AU625378B2 - Improvements relating to moulded paperboard - Google Patents
Improvements relating to moulded paperboard Download PDFInfo
- Publication number
- AU625378B2 AU625378B2 AU45732/89A AU4573289A AU625378B2 AU 625378 B2 AU625378 B2 AU 625378B2 AU 45732/89 A AU45732/89 A AU 45732/89A AU 4573289 A AU4573289 A AU 4573289A AU 625378 B2 AU625378 B2 AU 625378B2
- Authority
- AU
- Australia
- Prior art keywords
- laminate
- corrugated
- coated layer
- contact
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Ceased
Links
- 239000011087 paperboard Substances 0.000 title claims description 14
- 238000000034 method Methods 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 10
- 229920005989 resin Polymers 0.000 claims description 8
- 239000011347 resin Substances 0.000 claims description 8
- 229920002472 Starch Polymers 0.000 claims description 4
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 235000019698 starch Nutrition 0.000 claims description 4
- 239000008107 starch Substances 0.000 claims description 4
- 239000000853 adhesive Substances 0.000 claims description 3
- 230000001070 adhesive effect Effects 0.000 claims description 3
- 238000010276 construction Methods 0.000 claims description 3
- 238000003825 pressing Methods 0.000 claims description 3
- 241000274582 Pycnanthus angolensis Species 0.000 claims description 2
- 210000002837 heart atrium Anatomy 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 15
- 229920001169 thermoplastic Polymers 0.000 description 6
- 239000004416 thermosoftening plastic Substances 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 2
- -1 polyethylene Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 235000009917 Crataegus X brevipes Nutrition 0.000 description 1
- 235000013204 Crataegus X haemacarpa Nutrition 0.000 description 1
- 235000009685 Crataegus X maligna Nutrition 0.000 description 1
- 235000009444 Crataegus X rubrocarnea Nutrition 0.000 description 1
- 235000009486 Crataegus bullatus Nutrition 0.000 description 1
- 235000017181 Crataegus chrysocarpa Nutrition 0.000 description 1
- 235000009682 Crataegus limnophila Nutrition 0.000 description 1
- 235000004423 Crataegus monogyna Nutrition 0.000 description 1
- 240000000171 Crataegus monogyna Species 0.000 description 1
- 235000002313 Crataegus paludosa Nutrition 0.000 description 1
- 235000009840 Crataegus x incaedua Nutrition 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000002655 kraft paper Substances 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
- B31F1/0077—Shaping by methods analogous to moulding, e.g. deep drawing techniques
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
- B31F1/20—Corrugating; Corrugating combined with laminating to other layers
- B31F1/24—Making webs in which the channel of each corrugation is transverse to the web feed
- B31F1/26—Making webs in which the channel of each corrugation is transverse to the web feed by interengaging toothed cylinders cylinder constructions
- B31F1/28—Making webs in which the channel of each corrugation is transverse to the web feed by interengaging toothed cylinders cylinder constructions combined with uniting the corrugated webs to flat webs ; Making double-faced corrugated cardboard
- B31F1/2804—Methods
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
Description
i L r 6 25 3 7 COMMONWEALTH OF AUSTRALIA PATENTS ACT 1952 COMPLETE SPECIFICATION (Original) Class Int. Class Application Number: PJ 1731 Lodged: 1ST DECEMBER, 1988 Complete Specification Lodged: Accepted: Published: Priority: Related Art: Name of Applicant: EMHART AUSTRALIA PTY. LTD.
I
S2' Address of Applicant: P.O. BOX 50, THOMASTOWN, VICTORIA 3074,
AUSTRALIA
Actual Inventor: MICHAEL PRATLEY Address for Service: WATERMARK PATENT TRADEMARK ATTORNEYS, THE ATRIUM, 290 BURWOOD ROAD, HAWTHORN, VICTORIA 3122, AUSTRALIA S Complete Specification for the invention entitled: IMPROVEMENTS RELATING TO MOULDED PAPERBOARD
I
The following statement is a full description of this invention, 4' including the best method of performing it known to us.
