WO2003086746A1 - Composite structures - Google Patents

Composite structures Download PDF

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Publication number
WO2003086746A1
WO2003086746A1 PCT/GB2003/001516 GB0301516W WO03086746A1 WO 2003086746 A1 WO2003086746 A1 WO 2003086746A1 GB 0301516 W GB0301516 W GB 0301516W WO 03086746 A1 WO03086746 A1 WO 03086746A1
Authority
WO
WIPO (PCT)
Prior art keywords
sheet
sheet member
apertures
formations
panels
Prior art date
Application number
PCT/GB2003/001516
Other languages
French (fr)
Inventor
August Liza Florent Artois
Wilhelmus Albertus Joseph Streefland
Original Assignee
Sca Packaging Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sca Packaging Limited filed Critical Sca Packaging Limited
Priority to AU2003219322A priority Critical patent/AU2003219322A1/en
Publication of WO2003086746A1 publication Critical patent/WO2003086746A1/en

Links

Classifications

    • 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
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D3/00—Making articles of cellular structure, e.g. insulating board
    • B31D3/002—Methods for making cellular structures; Cellular structures
    • 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
    • B31F5/00—Attaching together sheets, strips or webs; Reinforcing edges
    • B31F5/02—Attaching together sheets, strips or webs; Reinforcing edges by crimping or slotting or perforating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42—Details of containers or of foldable or erectable container blanks
    • B65D5/44—Integral, inserted or attached portions forming internal or external fittings
    • B65D5/48—Partitions
    • B65D5/48024—Partitions inserted
    • B65D5/48026—Squaring or like elements, e.g. honeycomb element, i.e. at least four not aligned compartments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D65/00—Wrappers or flexible covers; Packaging materials of special type or form
    • B65D65/38—Packaging materials of special type or form
    • B65D65/40—Applications of laminates for particular packaging purposes
    • B65D65/406—Applications of laminates for particular packaging purposes with at least one layer provided with a relief other than corrugations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
    • B65D81/05—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents
    • B65D81/127—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using rigid or semi-rigid sheets of shock-absorbing material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2002/3488—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by frame like structures

