Method for manufacturing single-sided corrugated cardboard with half-cut ruled lines

Abstract

To provide a manufacturing method of a single-faced corrugated cardboard with excellent followability to the shape of an article and shock-absorbing properties.SOLUTION: The manufacturing method includes the steps of: putting ruled lines 3 perpendicular to a step direction by pressing a rotating disk-shaped ruling member 13 against a step of a corrugating medium 1 and crushing the step of the corrugating medium 1 in a thickness direction, while conveying a single-faced corrugated cardboard, which is a material with a liner 2 affixed to one side of the corrugating medium 1 forming wavy steps, in a direction perpendicular to the step direction; and cutting the steps of the corrugating medium 1 by means of a rotating disk-shaped blade member 14 to a depth that does not reach the liner 2, to put a half-cut 4 perpendicular to the step direction so as to form a single-faced corrugated cardboard C1 in which the ruled line 3 and the half-cut 4 are parallel with each other at a predetermined interval, wherein when putting the half-cut 4, a peripheral speed of the blade member 14 relative to a conveying speed of the single-faced corrugated cardboard is set appropriately according to a direction of rotation of the blade member 14 relative to the conveying direction of the single-faced corrugated cardboard and the type of blade member 14 to prevent the occurrence of cutting failure.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention mainly relates to a method for manufacturing a single-sided corrugated cardboard with half-cut ruled lines, which is used as a packaging material for articles.

Background Art

[0002] In recent years, mail-order sales using the Internet have become widespread. When shipping such products, in consideration of the impact on the environment, a packaging form has been tried in which articles are cushioned and held only with paper sheets instead of cushioning materials made of plastic sheets.

[0003] In order to meet such requirements, it is conceivable to use a cushioning material as described in Patent Document 1 below. As shown in FIG. 10, this cushioning material is composed of a single-sided corrugated cardboard C2 in which a liner 52 is adhered to one side of a middle corrugation 51 having a wavy step, and ruled lines 53 are formed by crushing the steps in the thickness direction so as to obliquely run at an angle of 45° in opposite directions with respect to the step direction of the middle corrugation 51.

[0004] According to this cushioning material, not only can the article be surrounded by being rolled into a cylindrical shape so that the direction orthogonal to the step direction of the single-sided corrugated cardboard C2 becomes the circumferential direction, but also by folding along the ruled lines 53 obliquely running in opposite directions, the inner surface of the portion surrounded by the ruled lines 53 can be brought into contact with the surface of the article in a state presenting the appearance of a polyhedron in the shape of a tortoise shell, and thus an irregularly shaped article such as a vase can be wrapped.

[0005] When manufacturing the cushioning material as described above, the ruled lines 53 are formed by pressing the middle corrugation 51 of the single-sided corrugated cardboard of the material with a roll having a convex ruled line pressing portion on the outer periphery.

[0006] In addition, as shown in FIG. 11 of Patent Document 2 below, there is a packaging bag made of a paper sheet composed of an outer bag 60 and a cushioning material 61 mounted inside it. The cushioning material 61 is formed by inserting cut lines 62 extending horizontally in a staggered pattern and folding it in half at the lower end, and the cushioning material 61 is suspended between the opposing inner surfaces of the outer bag 60. When an article is stored inside the cushioning material 61 of this packaging bag, the cushioning material 61 extends downward and a three-dimensional cushioning cell appears, protecting the article from impact.

[0007] In manufacturing the cushioning material 61 as described above, for similar cushioning materials, as described in Patent Documents 3 and 4 below, cuts may be made in the paper sheet with a processing machine so that cushioning cells are formed by stretching the paper sheet.

Prior Art Documents

Patent Documents

[0008]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0009] However, in the cushioning material of the single-sided corrugated cardboard C2 as shown in FIG. 10, when wrapping an article, the portion near the ruled line 53 that becomes the edge line of the polyhedron is considerably separated from the article, so there is a problem that the followability to the article shape is low.

