Doublewall Corrugated Board Structure to Prevent Flute Nesting
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Solution Overview
Problem
Existing corrugated packaging technologies face issues with bond strength, structural integrity, and printability due to crease alignment and flute nesting, particularly in doublewall and triplewall boards, leading to inefficiencies in fiber usage and increased costs.
Innovation Solution
A five-ply doublewall board design is introduced, featuring creased base layers with cross-flute bond lines oriented in alternating directions to enhance structural support and printability, utilizing creases as trusses to reinforce the board and improve cross-corrugator stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional singleface webs of larger flute type are bonded to inverted creased base layers of smaller flute type, then flute nesting is prevented, but cross-flute bond lines may lack structural integrity when wetted by starch
Solution Approach 1:
The patent uses the crease side of the CBL as a bonding surface that is structurally sound and doesn't require the cross-flute bond lines to provide structural integrity, effectively making the cross-flute bond lines serve only for adhesive application without bearing structural load
2Strength
If cross-flute bond lines are used to bond larger flute SFW to smaller flute CBL, then bonding is achieved, but printability is impacted when crease side faces bottom liner
Solution Approach 1:
The patent inverts the bonding orientation so that the crease side of the CBL faces the SFW rather than the bottom liner. This allows the smooth outer surface of the CBL to face the bottom liner, improving printability while the crease side provides adequate bonding surface area and strength to the SFW
3Strength
If conventional doublewall corrugated board is used, then fiber content is high, but structural strength and damage-free delivery are ensured
Solution Approach 1:
The patent creates a composite structure combining a smaller flute CBL with a larger flute SFW, where the two different flute types work together to provide enhanced structural strength. The smaller flute CBL provides rigidity and the larger flute SFW provides cushioning, creating a synergistic effect that allows for reduced fiber content while maintaining strength
Solution Approach 2:
The patent changes the flute size parameters by combining two different flute types (smaller flute CBL and larger flute SFW) rather than using uniform flute sizes. This parameter variation allows optimization of both strength and fiber content by selecting appropriate flute sizes for different functional requirements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new design achieves enhanced strength and printability while reducing fiber usage by downsizing basis weights, maintaining equivalent strength and eliminating flute nesting, thus optimizing material efficiency and performance.
Implementation Method 1
bonding the CBL with downward facing cross flute bond lines to a top liner
Implementation Method 2
utilizing creases as trusses to reinforce the board and improve cross-corrugator stiffness
Implementation Method 3
cross flute bond lines oriented in alternating directions to enhance structural support and prevent nesting of the flutes
Data Source
AI summary
The panel defined by the current invention is comprised of a creased base layer with cross flute bond lines facing in an upward direction bonded to a top liner with the crease side of the creased base layer bonded to a center liner which is then bonded to the crease side of another creased base layer with the cross-flute bond lines facing downward toward a bottom liner.