Definitions

  • the present invention relates to a composite structure for use in packing, structural panels, walls, floors, shelves, cylinders and so on. More particularly, the present invention relates to a reinforcing or protective structure made from sheet material . It is known to manufacture reinforcing, display and protective structures from plastics or board. Typically, however these structures are three dimensional and moulded, therefore requiring expensive equipment for their manufacture . The present invention seeks to provide an alternative form of structure.
  • the -.present invention provides a composite structure comprising a first sheet member and a second sheet member assembled with the first sheet member, the first sheet member having one or more apertures formed therein and the second sheet member being provided with one or more formations which project through the aperture (s) in the first sheet member .
  • a three dimensional structure can be formed from two sheet members without the need for complex moulding procedures .
  • the formation in the second sheet member comprises opposed panels which are hingedly connected together at one end.
  • the hinged connection may be along a single, double or multiple hinge line.
  • the panels taper in width towards their connecting hinge line so as to facilitate their insertion through the aperture in the first sheet member.
  • the panels are generally triangular or trapezoidal in shape .
  • the base end of at least one panel is provided with a flange for abutting the underside of the first sheet material, thereby limiting the degree of insertion of the panels into the aperture in the first sheet member.
  • the two sheet members are form interlocking, whereby they can be assembled together without the need for additional attachment .
  • the base end of at least some panels is formed so as to interlock with the first sheet member.
  • the panel is formed with a locking formation, for example a tab or notch, adjacent its base whereby when the panel is inserted in the aperture the notch engages a portion of the perimeter of the aperture so as to retain the panel in the aperture .
  • the perimeter of the aperture is formed with a tab to engage the panel notch or tab.
  • the aperture in the first sheet member is generally rectangular or square in shape .
  • a plurality of apertures is provided in the first sheet member, with a plurality of interengaging formations formed on the second sheet member.
  • the apertures and formations are formed in one or more rows .
  • the rows are arranged substantially parallel to each other.
  • the apertures and interengaging formations in adjacent rows are offset in the direction in which the rows extend, such that the loading on the reinforcing structure may be more evenly distributed.
  • at least one of the apertures in a particular row, most preferably an aperture at the end of the row, and the associated interengaging formations may be of reduced width compared to the others in the row.
  • the width and/or height of the formations on the second sheet may vary, for example, to provide reinforcement or protection for an item having an irregular shape .
  • a stabilising member may be provided over the ends of the projecting formation (s) of the second sheet member.
  • the stabilising member may be retained in position by adhesive but, preferably, the stabilising member is provided with one or more locating apertures which receive the ends of the formations.
  • the stabilising member is preferably also made from a sheet material.
  • the structure with or without a stabilising member, may be surrounded by a sleeve.
  • the respective sheet members may be formed from separate sheets or webs, which are assembled together. In other constructions, however, they may be formed from the same sheet or web of material. In such an arrangement, the sheet members may be attached to each other along a common hinge line. The two members can then be assembled by folding about the hinge line.
  • the first sheet may comprise just aperture (s) and the second sheet just projecting formation (s) .
  • both sheets may comprise both aperture (s) and projecting formation (s) .
  • the projection (s) of a first sheet may then be inserted through the aperture (s) of a second sheet and the projection (s) of the second sheet inserted through apertures formed in a third sheet, and so on, whereby a large structure can be built up from interlocking sheets .
  • any flexible sheet material may be employed to produce the first and second sheet members and/or the stabilising member.
  • paperboard, corrugated board, paper, cardboard, and non-woven materials are all suitable . Indeed any material capable of being formed into a sheet will potentially be suitable. Plastics sheet material would also be suitable.
  • the present invention further extends to the individual components of the structure of the invention and blanks therefor.
  • the present invention also extends to a method of making a composite structure comprising the steps of : providing a first sheet member having an aperture therein; providing a second sheet member; forming said second sheet member so as to provide a projecting formation; and assembling said second sheet to said first sheet such that said projection projects through said aperture .
  • the projecting formations may be formed by first cutting said second sheet to form respective opposed panels which and then folding the panels relative to each other.
  • the panels are folded at the same time as the projections are being inserted into the apertures of the first sheet .
  • the process is a continuous one .
  • the first and second sheets are moved together through the various steps of the process .
  • the present invention also extends to apparatus for forming a composite structure comprising means for forming one or more apertures in a first sheet; means for forming one or more projections in a second sheet; and means for inserting said projection (s) into said aperture (s) .
  • the means for forming the aperture (s) comprises a die cutter, for example a flat bed die cutter, but more preferably a rotary die cutter.
  • the means for forming the projections comprise a die cutter, for example a flat bed die cutter, but more preferably a rotary die cutter, for defining opposed panels in the second sheet and a former for folding the panels together to form the projections .
  • the former is a rotary former.
  • the former comprises a roll comprising a plurality of projections which engage the second sheet and fold the panels together.
  • the rotary former may comprise a second roll having complementary recesses with which the projections on the first roll engage.
  • the former is also configured and arranged to insert the formations through the apertures in the first sheet.
  • the apparatus comprises means for continuously feeding the respective sheets in registry through the apparatus .
  • the assembled structure may be deformed, for example bent or curved to fit the desired application.
  • it may be formed into an annular cylinder.