[0010] In addition, in the cushioning material 61 made of paper sheet as shown in FIG. 11, in the state of use where it extends to form cushioning cells, compared with the corrugated cardboard that forms a dense hollow structure with the undulating ridges and the liner adhered thereto, there is a problem that sufficient cushioning performance cannot be obtained.

[0011] Therefore, an object of the present invention is to provide a method capable of manufacturing a single-sided corrugated cardboard excellent in followability to the shape of an article and cushioning performance.

Means for Solving the Problems

[0012] In order to solve the above problems, the method for manufacturing a single-sided corrugated cardboard according to the present invention conveys a single-sided corrugated cardboard as a material with a liner adhered to one side of the undulating ridges in a direction orthogonal to the step direction, presses a rotating disk-shaped scoring member against the steps of the ridges, and crushes the steps of the ridges in the thickness direction to make score lines orthogonal to the step direction, cuts the steps of the ridges with a rotating disk-shaped cutting member to a depth that does not reach the liner to make half-cuts orthogonal to the step direction, and forms a single-sided corrugated cardboard with half-cut score lines where the score lines and the half-cuts are parallel at a predetermined interval.

[0013] Also, with respect to the conveyance direction of the single-sided corrugated cardboard, the cutting member is rotated forward, and the peripheral speed of the cutting member with respect to the conveyance speed of the single-sided corrugated cardboard is 3.0 times or more if the cutting member is a round blade, 2.5 times or more if the cutting member is a notch blade, 1.5 times or more if the cutting member is a saw blade, respectively set.

[0014] Alternatively, with respect to the conveyance direction of the single-sided corrugated cardboard, the cutting member is rotated backward, and the peripheral speed of the cutting member with respect to the conveyance speed of the single-sided corrugated cardboard is 1.5 times or more if the cutting member is a round blade, 1.0 times or more if the cutting member is a notch blade, If the cutting member is a saw blade, it is set to be 0.5 times or more. It was set respectively.

[0015] Also, the process of making the ruled line by the ruling member and the process of making the half cut by the cutting member are not performed simultaneously, but are performed at different timings.

[0016] Furthermore, due to the difference between the conveyance speed of the single-sided corrugated board and the peripheral speed of the cutting member, it is pulled in the direction in which the middle corrugation collapses, resulting in a corrugated flow state where the inclination on one side of the corrugation top is gentle and the inclination on the other side is steep.

Advantages of the Invention

[0017] The single-sided corrugated board manufactured by the method according to this invention, in addition to the property of being rolled so that the direction orthogonal to the direction of the middle corrugation becomes the circumferential direction, can be easily bent along the ruled line and the half cut. Therefore, when packaging an article, it can be flexibly bent in multiple directions so as not to be too far from the surface of the article, and high followability to the article shape can be obtained.

[0018] Also, since the middle corrugation is cut by a half cut and the corrugation is easily crushed when an impact acts, excellent cushioning performance can be obtained. When the middle corrugation is in a flowing state, the cushioning performance is further improved. When the ruled line and the half cut are made at different timings instead of simultaneously, the corrugated flow is likely to occur.

[0019] In the production of such a single-sided corrugated board, according to the rotational direction of the cutting member with respect to the conveyance direction of the single-sided corrugated board and the type of the cutting member, the peripheral speed of the cutting member with respect to the conveyance speed of the single-sided corrugated board is set to an appropriate speed ratio, and by making a half cut, it becomes difficult for a cutting defect of the half cut to occur.

Brief Description of the Drawings

[0020]

Figure 1

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Embodiments for Carrying Out the Invention

[0021] Hereinafter, embodiments of the present invention will be described based on the accompanying drawings.

[0022] <Regarding single-sided corrugated cardboard with half cut grid lines> As shown in FIG. 1, the single-sided corrugated cardboard C1 manufactured by the method according to the present invention uses a single-sided corrugated cardboard with a liner 2 attached to one side of the middle core 1 forming a wavy step as a material, and a large number of grid lines 3 and half cuts 4 are respectively inserted in parallel in the middle core 1 so as to extend in a direction orthogonal to the step direction in which the step top extends.

