board, said male die projecting part forming a raised arcuate portion around its periphery and about three-quarters of an inch wide and about three-sixteenths of an inch high whereas said depression around the periphery of said female die which is substantially exact mate of the male has dimensions corresponding to those of the male.
  • This invention also relates to the multiple wall corrugated fibre board product manufactured according to the method broadly set forth hereinabove and comprising a plurality of layers of corrugated medium interspersed between fiat liners which are of heavier weight on the two outermost layers than those forming the inner layers which thus are relatively thinner.
  • This product is remarkable notably in that said liners are all of equally very high density and preferably made of highly calendered pure kraft paper and are joined together with said corrugations on one side of the corrugated medium by at least one type of adhesive and on the other side by at least another type of adhesive, the adhesive being confined to the interconnecting parts and being firm and free from over-heating effects throughout the entire product.
  • said multiple wall fibre board product comprises corrugated medium of relatively very heavy weight combined with liners at least some of which are of possibly relatively reduced weight and caliper.
  • this invention advocates the use of heavier corrugating mediums for the purpose of increasing not only the column compression load which the finished fibre board may withstand but also its resistance to puncture by sharp objects during transit. It has frequently and emphatically been stated in prior art and present trade practice that the strength of combined corrugated fibre board except as concerns flat crush is entirely dependent of the strength of the liners or flat sheets and that the sole purpose of the corrugating medium is that of spacing the liners sufiicient-ly from the neutral axis of the board for the development of maximum strength by the fibre board. The weight and thickness of the corrugating medium have thus far been considered unimportant in their contribution to strength.
  • grades of board exactly like those shown as sample 2 of Table I may have a puncture value which ranges from a low of 1000' to a- TABLE I.IROPERTIES AND TEST RESULTS OF TYPICAL TRIPLE WALL CORRUGATED FIBRE BOARDS (C-A-A TYPE FLUTE CONFIGURATION) Fibre Board Total Liner Properties Total Medium Properties Total Fibre Board construction Properties Sample Puncture, Compression,
  • Equation 1 the amount of heat transferred through the board is greater. It must be remembered that increasing the thickness of the corrugating medium has the opposite effect. However, the total change due to reducing the liner thickness and increasing the medium thickness is a net reduction in overall paper board thickness through which the heat must travel.
  • thicker mediums also causes the gas or vapor layer between the liner and the medium to be reduced. This occurs since the single facer produces a flute of definite height which will be only slightly affected by the corrugating medium. If the cross sectional area, and thus the volume between the inner faces of the liners thus remains constant, it is obvious that the thicker corrugating mediums will occupy a greater amount of volume thus reducing the vapor volume and consequently its effective thickness. This reduction in thickness of the air layer again results in greater conductive heat transfer. The total increase in the amount of heat transfer by conduction is between 3 and 4%.
  • the steam and air stream rising through the board is the second major means by which heat is transferred through the fibre board.
  • the heated air portion of the stream transfers heat to the adhesive and the boa-rd components which are furthest from thehea-t source through loss of sensible heat.
  • the steam transfers heat not only through loss of sensible heat but also through repeated condensations and evaporations. However, the effect of the latter is small.
  • the percentage of air in the mixed stream increases as the stream moves up through the board with a resulting decrease in the partial pressure of water vapor.
  • the steam is held mainly in the vapor form and transfers heat through loss of sensible heat or superheat.
  • the amount of heat transferred is a function of the amount of vapor which is capable of passing up through the interstices of the components.
  • the passage of a fluid through any opening is given by a formula of the Poiseuille type dF 32/LV dL gcD V (5) It can be seen, that all other things being equal, the volume of fluid V capable of passing through an opening of diameter D is inversely proportional to the length L of the opening.
  • Equation 5 the diameter of the opening, in Equation 5 which shows that the amount of vapor is directly proportioned to the square of the opening.
  • dense liners are used having small interstices.