  • the structure may be used as s structural member, for example a structural panel, for example in walls and floors. It may also be used in shelving and in packaging as cushioning material. It may also be used as an insert in a tray, for example, to display products for example eggs and fruit .
  • Figure 1 shows a perspective view of one side of a structure according to the present invention
  • Figure 2 shows a perspective view of the other side of the structure
  • Figure 3 shows a blank for forming one component of the structure
  • Figure 4 shows a blank for forming the other component of the structure
  • Figure 5 shows the structure in an intermediate state of assembly
  • Figure 6 shows an optional stabilising web for the structure
  • Figure 7 shows a structure according to the present invention located inside a sleeve
  • Figure 8 shows, schematically, apparatus for making the structure
  • Figure 9 shows a second embodiment of the structure according to the present invention.
  • Figure 10 shows a blank for the second embodiment; and Figure 11 shows the blank of Figure 10 in its folded condition.
  • a composite structure 2 according to a first embodiment of the present invention is shown in Figure 1.
  • the structure 2 comprises a first sheet member or base member 4 and a second, formed, sheet member 6.
  • the base member 4 comprises a plurality of apertures 8 through which extend projecting formations 10 of the formed sheet member 6.
  • the apertures 8 formed in the base member 4 are arranged in parallel rows 14, 16, 18, 20, 22.
  • the apertures 8 in adjacent rows are offset longitudinally from each other, and the end aperture 24 formed in alternate rows 16, 20 have a reduced width to compensate for this.
  • the formed sheet member 6 comprises a plurality of formations 10 which extend through the apertures 8.
  • the formations are provided in rows 26, 28, 30, 32, 34 for engagement with the rows 14, 16, 18, 20, 22 of apertures 8.
  • the formations 10 in adjacent rows are thus also offset from each other longitudinally, with the formations 36 at the ends of alternate rows being narrower than the others .
  • Each formation 10 comprises a pair of opposed panels 38, 40 which are hingedly attached along a double hinge line 42. Adjacent rows of formations are joined by flanges 44 which underlie the base member 4. The panels 38, 40 are attached to the flanges about respective hinge lines 46, 48.
  • the formed member 6 is formed from a blank 50 of sheet material, as shown in Figure 3. Apertures 52 are cut in the blank 50 to form the formation defining panels 38, 40 and the blank suitably scored or embossed to form the various hinge lines 42, 46, 48.
  • each panel 38, 40 is formed with a notch 54, and the corners of each aperture 8 in the base sheet member 4 are each provided with tabs 56. As will be described further below, when assembled the tabs 56 will engage with the notches 54 to interlock the sheets together. The assembly of the above structure 2 will now be described with reference to Figure 5.
  • the blank 50 is folded so as to move the panels 38, 40 out of the plane of the blank 50.
  • the panels 38, 40 may be fully folded together about their hinge line 42 to form the formations 10 prior to insertion into the apertures 8 in the base sheet member 4, or the act of inserting the panels may fold the panels 38, 40 to the requisite degree .
  • the notches 54 will receive the tabs 56 and trap the sheet 4 between the panels 38, 40 and the connecting flanges 46 so as to lock the sheets 4, 6 together and locate the formations 10 within the apertures 8. If pressure is applied to the formations 10 , they will tend to splay outwardly, but will be prevented from doing so by the sheet member 4. Thus a rigid structure 2 results.
  • adhesive may be applied to bond the sheets 4, 6 together, but generally the interengagement of the notches 54 and tabs 56 will be sufficient.
  • a stabilising sheet 58 may be attached to the structure 2.
  • the stabilising sheet 58 is preferably formed with apertures 60 which may extend only partially through the thickness of the sheet 58.
  • the apertures 60 receive the apices 62 of the formations 10.
  • the apices 62 may be formed with tabs to engage the apertures 60.
  • the stabilising member may be bonded to the formations 10, but this is not essential.
  • the structure 2, with or without a stabilising sheet 58 may be received within a sleeve 64 , as shown in Figure 7.
  • a sleeve 64 as shown in Figure 7.
  • Such a construction could, for example, be use as a packing or as a constructional panel or a shelf.
  • the sheet members 4, 6 can be assembled by hand as described above, but in the preferred embodiment, the formation of the sheets 4, 6 and their assembly is effected automatically and continuously.
  • An apparatus 60 for forming the formed sheet 6 and the base sheet 4 , and subsequently assembling them is shown schematically in Figure 8.
  • the apparatus 70 comprises a first rotary die- cutting station 72 for forming the formed sheet member 6, a second rotary die-cutting station 74 for forming the base sheet member 4 and a forming station 76 for bringing the sheets together.
  • the sheets 4, 6 are fed to cutting stations 72, 74 in webs from rolls of material (not shown) .
  • the first cutting station 72 cuts and scores the sheet 6 and the second cutting station 74 cuts the sheet 4.
  • the forming station 76 comprises a first roller 78 and a second roller 80.
  • the first roller 78 has a plurality of projections 82 formed on its outer surface and the second roller 80 has a plurality of corresponding recesses (not shown) formed in its outer surface.
  • the rollers are driven in synchronisation so that the projections 82 intermesh with the recesses during rotation of the first and second rollers 78, 80.
  • a sheet member 100 is provided with both a row of projecting formations 102 and a row of receiving apertures 104.
  • the formations are formed form opposed tapering panels 106, 108 hingedly connected along a double hinge line 110.
  • the panels 106, 108 are provided with notches 112 adjacent the flanges 114, 116 to which they are joined along hinge lines 118, 120.
  • the apertures 104 are provided with tabs 122 at their corners for engagement with the notches 112.
  • a plurality of sheets 100 are assembled together. Each sheet 100 is formed up generally as shown in Figure 10. The projections 102 of one sheet 100 are then inserted through the apertures 104 of an adjacent sheet 100 and the sheets thereby interlocked together.
  • stabilising means such as a top sheet or sleeve may be used as in the earlier embodiment .
  • the structure of the invention will have broad application. Its rigidity and strength mean that it can be used as a reinforcing structure and even as a structural element such as a shelf. It may also be used for cushioning purposes in packaging, as a display insert for a tray or the like, and so on.
  • It may be made from any sheet material, for example board, corrugated board, plastics and so on. Although multi-row structures have been disclosed, single row structures are also envisaged.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Abstract