-iii i
'I
2 IMPROVEMENTS RELATING TO MOULDED PAPERBOARD This invention relates to a method and apparatus for manufacturing moulded paperboard panels useful in interior head lining and door linings and other furniture of motor cars.
There is considerable prior art on this subject as exemplified by Australian Patent Specification Nos. 562471 and 536688 relating to starch bonding and resin bonded boards. Also we refer to Australian Patent Nos. 484,085 (113794/76) relating to a curved paperboard process with thermoplastic resin layers treated by application of heat; 503,583 (26340/77) relating to a method of pressing a flat blank into a curved 1 0 portion which is inelasticafly compressed to eliminate creases; 492,630 (26880/77) relating to a trim panel with a substrate and a skin layer for decorative effects using S thermoplastic adhesive; 505,817 (35908/78) relating to a double sided thermoplastic to create relative displacement uilier heat and pressure conditions; 508,862 S (39754/78) relating to a method feeding a facing layer into a die to be pressed against 01 $1 paperboard; 505,213 (39873/78) relating to thermoplastic bonded paperboard S pre-heated prior to positioning in die.
Reference is also made to U.S, Patent Nos. 3,920,496 and 3,723,222.
""The present invention seeks to provide a moulded paperboard structure having the ideal combination of strength and moisture proofing at least the equal of prior art products whilst being capable of manufacture relatively cheaply.
0- There is provided according to the present invention a method of producing a mouldable paperboard structure comprising the steps of forming a non-resin bonded S corrugated board laminate, formed from a planar base sheet and a corrugated sheet, applying a layer having a heat sensitive coating thereon to the exposed corrugated surface of the corrugated board laminate to bring the heat sensitive coating into contact with I points of contact on the corrugated board laminate, placing and pressing the laminate and coated layer between a pair of heated dies to bond the coated layer to the corrugated laminate at said points of contact between the coated layer and the corrugated laminate, said coated layer forming a decorative or like surface on the paper board structure, Conveniently the non-resin bonded material is adhered by starch or the like low cost adhesive as used in lox cost box board construction.
The laminate so formed Is flexible and may be m e to jqVeRtAit ape pri to S7 Rp 992 I i 7 r TENT? ii j, r ;1 -I 1 3 application of the decorative or like outer layer to the laminate.
The invention wi!S now be described in greater detail with reference to proposed methods tf manufacture as follows: In the drawings Figure 1 is a perspective view of the base corrugated laminate and single layer; Figure 2 is a cross-sectional view of the completed lamimra.i; Figure 3 is an exploded view showing the various layers; and Figure 4 is a schematic view of a shaping die with the laminate inserted therein.
The substrate panel is made by forming a non-resin bonded single faced 1 0 corrugated sheet 11 on a base layer 10 to a desired shape and then bonding a skin of Spolyethylene coated material 12 to the open corrugated surface of the single faced S° structure. This coated material upon cooling will render the structure quite rigid in its desired shape.
Subsequently a skin 13, which may be a decorative panel material of non-woven S 1 15 fibre construction for example, is applied to the formed structure or alternatively the decorative layer may be integrally formed with the skin of the thermoplastic layer.
o*r, The polyethylene coated material may be Kraft high load bearing paper suitable for maintaining the structure in its desired shape.
Alternatively, the decorative panel material may be applicable directly to the 2 0 open corrugated surface of the non-resin bonded structure.
p S In both forms the panel material will embody a skin of polyethylene material for adhesion to the corrugated surface or to the formed structure upon application of heat.
64. In a practical arrangement of the invention, the thermoplastic layer 12 will react to heat applications in the range of 1050 to 150 0 C. The resin is preferably a thermoplastic, however, it is possible in some applications for thermosetting plastic to be S utilised. The forming dies 14 may be of any desired shape and are utilized to mould the laminate to a desired shape simultaneously with the application of the decorative or like surface layer to the laminate. The shape depicted is for a typical motor vehicle head-lining.