  • the corrugating medium is porous having larger interstices.
  • a further advantage of the present invention relates to the cost of the finished triple wall corrugated fibre board.
  • Comparison of samples 1 and 3 of Table I shows that board of greater strength can be obtained by using thicker corrugating mediums and thinner liners despite the fact that there is a net reduction in the total weight of paper board in the product. Since paperboard is purchased on a weight basis, there is obviously a net saving involved in using a lower weight of paper. This saving is amplified when it is remembered that the cost of corrugating mediums is lower than the cost of liner. Thus, in the present invention low cost medium is substituted for high cost .liner with an overall reduction in total weight resulting in significant savings.
  • FIG. 1 is a partial elevational side view of one single facer section of a corrugated fibre board machine showing the step wherein the corrugated medium is applied to one liner;
  • FIG. 2 is an enlarged partial side View of the double backer section of said machine showing the combining step wherein all three single face components and the fourth liner are put together;
  • FIG. 3 is an enlarged vertical section parallel to the direction of travel of the paper showing the effective adhesive bond obtained between all of the tips of the corrugation and the adjacent liner;
  • FIG. 4 is a perspective partial view of a scored board showing the possibility of creasing or scoring the new product so it may be folded as required to make a rectangular box for example;
  • FIG. 5 is a fragmentarycross-section of the score dies
  • FIGS. 6, 7 and 8 are graphs based upon test data included in Table I given hereinabove and wherein puncture and column compression strengths are plotted against total board weight, total liner weight and total liner caliper respectively.
  • the corrugating medium denoted by the reference numeral 1 is first formed in the nip between corrugating rolls 2 and 3 after first conditioning the medium with moisture as by steaming and with both corrugating rolls being properly heated. While on roll 3, the medium 1 has lines of adhesive 4, applied to each tip of each corrugation by means of adhesive applicator roll 5.
  • the usual starch or silicate adhesive may be used provided it is compounded to set at higher temperatures.
  • sodium silicate a normal 38 B. solution having a silica (SiO to soda (Na O) ratio in the range of 3.2 to 3.33 may be used directly.
  • starch a mix containing 20% solids and having 33 pounds of caustic in a 666 gallon batch will be satisfactory.
  • the previously described type of silicate adhesive containing starch protein and other ingredients besides water may be used.
  • corrugating material used may be any of those customarily used in making the older kinds of corrugated paper board.
  • the material that is considered to be best is medium weighing 33 to 36 pounds per 1000 square feet as stated hereinabove.
  • the liner 6 after being suitably heated is fed over a heated roll 7 which presses the liner 6 against the tips of the corrugations of medium 1, the heat causing the adhesive to set enough to hold the two components to gether thereafter.
  • This liner may be for example very dense highly calendered pure kraft paper. It may weigh pounds per 1000 square feet but due to its density it is not very thick. It is directly in contact with the heated roll 7.
  • the corrugated medium 1. is of course hot from the corrugating step and therefore the adhesive may be set easily during this phase of the manufacture.
  • the liner 6 may be of relatively light paper when intended for the mid portions of the final product. In these instances although still a more dense heavily calendered pure kraft paper, the liner may weigh only 42 pounds per 1000 square feet.
  • the liner material of the desired kind is only about .023" to .030" thick in the case of the 90 pound material and is only .013" to .016 thick in the case of the 42 pound material.
  • FIG. 2 the three layers of the materialshown being made in FIG. 1, are placed together with a fourth liner, this beneath the corrugations that would otherwise be exposed.
  • the tip of each exposed corrugation has the second adhesive 9 applied to it again in the form of a line running along the tip of the corrugation.
  • the adhesive is of the lower temperature setting formula.
  • the adhesive 9 applied to the exposed corrugations of the top layer has a formulation permitting the lowest temperature setting of all.
  • the plate 8 It is considered best to heat the plate 8 to temperatures ranging about 300 F. to some thirty or more degrees higher.
