Method for manufacturing composite fiberboard products

Abstract

The invention discloses a method for manufacturing composite fibreboard products, which includes the steps of providing double-faced corrugated paper sheets as raw material; of feeding the double-faced corrugated paper sheets through a coater; of gluing the double-faced corrugated paper sheets together to form a honeycomb block; of cutting the honeycomb block into honeycomb wafers each having two outer layers; of laminating the outer layers of the honeycomb wafers with paper to form a flat sandwiched composite fibreboard; and of cutting and trimming the flat sandwiched composite fibreboards to form composite fireboard products. The honeycomb block is cured to ensure dimensional stability. The honeycomb block is cut into honeycomb wafers by means of big saw means.

Description

[0001] METHOD FOR MANUFACTURING COMPOSITE FIBERBOARD PRODUCTS

[0002] FIELD OF INVENTION

[0003] The present invention relates to a method for manufacturing composite fibreboard products.

[0004] More particularly, the present invention related to a method for manufacturing composite fibreboard products for set-builders, industrial flatbed printers, retail display and exhibition booth manufacturers, hobbyists, joiners, furniture manufacturers, yacht builders, coffin manufacturers and shop fitters.

[0005] BACKGROUND TO INVENTION

[0006] The term fibreboard is used to describe a tough kraft-based paperboard or corrugated fibreboard for boxes. Corrugated fibreboard, corrugated cardboard, or corrugated is a type of packaging material consisting of a fluted corrugated sheet and one or two flat linerboards. It is made on "flute lamination machines" or "corrugators" and is used for making corrugated boxes. The corrugated medium sheet and the linerboards are made of kraft containerboard, a paperboard material usually over 0.25 millimetres thick. Known methods to manufacture fibreboards are unfortunately not always economical and the products are not always strong and durable.

[0007] It is an object of the invention to suggest a novel a method for manufacturing composite fibreboard products which will assist in overcoming the aforementioned obstacles.

[0008] SUMMARY OF INVENTION

[0009] According to the invention, a method for manufacturing composite fibreboard products includes the steps

[0010] (a) of providing double-faced corrugated paper sheets as raw material;

[0011] (b) of feedingthe double-faced corrugated paper sheets through a coater;

[0012] (c) of gluing the double-faced corrugated paper sheets together to form a honeycomb block;

[0013] (d) of cutting the honeycomb block into honeycomb wafers each having two outer layers;

[0014] (e) of laminating the outer layers of the honeycomb wafers with paper to form a flat sandwiched composite fibreboard; and

[0015] (f) of cutting and trimming the flat sandwiched composite fibreboards to form composite fireboard products. Also, according to the invention, a composite fibreboard product made according to the manufacturing method as described herein.

[0016] The honeycomb block may be cured to ensure dimensional stability.

[0017] The honeycomb block may be cut into honeycomb wafers by means of big saw means.

[0018] The step of cutting may include powerful suction means at various stages of the step to create a dust free working environment and ensure minimal dust remains on the wafer.

[0019] The method may include inline quality control means to ensure that all wafers are the exact same height throughout.

[0020] The step of laminating may occur in a highly sophisticated laminator coater adapted to laminate the two outer layers of specially developed paper onto the honeycomb wafers.

[0021] The step of laminating may form an accurate, flat, high quality sandwiched fibreboard product.

[0022] The method may include accurate machine controls to guarantee high dimensional accuracy and repeatability. The step of cutting may include cutting the flat sandwiched composite fibreboard to length and stacking onto conveyors to facilitate a continuous manufacturing method.

[0023] The step of trimming the final composite fibreboard sandwich is to ensure consistent width of the composite fibreboard product.

[0024] The double-faced corrugated paper sheet may include A / A 5 Ply - Semi- chem and / or A / A 4 Ply - Semi-chem double-faced corrugated paper sheet having a grammage of 350gsm

[0025] The double-faced corrugated paper sheet may include A / A 5 Ply - Recycled double-faced corrugated paper sheet having a grammage of 250gsm.

[0026] BRIEF DESCRIPTION OF DRAWINGS

[0027] The invention will now be described byway of example with reference to the accompanying schematic drawings.

[0028] In the drawings there is shown in

[0029] Figure 1 : the double-faced corrugated paper sheets used as raw materials;

[0030] Figure 2: the steps of forming the honeycomb blocks; Figure 3: a wafer cut from a honeycomb block;

[0031] Figure 4: the step of cutting the honeycomb blocks into honeycomb wafers using large saw means;

[0032] Figure 5: the step of laminating the honeycomb wafers to form the composite fibreboard sandwiches.