A composite structure (2) comprises a first sheet member (4) and a second sheet member (6) assembled with the first sheet member (4), the first sheet member (4) having one or more apertures (8) formed therein and the second sheet member (6) being provided with one or more formations (10) which project through the apertures (8) in the first sheet member (4). The structure can be used as cushioning, for display purposes or as a structural component.

Description

COMPOSITE STRUCTURES
The present invention relates to a composite structure for use in packing, structural panels, walls, floors, shelves, cylinders and so on. More particularly, the present invention relates to a reinforcing or protective structure made from sheet material . It is known to manufacture reinforcing, display and protective structures from plastics or board. Typically, however these structures are three dimensional and moulded, therefore requiring expensive equipment for their manufacture . The present invention seeks to provide an alternative form of structure.
Viewed from a first aspect, the -.present invention provides a composite structure comprising a first sheet member and a second sheet member assembled with the first sheet member, the first sheet member having one or more apertures formed therein and the second sheet member being provided with one or more formations which project through the aperture (s) in the first sheet member . In this way, a three dimensional structure can be formed from two sheet members without the need for complex moulding procedures .
Preferably the formation in the second sheet member comprises opposed panels which are hingedly connected together at one end. The hinged connection may be along a single, double or multiple hinge line.
Preferably, the panels taper in width towards their connecting hinge line so as to facilitate their insertion through the aperture in the first sheet member. Most preferably, therefore, the panels are generally triangular or trapezoidal in shape . Preferably the base end of at least one panel is provided with a flange for abutting the underside of the first sheet material, thereby limiting the degree of insertion of the panels into the aperture in the first sheet member.
Preferably, the two sheet members are form interlocking, whereby they can be assembled together without the need for additional attachment . Preferably therefore, the base end of at least some panels is formed so as to interlock with the first sheet member. In the arrangement described above, preferably the panel is formed with a locking formation, for example a tab or notch, adjacent its base whereby when the panel is inserted in the aperture the notch engages a portion of the perimeter of the aperture so as to retain the panel in the aperture . Preferably the perimeter of the aperture is formed with a tab to engage the panel notch or tab.
However additional attachments means such as adhesive can be provided if required.
Preferably the aperture in the first sheet member is generally rectangular or square in shape .
Preferably a plurality of apertures is provided in the first sheet member, with a plurality of interengaging formations formed on the second sheet member. Preferably the apertures and formations are formed in one or more rows . Preferably the rows are arranged substantially parallel to each other.
Most preferably the apertures and interengaging formations in adjacent rows are offset in the direction in which the rows extend, such that the loading on the reinforcing structure may be more evenly distributed. To compensate for the offset in rows, at least one of the apertures in a particular row, most preferably an aperture at the end of the row, and the associated interengaging formations, may be of reduced width compared to the others in the row. The width and/or height of the formations on the second sheet may vary, for example, to provide reinforcement or protection for an item having an irregular shape . To further stabilise the structure, a stabilising member may be provided over the ends of the projecting formation (s) of the second sheet member. The stabilising member may be retained in position by adhesive but, preferably, the stabilising member is provided with one or more locating apertures which receive the ends of the formations. The stabilising member is preferably also made from a sheet material.
If additional rigidity is required the structure, with or without a stabilising member, may be surrounded by a sleeve.
In one form of construction, the respective sheet members may be formed from separate sheets or webs, which are assembled together. In other constructions, however, they may be formed from the same sheet or web of material. In such an arrangement, the sheet members may be attached to each other along a common hinge line. The two members can then be assembled by folding about the hinge line.
The first sheet may comprise just aperture (s) and the second sheet just projecting formation (s) . However in one embodiment, both sheets may comprise both aperture (s) and projecting formation (s) . The projection (s) of a first sheet may then be inserted through the aperture (s) of a second sheet and the projection (s) of the second sheet inserted through apertures formed in a third sheet, and so on, whereby a large structure can be built up from interlocking sheets .