  • the exposure time of the layers being put together at such heat may vary from a minimum where there is danger of destroying the integrity or strength of the layer up to maximum, such as might be desired for high speed manufacture, that is just sufficient to set the adhesive 9 enough to hold the product firmly together. Moisture from the adhesive and from other causes should of course be driven off to a considerable degree.
  • the density of the liner 1.0 promotes heat conduction through this layer.
  • the small size of the first set of corrugations permits this heat to get quickly to the liner or fiat sheet to which the first set of corrugations were previously attached.
  • the only barriers then in the way of heat transfer are the two substantially thinner next upwardly flat liners and the air space produced by the corrugating medium between them. Radiation plus the thermal bath provided by rising steam gets the heat to the most diflicult to set locations, namely the lines of adhesive located on the bottoms of the corrugations of the upper most layer of previously put together corrugated medium and heavier liner sheet.
  • silicate may be used where a silicate formula is desired. Where a starch formula is desired an adhesive containing 33 pounds of caustic in a 666 gallon batch may be used giving a caustic content of about 2.7%.
  • the second step about 12% clay is added to the silicate where a silicate formula is desired.
  • the caustic content is raised to 40 pounds in a 666 gallon batch giving a caustic content of about 3.3% where a starch formula is desired.
  • a formula containing 70% silicate, 6% starch, 18% clay and 6% borax is used where a silicate formula is required.
  • the formula given under the second step may be modified to contain about 20% of a polyvinyl acetate emulsion. All percentages specified are on a dry adhesive weight basis.
  • the adhesive 9 must be set firmly enough to permit the relatively thick product to be handled.
  • the upper two layers of corrugated medium may be of the so-called A-type defined by a flute depth in the neighborhood of 9& of an inch with about thirty-six corrugations per lineal foot, wherea the lowermost corrugated medium having reference to FIG. 2, may be made with so-called C-type corrugations having a depth or height of about of an inch with about 42 corrugations per lineal foot.
  • the whole finished product may have a thickness of about 7 inch.
  • FIG. 3 the general contour of the finished bond of adhe ive 9 is shown as having the usually desired but not always attained restriction close to the tip of the corrugation,
  • Overheating causes the embrittlement of the adhesive so that the adhesive cracks or breaks when the board is handled resulting in the separation of the previously combined layers.
  • Relative slippage between layers before the adhesive is properly set causes the corrugated tips to wipe the adhesive in a wide band along the width of the board leaving an inadequate amount of adhesive in the correct position between the corrugated tip and the liner for a proper bond between the components. This wiping also causes the board to lose its proper configuration.
  • the present invention provides for the most desirable bond throughout the desired product.
  • FIG. 4 Such creasing or scoring is shown by FIG. 4.
  • the corrugations of boa-rd 13 are of course crushed but throughout a relatively wide zone, indicated at d and the various liners move towards each other. This zone d should be much wider than that ordinarily used for thinner corrugated materials.
  • the particular score line that is considered most effective is the one that would be made by the set of score wheels shown in FIG. 5.
  • the male score wheel 14 has a raised portion 15 around its periphery at the point where the board is to be scored.
  • the dimension a, the width of the raised portion is about three-quarters of an inch while dimension b, which is the height of the raised portion, is about three-sixteenths of an inch.
  • the female score wheel 16 is an exact mate of the male and has around its periphery a depression 17 whose dimensions correspond to those of the male.
  • the male score is pressed into the board perpendicular to the axis of the corrugations.
  • the corrugation are crushed in a band along the length of the board.
  • the upper liner conforms exactly to the contour of the raised portion of the male score wheel.
  • the bottom liner is not pushed completely into the depression of the female score wheel because of the crushing of the corrugations.
  • the liner in contact with the female score wheel does extend below the surface of the board.
  • This type of score offers the advantage that it stresses the board in the direction in which this portion must eventually be stressed after a carton is produced from the board.
