U.S. patent application number 16/999785 was filed with the patent office on 2020-12-03 for system and method for producing a facing for a board product with strategically placed scores.
The applicant listed for this patent is Scorrboard LLC. Invention is credited to Giles Greenfield.
Application Number | 20200376795 16/999785 |
Document ID | / |
Family ID | 1000005034501 |
Filed Date | 2020-12-03 |
United States Patent
Application |
20200376795 |
Kind Code |
A1 |
Greenfield; Giles |
December 3, 2020 |
SYSTEM AND METHOD FOR PRODUCING A FACING FOR A BOARD PRODUCT WITH
STRATEGICALLY PLACED SCORES
Abstract
A system and method for producing a board product made from
paper products that have a pre-scored facing in addition to a
medium (sometimes called fluting). Conventional corrugated board
may feature a cross-corrugated medium and one or more facing that
have no score lines that are impressed (at least prior to assembly
with the corrugated medium). Such a conventional board product may
be inferior because any score lines that are impressed will damage
the underlying corrugated medium in some manner. A breakdown in the
strength of the underlying medium leads to poor precision when the
eventual board product is scored, cut, and folded. A lack of
precision in folding a board product leads to gap variation and
fishtailing as any articulated portion of the board product may not
maintain a precise plane of articulation when folded.
Inventors: |
Greenfield; Giles; (Renton,
WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Scorrboard LLC |
Renton |
WA |
US |
|
|
Family ID: |
1000005034501 |
Appl. No.: |
16/999785 |
Filed: |
August 21, 2020 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15134153 |
Apr 20, 2016 |
10800133 |
|
|
16999785 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B31F 1/0012 20130101;
B32B 2307/50 20130101; B65D 5/4266 20130101; B32B 2553/00 20130101;
D21H 5/0092 20130101; B32B 7/12 20130101; B32B 2250/02 20130101;
D21H 25/005 20130101; B32B 7/14 20130101; B32B 3/28 20130101; B32B
2038/045 20130101; B32B 37/14 20130101; B32B 29/08 20130101; B32B
23/06 20130101; Y10T 428/24322 20150115; B32B 2250/03 20130101;
B32B 3/266 20130101; B32B 3/26 20130101; B31F 1/2822 20130101; B65D
5/02 20130101; B32B 2250/26 20130101; B32B 29/005 20130101; B32B
37/12 20130101; B32B 2307/718 20130101; B32B 38/1841 20130101; Y10T
428/24694 20150115; B32B 2317/12 20130101; B32B 2439/00 20130101;
D21H 25/00 20130101; B32B 29/06 20130101; B31F 1/2804 20130101;
B32B 37/1284 20130101 |
International
Class: |
B32B 3/26 20060101
B32B003/26; B65D 5/42 20060101 B65D005/42; D21H 25/00 20060101
D21H025/00; B32B 3/28 20060101 B32B003/28; B32B 29/06 20060101
B32B029/06; B31F 1/28 20060101 B31F001/28; B65D 5/02 20060101
B65D005/02; B31F 1/00 20060101 B31F001/00; B32B 29/00 20060101
B32B029/00; B32B 7/12 20060101 B32B007/12; B32B 7/14 20060101
B32B007/14; B32B 29/08 20060101 B32B029/08 |
Claims
1-17. (canceled)
18. A board-making machine, comprising: a scorer configured to
impress at least one score line in a paper facing at first
intervals; an embosser configured to emboss a paper product to
include a plurality of flutes at second intervals; and a combiner
configured to couple the paper facing to the embossed paper product
such that the first intervals are aligned with respect to the
second intervals.
19. The board-making machine of claim 18, further comprising a
plurality of feed rolls configured to feed paper to the scorer and
to the embosser.
20. The board-making machine of claim 18, wherein the combiner is
further configured to align the at least one score line with one or
more of plurality of flutes such that articulation of combined
paper facing and embossed paper product is biased to a precise
location with respect to the at least one score line.
21. The board-making machine of claim 18, wherein the scorer is
further configured to impress the score lines in the paper facing
in a machine direction.
22. The board-making machine of claim 18, wherein the scorer is
further configured to impress each score line in the paper facing
in equidistantly from each adjacent score line.
23. The board-making machine of claim 18, wherein the embosser is
further configured to emboss the flutes in the paper product in a
machine direction.
24. The board-making machine of claim 18, wherein the embosser is
further configured to emboss a first set of apex structures facing
a first orthogonal direction with respect to the paper product and
second set of apex structures facing second orthogonal direction
that is opposite the first orthogonal direction.
25. The board-making machine of claim 18, wherein the combiner
further comprises a glue reservoir for supplying glue to facilitate
the coupling of the paper facing with the paper product.
