WO2012021073A1 - Improvements in and relating to composite sheet material - Google Patents

Improvements in and relating to composite sheet material Download PDF

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Publication number
WO2012021073A1
WO2012021073A1 PCT/NZ2011/000156 NZ2011000156W WO2012021073A1 WO 2012021073 A1 WO2012021073 A1 WO 2012021073A1 NZ 2011000156 W NZ2011000156 W NZ 2011000156W WO 2012021073 A1 WO2012021073 A1 WO 2012021073A1
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WO
WIPO (PCT)
Prior art keywords
svacm
cutting
closed cell
cutting roller
roller
Prior art date
Application number
PCT/NZ2011/000156
Other languages
French (fr)
Inventor
Patrick Petrus Antoniuous Maria Van Berlo
Ceri Peter Keston Wells
Original Assignee
Corcel Ip Limited
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Corcel Ip Limited filed Critical Corcel Ip Limited
Publication of WO2012021073A1 publication Critical patent/WO2012021073A1/en

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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
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D3/00—Making articles of cellular structure, e.g. insulating board
    • B31D3/02—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section
    • B31D3/0223—Making honeycomb cores, e.g. by piling a plurality of web sections or sheets
    • B31D3/023—Making honeycomb cores, e.g. by piling a plurality of web sections or sheets by cutting webs longitudinally into strips, piling these strips and uniting them along lines perpendicular to the cuts
    • B31D3/0238—Making honeycomb cores, e.g. by piling a plurality of web sections or sheets by cutting webs longitudinally into strips, piling these strips and uniting them along lines perpendicular to the cuts involving laminating the expanded core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/13—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board all layers being exclusively wood
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/44—Number of layers variable across the laminate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/08—Closed cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles

Definitions

  • the present invention relates to improvements in and relating to composite sheet material.
  • composite board from single or double face corrugated paperboard
  • Xanita board as manufactured by Xanita of South Africa is a composite board referred to as a close cell coreboard.
  • This closed cell coreboard is manufactured from adjacent strips of single or double face corrugated paperboard which form a core which is sandwiched between two liner sheets so that the flutes/channels run vertically (i.e. the corrugations of the core intersect the liner sheets substantially orthogonally).
  • composite board provides an ideal medium for applying high quality graphic images for high end marketing purposes, such as point of sale displays and billboards: to name a few.
  • Xanita board as is detailed in WO2007052228 is very labour intensive and expensive. It would therefore be useful if there was provided a more cost effective alternative to Xanita board or like products.
  • a further drawback with Xanita board is the fact it uses a hot melt adhesive which requires 150 degrees of heat and is very dangerous to handle due to the chemicals involved. Moreover, the use of hot melt adhesive makes recycling difficult as hot melt adhesives are difficult to recycle
  • a further drawback with Xanita board is that it is typically around 5mm, 10mm or 16mm thick compared with only 3-4mm thickness for standard corrugated paperboard/cardboard.
  • Xanita board is a lot stronger than standard corrugated paperboard/cardboard, this strength comes at a price in terms of the relative space occupied by the material.
  • the extra space occupied by Xanita board is of concern to any exporters who might want to use packaging made from Xanita board for its additional strength. As exporters typically pay for transportation based upon the volume or weight being shipped, carted, or air freighted.
  • closed cell coreboard refers to composite paper board which has at least one first liner sheet and at least one second liner sheet which respectively sandwich a core having a plurality of cells there between.
  • closed cell coreboard includes honeycomb paper board which has a honeycomb core, or X-board as is manufactured by Xanita of South Africa, or 3CTM board as manufactured by Corcel.
  • X- board and 3CTM board are composite boards comprising a core manufactured from adjacent strips of laminated layers of single or double face corrugated paperboard sandwiched between two liner sheets so that the flutes run orthogonally (i.e. the flute channels extend from the top liner sheet to the bottom liner sheet).
  • the term 'edge surface' as used herein with reference the strips of vertical axis channel material (SVACM) refers to the face of strips where the top or bottom edge of the cells of each layer are visible.
  • 'strips of vertical axis channel material' and 'SVACM refers to a plurality of strips of material made from either:
  • a closed cell coreboard which includes: upper and lower liner sheets each bonded so as to sandwich a core layer said core layer comprising a plurality of adjacently abutted end aligned strips of vertical axis flute material (SVACM); characterised in that the SVACM have at least one edge surface which include(s) a plurality of projections formed there along which are: folded; or can become folded during lamination, to the upper and lower liner sheets.
