U.S. patent application number 14/855353 was filed with the patent office on 2017-06-08 for methods and apparatus for producing scored mediums, and articles and compositions resulting therefrom.
This patent application is currently assigned to SCORRBOARD, LLC. The applicant listed for this patent is Scorrboard, LLC. Invention is credited to Giles GREENFIELD.
Application Number | 20170157894 14/855353 |
Document ID | / |
Family ID | 56110303 |
Filed Date | 2017-06-08 |
United States Patent
Application |
20170157894 |
Kind Code |
A9 |
GREENFIELD; Giles |
June 8, 2017 |
METHODS AND APPARATUS FOR PRODUCING SCORED MEDIUMS, AND ARTICLES
AND COMPOSITIONS RESULTING THEREFROM
Abstract
Methods and apparatus for making scored mediums, particularly
but not exclusively for use in the corrugated board arts, and
articles of manufacture and compositions made there with and made
there by. When at least one scored medium is used in a layered or
laminated article, and particularly when selectively used as a
liner member and/or fluted member in a corrugated board, whether as
part of a corrugated board article of manufacture or a laminate
with at least one other member, the article will possess mechanical
qualities superior to those that would otherwise exist if a
non-scored medium was/were used. To achieve these desired
qualities, a major axis of the scores formed in the scored medium
runs askew, and preferably perpendicular, to the direction of beam
strength in any article or article intermediate to which the scored
medium is to be associated.
Inventors: |
GREENFIELD; Giles; (Renton,
WA) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Scorrboard, LLC |
Renton |
WA |
US |
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Assignee: |
SCORRBOARD, LLC
Renton
WA
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20160167338 A1 |
June 16, 2016 |
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|
Family ID: |
56110303 |
Appl. No.: |
14/855353 |
Filed: |
September 15, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/US2014/030909 |
Mar 17, 2014 |
|
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14855353 |
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61802009 |
Mar 15, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 29/005 20130101;
B32B 7/03 20190101; B32B 3/10 20130101; B32B 2250/26 20130101; B32B
7/12 20130101; B32B 29/08 20130101; B32B 3/266 20130101; B32B 3/28
20130101 |
International
Class: |
B32B 7/12 20060101
B32B007/12; B32B 3/28 20060101 B32B003/28 |
Claims
1. A corrugated or laminated board comprising a first medium and a
second medium, each of which includes two major surfaces and a
longitudinal direction, wherein the first and the second mediums
are attached to each other by an adhesive, characterized in that
the first medium comprises a plurality of scores having a major
axis direction and a score pitch, and the second medium comprises
one of a plurality of scores having a major axis direction and a
score pitch, or a plurality of flutes having a major axis direction
and a flute pitch, wherein the major axis direction of the first
medium's scores is not congruent with one of the major axis
direction of the second medium's scores or flutes.
2. The board of claim 1 wherein at least some of the first medium's
scores extend towards the second medium when the two mediums are
attached to each other.
3. The board of claim 1 wherein at least some of the first medium's
scores extend away from the second medium when the two mediums are
attached to each other.
4. The board of claim 1 wherein the major axis quality of at least
some of the first medium's scores is characterized as
continuous.
5. The board of claim 1 wherein the major axis quality of at least
some of the first medium's scores is characterized as
discontinuous.
6. The board of claim 1 wherein the major axis quality of at least
some of the first medium's scores is characterized as linear and
congruent with the major axis direction thereof.
7. The board of claim 1 wherein the major axis quality of at least
some of the first medium's scores is characterized as one of a
curvilinear or a rectilinear repeating pattern.
8. The board of claim 1 wherein the major axis quality of at least
some of the first medium's scores is characterized as having a
generally constant caliper.
9. The board of claim 1 wherein the major axis quality of at least
some of the first medium's scores is characterized as having a
generally variable caliper.
10. The board of claim 1 wherein at least some of the first
medium's scores have a constant pitch.
11. The board of claim 1 wherein at least some of the first
medium's scores have a variable pitch.
