Apparatus and method for manufacturing double-sided corrugated sheet

Abstract

Provided is an apparatus for manufacturing a double-sided corrugated sheet in a single station without using a separate adhesive application device or adhesive drying device, the apparatus comprising: a corrugating medium supply device for supplying a corrugating medium; a first surface liner supply device for supplying a first surface liner; a second surface liner supply device for supplying a second surface liner; a first roller and a second roller that are configured to heat-press the supplied corrugating medium so that ridges and grooves are formed corrugated and bent at regular intervals on the corrugating medium; a third roller configured to bond one side of the corrugating medium on which the ridges and grooves are formed and the supplied first surface liner to form a single-sided corrugated sheet; and a fourth roller configured to bond the other side of the single-sided corrugated sheet, having the first surface liner bonded to the one side, and the supplied second surface liner to form a double-sided corrugated sheet.

Description

Device and method for manufacturing double-sided corrugated cardboard sheets

[0001] The present invention relates to an apparatus and method for manufacturing double-sided corrugated cardboard sheets that can be manufactured at a single station without separate adhesive application and drying devices, and furthermore, in which the corrugated cardboard itself has cushioning, waterproofing, and cooling functions.

[0002] Generally, conventional packaging boxes have been made of double-sided corrugated cardboard to facilitate the storage and transportation of goods.

[0003] Generally, corrugated cardboard is broadly classified into single-sided corrugated cardboard (i.e., composed of two sheets of base paper) in which a surface liner is bonded to one side of a corrugated core paper having ridges and corrugations formed thereon, and double-sided corrugated cardboard (i.e., composed of three sheets of base paper) in which a surface liner is additionally bonded to the other side of the single-sided corrugated cardboard.

[0004] A conventional method for manufacturing double-sided corrugated cardboard, as illustrated in FIG. 1(a), involves a pair of interlocking rollers (2a, 2b) rotating together to form ridges and valleys on a supplied corrugated core (1). Next, a first adhesive application roller (4a) applies adhesive to the ridges formed on one side of the corrugated core (1). Then, a pressure belt (6) rotating through a pair of rollers (6a, 6b) presses an additionally supplied surface liner (1') against one side of the corrugated core (1) to which the adhesive has been applied in the direction of the arrow, thereby manufacturing a single-sided corrugated cardboard (1a) [single facer].

[0005] As shown in FIG. 1(b), the above single-sided corrugated cardboard (1a) is supplied continuously again, and the second adhesive application roll (4b) applies adhesive again to the ridge formed on the other side of the single-sided corrugated cardboard (1a). Then, the heat-tightening part (8) heat-presses the additionally supplied surface liner (1'') onto the other side of the corrugated core sheet to which the adhesive has been applied, thereby finally manufacturing a double-sided corrugated cardboard (1b) [double facer].

[0006] As such, conventional methods for manufacturing corrugated cardboard must include single facers and double facers that are carried out continuously in separate spaces and facilities, which requires a large installation space for the device. Additionally, there were problems that increased device costs and reduced work efficiency due to the adhesive application and adhesive drying processes required for each single facer and double facer.

[0007] In particular, conventional adhesive dispensing devices consist of rollers that rotate in engagement with the ridges of the corrugated cardboard, thereby applying adhesive only to the ridges; however, there was a problem in that excessive costs were incurred for maintaining the viscosity and temperature of the adhesive required to continuously and uniformly apply the adhesive to the corrugated cardboard.

[0008] Another objective of the present invention is to eliminate the need for conventional adhesive application and drying devices in the entire manufacturing process, thereby reducing the overall installation length of the device so that it can be installed even in relatively confined spaces, and also reduce the installation cost of the device, so that a significant overall cost reduction effect can be achieved.

[0009] In particular, the purpose of the present invention is to enable the continuous production of double-sided corrugated sheets at a single station by eliminating the need for an adhesive application device and a drying device. That is, the objective of the present invention is to enable the direct production of double-sided corrugated sheets at a single station without passing through the single-facers and double-facers of the prior art.

