High bulk laminated board using embossed plies and the method of manufacture

• US 8,900,393 B2
• Filed: 02/14/2008
• Issued: 12/02/2014
• Est. Priority Date: 02/14/2007
• Status: Active Grant

• Current Assignee: 3A Composites GmbH (Schweiter Technologies AG)
• Original Assignee: 3A Composites GmbH (Schweiter Technologies AG)
• Inventors: Adie, Victor
• Primary Examiner(s): Squalls, Margaret
• Application Number:
  US12/527,262
• Publication Number:
  US 20100028611A1
• Time in Patent Office: 2,483 Days
• Field of Search: 156/219, 156/210, 156/206, 156/209, 156/222, 156/264, 156/290, 156/292, 156/535, 428/166
• US Class Current: 156/219
• CPC Class Codes: B31F 1/07 Embossing , i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profilesB31F1/128 takes precedence; corrugating B31F1/20; embossing in combination with printing B41F19/02, B41M1/24; typewriters for embossing B41J3/38; stamping in combination with deforming B41K3/36
• CPC Class Codes: B31F 2201/0766 the layers being superposed tip to tip
• CPC Class Codes: B31F 2201/0769 the layers being shifted
• CPC Class Codes: B31F 2201/0787 Applying adhesive
• CPC Class Codes: B32B 2317/12 Paper, e.g. cardboard
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 29/00 Layered products comprising a layer of paper or cardboard
• CPC Class Codes: B32B 29/005 next to another layer of paper or cardboard layer
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 37/20 involving the assembly of continuous webs only
• CPC Class Codes: B32B 38/0036 Heat treatment for heating or cooling of layers during lamination B32B37/06, B32B37/08
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 156/1018 Subsequent to assembly of laminae
• CPC Class Codes: Y10T 156/1025 to form undulated to corrugated sheet and securing to base with parts of shaped areas out of contact
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 156/1044 of parallel stacked sheets only
• CPC Class Codes: Y10T 156/1075 of plural laminae from single stock and assembling to each other or to additional lamina
• CPC Class Codes: Y10T 156/14 Surface bonding means and/or assembly means with shaping, scarifying, or cleaning joining surface only
• CPC Class Codes: Y10T 428/24562 Interlaminar spaces

Abstract

A high bulk laminated board is produced using one or more embossed plies. A method of producing the laminated board comprises: embossing first and second plies to produce first embossed projections extending from first sides of the first and second plies; placing adhesive on the first embossed projections on the first side of each of the first and second embossed plies; bringing the first and second plies together such that the first embossed projections on the first and second embossed plies are aligned; applying pressure to the first side of each of the first and second embossed plies to cause the first and second embossed plies to adhere together to form a composite ply; and adhering first and second flat outer plies onto first and second sides of the composite ply. Corresponding apparatus is provided.

Claims

1. method of producing a laminated board for use in the production of large displays, show-cards, graphic panels and the like, comprising:

embossing first and second plies to produce raised projections and recessed depressions in each of the first and second plies;

placing adhesive on the raised projections of each of the first and second embossed plies;

bringing the first and second plies together to be attached by the raised projections;

applying pressure to the tops of the raised projections to cause the first and second embossed plies to adhere together to form a composite ply; and

adhering first and second flat outer plies simultaneously onto first and second sides of the composite ply,

wherein the raised projections and recessed depressions in each of the first and second plies are produced in an alternating symmetrical manner along both a length and a width of the first and second plies, and

wherein the recessed depressions in each of the first and second plies are aligned during the step of bringing the first and second plies together to form projections extending from the first and second sides of the composite ply, and wherein the first and second flat outer plies are adhered to the projections extending from the first and second sides of the composite ply.

2. The method of claim 1, further comprising conditioning the first and second plies by the addition of steam before embossing the first and second plies, and wherein the conditioning of both the first and second plies is carried out at substantially equal distances from a location at which embossing of the plies takes place.

3. The method of claim 1, further comprising preheating each outer ply before pressing each said outer ply to a respective side of the composite ply, wherein the preheating of the outer plies takes place at locations which are spaced at substantially equal distances from a location for pressing the outer plies to the composite ply.

4. The method of claim 1, where placing the adhesive on the first and second plies is carried out at substantially equal distances from a location at which pressure is applied to the tops of the raised projections.

5. The method of claim 1, wherein the first and second plies are embossed in a two-dimensionally symmetrical pattern.

6. The method of claim 1, wherein the embossing of the first and second plies comprises feeding the first and second plies into embossing rollers that intermesh to emboss the first and second plies to have the same construction both across and along a direction of the embossing rollers.

7. The method of claim 1, wherein raised projections and recessed depressions in each of the first and second plies have a cup and ball profile.

8. The method of claim 1, wherein a center ply is introduced between the first and second embossed plies.