12. The board of claim 1 wherein at least some of the first
medium's scores have a skewed pitch.
13. The board of claim 1 wherein at least some of the first
medium's scores are substantially homogeneous when compared to
other first medium scores.
14. The board of claim 1 wherein at least some of the first
medium's scores are substantially heterogeneous when compared to
other first medium scores.
15. The board of claim 1 wherein the major axis direction of the
first medium's scores is perpendicular with one of the major axis
direction of the second medium's scores or flutes.
16. The board of claim 1, further comprising a third medium that
includes a plurality of scores having a major axis direction and a
score pitch.
17. The board of claim 16 wherein the major axis of the first
medium's scores is congruent with the major axis of the third
medium's scores.
18. The board of claim 16 wherein the net displacement of all major
axes is substantially zero.
19. The board of claim 1 wherein the second medium comprises a
plurality of scores having a major axis direction and a score
pitch, and a plurality of flutes having a major axis direction and
a flute pitch, wherein the major axis direction of the second
medium's scores is not congruent with the major axis direction of
the second medium's flutes.
20. The board of claim 1 further comprising a single face
corrugated board having a fluted member and a single liner face
wherein the fluted member is selectively adhered to the first
medium or the single liner face is selectively adhered to the
second medium.
Description
PRIORITY CLAIM
[0001] The present application is a Continuation of International
Patent Application Serial No. PCT/US2014/030909, entitled METHODS
AND APPARATUS FOR PRODUCING SCORED MEDIUMS, AND ARTICLES AND
COMPOSITIONS RESULTING THERE FROM, filed Mar. 17, 2014; which
claims the benefit of U.S. Provisional Patent Application Ser. No.
61/802,009, filed Mar. 15, 2013, now expired; all of the foregoing
applications are incorporated herein by reference in their
entireties.
BACKGROUND OF THE INVENTION
[0002] Corrugated board, also known as corrugated cardboard or
colloquially as cardboard, represented a significant advancement in
the container arts. Single wall corrugated board comprised a fluted
paper medium bonded to and separating two flexible liners of paper
to create an engineered article having exceptional stiffness or
resistance to deflection in the in the strong axis or flute
direction (i.e., parallel to the flutes) due to beam strength
induced by the flutes, and good stiffness in the weak axis or
orthogonal direction thereto (i.e., perpendicular to the flutes)
due to one of the sheets resisting deflection through tensioned
resistance between flute peaks and an opposing sheet resisting
deflection through compressive resistance there between.
[0003] To increase resistance to deflection and/or increase
flexural stiffness of single and/or multiple wall corrugated board
in general, and particularly in the weak axis, one may increase the
basis weight of the liners and or fluted medium; increase the flute
pitch; modify the pulp characteristics of the material used for the
liners and/or fluted medium; control fiber orientation in the
materials used for the liners and/or fluted medium; and/or augment
the liners and/or flute medium by coating or other structural
modifications. Additionally, increased resistance to deflection
and/or increased flexural stiffness can be achieved by creating
multiple wall corrugated boards, e.g., double and triple wall
boards, by layering single faced corrugated board.
[0004] A common theme to the aforementioned solutions for
increasing resistance to deflection and/or increasing flexural
stiffness of a single wall corrugated board is the requirement for
modifying the constitution of the paper itself, i.e., material
properties such as basis weight, fiber orientation or material
composition, or modifying the flute configuration, i.e., flute
frequency (pitch) or amplitude (caliper). In each instance a change
in the material constitution or article design must be made prior
to formation of the corrugated board article, which may not be
suitable for other applications. As a consequence, more stock
materials must be stored for disparate purposes, production lines
must be changed for different runs, etc.
[0005] Heretofore, corrugated board liners have been characterized
as generally planar, the result of which has been single wall
corrugate board having a generally smooth surface on both major
sides thereof. If increased flexural stiffness was desired, a
plethora of pre- and post formation manipulations have been
employed: from the simple such as creating multiple faced
corrugated board (e.g., double or triple faced board) to the more
complex such as laminating multiple single wall corrugated board
during article converting processes.