Any flexible sheet material may be employed to produce the first and second sheet members and/or the stabilising member. For example, paperboard, corrugated board, paper, cardboard, and non-woven materials are all suitable . Indeed any material capable of being formed into a sheet will potentially be suitable. Plastics sheet material would also be suitable.
The present invention further extends to the individual components of the structure of the invention and blanks therefor.
The present invention also extends to a method of making a composite structure comprising the steps of : providing a first sheet member having an aperture therein; providing a second sheet member; forming said second sheet member so as to provide a projecting formation; and assembling said second sheet to said first sheet such that said projection projects through said aperture . The projecting formations may be formed by first cutting said second sheet to form respective opposed panels which and then folding the panels relative to each other.
Preferably the panels are folded at the same time as the projections are being inserted into the apertures of the first sheet .
Preferably the process is a continuous one . Preferably, therefore, the first and second sheets are moved together through the various steps of the process . The present invention also extends to apparatus for forming a composite structure comprising means for forming one or more apertures in a first sheet; means for forming one or more projections in a second sheet; and means for inserting said projection (s) into said aperture (s) .
Preferably the means for forming the aperture (s) comprises a die cutter, for example a flat bed die cutter, but more preferably a rotary die cutter. Preferably also the means for forming the projections comprise a die cutter, for example a flat bed die cutter, but more preferably a rotary die cutter, for defining opposed panels in the second sheet and a former for folding the panels together to form the projections .
Preferably the former is a rotary former. Most preferably the former comprises a roll comprising a plurality of projections which engage the second sheet and fold the panels together. The rotary former may comprise a second roll having complementary recesses with which the projections on the first roll engage. Preferably the former is also configured and arranged to insert the formations through the apertures in the first sheet.
Preferably the apparatus comprises means for continuously feeding the respective sheets in registry through the apparatus . The assembled structure may be deformed, for example bent or curved to fit the desired application. For example it may be formed into an annular cylinder. The structure may be used as s structural member, for example a structural panel, for example in walls and floors. It may also be used in shelving and in packaging as cushioning material. It may also be used as an insert in a tray, for example, to display products for example eggs and fruit .
Some preferred embodiments of the present invention will now be described by way of example only and with reference to the accompanying drawings in which:
Figure 1 shows a perspective view of one side of a structure according to the present invention;
Figure 2 shows a perspective view of the other side of the structure;
Figure 3 shows a blank for forming one component of the structure;
Figure 4 shows a blank for forming the other component of the structure; Figure 5 shows the structure in an intermediate state of assembly;
Figure 6 shows an optional stabilising web for the structure;
Figure 7 shows a structure according to the present invention located inside a sleeve;
Figure 8 shows, schematically, apparatus for making the structure;
Figure 9 shows a second embodiment of the structure according to the present invention;
Figure 10 shows a blank for the second embodiment; and Figure 11 shows the blank of Figure 10 in its folded condition.
A composite structure 2 according to a first embodiment of the present invention is shown in Figure 1. The structure 2 comprises a first sheet member or base member 4 and a second, formed, sheet member 6. The base member 4 comprises a plurality of apertures 8 through which extend projecting formations 10 of the formed sheet member 6. As can be seen more clearly in Figure 4, the apertures 8 formed in the base member 4 are arranged in parallel rows 14, 16, 18, 20, 22. The apertures 8 in adjacent rows are offset longitudinally from each other, and the end aperture 24 formed in alternate rows 16, 20 have a reduced width to compensate for this.
As stated above, the formed sheet member 6 comprises a plurality of formations 10 which extend through the apertures 8. The formations are provided in rows 26, 28, 30, 32, 34 for engagement with the rows 14, 16, 18, 20, 22 of apertures 8. The formations 10 in adjacent rows are thus also offset from each other longitudinally, with the formations 36 at the ends of alternate rows being narrower than the others .
Each formation 10 comprises a pair of opposed panels 38, 40 which are hingedly attached along a double hinge line 42. Adjacent rows of formations are joined by flanges 44 which underlie the base member 4. The panels 38, 40 are attached to the flanges about respective hinge lines 46, 48.
The formed member 6 is formed from a blank 50 of sheet material, as shown in Figure 3. Apertures 52 are cut in the blank 50 to form the formation defining panels 38, 40 and the blank suitably scored or embossed to form the various hinge lines 42, 46, 48.
