System and method for forming carton blanks

• US 5,783,030 A
• Filed: 01/17/1996
• Issued: 07/21/1998
• Est. Priority Date: 12/21/1992
• Status: Expired due to Term

• Current Assignee: Graphic Packaging International LLC (Graphic Packaging International Incorporated)
• Original Assignee: Graphic Packaging Corporation (Graphic Packaging International Incorporated)
• Inventors: Walsh, Joseph C.
• Primary Examiner(s): STEMMER, DANIEL J
• Application Number:
  US08/587,495
• Time in Patent Office: 916 Days
• Field of Search: 156/522, 156/549, 156/554, 156/555, 156/578, 156/301, 156/302, 156/303, 156/324, 156/270, 156/271, 493/110, 493/132, 493/335, 493/337
• US Class Current: 156/549
• CPC Class Codes: B31B 2105/001 made from laminated webs, e.g. including laminating the webs
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/1292 selectively, e.g. in stripes, in patterns B32B37/0076 takes precedence
• CPC Class Codes: B65D 5/563 Laminated linings; Coatings
• CPC Class Codes: Y10T 156/1095 Opposed laminae are running length webs
• CPC Class Codes: Y10T 156/1098 Feeding of discrete laminae from separate sources
• CPC Class Codes: Y10T 156/1727 Plural indefinite length or running length workpieces
• CPC Class Codes: Y10T 156/1739 Webs of different width, longitudinally aligned
• CPC Class Codes: Y10T 156/1741 Progressive continuous bonding press [e.g., roll couples]
• CPC Class Codes: Y10T 156/1798 with liquid adhesive or adhesive activator applying means

Abstract

Apparatus and method for forming a laminate comprising a relatively rigid material having an inner surface with at least one portion thereof comprising a central body portion and wherein the central body portion of a relatively flexible material, preferably fluid impervious, is secured to the central body portion of the relatively rigid material and the relatively flexible material has opposite edge portions not secured to other portions of the inner surface and to carton blanks formed therefrom. In some instances strips of another relatively flexible material are secured to the opposite edge portions but are not secured to the inner surface.

Claims

1. A system for forming a laminate of materials comprising:

a pair of laminating rolls having facing portions to form a nip therebetween;

first feeding means which feed a continuous strip of a relatively rigid material into said nip;

second feeding means which feed a continuous film of a relatively flexible fluid impervious material into said nip;

said continuous strip of a relatively rigid material and said continuous film of a relatively flexible fluid impervious material having substantially the same transverse width;

third feeding means which feed a plurality of continuous strips of a relatively flexible material in spaced apart relationship into said nip and located between said continuous strip of a relatively rigid material and said continuous film of a relatively flexible fluid impervious material;

coating means which apply a coating of an adhesive material as required so that said pair of laminating rolls secures said plurality of continuous strips of a relatively flexible material only to spaced apart portions of said continuous film of a relatively flexible fluid impervious material and other portions of said continuous film of a relatively flexible fluid impervious material to portions of said continuous strip of a relatively rigid material as they pass through said nip; and

processing apparatus for further processing said laminated material.

2. The system of claim 1 wherein:

said coating means applies said adhesive coating to exposed surfaces of said plurality of continuous strips of a relatively flexible material and said continuous strip of a relatively rigid material as they pass through said nip.

3. A system for forming a laminate of materials comprising:

a driven coating applicator roll mounted at a fixed location for rotational movement;

said coating applicator roll having a raised body portion for use in transferring coating materials;

coating means which apply an adhesive coating to said raised body portion;

an idler roll mounted for rotational movement and for applying pressure on said raised body portion;

first feeding means which feed a continuous film of a relatively flexible fluid impervious material between said coating applicator roll and said idler roll to apply a coating of adhesive on said continuous film of a relatively flexible fluid impervious material;

a first roll mounted at a fixed location for rotational movement in one direction;

a second roll mounted adjacent to said first roll for rotational movement in an opposite direction for forming a nip therebetween so that said first and second rolls are moving in the same direction at said nip;