26. The board-making machine of claim 18, wherein the embosser
comprises an embossing configured to emboss a C-flute profile in
the paper product.
27. The board-making machine of claim 18, wherein the embosser
comprises an embossing configured to emboss a E-flute profile in
the paper product.
Description
CROSS-RELATED APPLICATIONS
[0001] This application is a division of U.S. patent application
Ser. No. 15/134,153, entitled SYSTEM AND METHOD FOR PRODUCING A
FACING FOR A BOARD PRODUCT WITH STRATEGICALLY PLACED SCORES, filed
20 Apr. 2016. This application is also related to U.S. patent
application Ser. No. 15/077,250, entitled SYSTEM AND METHOD FOR
INDUCING FLUTING IN A PAPER PRODUCT BY EMBOSSING WITH RESPECT TO
MACHINE DIRECTION, filed 22 Mar. 2016, and is related to U.S.
patent application Ser. No. 15/088,999, entitled SYSTEM AND METHOD
FOR PRODUCING MULTI-LAYERED BOARD HAVING A CORRUGATED MEDIUM AND AN
EMBOSSED MEDIUM, filed 1 Apr. 2016; further, the present
application is also related to U.S. patent application Ser. No.
15/134,106, entitled SYSTEM AND METHOD FOR PRODUCING A
MULTI-LAYERED BOARD HAVING A MEDIUM WITH IMPROVED STRUCTURE filed
20 Apr. 2016; and is related to U.S. patent application Ser. No.
15/134,176 entitled SYSTEM AND METHOD FOR PRODUCING AN ARTICULATING
BOARD PRODUCT HAVING A FACING WITH SCORE LINES IN REGISTER TO
FLUTING filed 20 Apr. 2016; and is related to U.S. patent
application Ser. No. 15/134,206, entitled SYSTEM AND METHOD FOR
PRODUCING MULTI-LAYERED BOARD HAVING AT LEAST THREE MEDIUMS WITH AT
LEAST TWO MEDIUMS BEING DIFFERENT filed 20 Apr. 2016, all of the
foregoing applications are incorporated herein by reference in
their entireties.
BACKGROUND
[0002] Modern paper-making techniques use paper machines at paper
mills to produce rolls of paper that, in turn, can be used by board
makers to produce board products (i.e., corrugated board). As a
result, rolls of paper may be produced from machines that operate
continuously. Modern paper machines typically produce paper from a
number of substances including wood pulp that comprise wood fibers
(although other fibers may also be used). These fibers tend to be
elongated and suitable to be aligned next to one another. The fiber
starts as a slurry that can be fed onto a moving screen from a head
box of the paper machine. In modern paper machines, the fibers tend
to align with each other and align with a direction in which the
screen is moving. This alignment direction of underlying fibers is
called the major direction of the paper and is in line with the
machine direction. Thus, the major direction is often simply called
the machine direction (MD) and the paper that is produced has an
associated MD value.
[0003] When paper is used to make a board product, portions or
layers of the board product may be corrugated. Conventional
corrugating machines will corrugate the underlying paper product in
the cross direction (CD) of the paper thereby failing to take
advantage of the natural strength bias of the paper in the machine
direction. Further, the greater natural strength qualities of paper
in the machine direction are left unharnessed by cross corrugation
techniques in board making solutions. Further yet, conventional
corrugated medium includes flutes that take on a sinusoidal shape
because of the shape of the protrusions in a conventional pair of
corrugating rolls. As a result, companies that produce conventional
board products remain entrenched in old production processes that
limit the strength of the board product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Aspects and many of the attendant advantages of the claims
will become more readily appreciated as the same become better
understood by reference to the following detailed description, when
taken in conjunction with the accompanying drawings, wherein:
[0005] FIGS. 1A-1B are views of a corrugated single wall
conventional board product before and after major fold articulation
without benefit of score lines in one or more facings.
[0006] FIGS. 2A-2C show various states of a blank having slots cut
and conventional impression lines such that the blank may be
manipulated into a container.
[0007] FIG. 3 is an isometric cutaway view of a scored facing that
may be part of one or more board products according to one or more
embodiments of the subject matter disclosed herein.
[0008] FIG. 4 is an isometric cutaway view of an embossed medium
that may be part of one or more board products according to one or
more embodiments of the subject matter disclosed herein.
[0009] FIG. 5 is an isometric cutaway view of a board product
having the scored facing of FIG. 3 and medium of FIG. 4 according
to an embodiment of the subject matter disclosed herein.
[0010] FIGS. 6A-6C are a series of views of the board product of
FIG. 5 being articulated with benefit of score lines in one or more
facings according to an embodiment of the subject matter disclosed
herein.
