WO2012021073A1 - Améliorations d'un matériau en feuille composite et associées à celui-ci - Google Patents

Améliorations d'un matériau en feuille composite et associées à celui-ci Download PDF

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Publication number
WO2012021073A1
WO2012021073A1 PCT/NZ2011/000156 NZ2011000156W WO2012021073A1 WO 2012021073 A1 WO2012021073 A1 WO 2012021073A1 NZ 2011000156 W NZ2011000156 W NZ 2011000156W WO 2012021073 A1 WO2012021073 A1 WO 2012021073A1
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WO
WIPO (PCT)
Prior art keywords
svacm
cutting
closed cell
cutting roller
roller
Prior art date
Application number
PCT/NZ2011/000156
Other languages
English (en)
Inventor
Patrick Petrus Antoniuous Maria Van Berlo
Ceri Peter Keston Wells
Original Assignee
Corcel Ip 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 Corcel Ip Limited filed Critical Corcel Ip Limited
Publication of WO2012021073A1 publication Critical patent/WO2012021073A1/fr

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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
    • B31D3/02—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section
    • B31D3/0223—Making honeycomb cores, e.g. by piling a plurality of web sections or sheets
    • B31D3/023—Making honeycomb cores, e.g. by piling a plurality of web sections or sheets by cutting webs longitudinally into strips, piling these strips and uniting them along lines perpendicular to the cuts
    • B31D3/0238—Making honeycomb cores, e.g. by piling a plurality of web sections or sheets by cutting webs longitudinally into strips, piling these strips and uniting them along lines perpendicular to the cuts involving laminating the expanded core
    • 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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • 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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/13—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board all layers being exclusively wood
    • 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • 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
    • B32B3/02—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 features of form at particular places, e.g. in edge regions
    • 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
    • B32B3/02—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 features of form at particular places, e.g. in edge regions
    • B32B3/08—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 features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • 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
    • B32B3/10—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
    • B32B3/12—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 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • E04C2/36—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 transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—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 transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/44—Number of layers variable across the laminate
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/08—Closed cell foam
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • 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
    • B32B2439/00—Containers; Receptacles

Definitions

  • the present invention relates to improvements in and relating to composite sheet material.
  • composite board from single or double face corrugated paperboard
  • Xanita board as manufactured by Xanita of South Africa is a composite board referred to as a close cell coreboard.
  • This closed cell coreboard is manufactured from adjacent strips of single or double face corrugated paperboard which form a core which is sandwiched between two liner sheets so that the flutes/channels run vertically (i.e. the corrugations of the core intersect the liner sheets substantially orthogonally).
  • composite board provides an ideal medium for applying high quality graphic images for high end marketing purposes, such as point of sale displays and billboards: to name a few.
  • Xanita board as is detailed in WO2007052228 is very labour intensive and expensive. It would therefore be useful if there was provided a more cost effective alternative to Xanita board or like products.
  • a further drawback with Xanita board is the fact it uses a hot melt adhesive which requires 150 degrees of heat and is very dangerous to handle due to the chemicals involved. Moreover, the use of hot melt adhesive makes recycling difficult as hot melt adhesives are difficult to recycle
  • a further drawback with Xanita board is that it is typically around 5mm, 10mm or 16mm thick compared with only 3-4mm thickness for standard corrugated paperboard/cardboard.
  • Xanita board is a lot stronger than standard corrugated paperboard/cardboard, this strength comes at a price in terms of the relative space occupied by the material.
  • the extra space occupied by Xanita board is of concern to any exporters who might want to use packaging made from Xanita board for its additional strength. As exporters typically pay for transportation based upon the volume or weight being shipped, carted, or air freighted.
  • closed cell coreboard refers to composite paper board which has at least one first liner sheet and at least one second liner sheet which respectively sandwich a core having a plurality of cells there between.
  • closed cell coreboard includes honeycomb paper board which has a honeycomb core, or X-board as is manufactured by Xanita of South Africa, or 3CTM board as manufactured by Corcel.