  • SVACM vertical axis flute material
  • a closed cell coreboard substantially as described above wherein the SVACM is bonded to at least one upper, and at least one lower, liner sheet, wherein the respective upper and lower liner sheets are bonded on opposite edge surfaces of the SVACM so as to sandwich the core there between.
  • a closed cell coreboard which includes:
  • SVACM vertical axis channel material
  • the liner sheets and SVACM may preferably be made from Kraft paper.
  • the liner sheets and SVACM can be made from recycled paper or cardboard. It should also be appreciated that the liner sheets could be made from other sheet materials. It will be appreciated that where a high strength board is required virgin Kraft paper will be used as opposed to recycled paper. Additionally, in some embodiments as discussed below multiple layers of liner sheets may be bonded to one or both edge surfaces of the SVACM.
  • the SVACM may be formed by cutting pre-laminated corrugated sheet material or pre-laminated honeycomb board into strips and re-orienting so the channels are vertically positioned.
  • a strip of vertical flute material which includes:
  • the SVACM prior to being cut by the cutting roller(s) may be substantially 5 -7mm in height from top edge surface to bottom edge.
  • the projections can become flaps when folded/flattened during the lamination process to liner sheets and this has the effect of increasing the effective surface area of the core layer which is available to be bonded to the liner sheets.
  • the projections may preferably extend substantially 0.5mm to 2.5mm from a putative fold line. Preferably, the projections may span substantially 2.5mm across.
  • the composite closed cell coreboard of the present invention may be considered a type of: paperboard or cardboard product, depending on the grade of sheet material being used. However, other types of sheet material may be used.
  • the adhesive used with the present invention may be a water-based dispersion containing vinyl acetate copolymer.
  • a water-based adhesive containing vinyl acetate copolymer in dispersion is a non- hazardous substance, and can therefore be used safely provided normal ventilation is provided.
  • Vinyl acetate copolymer dispersions can be relatively quick setting at room temperature and do not require a high activation temperature - unlike starch based glues. Vinyl acetate copolymer dispersions have a low viscosity, good adhesion and a long open time. A relatively low viscosity is required to allow the adhesive to flow readily, (e.g., when being transferred from an applicator to the fluted sheet) while a good adhesion provides the ability to adhere quickly to a surface.
  • the open time is a measure of the time, under normal temperature and pressure that the adhesive can have an exposed surface before it loses its ability to wet the opposing surface and penetrate into the opposing surface fibres. This wetting and penetration is required to form an effective bond between the fluted paper and the liner.
  • An adhesive having a relatively long open time is preferred as the adhesive may be open to the atmosphere for some time prior to application to the flutes.
  • the adhesive is AdhesinTM Z9129W or Z9040, a vinyl acetate copolymer supplied by Henkel New Zealand Limited.
  • AdhesinTM Z9129W or Z9040 has the required viscosity, and long open time required for use with the present invention.
  • AdhesinTM Z9129W or Z9040 has a viscosity in the range 2100-2200 m.Pa.S and an open time of between 0.5 to 1 minute.
  • other adhesives having similar properties may also be used.
  • a cutting roller which includes radial corrugations over the surface thereof wherein said ridges of the radial corrugations are configured to form cutting edges.
  • the radial corrugations may be created in a variety of different ways. In some embodiments the corrugations may be created via a single helical groove.
  • the cutting roller has radial corrugations in the form of a right handed helical groove.
  • the cutting roller has radial corrugations in the form of a left handed helical groove.
  • the corrugations may be created by a plurality of radial grooves which are spaced apart.
  • the cutting edge may come in a variety of different forms.
  • the cutting edge may be in the form of a thin flat edge.
  • the thin flat edge may be substantially 0.5mm -1.0mm wide.
  • adjacent cutting edges are spaced between substantially 3mm-5mm apart.
  • the cutting edges may be substantially 3.5mm apart.
  • the cutting edge may be a tapered point.
  • the tapered point may be formed by one or both sides of the ridge.
  • the grooves have a depth of substantially 0.5mm to 3.5mm. Most preferably, the grooves have a depth of substantially 3.5mm.