SUMMARY OF THE INVENTION
[0006] The invention is directed to methods and apparatus for
making scored mediums, particularly but not exclusively for use in
the corrugated board arts, and articles of manufacture and
compositions made there with and made there by. When at least one
scored medium is used in a layered or laminated article, and
particularly when selectively used as a liner member and/or fluted
member in a corrugated board, whether as part of a corrugated board
article of manufacture or a laminate with at least one other
member, the article will possess mechanical qualities superior to
those that would otherwise exist if a non-scored medium was/were
used. To achieve these desired qualities, a major axis of the
scores formed in the scored medium runs askew, and preferably
perpendicular, to the direction of beam strength in any article or
article intermediate to which the scored medium is to be
associated.
[0007] For example, the direction of beam strength of a fluted
member is parallel to its major axis (the flute direction, i.e.,
the direction of a continuous peak or valley); similarly, the
direction of beam strength of a scored liner at a score is parallel
to the score's major axis (the score direction, i.e., the direction
of a continuous peak or valley).
[0008] As a result of integration and/or substitution of scored
mediums according to the invention with or in, for example,
corrugated boards, performance characteristics associated with
conventionally derived corrugated boards can be achieved even while
using lower basis weight materials (liners/fluted members), lower
quality materials (higher recycled content), and/or decreased
caliper. Moreover, in selected embodiments, preferential failure of
invention embodiments serve to localize deformations, thereby
increasing overall end article performance due to uniformity and
predictability of converting actions and in-use load
distributions.
[0009] As used herein, a "medium" refers to a flexible, yet
deformable, substantially planar material, which includes two major
surfaces and a longitudinal direction, of which a "sheet" is a
subset thereof. The medium may be formed from cellulose, plastic(s)
or combination thereof, and may be highly elongate in nature, e.g.,
a web. The medium is preferably intended for, but is not restricted
to, use as an element, member or component in corrugated boards,
laminated boards and combinations thereof.
[0010] The term "corrugated board" as used herein refers to single
face, single wall or multiple wall engineered boards having at
least one fluted element or component (an "element or component" is
also referred to herein as a "member"), and at least one liner
member attached thereto (the combination of a fluted member and a
liner member is conventionally referred to as a single face
corrugated board).
[0011] The term "laminated board" as used herein refers to
engineered boards having at least two sheets at least partially
adhered to each other in overlapping fashion. Laminated boards may
be used alone or as a member in a corrugated board.
[0012] The term "score" as used in the singular sense herein refers
to a type of surface feature characterized as an elongate,
non-penetrating deformation formed in a medium wherein the
deformation may be plastic, non-plastic or a combination thereof.
Examples of plastic deformation include embossing, pressing and
environmental modification (e.g., an elevated moisture and
temperature environment); examples of non-plastic deformation
include conventional roll forming (e.g., conventional scoring),
bending, and folding. For many of the articles of manufacture and
compositions comprising a scored medium that are disclosed herein,
plastic deformation during score formation is preferred.
[0013] The non-penetrating deformation or score is established in
the medium after its initial formation, i.e., not as part of the
medium's innate formation process such as would be the case during
an extrusion formation process. As will be discussed in greater
detail below, establishing scores after creation of the medium
provides exceptional economies and flexibility in creating articles
of manufacture and compositions comprising a scored medium such as
a liner member for corrugated boards.
[0014] Once established, the score is preferably permanent, meaning
that evidence of the score will remain at least until, and
preferably after, integration with other article elements--if the
scored medium is a liner member, then substantially all scores
exist after its attachment to a fluted member. Additionally, each
score defines a major axis corresponding to its primary direction
of elongation, and may define a greater than nominal minor
axis.
[0015] Scored mediums according the invention comprise a plurality
of spaced apart scores wherein the major axes of at least some of
the scores are preferably characterized as generally parallel to
one another.