  • X- board and 3CTM board are composite boards comprising a core manufactured from adjacent strips of laminated layers of single or double face corrugated paperboard sandwiched between two liner sheets so that the flutes run orthogonally (i.e. the flute channels extend from the top liner sheet to the bottom liner sheet).
  • the term 'edge surface' as used herein with reference the strips of vertical axis channel material (SVACM) refers to the face of strips where the top or bottom edge of the cells of each layer are visible.
  • 'strips of vertical axis channel material' and 'SVACM refers to a plurality of strips of material made from either:
  • a closed cell coreboard which includes: upper and lower liner sheets each bonded so as to sandwich a core layer said core layer comprising a plurality of adjacently abutted end aligned strips of vertical axis flute material (SVACM); characterised in that the SVACM have at least one edge surface which include(s) a plurality of projections formed there along which are: folded; or can become folded during lamination, to the upper and lower liner sheets.
  • SVACM vertical axis flute material
  • a closed cell coreboard substantially as described above wherein the SVACM is bonded to at least one upper, and at least one lower, liner sheet, wherein the respective upper and lower liner sheets are bonded on opposite edge surfaces of the SVACM so as to sandwich the core there between.
  • a closed cell coreboard which includes:
  • SVACM vertical axis channel material
  • the liner sheets and SVACM may preferably be made from Kraft paper.
  • the liner sheets and SVACM can be made from recycled paper or cardboard. It should also be appreciated that the liner sheets could be made from other sheet materials. It will be appreciated that where a high strength board is required virgin Kraft paper will be used as opposed to recycled paper. Additionally, in some embodiments as discussed below multiple layers of liner sheets may be bonded to one or both edge surfaces of the SVACM.
  • the SVACM may be formed by cutting pre-laminated corrugated sheet material or pre-laminated honeycomb board into strips and re-orienting so the channels are vertically positioned.
  • a strip of vertical flute material which includes:
  • the SVACM prior to being cut by the cutting roller(s) may be substantially 5 -7mm in height from top edge surface to bottom edge.
  • the projections can become flaps when folded/flattened during the lamination process to liner sheets and this has the effect of increasing the effective surface area of the core layer which is available to be bonded to the liner sheets.
  • the projections may preferably extend substantially 0.5mm to 2.5mm from a putative fold line. Preferably, the projections may span substantially 2.5mm across.
  • the composite closed cell coreboard of the present invention may be considered a type of: paperboard or cardboard product, depending on the grade of sheet material being used. However, other types of sheet material may be used.
  • the adhesive used with the present invention may be a water-based dispersion containing vinyl acetate copolymer.
  • a water-based adhesive containing vinyl acetate copolymer in dispersion is a non- hazardous substance, and can therefore be used safely provided normal ventilation is provided.
  • Vinyl acetate copolymer dispersions can be relatively quick setting at room temperature and do not require a high activation temperature - unlike starch based glues. Vinyl acetate copolymer dispersions have a low viscosity, good adhesion and a long open time. A relatively low viscosity is required to allow the adhesive to flow readily, (e.g., when being transferred from an applicator to the fluted sheet) while a good adhesion provides the ability to adhere quickly to a surface.
  • the open time is a measure of the time, under normal temperature and pressure that the adhesive can have an exposed surface before it loses its ability to wet the opposing surface and penetrate into the opposing surface fibres. This wetting and penetration is required to form an effective bond between the fluted paper and the liner.
  • An adhesive having a relatively long open time is preferred as the adhesive may be open to the atmosphere for some time prior to application to the flutes.
  • the adhesive is AdhesinTM Z9129W or Z9040, a vinyl acetate copolymer supplied by Henkel New Zealand Limited.
  • AdhesinTM Z9129W or Z9040 has the required viscosity, and long open time required for use with the present invention.
  • AdhesinTM Z9129W or Z9040 has a viscosity in the range 2100-2200 m.Pa.S and an open time of between 0.5 to 1 minute.
  • other adhesives having similar properties may also be used.