[0011] FIG. 7 shows a side-by-side comparison of an articulated
conventional board product and an articulate board product of FIG.
5.
[0012] FIGS. 8A-8B are views of a board product before and after
articulation with benefit of one score line in one or more facings
according to an embodiment of the subject matter disclosed
herein.
[0013] FIG. 9 is a diagram of aspects of a machine configured to
produce the board product of FIG. 3 according to an embodiment of
the subject matter disclosed herein.
DETAILED DESCRIPTION
[0014] The following discussion is presented to enable a person
skilled in the art to make and use the subject matter disclosed
herein. The general principles described herein may be applied to
embodiments and applications other than those detailed herein
without departing from the spirit and scope of the present detailed
description. The present disclosure is not intended to be limited
to the embodiments shown, but is to be accorded the widest scope
consistent with the principles and features disclosed or suggested
herein.
[0015] By way of overview, the subject matter disclosed herein may
be directed to a system and method for producing a board product
made from paper products that have a pre-scored facing in addition
to a medium (sometimes called fluting) such that precise
articulation may be induced. A conventional board product may
feature a cross-corrugated medium and one or more facings that have
no score lines that are imprinted (at least prior to assembly with
the corrugated medium). Such a conventional board product may be
inferior because any score lines that are imprinted will damage the
underlying corrugated medium in some manner. A breakdown in the
strength of the underlying medium leads to poor precision when the
eventual board product is scored, cut, and folded. A lack of
precision in a folded container leads to gap variation and
fishtailing, as any articulated portion of the board product may
not maintain a precise plane of articulation when folded. Hence,
the articulated portion "fishtails" out of alignment.
[0016] Having a pre-scored facing (sometimes called wall or liner)
with strategically placed score lines (e.g., strategically placed
with respect to an eventual articulation point and/or with respect
to underlying flutes in an attached medium), eliminates problems
with fishtailing. This is because the pre-score lines bias the
facing to give way at the score lines when articulated. As a
result, the fold line on the facing is precisely aligned along the
pre-score line (making any fold aligned with a desired box corner
pattern) as well as precisely placed with respect to any underlying
flutes (making any fold also aligned with the flute pattern). The
effects of pre-score lines in a facing may be enhanced when used in
conjunction with an embossed medium that exhibit greater structural
characteristics when compared to conventional cross-corrugated
medium. These advantages and additional aspects of various
embodiments of the subject matter disclosed herein are discussed
below with respect to FIGS. 1-8.
[0017] FIGS. 1A-1B are views of a conventional board product 100
before and after major fold articulation without benefit of score
lines in one or more facings. As discussed briefly in the summary,
score lines will assist with board articulation such that
articulation of the board product is precise. In an effort to show
problems of conventional board product 100, the views in FIGS.
1A-1Bare shown and then various problems with an eventual container
are shown in FIGS. 2B-2C to illustrate the effects of the problems
of the conventional board product 100. A conventional board product
100 may have some form of a medium 103 that is attached to a first
facing 101 and a second facing 202. Of course, these facings do not
have any score lines predisposed. As such, certainly there are no
score lines in register to the flutes of the medium 103. Further,
the medium 103 may also be a conventional cross-corrugated medium
having flutes aligned in the cross direction (discussed further
below) of the paper of the medium 103.
[0018] When one wishes to articulate the board product 100, which
is often the case when the board product is eventually used for
containers and boxes, a machine may produce a score line (or
sometimes, an indentation, an impression, or some other form of
marking in order to induce a fold line) at a line intended for
articulation (e.g., intended to be a corner or fold point without
reference to underlying flutes). Thus, in looking at FIG. 1B, a
fold may be intended at point 104. As can be seen, the board
product 100 is being articulated (at approximately 180 degrees in
this view). A 180 degree fold is sometimes called a major fold and
may be a manufacturer requirement for producing folded box blanks.
A blank is an unfolded container in a flat open state (as shown
FIG. 2A) that is manufactured to eventually be manipulated into a
container or box. A conventional regular slotted container (RSC)
blank is discussed below with respect to FIGS. 2A-2C.
[0019] When a machine makes an impression in the board product in
production of a blank, a mechanical impression collar may be used
to impress a crease line at a specific location. This location is
in relation to an edge of the blank (e.g., 36 inches from the edge
of the blank, as but one example); such a location, in conventional
methods, is not in relation to underlying flutes of the medium. As
a consequence, when the mechanical impression collar impresses a
fold line, any underlying flutes that happen to be within the
impression area are crushed. By crushing the interior flutes, a
significant localized amount of board structure is compromised.