[0023] Here, as shown in Fig. 2(a), the ruled line 3 is formed by crushing the step of the core 1 in the thickness direction, and as shown in Fig. 2(b), the half cut 4 is formed by cutting into the step of the core 1 to a depth that does not reach the liner 2. Also, as shown in Fig. 2(c), the step of the core 1 has a stepped flow state where the inclination on one side of the step top 1a is gentle and the inclination on the other side is steep.

[0024] This single-sided corrugated board C1, in addition to the property of being a single-sided corrugated board that is rounded so that the direction orthogonal to the step direction of the core 1 becomes the circumferential direction, easily bends along the ruled line 3 and the half cut 4 where the bending resistance is weakened.

[0025] Also, since the step of the core 1 is cut by the half cut 4 and is in a stepped flow state, the step of the core 1 is easily crushed during the impact action, excellent cushioning performance is obtained, and breakage during the transportation of the packaged article can be prevented.

[0026] <Packaging body of single-sided corrugated board with half cuts and ruled lines> As shown in Figs. 3(a) and (b), the single-sided corrugated board C1 is used, for example, to form a packaging body for shipping an article G such as a book which is a product sold by mail order. This packaging body is formed by facing two single-sided corrugated boards C1 of cushioning material with the core 1 on the inside, sandwiching the article G between the cores 1, and crimping the portions facing the peripheral edge of the single-sided corrugated board C1 to form an envelope-like shape where the liner 2 becomes the outer surface for attaching a slip or the like.

[0027] When packaging the article G in this way, the single-sided corrugated board C1 bends flexibly in multiple directions so as not to be too far from the surface of the article G, and high followability to the article shape is obtained, so it can be widely used for packaging various articles.

[0028] <Processing device> (Main part of the processing device) As shown in FIGS. 4 to 6, this processing apparatus for single-sided corrugated board C1 includes a disk-shaped pressing member 13 that crushes the steps of the middle core 1 of the single-sided corrugated board in the thickness direction as it rotates while conveying the single-sided corrugated board serving as the material, and a disk-shaped cutting member 14 that cuts into the steps of the middle core 1 of the single-sided corrugated board to a depth that does not reach the liner 2 as it rotates. In FIGS. 4 to 6, as the cutting member 14, one having a notch blade described later is illustrated.

[0029] The pressing member 13 and the cutting member 14 sandwich the single-sided corrugated board between them and an anvil roll 16 with urethane wound around its surface. The gap between the pressing member 13 and the cutting member 14 with respect to the anvil roll 16 can be adjusted by a gap adjusting mechanism 30. The single-sided corrugated board is conveyed in a state where tension acts along the outer circumference of the anvil roll 16.

[0030] In this processing apparatus, since the half-cut 4 is made by the rotating disk-shaped cutting member 14 in a state where no slack occurs in the single-sided corrugated board serving as the material, the steps of the middle core 1 can be accurately cut so as not to reach the liner 2.

[0031] (Arrangement of the pressing member and the cutting member) The pressing member 13 and the cutting member 14 are arranged at a predetermined interval so as to be alternately arranged in the axial direction of the rotation axes 20 and 22. The intervals between adjacent pressing members 13 and between adjacent cutting members 14 are set according to the intervals between the ruled lines 3 and the half-cuts 4 made in the single-sided corrugated board C1.

[0032] Also, the pressing member 13 and the cutting member 14 are arranged on the upstream side and the downstream side in the conveying direction of the single-sided corrugated board, and the ruled lines 3 and the half-cuts 4 are made at different timings instead of simultaneously. As a result, step flow is likely to occur in the single-sided corrugated board, and the cushioning property is improved. In this embodiment, a mechanism for separating the timings is adopted, but it is also possible to cause step flow by making the ruled lines and the half-cuts at the same timing.

