Method for reinforcing corrugated paper container

Abstract

A method for reinforcing a standard, regular, grooved, top loaded corrugated paper container having an outer liner board layer and an inner liner board layer and a wavy or corrugated paper intermediate layer glued between the two outer liner board layers, characterized in that: the corrugated paper container has a plurality of outer liner board layers; the three paper patches are glued to either the inside liner board or the outside liner board of the container board web sheet.

Description

Background Art

[0001] Reducing packaging raw materials is crucial to protecting our future environment. By increasing the compressive strength of the corrugated box top and the impact strength of the side panels, the present invention reduces material consumption by up to 30%. Conventional slotted corrugated (top-loaded) containers are made from up to 100% recyclable and biodegradable materials. Single-wall corrugated container board has an outer kraft linerboard and an inner kraft linerboard with a middle fluted (corrugated) kraft linerboard layer between them. According to the present invention, three kraft paper patches (representing 3% to 4% of the total kraft paper web area of ​​the container board) are glued to either the inner or outer linerboard of the container board web, overlapping the upper and lower top and bottom horizontal panel flaps formed from the container sleeve around the fold line, and also overlapping the top and bottom portions of the container board corner panels after the top and bottom portions of the container board, including the kraft paper patches, are fluted in the next manufacturing station, wherein the fifth panel at the corner of the fourth panel is glued and the container panel is folded into the finished container. Only three corners of the regular fluted corrugated container need to be reinforced because the fourth corner is already reinforced by the corrugated cardboard overlap panel of the fifth panel of the container. The fourth reinforcing paper corner patch is optional. First, glue is applied to either the inner or outer kraft linerboard layer of a containerboard web sheet by a flexographic printing press process in a subsequent continuous production station, wherein the glue pattern of the kraft patches is substantially identical and positioned substantially identically for the kraft patches to be applied by compression. A low-volume and economical kraft patch cutting and delivery method feeds kraft paper from a roll via dual feed rollers, stopping the kraft web at the desired kraft patch length and cutting the kraft web to the correct patch length using a serrated cutting blade. Multiple connecting linerboard web bridges are not severed, allowing the perforated kraft web to remain connected and the next linerboard patch to be safely fed without jamming. A fixed, anti-jam kraft web guide between each feed roller begins below the outer feed roller periphery and extends beyond the outer feed roller periphery after approximately 60° to 90°. Because the kraft patches are connected across the width of the kraft web by multiple small linerboard web bridges, the connected kraft patches (webs) can be transferred (requiring a small diameter transfer roller) to a rotating vacuum drum that transfers each kraft patch to a continuously moving inner linerboard container board web sheet or outer linerboard container board web sheet.A 25mm diameter drive shaft has ball bearings between each set of two or three dual kraft feed and vacuum drum transfer rollers. A 45mm diameter coaxial sleeve is designed to connect to the 25mm diameter drive shaft via coaxial spacer sleeves between each coaxial drive roller, secured to each end by a double-groove coil spring. The transfer coaxial drive rollers for the dual web feed and vacuum drums feature a straight knurled surface drive pattern consisting of multiple linear, micro-toothed, profiled top curved panels surrounding and on a smooth, rounded outer periphery. A serrated cutting blade located beneath the dual feed rollers is operated by a crankshaft driven by a stepper motor. After the kraft paper web perforation line leaves the vacuum drum's dual feed rollers, a kraft paper patch is torn from the kraft paper web by the vacuum drum. The kraft paper patch then passes around the rotating vacuum drum surface, compressing the kraft paper patch and sealing it to the continuously moving outer linerboard surface of the container board web sheet via the glued area. The vacuum drum rotates continuously. The vacuum drum does not have a perforated vacuum area across the entire drum width, but rather has a panel of four to six perforated circular vacuum lanes around the drum surface connected to a central bearing sleeve, where ball bearings rotate around an internal, fixed, non-rotating shaft, and the central, fixed shaft is attached to a vacuum stop bracket. Ultimately, there is one perforated circular vacuum lane panel (cross section) per vacuum line. Figure 3(Side view). A second high-capacity kraft web cutting and conveying method involves a servo motor driven by a servo drive connected to a microprocessor to drive and position a drive shaft with a serrated cutting blade, which requires the serrated cutting blade to rotate in a larger circular path. As the serrated blades perforate the kraft web, the shaft with the serrated blades should operate at an epicycle with a minimum speed coordinated with the speed of the kraft web during perforation, entering the anvil grove of the dual rollers. The serrated perforation rollers have protruding resilient compression pads on both sides of the serrated perforation blades, wherein the heads of the resilient compression pads are slightly raised to slightly above the tips of the multiple serrated cutting blade edges, thereby holding the kraft web in a stable position during perforation. Two kraft roll web widths will accommodate all container sizes because the attached kraft paper does not need to reach exactly to both edges of the container sleeve. In principle, only the corrugated container fold lines of the top and bottom panels need to be overlapped by the kraft patch. The kraft patch circulation begins with a section of the correct kraft patch length being perforated by a zigzag cutting blade and then sliding onto a rotating vacuum drum. This section is then held in a "hold" position by the dual vacuum drum web transfer rollers. As the web perforation line exits the vacuum drum dual web transfer rollers, the kraft patch is launched, releasing the entire kraft patch onto the rotating vacuum drum. The vacuum drum then precisely rotates, conveys, and compresses the kraft paper onto the glued area on the moving outer linerboard of the container web sheet. If the kraft patch does not match the glue mark on the paper to which it is attached after being glued to the corrugated container web sheet, glue of a color different from that of the linerboard web may appear outside the kraft patch area, and a color register mark sensor sends a reference signal to a microprocessor with a servo controller, thereby adjusting the position of the servo motor's serrated blade and correcting the kraft patch sending time for other kraft patches. In the case of precise positioning of the glue pattern, a non-stick fixed Teflon glue scraper for removing residual glue from any continuous roller and a rotating nylon brush with a vacuum cleaner may be unnecessary. The third kraft patch application method, which picks up kraft patches one by one from a pile of kraft patches that have been cut to size, will unfortunately slow down the machine production speed. The suction device picks up the linerboard patch from the top of the linerboard patch stack, and the rotary suction device rotates about the second outer circular periphery to match the speed of the continuously cut corrugated container board web to accurately convey and place the kraft paper patch on the adhesive pattern of the continuously cut outer linerboard printed on the container board web.The two automatically interchangeable kraft paper patch trays have a stepper motor controlled by a photoelectric sensor, which drives the lower layer of the patch tray to move up and down, thereby controlling the upper kraft paper patch level to always have the same position. Summary of the Invention