Thus, the fold point 104 begins to flex inward and the exterior
fold point begins to stretch out around the fold. The interior
flutes around the fold begin to narrow as the two legs begin to
come together.
[0020] FIG. 1B shows the conventional board product in full 180
degree articulation. The first facing 101 has been folded in half
so as to come into contact with itself. The second facing 102 has
stretched enough at point 104 to accommodate the additional
distance around the 180 degree fold point 104. As can be seen, the
interior fluting of the medium 103 loses structure as the localized
flutes are significantly damaged. Further, the second facing 102
may often fracture at the 180 degree fold point 104. Such
fracturing weakens the board product at point 104 significantly. As
a result of the fold point 104 causing a breakdown in medium
structure as well as possible fracturing in one or more facings,
additional undesirable variations in the eventual container or box
product will exhibit. These undesired variations are discussed next
with respect to FIGS. 2A-2C.
[0021] FIGS. 2A-2C show various states of a blank 105 having slots
106 cut and conventional impression lines 108b, 108c, 108d and 108e
such that the blank 105 may be manipulated into a container. In
FIG. 2A, the blank 105 is shown where a board product may be
altered to have the desired features, such as slots and impression
lines. Thus, the board product may have a pairs of slots 106 that
have been cut along eventual fold lines 108b, 108c, 108d and 108e.
The slots 106 should be precisely aligned and sized for the
intended purpose and the dimensions shown in FIG. 2A are for
illustrative purpose only as but one example of a flat blank 105.
As a typical requirement for the end user of a blank, the left-most
panel 107a may be folded (at fold line 108b) 180 degrees to lay
flat on top of panel 107b. This 180 degree fold is called a major
fold. Similarly, the right-most panel 107d may be folded (at fold
line 108d) 180 degrees to lay flat on top of panel 107c. Once
folded, the ends 108a and 10Be of the blank 105 may then be
situated adjacent to each other with a glue lap 109 positioned to
in an overlapping manner such that the edge 108a may be adhered to
the glue lap 109. When precisely aligned, the edge 108a is
positioned next to the edge 108e such that the distance between
edges 108a and 108e is the same width of other slots 106 in the
blank 105.
[0022] When articulated in the manner, the knocked down container
blank 105 may be in a folded condition to be fed into a machine for
erecting a box or container from the blank. Such an articulation
may be useful for packaging and shipping the resultant knocked-down
container blank 105 prior to being erected into the box or
container. These articulations, when performed on conventional
board product, often lead to undesired variations as shown in FIG.
2B-2C.
[0023] A first undesired variation is shown in FIG. 28 and is
called a gap variation. Gap variation may occur when the edge 108a
and 108e are not precisely aligned adjacent to each so as to
exhibit a gap that is the same as the width of other slots when the
glue lap 109 is adhered to the panel 107a. The gap may be too
narrow if the major folds at folds lines 108b and 108d are rolled
inward and may be too wide if the major folds at folds lines 108b
and 108d are rolled inward. In this view, one can see that the
panel 107a has been articulated 180 degrees along major fold line
108b and panel 107d has been articulated 180 degrees along major
fold line 108d. However, the glue lap 109 does not significantly
overlap the panel 107a and the edges 108a and 108e are too far
apart. Without precise overlap, the edges 108a and 108e with glue
lap 109 may not be in position to be properly adhered to each
other. This gap variation may be caused by compromised major fold
lines 108b and 108d because of a lack of precision in the fold
lines. Another variation that is not shown in the figures may be
when the edge 108a and 108e are too close or even overlap. Gap
variations may be characterized as the glue lap having too much
overlap or not enough overlap (or even no overlap) and is a
variability that leads to undesired problems in the finished
container.
[0024] A second undesired variation is shown in FIG. 2C and is
called "fishtailing." Fishtailing occurs when the fold results in
one or more panels being not parallel with other panels. In the
example shown in FIG. 2C, the panel 107a is not parallel with the
panel 107d. As such, the edge 108a is also not parallel with the
edge 108e and the glue lap will not interface with the panel 107a
in a precise manner Here, the major fold 108b may be precise
enough, but the major fold 108d is not precise and results in the
folded over panel 107d fishtailing out of alignment. This results
in problems for set-up machines that erect the RSC blanks into
boxes or containers.
[0025] The problems shown in FIGS. 2A-2C typically occur because of
scoring and folding conventional board product without regard to
the position of any underlying flutes in the medium. In addition,
after-assembly scoring (e.g., scoring that occurs after a board
product is assembled) causes damage to flutes as collateral flutes
becomes partially or completely crushed to prevent the flutes from
tracking the fold line on either side of the desired fold position.