  • a machine for making a closed cell coreboard from SVACM wherein the machine includes: a first cutting roller which presses down against an edge surface of SVACM oriented with the channels running vertically and wherein the SVACM is supported by a first squeeze roller which has a rotational axis vertically aligned with said first cutting roller; a second cutting roller which presses up against an edge surface of SVACM oriented with the channels running vertically and is supported by a second squeeze roller which has a rotational axis vertically aligned with said second cutting roller; wherein the first and second cutting rollers have radial corrugations over the surfaces thereof wherein said ridges of the radial corrugations form a cutting edge and wherein the machine is configured so the SVACM moves relative to the first and second cutting rollers.
  • the cutting rollers and squeeze rollers have a gap between their respective outer circumferential surfaces which allows the cutting edge to penetrate the edge surface of the SVACM the desired depth.
  • the gap between the cutting roller and the squeeze roller is adjusted so the cutting edge will penetrate substantially 2.5mm into the top edge surface of the SVACM.
  • the sheet material from which the SVACM is made is 250 microns thick this results in a SVACM having a height of substantially 3.75mm following cutting and folding of the projections formed on the SVACM via the cutting rollers.
  • a closed cell coreboard made in accordance with present invention substantially as described herein wherein the sheet material is substantially between 4mm - 4.5mm thick.
  • the squeeze roller may come in a variety of different forms without departing from the scope of the present invention.
  • the squeeze roller may be made from a steel, plastic or other hard wearing material.
  • the squeeze roller has substantially the same length as the cutting roller and is position so that the cutting roller can press down upon the SVAFM to perform the cutting action.
  • a machine substantially as described above wherein the first cutting roller has a left handed helix and the second cutting roller has a right handed helix or vice versa and wherein the first cutting roller is positioned upstream of the second cutting roller relative to the direction in which the SVACM moves past the respective first and second cutting rollers.
  • first and second cutting rollers are positioned to cut a one edge of the SVACM following the bonding of a first liner sheet to the other edge of the SVACM.
  • the cutting rollers may be driven directly or indirectly by a motor.
  • the cutting rollers are driven to rotate at twice the speed of the conveyor bringing SVACM core.
  • a machine for making a closed cell coreboard from SVACM wherein the machine includes: a first cutting roller assembly which causes a first cutting roller to press down against an edge surface of SVACM oriented with the channels of the SVACM running vertically; a second cutting roller assembly which causes a second cutting roller to press up against an edge surface of SVACM; wherein the first and second cutting rollers have radial corrugations over the surfaces thereof wherein said ridges of the radial corrugations form a cutting edge and wherein the machine is configured so that the SVACM moves relative to the first and second cutting rollers and wherein the machine includes: - a glue applicator station where glue is applied to the top and bottom edge surfaces of the SVACM which now include a plurality of projections thereon created by the first and second cutting rollers; and
  • a method of manufacturing a closed cell coreboard from SVACM comprising the step of: a) cutting top and/or bottom edges of the SVACM oriented with the channels (cells) of the SVACM running vertically, via an upper cutting roller and a lower cutting roller; wherein the upper and lower cutting rollers have radial corrugations over the surface thereof wherein said ridges of the radial corrugations form a cutting edge such that when the ridges are brought into contact with the edge surface(s) of the SVACM the ridges produce cuts along the edge surface(s) which in turn create a plurality of projections.
  • a method of making a closed cell coreboard from SVACM comprising the step of using pair of cutting rollers to cut into an edge SVACM wherein the cutting rollers each have radial corrugations over the surface thereof wherein ridges of the radial corrugations form a cutting edge and wherein one cutting roller has radial corrugations forming a right handed helix and the other roller has radial corrugations forming a left handed helix.
  • a method of making a closed cell coreboard substantially as described above including the extra step of gluing an edge surface of the SVACM which has been cut by the pair of rollers to at least one liner sheet.
  • the upper and/or lower cutting rollers are separated from corresponding squeeze rollers by a gap that is adjusted to produce the depth of cut required.