  • the score herein described is a flap score which is to say that it produces a line of bend in the board which separates the flaps used in forming the top and bottom of the box from the sides of the box.
  • the scoring or creasing need not be followed by bending or folding of the product.
  • the product in convenient lengths is preferably stacked and given time for What might be called a cure. During this time any remaining moisture evaporates and the fibre board components acquire a moisture content that is stabilized with respect to the humidity of the surrounding atmosphere. In some cases further setting of the adhesive may occur during this period.
  • the adhesive bond is in all cases of the type as shown in FIG. 3.
  • the use of the two types of adhesive is made evident by this bond and its characteristics because otherwise the lowermost bond points would not have the desired characteristics but would be brittle, out of shape and weak.
  • Graph of FIG. 6 shows the puncture and compression properties of the board plotted against total board weight.
  • the curves connect test points S S 8., representing samples l, 2 and 4 respectively which include the light weight medium with varying thicknesses of intermediate liners.
  • the variable for the curves is the liner weight.
  • These curves demonstrate and support the prior art concept that increases in the liner weight increase the puncture and compression properties of the board.
  • the points S and 8;, on this graph represent the heavy medium triple wall board and demonstrate the marked increase in puncture and compression properties. Curves are not shown for the heavy medium triple wall since the data only includes sample No. 3.
  • the graphs of FIGS. 7 and 8 show curves for the light weight medium against total liner weight and total liner caliper, respectively. As discussed with respect to the curves in FIG. 6, the graphs of FIGS. 7 and 8 also demonstrate the prior art concept that the properties of the board are dependent upon liner weight and liner caliper. Again as in FIG. 6, the points S 8;, representing the heavier medium triple wall point out the marked improvement achieved by this arrangement.
  • step of bonding a corrugated medium to a liner with said first adhesive having a first predetermined setting temper ature to form a single face corrugated paper board sheet further comprises using for said first adhesive an adhesive which may be heated to high temperatures before it is applied to the tips of the flutes of the corrugated medium, said first adhesive including sodium silicate, starch, clay, water, and additional additives.
  • Triple Wall corrugated paper board which is fiat and adapted for scoring and bending to form a shipping container comprising four paper liners, the outermost liners weighing about 90 pounds per 1000 square feet and being from about .023 to about .030 of an inch thick, two intermediate liners weighing about 42 pounds per 1000 square feet and being from about .013 to about .016 of an inch thick, three corrugated paper mediums, the mediums being interposed between the liners in each instance with the corrugations of the medium being parallel to each other per 1000 square feet and from about .011 to about .018
  • first and second adhesive applied to the ridges of the mediums corrugations for intimately and rigidly bonding the mediums and liners together, said first adhesive bonding each of the corrugated mediums at one side thereof to a different one of the liners, to form a single face corrugated paper board sheet, said first adhesive having a first predetermined setting temperature and being one of a sodium silicate mix added with about 12% clay and a starch mixture containing 40 pounds in a 666 gallon batch and giving a caustic content of about 3.3%, said second adhesive being applied to the ridges at the opposite side of the medium of each of said single face sheets and having a second setting temperature which is lower than said first setting temperature of said first adhesive, said second adhesive being of a sodium silicate formula containing about 70% sodium silicate, 6% starch, 18% clay, and 6% borax on a dry weight basis and a starch formula modified to contain about 20% of a polyvinyl acetate emulsion, the lower setting temperature of said second adhesive

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Making Paper Articles (AREA)
  • Machines For Manufacturing Corrugated Board In Mechanical Paper-Making Processes (AREA)
US188508A 1962-04-18 1962-04-18 Method of making corrugated fibre board and products obtained thereby Expired - Lifetime US3290205A (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US188508A US3290205A (en) 1962-04-18 1962-04-18 Method of making corrugated fibre board and products obtained thereby
GB15271/62A GB1018241A (en) 1962-04-18 1962-07-02 Improvements in or relating to method of making corrugated fibre board and products obtained thereby
LU42142D LU42142A1 (cs) 1962-04-18 1962-07-30
ES279700A ES279700A1 (es) 1962-04-18 1962-07-31 Perfeccionamientos en, o relativos al, procedimiento de fabricación de cartonajes de fibra acanalados, y sus medios de realización
DE19621411875 DE1411875A1 (de) 1962-04-18 1962-09-05 Verfahren zur Herstellung von Welltafeln aus Fasermaterial,und mittels desselben hergestellte Erzeugnisse
SE10719/62A SE310592B (cs) 1962-04-18 1962-10-05
JP48137466A JPS5220917B1 (cs) 1962-04-18 1973-12-11
NL7414025A NL7414025A (nl) 1962-04-18 1974-10-25 Werkwijze voor het maken van golfcarton en daaruit gemaakte produkten.