As can be seen most clearly from Figures 3 and 4 , the base end of each panel 38, 40 is formed with a notch 54, and the corners of each aperture 8 in the base sheet member 4 are each provided with tabs 56. As will be described further below, when assembled the tabs 56 will engage with the notches 54 to interlock the sheets together. The assembly of the above structure 2 will now be described with reference to Figure 5.
As can be seen from the figure, the blank 50 is folded so as to move the panels 38, 40 out of the plane of the blank 50. The panels 38, 40 may be fully folded together about their hinge line 42 to form the formations 10 prior to insertion into the apertures 8 in the base sheet member 4, or the act of inserting the panels may fold the panels 38, 40 to the requisite degree . When the formation 10 is fully inserted in its receiving aperture 8, the notches 54 will receive the tabs 56 and trap the sheet 4 between the panels 38, 40 and the connecting flanges 46 so as to lock the sheets 4, 6 together and locate the formations 10 within the apertures 8. If pressure is applied to the formations 10 , they will tend to splay outwardly, but will be prevented from doing so by the sheet member 4. Thus a rigid structure 2 results. Of course, adhesive may be applied to bond the sheets 4, 6 together, but generally the interengagement of the notches 54 and tabs 56 will be sufficient.
If further rigidity is required, then a stabilising sheet 58 may be attached to the structure 2. The stabilising sheet 58 is preferably formed with apertures 60 which may extend only partially through the thickness of the sheet 58. The apertures 60 receive the apices 62 of the formations 10. The apices 62 may be formed with tabs to engage the apertures 60.
The stabilising member may be bonded to the formations 10, but this is not essential.
In a yet further arrangement the structure 2, with or without a stabilising sheet 58, may be received within a sleeve 64 , as shown in Figure 7. This further increases the rigidity of the structure, and protects it from external damage. Such a construction could, for example, be use as a packing or as a constructional panel or a shelf.
With regard to assembly of the structure 2, the sheet members 4, 6 can be assembled by hand as described above, but in the preferred embodiment, the formation of the sheets 4, 6 and their assembly is effected automatically and continuously. An apparatus 60 for forming the formed sheet 6 and the base sheet 4 , and subsequently assembling them is shown schematically in Figure 8.
The apparatus 70 comprises a first rotary die- cutting station 72 for forming the formed sheet member 6, a second rotary die-cutting station 74 for forming the base sheet member 4 and a forming station 76 for bringing the sheets together. The sheets 4, 6 are fed to cutting stations 72, 74 in webs from rolls of material (not shown) .
The first cutting station 72 cuts and scores the sheet 6 and the second cutting station 74 cuts the sheet 4. Such cutting and creasing arrangements are common in the art and do not need further discussion. The forming station 76 comprises a first roller 78 and a second roller 80. The first roller 78 has a plurality of projections 82 formed on its outer surface and the second roller 80 has a plurality of corresponding recesses (not shown) formed in its outer surface. The rollers are driven in synchronisation so that the projections 82 intermesh with the recesses during rotation of the first and second rollers 78, 80.
It will be appreciated that as the sheets 4, 6 are fed continuously to the forming station 76 between the first and second rollers 78, 80, the projections 82 will simultaneously fold and push the panels 38, 40 through the associated apertures 8 in the base sheet member 6 to assemble the structure 2.
The above embodiments show the use of sheets 4, 6 with multiple rows of apertures and formations, for example as formed from continuous webs of material. However other forms of construction are possible. One such arrangement is shown in Figures 9 to 11.
In this embodiment, a sheet member 100 is provided with both a row of projecting formations 102 and a row of receiving apertures 104. As in the earlier embodiment, the formations are formed form opposed tapering panels 106, 108 hingedly connected along a double hinge line 110. The panels 106, 108 are provided with notches 112 adjacent the flanges 114, 116 to which they are joined along hinge lines 118, 120.
The apertures 104 are provided with tabs 122 at their corners for engagement with the notches 112.
To produce a composite structure 124, a plurality of sheets 100 are assembled together. Each sheet 100 is formed up generally as shown in Figure 10. The projections 102 of one sheet 100 are then inserted through the apertures 104 of an adjacent sheet 100 and the sheets thereby interlocked together.
As many sheets as necessary may be joined together in this manner, and stabilising means such as a top sheet or sleeve may be used as in the earlier embodiment . It will be appreciated that the structure of the invention will have broad application. Its rigidity and strength mean that it can be used as a reinforcing structure and even as a structural element such as a shelf. It may also be used for cushioning purposes in packaging, as a display insert for a tray or the like, and so on.
It may be made from any sheet material, for example board, corrugated board, plastics and so on. Although multi-row structures have been disclosed, single row structures are also envisaged.