[0033] Incidentally, with respect to the positional relationship between the scoring member 13 and the cutting member 14 in the conveying direction of the single-sided corrugated board, the cutting member 14 may be positioned on the upstream side and the scoring member 13 may be positioned on the downstream side.

[0034] (Scoring member) The scoring member 13 is a metal disk having a smooth outer circumference. A large number of them are arranged side by side around the rotating shaft 20 and are fixed against rotation with respect to the rotating shaft 20. Between adjacent scoring members 13, a spacer 21 fitted around the rotating shaft 20 is interposed to maintain the distance between them.

[0035] (Cutting member) The cutting member 14 is also a metal disk. As shown in FIG. 7, it has a round blade with a smooth outer circumference. As shown in FIG. 8, it has notches 14a which are a plurality of V-shaped cuts on the outer circumference. As shown in FIG. 9, a saw blade having triangular ridges 14b and valleys 14c arranged in a certain pattern on the outer circumference is considered. These cutting members 14 are arranged side by side around the rotating shaft 22, and a spacer 23 fitted around the rotating shaft 22 is interposed between adjacent cutting members 14 to maintain the distance between them.

[0036] <Process conditions for half-cutting> In the processing apparatus as described above, in order to find the process conditions for half-cutting, for each type of cutting member 14, when the rotation direction of the cutting member 14 with respect to the conveying direction of the single-sided corrugated board is forward and when it is reverse, the peripheral speed of the cutting member 14 with respect to the conveying speed of the single-sided corrugated board was changed, and the state of the half-cutting process was evaluated. The single-sided corrugated board used for this evaluation is liner: LC grade 120 g / m 2 and medium liner: MC grade 115 g / m 2 of E-flute. Also, the cutting members 14 are of three types: round blade, notch blade, and saw blade.

[0037] As a result, when the cutting tool member 14 is rotated clockwise with respect to the conveying direction of the single-sided corrugated board, if the peripheral speed of the cutting tool member 14 with respect to the conveying speed of the single-sided corrugated board is set to 3.0 times or more if the cutting tool member 14 has a round blade, 2.5 times or more if it has a notch blade, and 1.5 times or more if it has a saw blade, respectively, it was found that half-cutting is possible.

[0038] Also, when the cutting tool member 14 is rotated counterclockwise with respect to the conveying direction of the single-sided corrugated board, if the peripheral speed of the cutting tool member 14 with respect to the conveying speed of the single-sided corrugated board is set to 1.5 times or more if the cutting tool member 14 has a round blade, 1.0 times or more if it has a notch blade, and 0.5 times or more if it has a saw blade, respectively, it was found that half-cutting is possible.

[0039] Also, it was found that good processing results can be obtained if the peripheral speed of the cutting tool member 14 with respect to the conveying speed of the single-sided corrugated board is set as shown in Table 1.

[0040]

Table 1

[0041] From the above results, if the rotation direction of the cutting tool member 14 is counterclockwise with respect to the conveying direction of the single-sided corrugated board, the rotation speed of the cutting tool member 14 can be suppressed.

[0042] When the cutting tool member 14 has a notch blade or a saw blade, slip of the cutting tool member 14 with respect to the core 1 is prevented, and it becomes difficult for a cutting failure of the half-cut 4 to occur. Also, since the outer periphery of the cutting tool member 14 meshes with the step top of the core 1 and the step is knocked down, the steps of the core 1 are surely in a stepped flow state.

[0043] The speed ratio of the peripheral speed of the cutting tool member 14 / the conveying speed of the single-sided corrugated board is preferably high from the viewpoint of cutting, but if the speed ratio is too high, there is a risk that the single-sided corrugated board will wrap around the cutting tool member 14.

[0044] <Preferred specifications of single-sided corrugated board with half-cut ruled lines> By incorporating the ruled line 3 and the half cuts 4, the buffering performance is improved regardless of the steps (flutes marked as "F"). Therefore, the single-sided corrugated board C1 is designated as EF / ΔF / BF / CF / AF in order from the finest and thinnest steps. Note that ΔF has 60 ± 2 steps per 30 cm and a thickness of approximately 2 mm (manufactured by Rengo Co., Ltd.).