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US188508A US3290205A (en) 1962-04-18 1962-04-18 Method of making corrugated fibre board and products obtained thereby

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US (1) US3290205A (cs)
JP (1) JPS5220917B1 (cs)
DE (1) DE1411875A1 (cs)
ES (1) ES279700A1 (cs)
GB (1) GB1018241A (cs)
LU (1) LU42142A1 (cs)
NL (1) NL7414025A (cs)
SE (1) SE310592B (cs)

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3432372A (en) * 1964-02-14 1969-03-11 Anciens Etablissements Walton Manufacture of corrugated cardboard
US3936340A (en) * 1970-07-07 1976-02-03 G. D. Searle & Co. Method for making corrugated collimators for radiation imaging devices
US4177936A (en) * 1977-06-06 1979-12-11 International Paper Company Variable flute container
US4560429A (en) * 1977-05-09 1985-12-24 Montedison S.P.A. Process for preparing moisture-resistant packing cardboard
WO1986003928A1 (en) * 1984-12-20 1986-07-03 Lff And Associates Method and devices for making electro-acoustic transducer apparatus
US4604792A (en) * 1984-12-20 1986-08-12 Lff & Associates Method for making electro-acoustic transducer apparatus
WO1987002936A1 (en) * 1985-11-12 1987-05-21 Baird Richard L Paper products processed with sodium silicate material
US4729505A (en) * 1986-11-13 1988-03-08 Weyerhaeuser Company Heavy-duty shipping container for flowable bulk materials
US4748066A (en) * 1984-10-31 1988-05-31 Digital Equipment Corporation Fire resistant materials
US4765855A (en) * 1984-01-12 1988-08-23 I. T. I. Enterprises Ltd. Method of making a sandwich material with internal undulations and protective layers
US5266148A (en) * 1990-02-07 1993-11-30 Weyerhaeuser Company Triple wall fold construction and forming process and mechanism
EP0972812A1 (en) * 1998-07-13 2000-01-19 Korea Research Institute Of Chemical Technology Adhesive for a multi-ply sheet and a method for manufacturing the multi-ply sheet using the same
US20060165960A1 (en) * 2002-03-07 2006-07-27 Tommy Rydberg Packaging material of the corrugated cardboard type
US20110110612A1 (en) * 2009-11-12 2011-05-12 The Boeing Company Micropleated Vacuum Bag and Seal Method for Composite Parts
EP2969526A4 (en) * 2013-03-15 2016-08-31 Corrugated Synergies International Llc METHOD AND DEVICE FOR PRODUCING PURELY MEDIA AND RELATED ARTICLES AND COMPOSITIONS THEREOF
WO2019051530A1 (en) * 2017-09-15 2019-03-21 Brandon Penn CANNELÉE SHEET
US10328654B2 (en) 2016-04-20 2019-06-25 Scorrboard, Llc System and method for producing a multi-layered board having a medium with improved structure
US10363717B2 (en) 2013-03-15 2019-07-30 Scorrboard Llc Methods, apparatus and systems for establishing a registered score, slit or slot in a corrugated board, and articles produced there from
US10800133B2 (en) 2016-04-20 2020-10-13 Scorrboard, Llc System and method for producing a facing for a board product with strategically placed scores
US11027515B2 (en) 2016-04-20 2021-06-08 Scorrboard Llc System and method for producing multi-layered board having at least three mediums with at least two mediums being different
US11027513B2 (en) 2016-04-20 2021-06-08 Scorrboard Llc System and method for producing an articulating board product having a facing with score lines in register to fluting