[0016] Depending upon the embodiment, each score will have certain
score attributes, namely, a cross sectional profile, a directional
orientation relative to the medium, and a major axis quality, which
includes a continuity quality. Each of these attributes both
singularly and in combination affect the mechanical qualities of
the medium and/or articles and compositions that include the
medium. As will be described in more detail below, certain
attributes may have substantial effects with regard to the
resulting articles and compositions.
[0017] With respect to a score's cross sectional profile, three
principal types exist, namely, rectilinear (e.g., "V" or "I_I"),
curvilinear (e.g., semicircular) and hybrid (e.g., "U"). Each of
these profiles in turn has a directional orientation relative to
the medium, i.e., positive (a protrusion or land) or negative (a
recess or groove) when viewed from one side thereof. Because a land
on one side of the medium usually constitutes a groove on the
other, the nomenclature is inherently indefinite unless only one
side of the medium is being considered. Therefore, when describing
the directional orientation of score profiles, it is necessary to
maintain reference to a single side of the medium.
[0018] The major axis quality of a score considers the score's
characteristics along its run length. Such characteristics include
planar orientation, i.e., directional orientation relative to the
medium's major axis (e.g., parallel or non-parallel), and/or
deviation(s) from the score's nominal major axis (e.g., sinusoidal,
square or sawtooth geometry); and consistency or variability of
score depth along its run length relative to the adjacent surface
of the un-scored medium. The score depth may have constant or
variable caliper and may include no depth, thereby creating
non-scored portions or a segmented score. If in segmented form, the
major axis quality of this characteristic may be characterized as
patterned or random in segment length and/or pitch. As a corollary,
a score need not extend a majority of a medium, although in many
embodiment applications it does.
[0019] Depending upon the embodiment, a plurality of scores will
have certain group qualities or attributes that may be
characterized in certain ways. With respect to score attributes,
two adjacent scores having identical score attributes will be
considered homogeneous scores; a plurality of adjacent scores
having identical score attributes will be considered a homogeneous
group of scores. The converse is then also true: two adjacent
scores having non-identical score attributes will be considered
heterogeneous scores; a plurality of adjacent scores having
non-identical score attributes will be considered a heterogeneous
group of scores (although a subset of scores within the plurality
may have identical score attributes and therefore the subset would
be considered homogeneous scores).
[0020] With respect to score pitch, a plurality of adjacent scores
having identical lateral spacing, preferably over each score's run
length, will be considered to have a constant score pitch while a
plurality of adjacent scores having non-identical lateral spacing
will be considered to have a variable score pitch (although a
subset of scores within such plurality may have constant spacing
and therefore the subset would have a constant score pitch).
[0021] The foregoing definitions presumed that the scores within a
plurality were parallel to one another. However, such a geometric
relationship is not necessary in order to fall within the scope of
the invention. In such instances, the relative score pitch is
variable along the run length of adjacent score, and is referenced
herein as a skewed score pitch. Again, the degree of relative
convergence/divergence over a run length may be constant between
adjacent scores or may be variable.
[0022] Corrugated article embodiments of the invention comprise at
least one scored member in combination with its counterpart member.
In other words, if the scored member is a liner member, then the
counterpart member is a fluted member; if the scored member is a
fluted member, then the counterpart member is a liner member. In
this basic form, the article is considered a scored single face
corrugated board. When an additional liner member is attached to
the fluted member, the resulting article is considered a scored
single wall corrugated board. Corrugated article embodiments of the
invention also include single wall corrugated board comprising two
scored liner members, with or without incorporation of a scored
fluted member. By extension, double wall corrugated boards can
comprise one, two or three scored liner members (with or without
incorporation of one or two scored fluted members), and triple wall
corrugated board can comprise one, two, three or four scored liner
members (with or without incorporation of one, two or three scored
fluted members).