  • a method of making a closed cell coreboard comprising the steps of: a) cutting top and bottom edge surfaces of the SVACM oriented with the corrugations of the SVACM running vertically via an upper cutting roller and a lower cutting roller, wherein the upper and lower cutting rollers have radial corrugations over the surface thereof wherein said ridges of the radial corrugations form cutting edges; b) applying glue to the top and bottom edge surfaces of the SVACM which now include a plurality of projections thereon created by the first and second cutting rollers; c) bonding sheet material to the top and bottom edge surfaces of a plurality of SVACM which collectively form a continuous array/bed of adjacently abutted SVACM.
  • a closed cell coreboard which includes: • a first sheet of material which is selected from particle board, mdf or other wood chip derived composite; and
  • the box has ventilation channel-cut outs which extend from the base of a side wall to the top thereof wherein the coreboard has a thickness of substantially between 4mm-4.5mm.
  • the ventilation channel-cut outs may be similar to that disclosed in the Applicants' earlier filed PCT specification published as WO2010/056137.
  • the box is made from closed cell coreboard material in accordance with the present invention.
  • the box is made from a closed cell coreboard having a thickness of substantially 4mm -4.5mm.
  • the box being constructed from SVACM made of laminated layers of single face paperboard comprising 150gsm corrugating medium and a 125gsm liner sheet.
  • the thickness of the liner sheets bonded to the top and bottom edges of the SVACM will depend on the end use of the closed cell coreboard.
  • the SVACM may be made from 175gsm -275gsm Kraft paper and the liner sheets may be 175gsm - 275 gsm Kraft paper. In general the thicker the paper or board used the stronger the resulting close cell coreboard.
  • a display stand made with a closed cell coreboard substantially as described above.
  • Preferred embodiments of the present invention provide a number of advantages over the prior art which can include: providing a composite board which has increased strength; providing a composite board which is relatively thin (i.e. substantially
  • Figure 1 shows a schematic partial perspective exploded view of a sheet of closed cell coreboard (composite board) in accordance with one preferred embodiment of the present invention
  • Figure 2 shows a side view of the composite board of Figure 1 looking along line A;
  • Figure 3 shows a schematic plan view of a bed of end aligned strips of vertical axis channel material forming the core in the composite board in Figure 1 ;
  • Figure 4 shows a schematic side view of a strip of vertical axis channel material (SVACM) showing what the core looks like viewed along line B in Figure 1 ;
  • SVACM vertical axis channel material
  • FIG. 5a shows a schematic perspective view of the abutted strips of vertical channel material (SVACM) as depicted in Figure 4;
  • Figure 5b shows a schematic top view of the abutted strips of vertical channel material (SVAF ) as depicted in Figure 4;
  • Figure 6 shows a partial perspective view of the SVACM depicted in Figures
  • Figure 7 shows a partial view of a cutting roller in accordance with one preferred embodiment of the present invention
  • Figure 12 shows a partial view of the first cutting roller in Figure 11 having corrugations formed via a right handed helical groove in accordance with a preferred embodiment of the present invention.
  • Figure 13 shows a partial view of the second cutting roller in Figure 11 having corrugations formed via a left handed helical groove in accordance with a preferred embodiment of the present invention.
  • Figures 1 and 2 broadly illustrate the nature of the closed cell coreboard (composite board) of the present invention which is indicated by arrow 1.
  • Figure 3 shows in greater detail the unique SVACM core of the present invention.
  • the composite board 1 is made from Kraft paper and has an upper liner sheet 2 and lower sheet 3 which are bonded to a core layer 4 comprised of a plurality of abutted end aligned strips of vertical channel axis material (SVACM) 5a, 5b, and 5c.
  • the SVACM 5a - 5c are made up of four layers of single face paperboard 5' - 5 IV bonded together which can be seen clearly in Figure 2 and Figure 6.
  • Figure 2 shows the vertical axis line A-A that extends along the channels which in this embodiment are formed between the fluted medium and liner sheets of the single face paperboard forming the layers.
  • the nature of the SVACM core layer is shown in Figure 3.
  • the strips (individual SVACM) 5a - 5c are abutted together to form a bed upon which liner sheet 2 and then liner sheet 3 can be bonded.
  • the ends 101 and 102 of the strips 5a - 5c are end aligned to match the edge of the upper and lower liner sheets (not shown).
  • the corrugations shown by the zig-zag line can clearly be
  • the SVACM generally indicated by arrow 100 have ends 101 and 102.
  • the view shown in Figure 4 is along line B in Figures 1 and.
  • the SVACM has a number of projections 103 on the top and bottom edges thereof.