US11420418B2 (en) 2013-03-15 2022-08-23 Scorrboard Llc Methods and apparatus for producing scored mediums, and articles and compositions resulting there from
CN116852806A (zh) * 2023-07-17 2023-10-10 上海万戈工贸发展有限公司 一种防水纸板的制备方法及应用
US20230408022A9 (en) * 2021-07-30 2023-12-21 Temperpack Technologies Inc. Insulation products and methods and machines for making insulation products

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4886696A (en) * 1988-05-10 1989-12-12 Manville Corporation Corrugated paperboard automotive liner
FR2807077B1 (fr) * 2000-03-31 2002-06-07 Papeteries Et Cartonneries Lac Procede de fabrication de carton ondule ignifuge, et carton ondule ainsi obtenu

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US2160221A (en) * 1935-07-12 1939-05-30 Orville M Masters Shipping container construction
US2434466A (en) * 1944-05-23 1948-01-13 Carey Philip Mfg Co Composite board
US2759523A (en) * 1953-10-02 1956-08-21 Corro Ltd Method and machine for making triple wall corrugated paper board
US2985553A (en) * 1957-09-26 1961-05-23 Tri Wall Containers Inc Triple-wall corrugated board
US3033708A (en) * 1958-10-01 1962-05-08 Paper Chemistry Inst Process of impregnating an assembled corrugated container board
US3096224A (en) * 1961-11-03 1963-07-02 Tri Wall Containers Inc Corrugated paper board product

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2160221A (en) * 1935-07-12 1939-05-30 Orville M Masters Shipping container construction
US2434466A (en) * 1944-05-23 1948-01-13 Carey Philip Mfg Co Composite board
US2759523A (en) * 1953-10-02 1956-08-21 Corro Ltd Method and machine for making triple wall corrugated paper board
US2985553A (en) * 1957-09-26 1961-05-23 Tri Wall Containers Inc Triple-wall corrugated board
US3033708A (en) * 1958-10-01 1962-05-08 Paper Chemistry Inst Process of impregnating an assembled corrugated container board
US3096224A (en) * 1961-11-03 1963-07-02 Tri Wall Containers Inc Corrugated paper board product

Cited By (31)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3432372A (en) * 1964-02-14 1969-03-11 Anciens Etablissements Walton Manufacture of corrugated cardboard
US3936340A (en) * 1970-07-07 1976-02-03 G. D. Searle & Co. Method for making corrugated collimators for radiation imaging devices
US4560429A (en) * 1977-05-09 1985-12-24 Montedison S.P.A. Process for preparing moisture-resistant packing cardboard
US4177936A (en) * 1977-06-06 1979-12-11 International Paper Company Variable flute container
US4765855A (en) * 1984-01-12 1988-08-23 I. T. I. Enterprises Ltd. Method of making a sandwich material with internal undulations and protective layers
US4748066A (en) * 1984-10-31 1988-05-31 Digital Equipment Corporation Fire resistant materials
US4604792A (en) * 1984-12-20 1986-08-12 Lff & Associates Method for making electro-acoustic transducer apparatus
WO1986003928A1 (en) * 1984-12-20 1986-07-03 Lff And Associates Method and devices for making electro-acoustic transducer apparatus
WO1987002936A1 (en) * 1985-11-12 1987-05-21 Baird Richard L Paper products processed with sodium silicate material
US4729505A (en) * 1986-11-13 1988-03-08 Weyerhaeuser Company Heavy-duty shipping container for flowable bulk materials
US5266148A (en) * 1990-02-07 1993-11-30 Weyerhaeuser Company Triple wall fold construction and forming process and mechanism