[0002] It is therefore an object of the present invention to eliminate the above-mentioned drawbacks and disadvantages associated with the known reinforcement methods for corrugated containers in the prior art.

[0003] Another object of the present invention is to provide a corrugated container having a reduced paperboard weight, which will be more economical.

[0004] Furthermore, another object of the present invention is to provide a corrugated container that will reduce the consumption of natural resources. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is an axonometric view of a corrugated container with linerboard applied around the vertical outside corners of the corrugated container so as to overlap the horizontal top and bottom panel edges of the corrugated container.

[0006] Figure 2 is a side view of a rotary glue applicator applying dots of glue to either the inner linerboard layer or the outer linerboard layer of a corrugated container board sheet in a continuous manufacturing process, wherein the glue pattern and location are substantially the same for the kraft linerboard patch being applied.

[0007] Figure 3 is a side view of a method of manufacturing kraft linerboard by tearing and applying kraft paper patches to the outer kraft linerboard of a continuously moving web of corrugated container board via a vacuum cylinder. DETAILED DESCRIPTION

[0008] according to Figure 2 , Figure 2 1 is a side view of a flexographic adhesive application printing unit that prints an adhesive pattern onto the inner linerboard or outer linerboard of a container board web sheet 1. From an adhesive tray 2, a fountain roller 3 picks up a layer of adhesive as it rotates, delivers the adhesive layer to a rotating anilox roller 5 with a rotating metering roller 4, and provides a uniform adhesive layer to a flexographic printing plate 6 fixed to a plate cylinder 7. The adhesive pattern is rotated and transferred to the linerboard of the container board web sheet 1 by an impression cylinder 8.

[0009] according to Figure 3 , Figure 3This is a side view of a simple kraft paper patch application unit. A kraft paper web 9 is fed by dual feed rollers 10, operated by a dancer roller 11. Following a main feed roller 12, the kraft paper web 9 enters a dual kraft web feed roller 14 with a non-slip outer web nip surface. A continuous kraft web is provided by a dual vacuum drum kraft transfer roller 17, which provides support until stopped by a stepper motor or electromagnetic coupling. The kraft paper patch is then precisely cut to length by a serrated cutting blade 15 driven by a crankshaft 16 with a stroke length of <5 mm. A fixed, anti-jam kraft web guide 13 is positioned between each feed roller, starting below the outer roller periphery and extending beyond the outer feed roller periphery after approximately 60° to 90° in the web feed direction. A kraft patch 22, still attached to the kraft web by a plurality of small kraft web connecting bridges, slides around a rotating vacuum drum 23 until the end of the kraft patch 22 clears the dual vacuum drum kraft transfer roller 17 and the kraft web connecting bridges are severed, leaving the kraft patch 22 securely attached to the rotating vacuum drum 23. Vacuum is provided to the rotating vacuum drum 23 from outside the drum periphery by a non-rotating vacuum manifold 19, and the vacuum is stopped by a non-rotating vacuum stop bracket 21 inside the drum. As the kraft patch 22 moves around the vacuum drum 23, it is compressed and attached to the continuously moving outer linerboard of the container board web sheet by means of an impression cylinder 24, thereby bonding the kraft patch 22 to the continuously cut container board web sheet. A non-rotating vacuum stop bracket 21 stops the vacuum in the perforated vacuum drum surface and releases a kraft paper patch 22 from the rotating drum and is attached to the outer linerboard of the corrugated board web sheet by an impression cylinder 24. A rotating nylon brush 18 and a stationary Teflon scraper 20 release residual glue from the rotating vacuum drum surface and the released residual glue is picked up by a vacuum supply line 20.