[0033] Figure 6: A / A 5 ply - semi-chem double-faced corrugated paper sheet adapted to be used as raw material for the method according to the invention;

[0034] Figure ?: A / A 4 ply - semi-chem double-faced corrugated paper sheet adapted to be used as raw material for the method according to the invention; and

[0035] Figure s: A / A 5 ply - recycled double-faced corrugated paper sheet adapted to be used as raw material for the method according to the invention. DETAILED DESCRIPTION OF DRAWINGS

[0036] Referring to the drawings and according to the invention, a method for manufacturing composite fibreboard products which includes the steps

[0037] (a) of providing double-faced corrugated (Kraft) paper sheets (DFK) as raw material;

[0038] (b) of feedingthe double-faced corrugated paper sheets through a coater;

[0039] (c) of gluing the double-faced corrugated paper sheets together to form a honeycomb block;

[0040] (d) of cutting the honeycomb block into honeycomb wafers each having two outer layers;

[0041] (e) of laminating the outer layers of the honeycomb wafers with paper to form a flat sandwiched composite fibreboard; and

[0042] (f) of cutting and trimming the flat sandwiched composite fibreboards to form composite fireboard products.

[0043] The invention also extends to a composite fibreboard product made according to the manufacturing method as described herein.

[0044] The honeycomb block is cured to ensure dimensional stability. The honeycomb block is cut into honeycomb wafers by means of big saw means.

[0045] The step of cutting includes powerful suction means at various stages of the step to create a dust free working environment and ensure minimal dust remains on the wafer.

[0046] The method includes inline quality control means to ensure that all wafers are the exact same height throughout.

[0047] The step of laminating occurs in a highly sophisticated laminator coater adapted to laminate the two outer layers of specially developed paper onto the honeycomb wafers.

[0048] The step of laminating forms an accurate, flat, high quality sandwiched fibreboard product.

[0049] The method includes accurate machine controls to guarantee high dimensional accuracy and repeatability.

[0050] The step of cutting includes cutting the flat sandwiched composite fibreboard to length and stacking onto conveyors to facilitate a continuous manufacturing method. The step of trimming the final composite fibreboard sandwich is to ensure consistent width of the composite fibreboard product.

[0051] The double-faced corrugated paper sheet can include A / A 5 Ply - Semi-chem and / or A / A4 Ply - Semi-chem double-faced corrugated paper sheet having a grammage of 350gsm and width of 1285mm

[0052] The double-faced corrugated paper sheet can include A / A 5 Ply - Recycled double-faced corrugated paper sheet having a grammage of 250gsm and a width of 1285mm.

Claims

PATENT CLAIMS1. A method for manufacturing composite fibreboard products, which includes the steps(a) of providing double-faced corrugated paper sheets as raw material;(b) of feeding the double-faced corrugated paper sheets through a coater;(c) of gluing the double-faced corrugated paper sheets together to form a honeycomb block;(d) of cutting the honeycomb block into honeycomb wafers each having two outer layers;(e) of laminating the outer layers of the honeycomb wafers with paper to form a flat sandwiched composite fibreboard; and(f) of cutting and trimming the flat sandwiched composite fibreboards to form composite fireboard products.

2. A method as claimed in claim 1 , in which the honeycomb block is cured to ensure dimensional stability.

3. A method as claimed in claim 1 or claim 2, in which the honeycomb block is cut into honeycomb wafers by means of big saw means.

4. A method as claimed in any one of the preceding claims, in which the step of cutting includes powerful suction means at various stages of the step to create a dustfree workingenvironment and ensure minimal dust remains on the wafer.

5. A method as claimed in any one of the preceding claims, which includes inline quality control means to ensure that all wafers are the exact same height throughout.

6. A method as claimed in any one of the preceding claims, in which the step of laminating occurs in a highly sophisticated laminator coater adapted to laminate the two outer layers of specially developed paper onto the honeycomb wafers.

7. A method as claimed in any one of the preceding claims, in which the step of laminating forms an accurate, flat, high quality sandwiched fibreboard product.

8. A method as claimed in any one of the preceding claims, which includes accurate machine controls to guarantee high dimensional accuracy and repeatability.

9. A method as claimed in any one of the preceding claims, in which the step of cutting includes cutting the flat sandwiched compositefibreboard to length and stacking onto conveyors to facilitate a continuous manufacturing method.

10. A method as claimed in any one of the preceding claims, in which the step of trimming the final composite fibreboard sandwich is to ensure consistent width of the composite fibreboard product.

11. A method as claimed in any one of the preceding claims, in which the double-faced corrugated paper sheet includes A / A 5 Ply - Semi-chem and / or A / A 4 Ply - Semi-chem double-faced corrugated paper sheet.

12. A method as claimed in claim 11 , in which the double-faced corrugated paper sheet has a grammage of 350gsm.

13. A method as claimed in any one of the preceding claims, in which the double-faced corrugated paper sheet includes A / A 5 Ply - Recycled double-faced corrugated paper sheet.

14. A method as claimed in claim 13, in which the double-faced corrugated paper sheet has a grammage of 250gsm.

15. A composite fibreboard product made according to the manufacturing method as described herein.

16. A method for manufacturing composite fibreboard products substantially as hereinbefore described with reference to the accompanying drawings.

17. A composite fibreboard product substantially as hereinbefore described with reference to the accompanying drawings.

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