Not only does this degrade board/box strength, it allows for
irregular folding (rolling scores), resulting in gap variation, as
measured at the manufacturers joint. These and other problems may
be overcome by pre-scoring facings and then assembling a board
product with score lines in register to the underlying flutes of
the medium.
[0026] Prior to discussing the various embodiments, a brief
discussion about cross corrugating and linear embossing is
presented. As has been briefly stated above, conventional board
products include a conventionally produced corrugated medium
(sometimes called a corrugated fluting), e.g., a cross-corrugated
medium. A cross-corrugated medium has flutes formed perpendicular
to most underlying fibers of the paper product. This results in
flutes that are not aligned with the majority of underlying fibers
and, therefore, do not take advantage of the natural strength of
the MD value of the paper (when compared to the CD value). Such a
failure to harness the MD value of the paper leads to loss of
opportunity in the manufacturing of board products when specific
board strength is to be realized. That is, it will necessarily take
more paper (heavier paper, larger flutes, and the like) to realize
the required board strength.
[0027] A linearly-embossed medium is different from a
cross-corrugated medium in that the induced flutes are aligned with
the MD value of the paper product. This results in flutes that are
aligned with the majority of underlying fibers and, therefore, take
advantage of the natural strength of the MD value of the paper
(when compared to the CD value). Harnessing the MD value of the
paper leads to efficiencies in the manufacturing of board products
when specific board strength is to be realized. That is, it will
necessarily take less paper (lighter paper, smaller flutes, and the
like) to realize the required board strength. Aspects of making,
producing, and using linearly embossed mediums are discussed in
greater detail in U.S. patent application Ser. No. 15/077,250
entitled "SYSTEM AND METHOD FOR INDUCING FLUTING IN A PAPER PRODUCT
BY EMBOSSING WITH RESPECT TO MACHINE DIRECTION" and filed on Mar.
22, 2016, which is incorporated herein by reference in its entirety
and for all purposes. Some aspects of a linearly embossed medium
are discussed below with respect to FIG. 4. Next, aspects of a
pre-scored liner are discussed with respect to FIG. 3.
[0028] FIG. 3 is an isometric cutaway view of a scored facing 110
that may be part of one or more board products according to one or
more embodiments of the subject matter disclosed herein. In this
embodiment, a facing may be produced having a MD value in the MD
direction 122 and having a weight and materials commonly used for a
board product facing. The facing 110 may sometimes be called a
liner or wall as this layer of a board product is often an
innermost portion of the board product. As was briefly discussed
above, a facing 110 may often be scored to elicit articulation
along a particular line. However, if the facing has already been
coupled with one or more additional layers of a board product
(e.g., a corrugated medium, an embossed medium, another facing, and
the like), then the scoring process will not only leave an
impression on the facing 110, but also on any other layer in the
board product. As shown in FIGS. 2B-2C, such after-assembly scoring
leads to undesired variations and structural damage of the
additional layers of the board product, which, in turns, weakens
the board product significantly at the articulation point.
[0029] The embodiment of FIG. 3, however, may be a facing 110 that
has undergone a pre-scoring process such that score lines 115 are
impressed into the facing 110 prior to the facing 110 being
combined with any other paper product (e.g., any other layer of a
board product). In the embodiment shown in FIG. 3, the pre-score
lines 115 are equidistant with respect to each other and may be
strategically spaced to also be in alignment with an eventual
embossed medium (not shown in FIG. 3) having flutes of a similar
specific pitch dimension. Further, the score lines may be
continuous impressions into the facing 110. However, the "score"
line may be any localized weakening of the facing 110 at the
desired point of fold of the board product that is strategically
placed with respect to the underlying flutes. In other embodiments
then, the score may be a crease impression (continuous linear or
intermittent), partial slit through the facing 110 (continuous
linear or intermittent), perforation in the facing 110, and the
like.
[0030] In other embodiments not shown, the pre-score lines 115 may
be less than consistent across a facing 110. For example, two score
lines 115 may be grouped together at approximately five mm apart
from each other and then spaced apart from another grouping of two
of these five-mm-spaced score lines. In yet another example, only a
single grouping of scores may be present on a facing or even a
single score line. Although five mm intervals are given as an
example, any width of interval may be possible and common intervals
will match common flute profiles, such as C-Flute, B- Flute,
R-Flute and the like. These groupings may correspond to anticipated
articulation points for a specific box machine. However, for the
purposes of efficient production of a consistent facing 110, score
lines 115 may be impressed by a scoring machine at strategically
selected intervals (e.g., every five mm) such that any portion of
the pre-scored facing 110 may be combined with other layers of an
eventual board product. The embossed medium 130 of FIG. 4 may be
one such additional layer.