  • a cutting roller which includes radial corrugations over the surface thereof wherein said ridges of the radial corrugations are configured to form cutting edges.
  • the radial corrugations may be created in a variety of different ways. In some embodiments the corrugations may be created via a single helical groove.
  • the cutting roller has radial corrugations in the form of a right handed helical groove.
  • the cutting roller has radial corrugations in the form of a left handed helical groove.
  • the corrugations may be created by a plurality of radial grooves which are spaced apart.
  • the cutting edge may come in a variety of different forms.
  • the cutting edge may be in the form of a thin flat edge.
  • the thin flat edge may be substantially 0.5mm -1.0mm wide.
  • adjacent cutting edges are spaced between substantially 3mm-5mm apart.
  • the cutting edges may be substantially 3.5mm apart.
  • the cutting edge may be a tapered point.
  • the tapered point may be formed by one or both sides of the ridge.
  • the grooves have a depth of substantially 0.5mm to 3.5mm. Most preferably, the grooves have a depth of substantially 3.5mm.
  • a machine for making a closed cell coreboard from SVACM wherein the machine includes: a first cutting roller which presses down against an edge surface of SVACM oriented with the channels running vertically and wherein the SVACM is supported by a first squeeze roller which has a rotational axis vertically aligned with said first cutting roller; a second cutting roller which presses up against an edge surface of SVACM oriented with the channels running vertically and is supported by a second squeeze roller which has a rotational axis vertically aligned with said second cutting roller; wherein the first and second cutting rollers have radial corrugations over the surfaces thereof wherein said ridges of the radial corrugations form a cutting edge and wherein the machine is configured so the SVACM moves relative to the first and second cutting rollers.
  • the cutting rollers and squeeze rollers have a gap between their respective outer circumferential surfaces which allows the cutting edge to penetrate the edge surface of the SVACM the desired depth.
  • the gap between the cutting roller and the squeeze roller is adjusted so the cutting edge will penetrate substantially 2.5mm into the top edge surface of the SVACM.
  • the sheet material from which the SVACM is made is 250 microns thick this results in a SVACM having a height of substantially 3.75mm following cutting and folding of the projections formed on the SVACM via the cutting rollers.
  • a closed cell coreboard made in accordance with present invention substantially as described herein wherein the sheet material is substantially between 4mm - 4.5mm thick.
  • the squeeze roller may come in a variety of different forms without departing from the scope of the present invention.
  • the squeeze roller may be made from a steel, plastic or other hard wearing material.
  • the squeeze roller has substantially the same length as the cutting roller and is position so that the cutting roller can press down upon the SVAFM to perform the cutting action.
  • a machine substantially as described above wherein the first cutting roller has a left handed helix and the second cutting roller has a right handed helix or vice versa and wherein the first cutting roller is positioned upstream of the second cutting roller relative to the direction in which the SVACM moves past the respective first and second cutting rollers.
  • first and second cutting rollers are positioned to cut a one edge of the SVACM following the bonding of a first liner sheet to the other edge of the SVACM.
  • the cutting rollers may be driven directly or indirectly by a motor.
  • the cutting rollers are driven to rotate at twice the speed of the conveyor bringing SVACM core.
  • a machine for making a closed cell coreboard from SVACM wherein the machine includes: a first cutting roller assembly which causes a first cutting roller to press down against an edge surface of SVACM oriented with the channels of the SVACM running vertically; a second cutting roller assembly which causes a second cutting roller to press up against an edge surface of SVACM; wherein the first and second cutting rollers have radial corrugations over the surfaces thereof wherein said ridges of the radial corrugations form a cutting edge and wherein the machine is configured so that the SVACM moves relative to the first and second cutting rollers and wherein the machine includes: - a glue applicator station where glue is applied to the top and bottom edge surfaces of the SVACM which now include a plurality of projections thereon created by the first and second cutting rollers; and
  • a method of manufacturing a closed cell coreboard from SVACM comprising the step of: a) cutting top and/or bottom edges of the SVACM oriented with the channels (cells) of the SVACM running vertically, via an upper cutting roller and a lower cutting roller; wherein the upper and lower cutting rollers have radial corrugations over the surface thereof wherein said ridges of the radial corrugations form a cutting edge such that when the ridges are brought into contact with the edge surface(s) of the SVACM the ridges produce cuts along the edge surface(s) which in turn create a plurality of projections.