at least second feeding means which feed a plurality of relatively narrow continuous strips of a relatively flexible material into a superposed relationship with spaced apart portions of said adhesive coated surface of said continuous film of a relatively flexible fluid impervious material and leaving exposed portions of said adhesive coated surface of said continuous film of a relatively flexible fluid impervious material and at least a third feeding means which feed a continuous strip of a relatively rigid material having a transverse width substantially the same as the transverse width of said continuous film of a relatively flexible fluid impervious material in a superposed relationship with said plurality of relatively narrow continuous strips of a relatively flexible material and said exposed portions of said continuous film of a relatively flexible fluid impervious material so that said adhesive coated continuous film of a relatively flexible fluid impervious material, said plurality of relatively narrow continuous strips of a relatively flexible material in spaced apart relationship and said continuous strip of a relatively rigid material having a transverse width substantially the same as the transverse width of said continuous film of a relatively flexible fluid impervious material move between said first roll and said second roll to laminate and secure together said plurality of spaced apart, relatively narrow continuous strips of a relatively flexible material to said spaced apart portions of said adhesive coated continuous film of a relatively flexible fluid impervious material and portions of said continuous strip of a relatively rigid material to said exposed portions of said continuous film of a relatively flexible fluid impervious material; and

processing apparatus for further processing said laminated materials.

4. The system of claim 3 wherein:

said coating applicator roll applies said adhesive coating to the bottom surface of said continuous film of a relatively flexible fluid impervious material; and

inverting means for inverting said continuous film of a relatively flexible fluid impervious material so that said bottom surface becomes a top surface.

5. The system of claim 4 wherein:

said raised body portion comprises the entire outer surface of said applicator roll.

6. The system of claim 4 wherein:

said raised body portion comprises two circumferentially extending edge portions; and

a plurality of spaced apart axially extending portions extending into said two circumferentially extending edge portions.

7. A method for forming carton blanks comprising:

feeding a continuous film of a relatively flexible fluid impervious material between a coating applicator roll having at least one raised body portion and an idler pressure applying roll;

coating said at least one raised body portion with an adhesive material;

transferring at least a portion of said adhesive material from said at least one raised body portion to coat at least one surface of said continuous film of a relatively flexible fluid impervious material with said adhesive material;

feeding said adhesive coated continuous film of a relatively flexible fluid impervious material, a plurality of strips of a relatively flexible material in spaced apart relationship and a continuous strip of a relatively rigid material having a transverse width substantially the same as the transverse width of said continuous film of a relatively flexible fluid impervious material between a drive roll and an idler pressure applying roll to adhesively secure together said plurality of continuous strips of a relatively flexible material to portions of said continuous film of a relatively flexible fluid impervious material and portions of said continuous strip of a relatively rigid material to other portions of said continuous strip of a relatively flexible fluid impervious material; and

forming cut lines and fold lines in said laminated materials to produce a carton blank.

8. The method of claim 7 wherein said plurality of continuous strips of a relatively flexible material comprises at least two spaced apart strips having substantially the same width and at least one strip centrally located between said at least two spaced apart strips and having a width twice as great as the width of either of said at least two spaced apart strips comprising:

cutting said at least one strip in half to form two continuous strips of said laminated material each having a central body portion comprising laminated portions of said continuous strip of a relatively rigid material and said relatively flexible fluid impervious material and opposite edge portions, each of said opposite edge portions comprising laminated portions of said relatively flexible fluid impervious material and said continuous strip of said relatively flexible material overlying edge portions of said continuous strip of relatively rigid material.

9. The method of claim 8 and further comprising:

folding said opposite edge portions of said laminated portions of said relatively flexible fluid impervious material and said continuous strip of a relatively flexible material over portions of said central body portion; and

forming cut lines in said edge portions of said continuous strip of a relatively rigid material to provide for top and bottom panel portions.

10. A method for forming carton blanks comprising:

mounting a pair of laminating rolls to form a nip therebetween;

feeding a continuous strip of a relatively rigid material into said nip;

applying an adhesive coating to one surface of a continuous film of a relatively flexible fluid impervious material;

feeding said adhesive coated continuous film of a relatively flexible fluid impervious material into said nip with said strip of a relatively rigid material and said continuous film of a relatively flexible fluid impervious material having substantially the same transverse width;

feeding a plurality of strips of a relatively flexible material in spaced apart relationship into said nip and located between portions said continuous strip of a relatively rigid material and portions of said continuous film of a relatively flexible fluid impervious material;

securing together said plurality of continuous strips of a relatively flexible material only to portions of said continuous film of a relatively flexible fluid impervious material and other portions of said continuous film of a relatively flexible fluid impervious material to portions of said continuous strip of a relatively rigid material; and

forming cut and fold lines in said laminated materials to produce a carton blank.