[0023] Turning first to scored liner member embodiments of the
invention, for maximum performance (e.g., stiffness) the overall
score run direction/axes of a scored liner member is established
perpendicular to the fluted member axis, thereby creating beam
strength in the liner member that is parallel to the fluted
member's weak axis. While the directional orientation of liner
member scores can be positive and/or negative in reference to the
exposed or outer (non-fluted) side of a single face corrugated
board, the scores are preferably characterized as negative. In this
manner, positive surface features extend towards and into the peaks
of the fluted member. Since the exposed or outer side of the liner
member only has negative surface features, the caliper of
corrugated boards comprising such scored liner member(s) remains
unaffected by the inclusion thereof. Moreover, when viewed from the
inner surface of the liner member, the positive surface features
presenting to the peaks of the fluted member function to
mechanically interact therewith, which when combined with the use
of adhesive increases the strength of the bond there between.
[0024] Alternatively, if the directional orientation of the scores
in the liner member are reversed, a glue pocket may be created at
the interface between the flute peak of the fluted member and the
negative features of the liner member's inner surface. If glue is
applied to the liner member as opposed to the flute peaks, the
inner surface negative features may receive additional glue and
thereby enhanced structural properties after its cure. In addition,
because the scored liner member in such embodiments will have
positive surface features present on the outer surface thereof, the
coefficient of friction for such liner member will be altered,
which may have functional benefits in certain applications.
[0025] Finally, a scored liner member can have a heterogeneous mix
of score orientations, thereby potentially realizing benefits of
both orientations described above. In such embodiments, at least
some of the scores have a directional orientation substantially
opposite to that of at least some other scores. The mix may present
a pseudo-sinusoidal pattern (i.e., adjacent scores have opposite
orientations), grouped patterns of orientations and/or random
orientations.
[0026] Corrugated boards comprising a scored medium also include
embodiments wherein the fluted member comprises a plurality of
scores. As was the case with scored liner member embodiments, the
overall score run direction/axes is established perpendicular to
the fluted member major axis, thereby creating beam strength in the
fluted member that is parallel to the fluted member's weak axis. It
should be appreciated that the minor axis width of such scores as
well as their pitch will likely be larger and greater than of those
for liner members. Although this preferred difference results from
optimizing the formation of the fluted member, it is not necessary
to the functioning of various invention embodiments.
[0027] Because scored liner members according to the invention may
be used for enhancing structural properties of single face
corrugated boards, many embodiments of the invention will comprise
a liner member having a plurality of constant pitch, homogeneous
linear scores formed therein, wherein several factors are
considered when determining the nature of the scored liner member,
namely, score amplitude (i.e., relief or caliper), score pitch and
score displacement. Preferably, these factors are also considered
in light of the nature of the fluted member that forms part of the
ultimate corrugated board.
[0028] The parameters of score amplitude and pitch for any liner
member depend upon a variety factors, which are highly application
dependent. Nevertheless, amplitude and pitch considerations
include, but are not limited to, the amount of lateral take-up, the
liner member basis weight or caliper, and the corrugating
environment if the scored liner member forms one part of a single
face corrugated board or similar board.
[0029] In addition to score amplitude and pitch, score displacement
relative to the major axis of the flutes formed in the fluted
member is another important factor when discussing corrugated
boards comprising at least one scored liner. Score displacement
considers the relative angle between the predominant score major
axis or run direction of the scored liner member and the flute
direction (or, in the non-corrugated arts, the predominant score
major axis of a second scored sheet). Generally speaking, the score
displacement will be 90.degree. relative to the flute direction for
maximum resistance to weak axis bending of the fluted member.
However, there may be instances wherein predictable localization of
stresses is more desired than maximum stiffness and resistance to
shear. Thus, score displacement need not be 90.degree. in order to
be within the scope of the invention.
[0030] It should be again understood that the scoring methods and
resulting liner members disclosed herein can be used when forming
any corrugated board, and need not nor should be limited to "first
face" applications to form single face corrugated boards.