[0031] FIG. 4 is an isometric cutaway view of an embossed medium
130 that may be part of one or more board products according to one
or more embodiments of the subject matter disclosed herein. This
diagram shows an isometric view of a portion of an embossed medium
130 that may be formed from an embossing process. That is, flutes
131 are formed from passing the initial paper product through
embossing rolls using a linear-embossing technique such that the
flutes 131 are formed congruent with a majority of underlying
fibers 125 of the paper. The flutes 131 are also formed congruent
with the machine direction 122. A linearly-embossed medium 130
harnesses the natural strength of the paper in the machine
direction 122 as the flutes 131 are formed in the machine direction
122 of the paper (e.g., congruent with a majority the underlying
fibers 125). Therefore, a linearly-embossed medium 130 harnesses
the natural strength of the paper in the machine direction 122.
Such an embossed medium 130 may be a component/layer of a board
product as discussed below with respect to FIG. 5.
[0032] Further, as is shown in FIG. 4, the flutes 131 may form a
triangular pattern when viewed from a cutaway perspective. This
flute pattern having a triangular repeating shape is referred to as
a flute profile. This flute profile provides an improvement in
structural integrity of the embossed medium 130 when compared to a
flute profile the exhibits a curvilinear or sinusoidal flute
profile. Such a curvilinear or sinusoidal flute profile is
prevalent in conventional cross-corrugated mediums. Therefore, the
triangular flute profile as shown in FIG. 4 is also superior to
corrugated mediums with respect to board strength and structural
integrity. The flute profile exhibits apexes 132 that may be
adhered to a facing (not shown). The apexes may be spaced apart in
a repetitive manner at a specific distance (such as five mm, for
example). As will be discussed next, when coupled to a matching
pre-scored facing 110 of FIG. 3, the apexes 132 of the embossed
medium 130 may be precisely aligned in a desired manner to yield
precise and less damaging articulation of any resulting board
product.
[0033] FIG. 5 is an isometric cutaway side view of a board product
300 having the scored facing 110 of FIG. 1 and the medium 130 of
FIG. 4 according to an embodiment of the subject matter disclosed
herein. In this embodiment, the board product 300 includes three
layers: the first facing 110, the medium 130, and a second facing
140. As is shown, the first facing 110 may form an inner wall
(although the top/bottom direction reference to alignment of the
board product 300 is arbitrary) that is coupled to one side of the
embossed medium 130. The coupling may be through an adhesive
applied to the apex of each flute on the top-side of the medium 130
such that the facing 110 is glued to the medium 130 where adhesive
is applied. In other embodiments, glue may be applied to the
entirety of the facing 110 prior to being coupled to the medium
130.
[0034] Likewise, a second facing 140 may form a bottom-side outer
wall (again, the top/bottom direction reference is arbitrary) that
is coupled to an opposite side of the embossed medium 130. The
coupling may be through an adhesive applied to the apex of each
flute on the bottom-side of the embossed medium 130 such that the
facing 140 is glued to the embossed medium 130 where adhesive is
applied. In other embodiments, glue may be applied to the entirety
of the facing 140 prior to being coupled to the embossed medium
130.
[0035] The score lines 115 are aligned in the direction of
underlying flutes of the embossed medium. Both the score lines and
the flutes are also aligned with the machine direction 122 of the
underlying paper in the scored facing 110, the facing 140 and the
medium 130. Further, in this embodiment, the score lines 115 of the
scored facing 110 are aligned in a manner such that the score lines
are placed equidistant from respective apex locations of the
affixed embossed medium. For example, if the top-side apexes of the
embossed medium 130 are spaced five mm apart from each other, then
the score lines 115 are also spaced five mm apart from each other,
but offset by 2.5 mm. That is, for every pair of top-side apexes
that are five mm apart, the affixed facing 110 features a score
line 115 half way between each pair of top-side apexes at
approximately 2.5 mm from each one.
[0036] With precisely placed score lines in a facing that is
affixed to a medium having linear flutes, precise articulation
lines may be induced. That is, if one were to fold the board
product 300, the scored facing would give way along one or more
score lines in a precise manner. That is, the fold would precisely
lie in a single plane that is normal to the score line being
articulated. Such a fold may be precise and will serve to prevent
the articulation direction from veering out of the normal to the
plane of the score line. In other embodiments (not shown), the
bottom-side facing 140 may also be pre-scored with a similar
pattern of score lines precisely aligned with bottom-side apexes of
the embossed medium 130. Further, the pre-scored lines in any
facing may cover less than all of the area of the facing (e.g.,
only score lines in anticipated articulation points).