[0010] Another objective of the present invention is to enable a total of six additional layers of heat-sealing material (i.e., protective layers) to be secured in addition to the three sheets of paper in the corrugated cardboard, by providing the heat-sealing material coated on each side of the three sheets of paper with an air-blocking function, a waterproof function, and a heat-blocking function.

[0011] One embodiment of the present invention for achieving the above-mentioned purpose provides a device for manufacturing a double-sided corrugated sheet at a single station without a separate adhesive application device and an adhesive drying device, wherein the manufacturing device comprises: a corrugated core supply device for supplying a corrugated core, wherein at least one surface of the corrugated core is coated with a heat-bonding material; a first surface liner supply device for supplying a first surface liner, wherein at least one surface of the first surface liner is coated with a heat-bonding material; a second surface liner supply device for supplying a second surface liner, wherein at least one surface of the second surface liner is coated with a heat-bonding material; a first roller and a second roller configured to rotate by interlocking with each other, wherein the first roller and the second roller are configured to heat-press the supplied corrugated core so that the corrugated core is formed with corrugations at regular intervals and corrugations; and a third roller configured to bond one side of the corrugated core with the corrugated core having the corrugations and corrugations formed thereon with the supplied first surface liner to form a single-sided corrugated sheet. and is configured to include a fourth roller configured to bond the other side of a single-sided corrugated cardboard, on which the first surface liner is bonded to one side, and the supplied second surface liner to form a double-sided corrugated cardboard.

[0012] Another embodiment of the present invention provides a method for manufacturing a double-sided corrugated sheet at a single station without a separate adhesive application device and an adhesive drying device. The manufacturing method comprises the steps of: coating a heat-bonding material on at least one surface of a corrugated core, a first surface liner, and a second surface liner; supplying the corrugated core from a first side; supplying the first surface liner from a second side; applying heat to the heat-bonding material coated on the supplied corrugated core and pressing to form crests and ridges at regular intervals on the corrugated core; bonding one side of the corrugated core with the crests and ridges formed thereon with the supplied first surface liner to form a single-sided corrugated sheet; supplying the second surface liner from a third side; and bonding the other side of the single-sided corrugated sheet with the first surface liner bonded to one side with the supplied second surface liner to form a double-sided corrugated sheet.

[0013] According to the present invention, since adhesive application and drying devices are unnecessary, the device can be installed in a relatively small space, and installation costs are reduced, resulting in significant overall cost savings. Furthermore, double-sided corrugated sheets can be continuously manufactured directly at a single station without passing through the single-facers and double-facers of the prior art.

[0014] According to the present invention, in addition to the three sheets of paper in the corrugated cardboard, an air-blocking function, a waterproof function, and a heat-blocking function can be additionally obtained by a total of six layers of heat-adhesive material (i.e., protective layers) coated on each side of the three sheets of paper.

[0015] FIGS. 1(a) and FIGS. 1(b) are cross-sectional views illustrating a single facer and a double facer according to the prior art, respectively.

[0016] FIG. 2 is a cross-sectional view illustrating a double-sided corrugated sheet manufacturing apparatus (100) according to one embodiment of the present invention.

[0017] FIG. 3(a) is a cross-sectional view illustrating a cross-section of a single-sided corrugated cardboard manufactured by the manufacturing device of the present invention, and FIG. 3(b) is a cross-sectional view illustrating a cross-section of a double-sided corrugated cardboard manufactured by the manufacturing device of the present invention.

[0018] FIG. 4 is a process flow diagram of a method for manufacturing a double-sided corrugated sheet according to one embodiment of the present invention.

[0019] Hereinafter, preferred embodiments of the present invention will be described in more detail with reference to the drawings.

[0020] FIG. 2 is a cross-sectional view illustrating a double-sided corrugated sheet manufacturing apparatus (100) according to one embodiment of the present invention.