[0010] The present invention should not be considered as being limited to the examples described above, but should be understood to cover all aspects of equivalent methods and processes and various structures to which the present invention may be applicable. After reading this application document, the above-mentioned equivalent methods and processes and structures are technically applicable to the field of the present invention.

[0011] will become apparent to the technician.

Claims

1. A method of reinforcing a standard regular fluted (top loaded) corrugated container having an outer linerboard layer and an inner linerboard layer with a corrugated (corrugated) intermediate layer glued between the two outer linerboard layers, characterized in that Three paper patches are glued to the inner or outer linerboard of the container board web sheet, each of said paper patches overlapping the peripheral fold lines of the upper and lower horizontal panel wings of the container board sleeve for the top and bottom of the container, and, after the creasing / folding lines and notching are applied in the next machine station, the three paper patches also overlap the corner panel portions of the three container board sleeves, wherein the fifth panel at the corner of the fourth panel is glued and the container sleeve is opened, and in a separate operation, the container panels are folded into the finished container.

2. The method for reinforcing a standard fluted (top loaded) corrugated container according to claim 1, wherein: A plurality of connecting paper patches have perforation lines between each other, the perforation lines having a plurality of uncut web bridges, the paper uncut web bridges being torn before or during attachment of the individual paper patches to the continuously moving outer linerboard of the container board web sheet.

3. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 and 2, characterized in that The upper horizontal end panel portion and the lower horizontal end panel portion formed from the horizontal surrounding fold line of the container end panel include a paper patch that is divided into two parts, wherein the folded and completed box has a part of the paper patch attached to the corresponding top side panel edge and bottom side panel edge of one horizontal panel enclosure edge, and the folded and completed box has another part of the paper patch attached to the corresponding top side edge and bottom side edge of the other horizontal panel edge.

4. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 and 3, characterized in that A paper patch is compressed and attached to the glue area of ​​the moving inner linerboard or outer linerboard of the container board web sheet by a rotating vacuum cylinder.

5. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 4, characterized in that: A servo motor drives a rotating shaft having a sawtooth perforating blade having a cross section of a plurality of discontinuous uncut paper web bridges, whereby a perforation line is cut in the continuously moving paper web by the edge of the sawtooth perforating blade abutting against a second rotating anvil roller, the edge of the sawtooth perforating blade overlapping the outer cylindrical periphery of the second rotating anvil roller during cutting and the edge of the sawtooth perforating blade entering a groove generally transverse to the second rotating anvil roller when cutting.

6. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 5, characterized in that The web is held in a non-moving position between two dual intermittently operating rotating rollers, wherein the sawtooth perforation blade is located between the two dual intermittently operating rotating rollers, wherein the sawtooth perforation blade has a plurality of discontinuous sections of uncut paper web, thereby cutting a substantially straight perforation line in the paper web against a permanently fixed groove anvil.

7. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 6, characterized in that The paper patches are picked up one by one from the stack of paper patches by a vacuum device, which is moved and attached to the glue area on the moving outer linerboard of the container board web sheet by rotating the vacuum suction device.

8. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 7, characterized in that The glue pattern on the paper patch and the glue pattern on the outer linerboard of the container board web sheet typically have the same surface pattern.

9. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 8, characterized in that A moving compressive force is generated and transmitted from a rotating roller to compress the paper patch against the moving inner or outer linerboard of the container board web with the adhesive layer therebetween.

10. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 9, characterized in that The color registration mark sensor registers the printed color mark on the container sheet, thereby sending a registration signal to a microprocessor with a servo motor controller to position the axis of the paper web serrated rotary cutting blade to cut a perforation line at the precise patch tearing position, so that the rotating vacuum sleeve separates a paper patch from the paper web and accurately attaches the separated paper patch surface to the glue mark printed on the moving container sheet.

11. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 10, characterized in that The paper patch rotating perforated vacuum applicator drum rotates around an external non-rotating vacuum supply line and an internal non-rotating vacuum stop bracket.

12. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 11, characterized in that The rotating paper patch vacuum application drum is fed through a series of multiple identical dual feed and transfer rollers, which have protruding web guides and coaxial distance spacers located between the dual feed and transfer rollers, and the dual feed and transfer rollers are respectively connected to and driven by one or two drive shafts.

13. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 12, characterized in that At least one glue scraper and at least one rotating nylon brush collect residual glue from the rotating vacuum drum and the residual glue is removed from the glue scraper and the rotating nylon brush by a vacuum inlet / hose cleaner.

14. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 13, characterized in that The paper patch glue has a different color than the brown linerboard web, and the different color can be identified by the color register mark sensor to discern the color difference between the patch glue and the linerboard web.

15. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 14, characterized in that The design of the corrugated container can differ from that of a standard (top loading) corrugated container by having three or four overlapping reinforced paper patch corner sections.

16. A method for reinforcing a standard fluted (top loaded) corrugated container according to claims 1 to 15, characterized in that The kraft paper patch is compressed and laminated by forces generated and transmitted by rotating rollers and attached to either side of any of the three continuously moving webs or web sheets by gluing.

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