  • a method of making a closed cell coreboard from SVACM comprising the step of using pair of cutting rollers to cut into an edge SVACM wherein the cutting rollers each have radial corrugations over the surface thereof wherein ridges of the radial corrugations form a cutting edge and wherein one cutting roller has radial corrugations forming a right handed helix and the other roller has radial corrugations forming a left handed helix.
  • a method of making a closed cell coreboard substantially as described above including the extra step of gluing an edge surface of the SVACM which has been cut by the pair of rollers to at least one liner sheet.
  • the upper and/or lower cutting rollers are separated from corresponding squeeze rollers by a gap that is adjusted to produce the depth of cut required.
  • a method of making a closed cell coreboard comprising the steps of: a) cutting top and bottom edge surfaces of the SVACM oriented with the corrugations of the SVACM running vertically via an upper cutting roller and a lower cutting roller, wherein the upper and lower cutting rollers have radial corrugations over the surface thereof wherein said ridges of the radial corrugations form cutting edges; b) applying glue to the top and bottom edge surfaces of the SVACM which now include a plurality of projections thereon created by the first and second cutting rollers; c) bonding sheet material to the top and bottom edge surfaces of a plurality of SVACM which collectively form a continuous array/bed of adjacently abutted SVACM.
  • a closed cell coreboard which includes: • a first sheet of material which is selected from particle board, mdf or other wood chip derived composite; and
  • the box has ventilation channel-cut outs which extend from the base of a side wall to the top thereof wherein the coreboard has a thickness of substantially between 4mm-4.5mm.
  • the ventilation channel-cut outs may be similar to that disclosed in the Applicants' earlier filed PCT specification published as WO2010/056137.
  • the box is made from closed cell coreboard material in accordance with the present invention.
  • the box is made from a closed cell coreboard having a thickness of substantially 4mm -4.5mm.
  • the box being constructed from SVACM made of laminated layers of single face paperboard comprising 150gsm corrugating medium and a 125gsm liner sheet.
  • the thickness of the liner sheets bonded to the top and bottom edges of the SVACM will depend on the end use of the closed cell coreboard.
  • the SVACM may be made from 175gsm -275gsm Kraft paper and the liner sheets may be 175gsm - 275 gsm Kraft paper. In general the thicker the paper or board used the stronger the resulting close cell coreboard.
  • a display stand made with a closed cell coreboard substantially as described above.
  • Preferred embodiments of the present invention provide a number of advantages over the prior art which can include: providing a composite board which has increased strength; providing a composite board which is relatively thin (i.e. substantially
  • Figure 1 shows a schematic partial perspective exploded view of a sheet of closed cell coreboard (composite board) in accordance with one preferred embodiment of the present invention
  • Figure 2 shows a side view of the composite board of Figure 1 looking along line A;
  • Figure 3 shows a schematic plan view of a bed of end aligned strips of vertical axis channel material forming the core in the composite board in Figure 1 ;
  • Figure 4 shows a schematic side view of a strip of vertical axis channel material (SVACM) showing what the core looks like viewed along line B in Figure 1 ;
  • SVACM vertical axis channel material
  • FIG. 5a shows a schematic perspective view of the abutted strips of vertical channel material (SVACM) as depicted in Figure 4;
  • Figure 5b shows a schematic top view of the abutted strips of vertical channel material (SVAF ) as depicted in Figure 4;
  • Figure 6 shows a partial perspective view of the SVACM depicted in Figures
  • Figure 7 shows a partial view of a cutting roller in accordance with one preferred embodiment of the present invention
  • Figure 12 shows a partial view of the first cutting roller in Figure 11 having corrugations formed via a right handed helical groove in accordance with a preferred embodiment of the present invention.