Consequently, conventionally formed single face corrugated board
can be used in conjunction with a scored second liner member to
form a single wall corrugated board. Additionally, single face
corrugated board comprising a scored liner member can be combined
with another scored liner member to form a single wall corrugated
board with two scored liner members. Moreover, a scored fluted
member can be used in conjunction with any of the foregoing
combinations. Thus, the scope of the invention extends to any
medium making up part of a corrugated board.
[0031] The term "flutes" as used herein refers to a manipulation
(as opposed to a modification) of a medium to transform it from a
generally planar geometry to a generally sinusoidal geometry, which
may have constant pitch, i.e., period, and conventionally forms one
part of a single face corrugated board.
[0032] As noted previously, scored mediums according to the
invention need not be used as a liner member in conjunction with a
fluted member, whether scored or not-at least one scored medium can
be associated with one or a plurality of non-scored members.
However, optimal performance can be achieved when pairs of
orthogonally oriented scored members are used in a laminated
article of manufacture, or when a plurality of scored members are
so used and the net score major axis is minimal or zero (for
example, a 3.times.120.degree. displacement; a 5.times.72.degree.
displacement; a 6.times.60.degree. displacement; etc.). Although a
corrugated fluted member is not used, many, if not most, of the
same characterizations apply as did with respect to embodiments
comprising a corrugated fluted member. Moreover, in many respects,
a scored member can be considered to have analogous performance
qualities to that of a corrugated fluted member.
[0033] By extension, certain articles of manufacture incorporating
the invention comprise corrugated board having (a) laminated
face(s) comprising at least one scored liner member in combination
with one of a non-scored liner member or another scored liner
member. These hybrid corrugated boards therefore have one or more
liner members having enhanced caliper, and preferably, enhanced
stiffness due to the presence of at least one scored liner
member.
[0034] While a web of scored medium may be created at the time of
its manufacture, enhanced benefit of the invention can be realized
through on-site formation of scored mediums from generic webs of
the medium to meet the requirements of any given production run; by
so doing, storage and setup of dedicated webs of scored mediums are
thereby eliminated. In addition, roll density (run length) is
greater for non-scored mediums than for scored mediums. Moreover,
unintentional crushing of the surface features that characterize
the scores is avoided if it is created just prior to incorporation
with, for example, a fluted member.
[0035] Perhaps the greatest advantage to concurrent score formation
and corrugation occurs due to the environment in which the single
face corrugating process preferably takes place. To properly
condition the medium that ultimately forms the fluted member, the
medium is exposed to elevated temperature and humidity in this
preferred environment. These conditions permit the medium to more
easily conform to the corrugating rollers and retain the sinusoidal
shape after release there from. Similarly, by exposing the medium
that ultimately forms the single face liner member to such an
environment prior to scoring, the medium will be more compliant and
the impressed scores will better retain their shape during
subsequent handling and processing. Similarly, creation of scores
in the material that ultimately becomes the fluted member will be
concurrent with the corrugation process, again benefiting from the
elevated temperature and humidity environment in this preferred
environment.
[0036] The container arts frequently manipulate single, double and
triple wall corrugated board into variously shaped containers. This
manipulation requires converting the planar corrugated board (i.e.,
blank) into multiple sided containers or boxes. The converting
process relies upon, inter alia, establishing scores that serve to
localize a crease that results when forming container edges/corners
through bending or folding of the corrugated board. The resulting
crease is the manifestation of an intentional failure of the
corrugated board: compression of the putative inner liner of the
container or box is biased at or towards the score. As those
persons skilled in the art appreciate, there is balance between
creating a sufficiently effective score (high relief) and not
breaching or penetrating the scored liner. Too little compression
by a scoring wheel and the score's effectiveness is marginalized;
too much compression by the scoring wheel and the liner can be
penetrated, thereby materially weakening the resulting edge or
corner joint.
[0037] Because integrated scored liner members according to the
invention enhance the stiffness of a corrugated board article by
creating beam strength in the scored liner preferably in opposition
to the weak axis of the board, it follows that mechanically
destroying the structure associated with the induced beam strength
will localize stresses imparted upon the board at or proximate to
such locations.