Accordingly, it will be appreciated that the finished corrugated laminate structure will have the twin virtue of incorporating a roi!t!vely cheap starch bonded laminate base, coupled with a waterproof therroplastic outer layer which may 2
A
Ii..
4 incorporate a decorative or high strength finish, suitable for use in interior decor of a motor vehicle or the like.
00 0 @6 9 Q 6040 0 4 91]
Claims (4)
1. A method of producing a mouldable paperboard structure comprising the steps of forming a non-resin bonded corrugated board laminate formed from a planar base sheet and a corrugated sheet, applying a layer having a heat-sensitive coating thereon to the exposed corrugated surface of the corrugated board laminate to bring the heat sensitive coating into contact with points of contact on the corrugated board laminate, placing and pressing the laminate and coated layer between a pair of heated dies to bond the coated layer to the corrugated laminate at said points of contact between the coated layer and the corrugated laminate, said coated layer forming a decorative or like surface on the paper board structure. *1
2. A method as claimed in Claim 1, wherein the non-resin bonded material is adhered by starch or the like low cost adhesive as used in box board construction. o S
3. A method as claimed in Claim 1 or Claim 2, wherein the laminate is formed from flexible materials and moulded to a desired shape in a mould simultaneously with the application of said coated layer to the corrugated laminae.
4. The product of the method as claimed In any one of Claims 1 to 3. S* DATED this 2nd day of April, 1992. EMHART AUSTRALIA PTY. LTD. WATERMARK PATENT TRADEMARK ATTORNEYS THE ATRIUM 290 BURWOOD ROAD HAWTHORN, VICTORIA 3122 AUSIBAL[ LJD:BB ,T t I 9 !I a\I i
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AUPJ173188 | 1988-12-01 | ||
| AUPJ1731 | 1988-12-01 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| AU4573289A AU4573289A (en) | 1990-06-07 |
| AU625378B2 true AU625378B2 (en) | 1992-07-09 |
Family
ID=3773551
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU45732/89A Ceased AU625378B2 (en) | 1988-12-01 | 1989-12-01 | Improvements relating to moulded paperboard |
Country Status (1)
| Country | Link |
|---|---|
| AU (1) | AU625378B2 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1995035204A1 (en) * | 1994-06-20 | 1995-12-28 | Newark Group Industries, Inc. | Method for forming corrugated paper container and container made therefrom |
| EP1188688A1 (en) * | 2000-09-15 | 2002-03-20 | Ekco Packaging Limited | A container for food |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3723222A (en) * | 1970-05-01 | 1973-03-27 | Mitsui Petrochemical Ind | Process for manufacturing corrugated thermoplastic synthetic resin cardboard sheet |
| US3920496A (en) * | 1972-02-22 | 1975-11-18 | Michael C Wilkinson | Corrugated paperboard and its method of manufacture |
| EP0341652A2 (en) * | 1988-05-10 | 1989-11-15 | Manville Corporation | Corrugated paperboard automative liner |
-
1989
- 1989-12-01 AU AU45732/89A patent/AU625378B2/en not_active Ceased
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3723222A (en) * | 1970-05-01 | 1973-03-27 | Mitsui Petrochemical Ind | Process for manufacturing corrugated thermoplastic synthetic resin cardboard sheet |
| US3920496A (en) * | 1972-02-22 | 1975-11-18 | Michael C Wilkinson | Corrugated paperboard and its method of manufacture |
| EP0341652A2 (en) * | 1988-05-10 | 1989-11-15 | Manville Corporation | Corrugated paperboard automative liner |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1995035204A1 (en) * | 1994-06-20 | 1995-12-28 | Newark Group Industries, Inc. | Method for forming corrugated paper container and container made therefrom |
| EP1188688A1 (en) * | 2000-09-15 | 2002-03-20 | Ekco Packaging Limited | A container for food |
Also Published As
| Publication number | Publication date |
|---|---|
| AU4573289A (en) | 1990-06-07 |
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