[0021] Referring to FIG. 2, the present invention provides a device for manufacturing a double-sided corrugated sheet at a single station without a separate adhesive application device and an adhesive drying device. A manufacturing device (100) for a double-sided corrugated sheet according to one embodiment of the present invention comprises: a corrugated core supply device (not shown) for supplying a corrugated core (101); a first surface liner supply device (not shown) for supplying a first surface liner (102a); a second surface liner supply device (not shown) for supplying a second surface liner (102b); a first roller (110a) and a second roller (110b) configured to rotate by interlocking with each other, wherein the first roller (110a) and the second roller (110b) are configured to heat-press the corrugated core (101) so that the corrugated core (101) is formed with crests and valleys at regular intervals and curves are formed. The apparatus is configured to include: a third roller (120) which is formed with a flat surface and is configured to press in contact with the second roller (110b), thereby forming a single-sided corrugated cardboard (103) by joining one side of a corrugated core (101) having peaks and grooves and the supplied first surface liner (102a); and a fourth roller (130) which is formed with a flat surface and is configured to press in contact with the third roller (120), thereby forming a double-sided corrugated cardboard (104) by joining the other side of the single-sided corrugated cardboard (103) to which the first surface liner (102a) is joined to one side and the supplied second surface liner (102b) to the other side.

[0022] The first corrugated core (101), the first surface liner (102a), and the second surface liner (102b), supplied by the corrugated core supply device, the first surface liner supply device, and the second surface liner supply device, respectively, have a heat bonding material pre-coated on at least one side. Preferably, a heat bonding material is pre-coated on both sides of the first corrugated core (101), the first surface liner (102a), and the second surface liner (102b). More preferably, in addition to the heat bonding function, the heat bonding material additionally has an air blocking function, a waterproof function, and a heat blocking function, thereby allowing additional air blocking, waterproof function, and heat blocking function to be obtained by a total of six layers of heat bonding material coated on both sides of the three sheets of paper (i.e., the first corrugated core (101), the first surface liner (102a), and the second surface liner (102b)).

[0023] The manufacturing apparatus (100) according to the present invention adopts a method of bonding the first corrugated core (101), the first surface liner (102a), and the second surface liner (102b) by applying heat as needed to a heat bonding material pre-coated on at least one side thereof, so that a separate adhesive application device and an adhesive drying device are not required. Accordingly, the manufacturing apparatus (100) according to the present invention can be installed in a relatively small space, for example, in a single station, and the installation costs of the adhesive application device, etc. are also reduced, thereby achieving a significant overall cost reduction effect.

[0024] Referring to FIG. 2, a pair of rollers configured to rotate in contact with each other [i.e., a first roller (110a) and a second roller (110b)] heat-press a continuously supplied corrugated core sheet (101) to form crooked peaks and valleys at regular intervals on the corrugated core sheet (101). A third roller (120) configured to press in contact with the second roller (110b) joins one side of the corrugated core sheet (101) with peaks and valleys formed with a continuously supplied first surface liner (102a) to form a single-sided corrugated cardboard (103). A fourth roller (130), configured to be in contact with and pressurized by the third roller (120), heat-bonds the other side of a single-sided corrugated cardboard (103) on which a first surface liner (102a) is bonded to one side, and the supplied second surface liner (102b) to form a double-sided corrugated cardboard (104).

[0025] Referring to FIG. 2, the manufacturing apparatus (100) of the present invention further includes a guide section (140) positioned adjacent to the third roller (120) and the fourth roller (130) to guide the double-sided corrugated cardboard (104) toward the discharge port. The guide section (140) may be configured to include a first rotating belt (140c) rotating through a pair of rollers (140a) on one side and a second rotating belt (140d) rotating through another pair of rollers (140b) on the opposite side. The guide section (140) functions to support or maintain the heat-bonded double-sided corrugated cardboard (104) in its bonded state while cooling it (e.g., cooling to room temperature). FIG. 2 illustrates only one example of the guide section (140) that can be implemented in the present invention, and it is obvious that the present invention is not limited to the specific configuration of the guide section (140) described above. Accordingly, the guide portion (140) may be implemented in various configurations and arrangements by those skilled in the art.

