Corrugated Cardboard Adhesive Application Speed Ratio
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Solution Overview
Problem
The existing methods for producing corrugated cardboard result in permanent deformation of flutes due to excessive adhesive application, leading to reduced strength and surface quality, as the flutes become overly wetted and saturated, causing them to lose their original shape.
Innovation Solution
Operating the applicator roll at a speed greater than the web speed, with a roll speed ratio of at least 105% to 150%, allows for precise adhesive application only to the crests of the flutes, minimizing adhesive on the sloped faces and reducing the amount of glue used, while maintaining or improving bond strength and surface smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the rider roll applies sufficient downward pressure to force flute tips into contact with the applicator roll, then adhesive application to flute crests is achieved, but the flutes become overly wetted or saturated with adhesive and permanently deformed
Solution Approach 1:
The patent changes the speed parameter of the applicator roll, operating it at a lower speed than the web speed (roll speed ratio less than 1.0). This parameter change reduces the dwell time of flutes in the adhesive layer, preventing over-wetting and permanent deformation while maintaining accurate adhesive application to flute crests.
2Manufacturing precision
If the applicator roll operates at lower speed than web speed, then glue weight control is improved, but production efficiency is reduced
Solution Approach 1:
The patent optimizes the roll speed ratio parameter to a specific range (less than 1.0 but not excessively low), balancing glue weight control with production efficiency. This optimized parameter setting achieves uniform glue application while minimizing negative impact on production speed.
3Strength
If flutes become overly wetted with adhesive, then adhesive bonding is achieved, but the flutes do not return to their original shape and permanent deformation occurs
Solution Approach 1:
The patent changes the dwell time parameter by adjusting the applicator roll speed, reducing it to less than 1.0 times the web speed. This reduced dwell time prevents excessive adhesive penetration into the flute structure, allowing flutes to return to their original shape while maintaining adequate bond strength.
4Quantity of substance
If adhesive is applied to leading or trailing faces of flutes, then coverage is increased, but washboarding and surface smoothness are reduced
Solution Approach 1:
The patent applies adhesive selectively to the flute crests only, avoiding the leading and trailing faces. This localized application approach concentrates adhesive where bonding is needed (at the crests) while preventing washboarding on the sloped faces, maintaining surface smoothness.
Data Source
AI summary
A method is provided for applying adhesive to the flutes of a corrugated sheet web. An applicator roll is provided with a uniform thin coating of adhesive by a metering rod. Exposed crests of the flutes are brought into contact with a coating of adhesive that has been applied to a surface of an applicator roll in order to provide a uniform bead of adhesive on the flute crests. The flutes are compressed against the applicator roll surface in a forward direction relative to the direction in which the web is moving adjacent the applicator roll surface. In one embodiment, the applicator roll has a surface linear velocity greater than the speed at which the web is traveling.