  • Figure 13 shows a partial view of the second cutting roller in Figure 11 having corrugations formed via a left handed helical groove in accordance with a preferred embodiment of the present invention.
  • Figures 1 and 2 broadly illustrate the nature of the closed cell coreboard (composite board) of the present invention which is indicated by arrow 1.
  • Figure 3 shows in greater detail the unique SVACM core of the present invention.
  • the composite board 1 is made from Kraft paper and has an upper liner sheet 2 and lower sheet 3 which are bonded to a core layer 4 comprised of a plurality of abutted end aligned strips of vertical channel axis material (SVACM) 5a, 5b, and 5c.
  • the SVACM 5a - 5c are made up of four layers of single face paperboard 5' - 5 IV bonded together which can be seen clearly in Figure 2 and Figure 6.
  • Figure 2 shows the vertical axis line A-A that extends along the channels which in this embodiment are formed between the fluted medium and liner sheets of the single face paperboard forming the layers.
  • the nature of the SVACM core layer is shown in Figure 3.
  • the strips (individual SVACM) 5a - 5c are abutted together to form a bed upon which liner sheet 2 and then liner sheet 3 can be bonded.
  • the ends 101 and 102 of the strips 5a - 5c are end aligned to match the edge of the upper and lower liner sheets (not shown).
  • the corrugations shown by the zig-zag line can clearly be
  • the SVACM generally indicated by arrow 100 have ends 101 and 102.
  • the view shown in Figure 4 is along line B in Figures 1 and.
  • the SVACM has a number of projections 103 on the top and bottom edges thereof.
  • the projections are formed by a roller discussed later in relation to Figure 7 which forms cuts 104 into the top and bottom edge surfaces.
  • the projections 103 become folded /flattened during lamination roughly along putative fold line 105 shown by the dotted lines.
  • the projections 105 become folded/flattened - refer Figure 5 - the projections 103 effectively increase the available surface area for bonding to the liner sheets 2 and 3 shown in Figures 1 and 2.
  • the projections are initially folded/flattened when they come into contact with a glue roller as is discussed in more detail below in relation to Figure 8.
  • FIG 7 there is shown a cutting roller generally indicated by arrow 1000.
  • the cutting roller has radial corrugations generally indicated by arrow 1001 made up of ridges 1002 and grooves 1003.
  • the ridges have a tapered cutting edge 1004.
  • FIG 8 there is provided a machine for making a composite sheet material from strips of vertical axis channel material (SVACM) generally indicated by arrow 5000.
  • SVACM vertical axis channel material
  • the machine has a first conveyor belt assembly 5001 which transports SVACM 5002 in the direction of arrow A.
  • the SVACM 5002 are then delivered onto a slip bridge 5003 which is made of polypropylene (or other low friction surface) over which the SVACM 5002 slide as they are pushed to a first cutting roller assembly 5004.
  • the first cutting roller assembly has a first cutting roller 5005 and a squeeze roller 5006. The gap between the first cutting roller 5005 and squeeze roller 5006 is slightly smaller than the thickness of the SVACM 5002 which passes therethrough.
  • the first cutting roller 5005 cuts notches into the top edge of the SVAFM which creates the projections as previously described and shown in Figures 4 - 6.
  • the SVACM 5002 are then moved by the rotation of the rollers 5005 and 5006 and onto a second slip bridge 5007, before being conveyed by a second conveyor belt assembly 5008 to a first glue application station 5009.
  • the first glue application station 5009 has a doctor roller 5010 and a glue applicator roller 5011 which are counter rotate with respect to one another. Adhesive is pumped from a reservoir (not shown) via conduits (not shown) to deliver adhesive to the region shown by arrow 5200 between the top portion of two rollers 5010 and 5011. The distance the doctor roller 5010 is separated from the glue applicator roller 5011 determines the thickness of the adhesive layer applied by the glue applicator roller 5011. As the glue applicator roller 5011 contacts the top edge surface of the SVACM and applies a layer of adhesive thereto. Any excess adhesive not applied falls off the end of the rollers and is collected by a tray (not shown) and returned to the reservoir and recirculated. Following glue application station 5009 the SVACM then passes to a first laminating station 5012 where sheet material in the form of Kraft paper 500 is laminated to the SVACM via nip rollers 5013 to form single face SVACM board.
