Embossed or dimpled combined board

• US 5,374,468 A
• Filed: 03/31/1994
• Issued: 12/20/1994
• Est. Priority Date: 07/16/1992
• Status: Expired due to Fees

• Current Assignee: Vladislay A. Babinsky, Warren G. Mumford
• Original Assignee: Vladislay A. Babinsky, Warren G. Mumford
• Inventors: Babinsky, Vladislay A., Mumford, Warren G.
• Primary Examiner(s): Ryan, Patrick J.
• Assistant Examiner(s): Krynski, William A.
• Application Number:
  US08/220,479
• Time in Patent Office: 264 Days
• Field of Search: 162/109, 162/115, 162/117, 162/204, 162/206, 162/205, 162/362, 428/166, 428/172, 428/178, 428/179, 428/182, 428/184, 428/195, 428/154
• US Class Current: 428/172
• CPC Class Codes: B31F 1/20 Corrugating; Corrugating combined with laminating to other layers
• CPC Class Codes: B32B 2250/26 All layers being made of paper or paperboard
• CPC Class Codes: B32B 2439/62 Boxes, cartons, cases
• CPC Class Codes: B32B 29/005 next to another layer of paper or cardboard layer
• CPC Class Codes: B32B 29/08 Corrugated paper or cardboard
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 428/24562 Interlaminar spaces
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/24661 Forming, or cooperating to form cells
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Abstract

A method and apparatus for making an embossed or dimpled combined board is disclosed. The combined board has two outer or facing layers or webs of paperboard which sandwich an embossed or dimpled middle paperboard layer or web. The middle web is embossed by passing it over two apertured vacuum drums. Embossments extending in one direction are vacuum formed on one surface of the middle web by the first vacuum drum, while embossments extending in the opposite direction are formed on the other surface of the middle web by the second vacuum drum. The embossments, i.e., concave and convex impressions, are located in a generally chess board pattern. The vacuum openings or apertures of the second drum are larger (larger average diameter) than those of the first drum, to thereby compensate for diminishing flexibility of the middle web due to drying as it passes sequentially over the first and second vacuum drums. This vacuum opening size difference permits the formation of embossments of equal height on both surfaces of the middle web. Preferably each of the three webs are fed directly from a paperboard making apparatus and the combined board formed prior to final drying of the webs. Alternatively, the middle web may be wetted if already fully or partially dried prior to forming the embossments. While being deformed by the vacuum drums, an external source of heat or radiation, such as steam, hot air, infrared lamps, or the like, may be directed to the web such that the web is concurrently dried as it is being deformed to form the embossments or dimples.

Claims

1. A laminate including three layers of paperboard, two outermost of the layers being flat, the inner layer sandwiched by the two outermost layers, the inner layer having a first set of embossments all of which extend upwardly and a second set of embossments all of which extend downwardly, both sets of embossments having tips which are adhered to respective of said flat outermost layers, the average diameters of the embossments of one set being larger than the average diameters of the embossments of the other set, the embossments of said first set being non overlapping with the embossments of said second set, the two sets of embossments forming a chess board pattern.

2. The laminate of claim 1 wherein both sets of embossments are of substantially the same height.

3. The laminate of claim 1 wherein both sets of embossments are of substantially the same shape.

4. The laminate of claim 1 wherein not all of the embossments are of the same shape.

5. A laminate including two layers of paperboard, one of the layers being flat, the other layer having a first set of embossments all of which extend upwardly and a second set of embossments all of which extend downwardly, both sets of embossments having tips, the tips of one of said sets being adhered to said flat layer, the average diameters of the embossments of one set being larger than the average diameters of the embossments of the other set, the embossments of said first set being non overlapping with the embossments of said second set, the two sets of embossments forming a chess board pattern.

6. The laminate of claim 5 wherein both sets of embossments are of substantially the same height.

7. The laminate of claim 5 wherein both sets of embossments are of substantially the same shape.

8. The laminate of claim 5 wherein not all of the embossments are of the same shape.