EP0972812A1 (en) * 1998-07-13 2000-01-19 Korea Research Institute Of Chemical Technology Adhesive for a multi-ply sheet and a method for manufacturing the multi-ply sheet using the same
US20060165960A1 (en) * 2002-03-07 2006-07-27 Tommy Rydberg Packaging material of the corrugated cardboard type
US20110110612A1 (en) * 2009-11-12 2011-05-12 The Boeing Company Micropleated Vacuum Bag and Seal Method for Composite Parts
EP2969526A4 (en) * 2013-03-15 2016-08-31 Corrugated Synergies International Llc METHOD AND DEVICE FOR PRODUCING PURELY MEDIA AND RELATED ARTICLES AND COMPOSITIONS THEREOF
US11420417B2 (en) 2013-03-15 2022-08-23 Scorrboard Llc Methods and apparatus for producing scored mediums, and articles and compositions resulting therefrom
US11420418B2 (en) 2013-03-15 2022-08-23 Scorrboard Llc Methods and apparatus for producing scored mediums, and articles and compositions resulting there from
US10363717B2 (en) 2013-03-15 2019-07-30 Scorrboard Llc Methods, apparatus and systems for establishing a registered score, slit or slot in a corrugated board, and articles produced there from
US11001027B2 (en) 2013-03-15 2021-05-11 Scorrboard Llc Methods and apparatus and systems for establishing a registered score, slit or slot in a corrugated board, and articles produced there from
US10800133B2 (en) 2016-04-20 2020-10-13 Scorrboard, Llc System and method for producing a facing for a board product with strategically placed scores
US11027515B2 (en) 2016-04-20 2021-06-08 Scorrboard Llc System and method for producing multi-layered board having at least three mediums with at least two mediums being different
US11027513B2 (en) 2016-04-20 2021-06-08 Scorrboard Llc System and method for producing an articulating board product having a facing with score lines in register to fluting
US10328654B2 (en) 2016-04-20 2019-06-25 Scorrboard, Llc System and method for producing a multi-layered board having a medium with improved structure
US11446893B2 (en) 2016-04-20 2022-09-20 Scorrboard Llc System and method for producing a multi-layered board having a medium with improved structure
US11458702B2 (en) 2016-04-20 2022-10-04 Scorrboard, Llc System and method for producing multi-layered board having at least three mediums with at least two mediums being different
US11465386B2 (en) 2016-04-20 2022-10-11 Scorrboard, Llc Method for producing multi-layered board having at least three mediums with at least two mediums being different
US11465385B2 (en) 2016-04-20 2022-10-11 Scorrboard Llc System and method for producing a facing for a board product with strategically placed scores
WO2019051530A1 (en) * 2017-09-15 2019-03-21 Brandon Penn CANNELÉE SHEET
US20230408022A9 (en) * 2021-07-30 2023-12-21 Temperpack Technologies Inc. Insulation products and methods and machines for making insulation products
US12422085B2 (en) * 2021-07-30 2025-09-23 Temperpack Technologies Inc. Insulation products and methods and machines for making insulation products
CN116852806A (zh) * 2023-07-17 2023-10-10 上海万戈工贸发展有限公司 一种防水纸板的制备方法及应用

Also Published As

Publication number Publication date
JPS5220917B1 (cs) 1977-06-07
NL7414025A (nl) 1975-04-29
DE1411875A1 (de) 1968-10-24
LU42142A1 (cs) 1962-10-01
GB1018241A (en) 1966-01-26
ES279700A1 (es) 1962-12-01
SE310592B (cs) 1969-05-05

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