  • the single face SVACM board then passes to a second cutting roller assembly 5014 having a second cutting roller 5015 and squeeze roller 5016.
  • the second cutting roller 5015 cuts notches into the bottom edge of the SVACM which creates the projections as previously described and shown in Figures 4 - 6.
  • the cutting rollers 5005 and 5015 are driven by motors not shown that rotate the others at the same speed as the SVACM travels along the first conveyor 5001.
  • the newly formed single face SVACM board then passes a second glue application station 5017 wherein a doctor roller 5018 transfers adhesive to a glue applicator roller 5019.
  • the second glue station operates in substantially the same manner as the first glue application station 5009 discussed above.
  • the glue applicator roller 5019 contacts the bottom edges of the SVACM and applies a layer of adhesive thereto.
  • the single face SVACM board then passes to a second laminating station 5020 where a second sheet material in the form of Kraft paper 501 is laminated to the single face SVACM board via nip roller 5021 and opposed pressure belt assemblies 5022 and 5023: to thereby create composite corrugated sheet material (composite board) 5024.
  • FIG 9 there is provided a cutting roller generally indicated by arrow 6000.
  • the cutting roller 6000 has radial projections 6001 which extend above the circumferential surface 6002 of the cutting roller 6000.
  • the ridges have a tapered cutting edge 6003.
  • the height of the radial projections substantially corresponds to the depth of cut (and hence height of the projections) which will be formed on the SVACM core.
  • the advantage of this configuration of cutting roller is shown in Figure 10. As can been this cutting roller assembly 7000 obviates the need for a squeeze roller and enables two opposed cutting rollers 7001 and 7002 to cut upper and lower edges of the SVAFM simultaneously.
  • FIG 10 there is shown a cutting assembly 7000 which has vertically opposed first and second cutting rollers 7001 and 7002 respectively.
  • the first and second cutting rollers 7001 and 7002 rotate in the direction of arrows A and B respectively.
  • the rollers 7001 and 7002 cut notches 7003 into SVACM 7004 as is most clearly seen in enlargement bubble.
  • the SVACM 7004 is supported as it enters and exits the cutting assembly 7000 via first and second clip bridges 7005 of which only one is shown.
  • FIG. 1 1 there is shown a pair of cutting rollers forming a cutting assembly
  • the cutting assembly has a first cutting roller 10001 and associated squeeze roller 10002 and a second cutting roller 10003 and associated squeeze roller 10004.
  • the cutting rollers and squeeze rollers are fabricated from stainless steel.
  • the cutting assembly cuts notches into the top edge 10005 of the SVAFM 10006 which is bonded on the bottom edge to liner sheet 10007.
  • the SVAFM travels in the direction of arrow A.
  • the individual strips 10008 of SVACM 10006 already present a flat bottom edge as they are bonded to liner sheet 10007.
  • the same is not true for the top edge of the SVAFM where the top edge of each strip is not aligned and instead forms a stepped top edge of the SVACM.
  • FIG. 12 there is shown a first cutting roller 10001 which has corrugations having ridges 12001 which form the cutting edge.
  • the corrugations are formed from a single right handed (clockwise) helical groove when looked at from the direction of arrow B.
  • FIG 13 there is shown a second cutting roller 10003 which has corrugations having ridges 12002 which form the cutting edge.
  • the corrugations are formed from a single left handed (anti-clockwise) helical groove when looked at from the direction of arrow C.
  • This form of closed cell coreboard has a SVACM core made from layers of single face paperboard.
  • the SVACM has a 5mm core in height (thickness) from top edge surface to bottom edge surface.
  • the SVACM core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick and cut into sheets.
  • the top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 1 1 to a depth of 2.0mm.