[0038] In many corrugated board embodiments of the invention, the
predominant major axes of the scores (run length) in at least one
scored liner member are oriented perpendicular to the fluted member
major axis, as has been previously described. Because blank scoring
predominately occurs parallel to the fluted member major axis
(which is perpendicular to its weak axis), such blank scores will
necessary run perpendicular to the liner member score run lengths
(major axes).
[0039] Consequently, any re-scoring of the scored liner member
(particularly, but not exclusively, on the positive surface feature
side of the liner member) will compromise the integrity of the
liner member scores, thereby directing stress induced failures
(such as resulting from compressive converting actions) to the
locations where the re-scoring has occurred. In this manner and
particularly with respect to the re-scoring of positive feature
side scores, it is only necessary to defeat the initial scoring
rather than to mechanically deform the base liner member and/or
fluted member through relatively high compression scoring in order
to facilitate formation of a corrugated board fold/corner. An
additional advantage of this ability is realized through the use of
lower basis weight inner liners: since it is only necessary to
defeat the scoring that results in beam formation, which itself was
a result of material deformation, less consideration need be given
to concerns regarding over-compression and medium penetration.
[0040] As touched upon above and to enhance the likelihood of
failure in such instances and minimize unintended destruction of
the scored liner in one series of embodiments, a scored liner of a
blank, which forms an inner surface of a corner or fold, preferably
comprises positive surface feature scores on the exposed side of a
corrugated board blank inner surface (the side opposite the fluted
member). By so doing, when such inner liner member is subjected to
compressive force through rescoring, the previous score-induced
beams are intentionally destroyed, beneficially with minimal
mechanical consequences to the virgin (non-previously scored)
portions of the inner liner member. While the foregoing embodiments
are presently preferred, in another series of embodiments the
scored inner liner member presents its positive surface features to
the fluted member side of the corrugated board blank. While greater
scoring pressure is needed in such embodiments, certain advantages
over the first series embodiments exist: In both series of
embodiments, the subsequent re-scoring biases compressive failure
of the inner liner member towards the outer liner member, thereby
increasing the density of material within the fold/joint structure
during the bending process, however, in the second series of
embodiments, the reliability of such directional failure is
considered more robust.
[0041] It should be noted that blank scoring may be optional during
the blank converting process: in situations wherein the scored
liner member of a corrugated board (for simplification, a single
wall board is presumed) forms an inner surface of the converted
form, simple bending of the board induces a compression load to all
scores at the common axis of the hinge moment, which results in the
scores generally uniformly failing at their mid points between
flute peaks; these points are the most susceptible to compression
failure. The resulting uniform "failure" of the scores at this
common location along a fluted member, which corresponds to a flute
valley, permits the inner liner member to displace into the valley,
thereby creating a clean bend or fold or edge. Moreover, because
the valley corresponds to a peak on the opposite side of the
corrugated board, there is only minimal or nominal tension induced
into the outer liner member at the bend/fold/edge location. As a
consequence of this optimal arrangement, the inner surface of the
bend/fold/edge remains cleans and consistent along the length of
the flute valley while the outer surface thereof retains most if
not all original structural integrity. This optimization also
permits a materially higher article reuse value: the hinge created
by this arrangement is much less susceptible to material
degradation over many cycles. And while an inner side scored liner
member is preferred, similar functionality can also be achieved
through use of an outer side scored liner member, although the
results may not be as consistent or optimized.
[0042] For purposes of this patent, the terms "area", "boundary",
"part", "portion", "surface", "zone", and their synonyms,
equivalents and plural forms, as may be used herein and by way of
example, are intended to provide descriptive references or
landmarks with respect to the article and/or process being
described. These and similar or equivalent terms are not intended,
nor should be inferred, to delimit or define per se elements of the
referenced article and/or process, unless specifically stated as
such or facially clear from the several drawings and/or the context
in which the term(s) is/are used.
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