[0045] Also, the depth of the cut of the half cuts 4 ranges from half to all of the height of the steps of the central ridge 1, depending on the properties of the single-sided corrugated board used as the material and the shape of the item to be packaged.

[0046] Also, the step flow may be absent, but having it further improves the buffering performance.

[0047] And the distance between the ruled line 3 and the half cuts 4 is set to be 5 mm or more and 10 mm or less because excessive widening reduces the buffering performance.

[0048] Also, the ratio of the number of the ruled lines 3 to the half cuts 4 is not limited to 1:1 and is in the range of 2:1 to 1:2, and the ruled lines 3 and the half cuts 4 are arranged in the same order over the entire surface.

[0049] <Other uses of the single-sided corrugated board with half cuts and ruled lines> Incidentally, the single-sided corrugated board C1 as described above can be used not only as a packaging material for exterior as shown in Fig. 3 but also as a cushioning material to be inserted into an outer box in a state where an item is wrapped. Therefore, it can replace bubble cushioning materials made of plastic sheets, etc., and is expected to have a wide range of uses considering the environment. Furthermore, in addition to its use as a packaging material, it can also be used as a material for displays that takes advantage of its flexible formability.

Explanation of symbols

[0050] C1 Single-sided corrugated board G Item 1 Central ridge 1a Top of the step 2 Liner 3 Ruled line 4 Half cut 13 Ruled line pressing member 14 Blade member 14a Notch 14b Crest 14c Trough 16 Anvil roll 20 Rotation axis 21 Spacer 22 Rotation axis 23 Spacer 30 Clearance adjustment mechanism

Claims

1. While conveying a single-sided corrugated cardboard, which is a material with a liner (2) adhered to one side of a middle core (1) forming a wavy step, in a direction orthogonal to the step direction, pressing a rotating disk-shaped ruling member (13) against the step of the middle core (1) and crushing the step of the middle core (1) in the thickness direction to form a ruling line (3) orthogonal to the step direction, cutting into the step of the middle core (1) to a depth that does not reach the liner (2) with a rotating disk-shaped cutting member (14) to form a half cut (4) orthogonal to the step direction, the ruling line (3) and the half cut (4) being parallel at a predetermined interval, pulling the step of the middle core (1) in the falling direction by the difference between the conveying speed of the single-sided corrugated cardboard and the peripheral speed of the cutting member (14) to form a single-sided corrugated cardboard (C 1 ) in a stepped flow state where one side of the step top (1a) has a gentle slope and the other side has a steep slope. A method for manufacturing a single-sided corrugated cardboard with a half cut and ruling line.

2. Rotating the cutting member (14) clockwise with respect to the conveying direction of the single-sided corrugated cardboard, and setting the peripheral speed of the cutting member (14) with respect to the conveying speed of the single-sided corrugated cardboard, to be 3.0 times or more if the cutting member (14) is a round blade, to be 2.5 times or more if the cutting member (14) is a notch blade, to be 1.5 times or more if the cutting member (14) is a saw blade, respectively. The method for manufacturing a single-sided corrugated cardboard according to Claim 1, characterized in that.

3. Rotating the cutting member (14) counterclockwise with respect to the conveying direction of the single-sided corrugated cardboard, and setting the peripheral speed of the cutting member (14) with respect to the conveying speed of the single-sided corrugated cardboard, to be 1.5 times or more if the cutting member (14) is a round blade, to be 1.0 times or more if the cutting member (14) is a notch blade, to be 0.5 times or more if the cutting member (14) is a saw blade, respectively. The method for manufacturing a single-sided corrugated cardboard according to Claim 1, characterized in that.

4. The method for manufacturing a single-sided corrugated board according to any one of claims 1 to 3, characterized in that the process of forming the ruled line (3) by the ruling member (13) and the process of forming the half cut (4) by the cutting member (14) are not performed simultaneously but at different timings.

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