  • a tri-laminate is formed from two 275gsm Kraft liner sheets which are 250 microns thick and an outer liner sheet of SBS (solid bleached sulphate) board which is 500 microns thick.
  • SBS solid bleached sulphate
  • This tri-layer laminate is left to dry and then is bonded to the top edge surface SVACM so the SBS board forms the outer facing sheet of the art board.
  • Another tri-layer laminate of Kraft board and SBS board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the SVACM. Again the SBS board forms the outer facing sheet.
  • the final step is to press the art board to assist with lamination and this also compresses the art board to a thickness of 5mm.
  • This form of closed cell coreboard has a SVACM core made from layers of single face paperboard.
  • the SVACM has 9.3mm core in height (thickness) from top edge surface to bottom edge surface.
  • the SVACM core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick and then cut into sheets.
  • the top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 11 to a depth of 1.3mm.
  • a tri-laminate is formed from two 275gsm Kraft liner sheets which are 250 microns thick and an outer liner sheet of SBS (solid bleached sulphate) board which is 500 microns thick.
  • SBS solid bleached sulphate
  • Another tri-layer laminate of Kraft board and SBS board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the SVACM. Again the SBS board forms the outer facing sheet.
  • the final step is to press the art board to assist with lamination and this also compresses the art board to a thickness of 10mm.
  • This form of closed cell coreboard has a SVACM dual core made from layers of single face paperboard.
  • the two SVACM cores are 9.3mm in height (thickness) from top edge surface to bottom edge surface.
  • the two SVACM cores are bonded to each other before the bottom edge surface of the resulting double core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick before being cut into sheets.
  • the top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 11 to a depth of 1.3mm.
  • a tri-laminate is formed from two 275gsm Kraft liner sheets which are 250 microns thick and an outer liner sheet of SBS (solid bleached sulphate) board which is 500 microns thick.
  • This tri-layer laminate is left to dry and then is bonded to the top edge surface dual core SVACM so the SBS board forms the outer facing sheet of the art board.
  • Another tri-layer laminate of Kraft board and SBS board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the dual core SVACM. Again the SBS board forms the outer facing sheet.
  • the final step is to press the art board to assist with lamination and this also compresses the art board to a thickness of 20mm.
  • This form of closed cell coreboard has a SVACM core made from layers of single face paperboard.
  • the close cell coreboard is produced via the machine of Figure 8 to have one layer of 275gsm Kraft liner bonded to each side of the SVACM core following cutting of the top and bottom surface edges of the SVACM.
  • This form of closed cell coreboard has a SVACM core made from layers of single face paperboard.
  • the SVACM has a 5mm core in height (thickness) from top edge surface to bottom edge surface.
  • the SVACM core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick and cut into sheets.
  • the top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 11 to a depth of 2.0mm.
  • a tri-laminate is formed from three 275gsm Kraft liner sheets which are 250 microns thick.
  • This tri-layer laminate is left to dry and then is bonded to the top edge surface SVACM. .
  • Another tri-layer laminate of Kraft board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the SVACM.
  • the final step is to press the structural board to assist with lamination and this also compresses the structural board to a thickness of 5mm.
  • Example 6 Thin High Strength Box Close Cell Coreboard
  • This form of closed cell coreboard has a SVACM core made from layers of single face paperboard.
  • the thickness of the SVACM core is 6mm prior to being cut via the cutting rollers which are set to penetrate a depth of 2.5mm.
  • the close cell coreboard is produced via the machine of Figure 8 to have one layer of 275gsm Kraft liner 250 microns thick bonded to each side of the SVACM core following cutting of the top and bottom surface edges of the SVACM.
  • the resulting board has a thickness of substantially 4.25mm which is the same as C Flute paperboard.