[0037] When all three layers are assembled and affixed, the
resultant board product 300 is superior to conventional board
product because of several factors. First, because the flutes of
the embossed medium 130 are strategically aligned with respect to
the score lines of the pre-scored facing 110, any articulation of
the board product will be precise resulting in accuracy in the
finished box container. Such precision prevents gap variation and
fishtailing. Further, the linearly embossed medium 130 includes a
flute profile that exhibits superior strength because of the leg
structures of the triangular nature of each flute. Further yet,
adhesive may be continuously and uniformly applied to each apex in
a predictable manner with greater precision as portions of the
adhesive will not spill over to the legs as may be the case with
sinusoidal apexes having no flat receiving area. Lastly, a
pre-scored facing 110 prevents having a scoring step after board
assembly that leads to damage of underlying layers (e.g., the
embossed medium 130) when conventional board scoring techniques are
used.
[0038] FIGS. 6A-6C are a series of views of the board product 300
of FIG. 5 being articulated with benefit of score lines in one or
more facings according to an embodiment of the subject matter
disclosed herein. In FIG. 6A, the board product 300 is shown from
an edge view so as to better illustrate what happens when the board
product 300 is articulated. As shown, the board product 300
includes a first facing 110, a second facing 140 and a medium 130.
The medium 130 is disposed between the first facing 110 and the
second facing 140. The first facing may further include score lines
115. In this example view of FIG. 6A, the first facing 110 is shown
facing down simply for illustrative purposes. Further, only two
score lines 115 are shown for ease of illustration as there may be
many more score lines in register to the flutes of the medium 130
including score lines on the second facing 140 as well. Further
yet, the medium 130 is shown having a sinusoidal flute profile,
though it is understood that any shape of flute profile may be
used.
[0039] In the next view of FIG. 68, the board product 300 has begun
articulation. Here, the fold lines will follow precisely the score
lines 115 in the facing 110. Thus a first fold point 603
corresponds to a first score line 115 and a second point 604
corresponds to a second score line. As can be seen is this view of
FIG. 68, an articulation that will result in an eventual 180 degree
articulation will comprise two different folds of approximately 90
degrees each. Further, the first fold point 603 is located directly
between two apexes (of downward facing flutes--i.e., two apexes
affixed to the first facing 110) of the medium 130 such that the
legs of this flute begin to move toward each other. As a result, a
first stretch point 601 of the second facing 140 begins to forms
directly over the first fold point 603. Similarly, the second fold
point 604 is located directly between two apexes (of downward
facing flutes--i.e., two apexes affixed to the first facing 110) of
the medium 130 such that the legs of this flute also begin to move
toward each other. As a result, a second stretch point 602 of the
second facing 140 begins to forms directly over the second fold
point 604.
[0040] In FIG. 6C, the board product 300 is shown fully articulated
to the 180 degree position. Thus, the first stretch point 601 and
the second stretch point 602 are each approximately 90 degrees.
Different from the conventional example of FIGS. 1A-18 where the
stretch point folded a full 180 degrees, this embodiment
accomplishes a full 180 degrees of board product articulation with
only having approximately 90 degrees of fold causing a stretch at
any given location. Having a full 180 degree articulation with only
90 degrees of stretch at any given point leads to less stress at
the stretch points to underlying fibers in the facing 140. This, in
turn, leads to greater strength at corners of boxes and containers
due to less stretch damage to the facing 140 and no loss of flute
structure in the medium 130.
[0041] Further, the fold points 603 and 604 fold all the way into a
respective flute such that secondary flutes are formed to provide
additional corner structure from liner 110. That is, at the first
fold point 603, a first secondary fold flute 610 is formed from
facing 110 inside of a first primary fold flute 605. Likewise, a
second secondary fold flute 611 is formed from facing 110 inside of
a second primary fold flute 606. Secondary flutes 610 and 611
provide additional corner strength in boxes and containers.
[0042] FIG. 7 shows a side-by-side comparison of an articulated
conventional board product 100 and an articulate board product 300
of FIG. 5. As can be seen, the conventional board 100 shows a
distortion in the medium structure at and adjacent to the 180
degree articulation point. Here, the underlying flutes have been
compromised because the fold point did not happen to line up with a
respective flute in the medium. This corner will have demonstrably
less predictability in folding. Differently, the embodiment of the
board product with precisely located score lines exhibits the
additional secondary flutes as discussed above with respect to FIG.
6C. This articulation point in the board product 300 will have
superior strength when compared to the conventional example
100.
[0043] FIGS. 8A-8B are views of a board product before and after
articulation with benefit of one score line in one or more facings
according to an embodiment of the subject matter disclosed herein.