Claims

CLAIMS :
1. A composite structure comprising a first sheet member and a second sheet member assembled with the first sheet member, the first sheet member having one or more apertures formed therein and the second sheet member being provided with one or more formations which project through the aperture (s) in the first sheet member .
2. A structure as claimed in claim 1 wherein the formation in the second sheet member comprises opposed panels which are hingedly connected together at one end.
3. A structure as claimed in claim 2 wherein the panels taper towards their connecting hinge line.
4. A structure as claimed in claim 3 wherein the panels are generally triangular or trapezoidal in shape.
5. A structure as claimed in any of claims 2 to 4 wherein the base end of a panel is provided with a flange for abutting the underside of the first sheet.
6. A structure as claimed in any preceding claim wherein the two sheet members are interlocking.
7. A structure as claimed in claim 6 as dependent upon any of claims 2 to 5 wherein the base end of a panel is formed to interlock with the first sheet member.
8. A structure as claimed in claim 7 wherein the panel is formed with a locking formation adjacent its base.
9. A structure as claimed in claim 8 wherein the perimeter of the corresponding aperture in the first sheet member is formed with a tab to engage the panel locking formation.
10. A structure as claimed in any preceding claim wherein the aperture in the first sheet member is generally rectangular or square in shape.
11. A structure as claimed in any preceding claim wherein a plurality of apertures is provided in the first sheet member, with a plurality of interengaging formations provided on the second sheet member.
12. A structure as claimed in claim 11 wherein the apertures and formations are formed in one or more rows.
13. A structure as claimed in claim 12 wherein the rows are arranged substantially parallel to each other.
14. A structure as claimed in claim 12 or 13 wherein the apertures and interengaging formations in adjacent rows are offset in the direction in which the rows extend.
15. A structure as claimed in claim 14 wherein at least one of the apertures in a particular row and the associated interengaging formation are of reduced width compared to the others in the row.
16. A structure as claimed in any preceding claim comprising a stabilising member arranged over the ends of the projecting formation (s) of the second sheet member .
17. A structure as claimed in claim 16 wherein the stabilising member is provided with one or more locating apertures which receive the ends of the formations.
18. A structure as claimed in any preceding claim further comprising a sleeve around the structure.
19. A structure as claimed in any preceding claim wherein the respective sheet members are formed from separate sheets or webs.
20. A structure as claimed in any of claims 1 to 18 wherein the respective sheets are formed from the same sheet or web of material attached to each other along a common hinge line.
21. A structure as claimed in any preceding claim wherein the first sheet comprise just aperture (s) and the second sheet just projecting formation (s) .
22. A structure as claimed in any of claims 1 to 20 wherein both sheets comprise both aperture (s) and projecting formation (s) , with the projection (s) of a first sheet extending through the aperture (s) of a second sheet.
23. A structure as claimed in any preceding claim wherein said first and second sheet members are made from paperboard, corrugated board, paper, cardboard, a non-woven or a plastic sheet material.
24. A method of making a composite structure comprising the steps of: providing a first sheet member having one or more apertures therein; providing a second sheet member; forming said second sheet member so as to provide one or more projecting formations; and assembling said second sheet to said first sheet such that said projections project through said apertures.
25. A method as claimed in claim 24 wherein the projecting formations are formed by cutting said second sheet to form respective opposed panels and then folding the panels relative to each other.
26. A method as claimed in claim 25 wherein the panels are folded at the same time as the projections are being inserted into the apertures of the first sheet .
27. A method as claimed in claim 24, 25 or 26 wherein the process is continuous, with the first and second sheets moving together through the various steps of the process.
28. Apparatus for forming a composite structure comprising means for forming one or more apertures in a first sheet; means for forming one or more projections in a second sheet; and means for inserting said projection (s) into said aperture (s) .
29. Apparatus as claimed in claim 28 wherein the means for forming the aperture (s) comprises a die cutter, preferably a rotary die cutter
30. Apparatus as claimed in claim 28 or 29 wherein the means for forming the projections comprise a die cutter, preferably a rotary cutter, for defining opposed panels in the second sheet and a former for folding the panels together to form the projections.
31. Apparatus as claimed in claim 30 wherein the former is a rotary former.
32. Apparatus as claimed in claim 31 wherein the rotary former comprises a first roll comprising a plurality of projections which engage the second sheet and fold the panels together and a second roll having complementary recesses with which the projections on the first roll engage .
Figure imgf000017_0001
- 15 -
33. Apparatus as claimed in claim 32 wherein the former is configured and arranged to insert the formations through the apertures in the first sheet.
34. Apparatus as claimed in any of claims 28 to 33 comprising means for continuously feeding the respective sheets in registry through the apparatus.
35. The first sheet member of a structure as claimed in any of claims 1 to 23.
36. The second sheet member of a structure as claimed in any of claims 1 to 23.
37. A structural panel comprising a composite structure as claimed in any of claims 1 to 23.
38. A cushioning structure comprising a composite structure as claimed in any of claims 1 to 23.
39. A display insert comprising a composite structure as claimed in any of claims 1 to 23.
PCT/GB2003/001516 2002-04-10 2003-04-10 Composite structures WO2003086746A1 (en)