[0026] Another embodiment of the present invention provides a method for manufacturing a double-sided corrugated sheet at a single station without a separate adhesive application device and an adhesive drying device. Referring to FIG. 4, the manufacturing method comprises the steps of: coating a heat bonding material on at least one surface of a corrugated core (101), a first surface liner (102a), and a second surface liner (102b); supplying the corrugated core (101) from a first side; supplying the first surface liner (102a) from a second side; applying heat to the heat bonding material coated on the supplied corrugated core (101) and applying pressure to form crooks and valleys at regular intervals on the corrugated core (101); bonding one side of the corrugated core (101) with the crooks and valleys formed thereon with the supplied first surface liner (102a) to form a single-sided corrugated sheet (103); and supplying the second surface liner (102b) from a third side. The method is configured to include the step of forming a double-sided corrugated board (104) by joining the other side of the single-sided corrugated board (103), on which the first surface liner (102a) is joined to one side, and the supplied second surface liner (102b) to each other. Preferably, the method may additionally include the step of guiding the heat-bonded double-sided corrugated board (104) toward the discharge port while supporting or maintaining it in the joined state. In this way, the double-sided corrugated board (104) can be cooled to room temperature while being guided toward the discharge port.

[0027] Although the present invention has been described in detail above with reference to specific embodiments with reference to the drawings, the present invention is not limited to such specific structures. Those skilled in the art will be able to make various modifications or changes to the present invention without departing from the technical spirit and scope of the present invention as described in the following claims.

Claims

1. A device for manufacturing double-sided corrugated cardboard sheets at a single station without a separate adhesive application device and adhesive drying device, A corrugated core supply device for supplying corrugated cores, wherein at least one surface of the corrugated core is coated with a heat bonding material; A first surface liner supply device for supplying a first surface liner, wherein at least one surface of the first surface liner is coated with a heat bonding material; A second surface liner supply device for supplying a second surface liner, wherein at least one surface of the second surface liner is coated with a heat bonding material; A first roller and a second roller configured to rotate by interlocking with each other, wherein the first roller and the second roller are configured to heat-press the supplied corrugated core so that the peaks and valleys are formed at regular intervals and folded. A third roller configured to form a single-sided corrugated cardboard by joining one side of the corrugated core sheet having the above-mentioned peaks and valleys with the first surface liner supplied thereto; and A fourth roller configured to form a double-sided corrugated board by joining the other side of a single-sided corrugated board, on which the first surface liner is joined to one side, with the second surface liner supplied thereto; A manufacturing apparatus for double-sided corrugated sheets characterized by including 2. An apparatus for manufacturing a double-sided corrugated sheet according to claim 1, further comprising a guide portion disposed adjacent to the third roller and the fourth roller to guide the double-sided corrugated sheet toward the discharge port.

3. An apparatus for manufacturing a double-sided corrugated sheet according to paragraph 2, wherein the guide portion supports or maintains the heat-bonded double-sided corrugated sheet in its bonded state while cooling it.

4. An apparatus for manufacturing a double-sided corrugated sheet according to claim 1, wherein the heat-bonding material pre-coated on both sides of the corrugated core, the first surface liner, and the second surface liner additionally has an air-blocking function, a waterproof function, and a heat-blocking function in addition to the heat-bonding function.

5. A method for manufacturing double-sided corrugated cardboard sheets at a single station without separate adhesive application and adhesive drying devices, A step of coating a heat bonding material on at least one surface of the core sheet, the first surface liner, and the second surface liner; A step of supplying the above-mentioned corrugated core from the first side; A step of supplying the first surface liner from the second side; A step of applying heat and applying pressure to the heat-bonding material coated on the supplied corrugated core to form peaks and valleys at regular intervals on the corrugated core; A step of forming a single-sided corrugated cardboard by joining one side of the corrugated core sheet having the above-mentioned peaks and valleys with the supplied first surface liner; A step of supplying the second surface liner from the third side; and A step of forming a double-sided corrugated board by joining the other side of a single-sided corrugated board, on which the first surface liner is joined to one side, and the supplied second surface liner to each other; A method for manufacturing a double-sided corrugated sheet including 6. A method for manufacturing a double-sided corrugated cardboard sheet according to claim 5, further comprising the step of guiding the heat-bonded double-sided corrugated cardboard toward the discharge port while supporting or maintaining it in the bonded state.

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