In FIG. 8A, the board product 800 is shown from a edge view so as
to better illustrate what happens when the board product 800 is
articulated. As shown, the board product 800 includes a first
facing 810, a second facing 840 and a medium 830. The medium 830 is
disposed between the first facing 810 and the second facing 840.
The first facing may further include one score line 815. In this
example view of FIG. 8A, the first facing 810 is shown facing down
simply for illustrative purposes. Further, only one score line 815
is shown that is precisely located below an apex of a flute in the
medium 830. Further yet, the medium 830 is shown having a
sinusoidal flute profile, though it is understood that any shape of
flute profile may be used and the medium 830 may be embossed or
corrugated.
[0044] In the next view of FIG. 88, the board product 300 has begun
articulation. Here, the fold line will follow precisely the score
line 815 in the facing 810. Thus a first fold point 804 corresponds
to a first score line 815. As can be seen is this view of FIG. 88,
an articulation will result in an eventual approximately 90 degree
articulation without damage to underlying flutes. Further, the fold
point 804 is located directly between two apexes (of downward
facing flutes--i.e., two apexes affixed to the first facing 810) of
the medium 830 such that the legs of this flute begin to move
toward each other. As a result, a stretch point 805 of the second
facing 840 begins to forms directly over the fold point 804. With a
precisely located score line 815, a 90 degree fold may be realized
without causing undesired damage to the flutes of the medium 830.
Additional aspects of various embodiments of board products are
discussed next with respect to the machine of FIG. 9.
[0045] FIG. 9 is a diagram of aspects of a machine 500 configured
to produce the board product 300 of FIG. 5 according to an
embodiment of the subject matter disclosed herein. The machine 500
may produce other embodiments as well including the embodiment of
the board product 800 from FIG. 8A. The machine 500 includes three
feed rolls 510, 530, and 540 of paper that are used to produce a
board product. These feed rolls include a first facing feed roll
510, an embossed medium feed roll 530, and a second facing feed
roll 540. Note that the paper that is wound on the first facing
feed roll 510 is prior to scoring and the paper that is wound on
the embossed medium feed roll 530 is prior to embossing. The
weights and composition of the paper for each respective feed roll
may be different and designed specifically for the respective
purpose.
[0046] The paper from each roll may be unwound from each respective
roll and fed toward a combiner 550 that is configured to combine
the various layers of paper together to form a resultant board
product. Prior to entering the combiner 550, at least some of the
paper from the feed rolls may be passed through one or more stages
for scoring the paper. Thus, the first facing feed roll 510 may
feed paper into a scoring stage 590 that scores the paper with
impressions in a precise manner. In other embodiments, the lines
impressed upon the facing 110 may be perforations, intermittent
cuts or some other form of localized weakening the facing 110 along
a precise line. As the paper exits the scoring stage 590, it
becomes the scored facing 110 as discussed above with respect to
FIG. 3. The scored facing 110 is then fed into the combiner 550 to
be combined with other materials.
[0047] Further, also prior to entering the combiner 550, at least
some of the paper from the feed rolls may be passed through one or
more stages for forming the paper into a medium. As used herein and
in the industry, a medium may refer to a paper product that has
been formed into paper having flutes. Thus, the embossed medium
feed roll 530 may feed paper into first and second embossing rolls
531a and 531b that are aligned with respect to each other. As the
paper exits the embossing stage (e.g., embossing rolls 531a and
531b), it becomes the embossed medium 130 as discussed above with
respect to FIG. 4. The embossed medium 130 is then fed into the
combiner 550 to be combined with other materials.
[0048] Once passed through the embossing rolls 531a and 531b, the
embossed medium 130 may be passed to an applicator 570 for applying
adhesive to the newly formed apexes. The applicator may include a
device for identifying the locations of each apex and then aligning
a series of adhesive dispensers with the identified apexes. In
other embodiments, adhesive may be transferred to the flute tips
with a glue roll or rolls where the paper contacts a glue film and
adheres to the flute tips. In this manner, adhesive may be applied
with precision in a continuous and uniform manner. Then, the first
facing 110, the embossed medium 130, and the second facing 140 are
combined in the combiner 550 using various techniques such as
adhesion, curing, wetting, drying, heating, and chemical treatment.
The resultant board product 300 features at least one scored facing
precisely aligned with at least one linearly-embossed medium 130
wherein the board product may be articulated with accuracy.
[0049] While the subject matter discussed herein is susceptible to
various modifications and alternative constructions, certain
illustrated embodiments thereof are shown in the drawings and have
been described above in detail. It should be understood, however,
that there is no intention to limit the claims to the specific
forms disclosed, but on the contrary, the intention is to cover all
modifications, alternative constructions, and equivalents falling
within the spirit and scope of the claims.
* * * * *