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GB0208304A GB0208304D0 (en) 2002-04-10 2002-04-10 Composite structures
GB0208304.6 2002-04-10

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FR2922476A1 (en) * 2007-10-17 2009-04-24 Onera (Off Nat Aerospatiale) THREE DIMENSIONAL SHEET STRUCTURE, MANUFACTURING METHOD THEREOF, AND SANDWICH STRUCTURAL MATERIAL COMPRISING SUCH A STRUCTURE.
WO2013113116A1 (en) * 2012-02-01 2013-08-08 Horia Nica Structural sandwich material with intersected cores
US11440284B2 (en) 2018-11-21 2022-09-13 Star Board Materials, LLC Paperboard panel and method of making same
DE102021105847A1 (en) 2021-03-10 2022-09-15 Kraus Maschinenbau GmbH Device for the production of a packaging insert from paper for the positional fixing of an object in a box
EP4406877A1 (en) * 2023-01-24 2024-07-31 Buhl-PaperForm GmbH Cushioning element for cushioning an object to be packaged

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2922476A1 (en) * 2007-10-17 2009-04-24 Onera (Off Nat Aerospatiale) THREE DIMENSIONAL SHEET STRUCTURE, MANUFACTURING METHOD THEREOF, AND SANDWICH STRUCTURAL MATERIAL COMPRISING SUCH A STRUCTURE.
WO2009087304A1 (en) * 2007-10-17 2009-07-16 Onera (Office National D'etudes Et De Recherches Aerospatiales) Three-dimensional sheet structure, method for making same, and sandwich-type structural material comprising such structure
WO2013113116A1 (en) * 2012-02-01 2013-08-08 Horia Nica Structural sandwich material with intersected cores
US11440284B2 (en) 2018-11-21 2022-09-13 Star Board Materials, LLC Paperboard panel and method of making same
US20230057213A1 (en) * 2018-11-21 2023-02-23 Star Board Materials, LLC Paperboard panel and method of making same
US11975518B2 (en) * 2018-11-21 2024-05-07 Star Board Materials, LLC Paperboard panel and method of making same
DE102021105847A1 (en) 2021-03-10 2022-09-15 Kraus Maschinenbau GmbH Device for the production of a packaging insert from paper for the positional fixing of an object in a box
EP4406877A1 (en) * 2023-01-24 2024-07-31 Buhl-PaperForm GmbH Cushioning element for cushioning an object to be packaged

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