Landscapes

  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un panneau de cœur à cellules fermées qui comprend : au moins une feuille supérieure et/ou au moins une feuille de support inférieure ; une couche de cœur, ladite couche de cœur comprenant une pluralité de bandes de matériau cannelé d'axe vertical (SVAFM) alignées par leurs extrémités et disposées bout à bout de manière adjacente ; caractérisé en ce que les SVACM ont au moins une surface de bord qui comporte une pluralité de saillies formées le long de celle-ci, ou qui peuvent être pliées au cours d'un laminage sur une feuille supérieure et/ou une feuille de support inférieure.
PCT/NZ2011/000156 2010-08-12 2011-08-12 Améliorations d'un matériau en feuille composite et associées à celui-ci WO2012021073A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US37301310P 2010-08-12 2010-08-12
NZ58732710 2010-08-12
US61/373,013 2010-08-12
NZ587327 2010-08-12

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WO2012021073A1 true WO2012021073A1 (fr) 2012-02-16

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014071306A1 (fr) * 2012-11-05 2014-05-08 Gordon Holdings, Inc. Structure composite légère à haute résistance, son procédé de fabrication et d'utilisation
JP2014156037A (ja) * 2013-02-15 2014-08-28 Kawakami Sangyo Co Ltd サンドイッチ構造体
CN110091559A (zh) * 2018-01-31 2019-08-06 成都天府轨谷科技有限公司 一种轨道交通车装饰地板复合材料及其制备方法
WO2021219804A1 (fr) 2020-04-30 2021-11-04 Unilever Ip Holdings B.V. Composition permettant de fabriquer des bouillons

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2983038A (en) * 1958-03-24 1961-05-09 Bahia Mision Dev Co Inc Method of attaching a structural member to a core of a structural sandwich
US3137604A (en) * 1960-07-12 1964-06-16 Michael C Bosch Honeycomb structure and process of manufacture
US3774365A (en) * 1972-07-24 1973-11-27 Steel Corp Panel and core
US4045268A (en) * 1974-07-25 1977-08-30 Bell Fibre Products Corporation Mastic composition and composite structural panels formed therefrom
US5389059A (en) * 1992-07-22 1995-02-14 Corwin; Charles H. Honeycomb structural material
US6183836B1 (en) * 1995-07-18 2001-02-06 Jochen Pflug Folded-sheet honeycomb structure
WO2002045952A1 (fr) * 2000-12-08 2002-06-13 Jeffrey Don Johnson Structure en nid d'abeilles a rabats et procede de fabrication

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2983038A (en) * 1958-03-24 1961-05-09 Bahia Mision Dev Co Inc Method of attaching a structural member to a core of a structural sandwich
US3137604A (en) * 1960-07-12 1964-06-16 Michael C Bosch Honeycomb structure and process of manufacture
US3774365A (en) * 1972-07-24 1973-11-27 Steel Corp Panel and core
US4045268A (en) * 1974-07-25 1977-08-30 Bell Fibre Products Corporation Mastic composition and composite structural panels formed therefrom
US5389059A (en) * 1992-07-22 1995-02-14 Corwin; Charles H. Honeycomb structural material
US6183836B1 (en) * 1995-07-18 2001-02-06 Jochen Pflug Folded-sheet honeycomb structure
WO2002045952A1 (fr) * 2000-12-08 2002-06-13 Jeffrey Don Johnson Structure en nid d'abeilles a rabats et procede de fabrication

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014071306A1 (fr) * 2012-11-05 2014-05-08 Gordon Holdings, Inc. Structure composite légère à haute résistance, son procédé de fabrication et d'utilisation
EP2914395A4 (fr) * 2012-11-05 2016-08-03 Gordon Holdings Inc Structure composite légère à haute résistance, son procédé de fabrication et d'utilisation
JP2014156037A (ja) * 2013-02-15 2014-08-28 Kawakami Sangyo Co Ltd サンドイッチ構造体
CN110091559A (zh) * 2018-01-31 2019-08-06 成都天府轨谷科技有限公司 一种轨道交通车装饰地板复合材料及其制备方法
WO2021219804A1 (fr) 2020-04-30 2021-11-04 Unilever Ip Holdings B.V. Composition permettant de fabriquer des bouillons

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