  • the projections are formed by a roller discussed later in relation to Figure 7 which forms cuts 104 into the top and bottom edge surfaces.
  • the projections 103 become folded /flattened during lamination roughly along putative fold line 105 shown by the dotted lines.
  • the projections 105 become folded/flattened - refer Figure 5 - the projections 103 effectively increase the available surface area for bonding to the liner sheets 2 and 3 shown in Figures 1 and 2.
  • the projections are initially folded/flattened when they come into contact with a glue roller as is discussed in more detail below in relation to Figure 8.
  • FIG 7 there is shown a cutting roller generally indicated by arrow 1000.
  • the cutting roller has radial corrugations generally indicated by arrow 1001 made up of ridges 1002 and grooves 1003.
  • the ridges have a tapered cutting edge 1004.
  • FIG 8 there is provided a machine for making a composite sheet material from strips of vertical axis channel material (SVACM) generally indicated by arrow 5000.
  • SVACM vertical axis channel material
  • the machine has a first conveyor belt assembly 5001 which transports SVACM 5002 in the direction of arrow A.
  • the SVACM 5002 are then delivered onto a slip bridge 5003 which is made of polypropylene (or other low friction surface) over which the SVACM 5002 slide as they are pushed to a first cutting roller assembly 5004.
  • the first cutting roller assembly has a first cutting roller 5005 and a squeeze roller 5006. The gap between the first cutting roller 5005 and squeeze roller 5006 is slightly smaller than the thickness of the SVACM 5002 which passes therethrough.
  • the first cutting roller 5005 cuts notches into the top edge of the SVAFM which creates the projections as previously described and shown in Figures 4 - 6.
  • the SVACM 5002 are then moved by the rotation of the rollers 5005 and 5006 and onto a second slip bridge 5007, before being conveyed by a second conveyor belt assembly 5008 to a first glue application station 5009.
  • the first glue application station 5009 has a doctor roller 5010 and a glue applicator roller 5011 which are counter rotate with respect to one another. Adhesive is pumped from a reservoir (not shown) via conduits (not shown) to deliver adhesive to the region shown by arrow 5200 between the top portion of two rollers 5010 and 5011. The distance the doctor roller 5010 is separated from the glue applicator roller 5011 determines the thickness of the adhesive layer applied by the glue applicator roller 5011. As the glue applicator roller 5011 contacts the top edge surface of the SVACM and applies a layer of adhesive thereto. Any excess adhesive not applied falls off the end of the rollers and is collected by a tray (not shown) and returned to the reservoir and recirculated. Following glue application station 5009 the SVACM then passes to a first laminating station 5012 where sheet material in the form of Kraft paper 500 is laminated to the SVACM via nip rollers 5013 to form single face SVACM board.
  • the single face SVACM board then passes to a second cutting roller assembly 5014 having a second cutting roller 5015 and squeeze roller 5016.
  • the second cutting roller 5015 cuts notches into the bottom edge of the SVACM which creates the projections as previously described and shown in Figures 4 - 6.
  • the cutting rollers 5005 and 5015 are driven by motors not shown that rotate the others at the same speed as the SVACM travels along the first conveyor 5001.
  • the newly formed single face SVACM board then passes a second glue application station 5017 wherein a doctor roller 5018 transfers adhesive to a glue applicator roller 5019.
  • the second glue station operates in substantially the same manner as the first glue application station 5009 discussed above.
  • the glue applicator roller 5019 contacts the bottom edges of the SVACM and applies a layer of adhesive thereto.
  • the single face SVACM board then passes to a second laminating station 5020 where a second sheet material in the form of Kraft paper 501 is laminated to the single face SVACM board via nip roller 5021 and opposed pressure belt assemblies 5022 and 5023: to thereby create composite corrugated sheet material (composite board) 5024.
  • FIG 9 there is provided a cutting roller generally indicated by arrow 6000.
  • the cutting roller 6000 has radial projections 6001 which extend above the circumferential surface 6002 of the cutting roller 6000.
  • the ridges have a tapered cutting edge 6003.
  • the height of the radial projections substantially corresponds to the depth of cut (and hence height of the projections) which will be formed on the SVACM core.
  • the advantage of this configuration of cutting roller is shown in Figure 10. As can been this cutting roller assembly 7000 obviates the need for a squeeze roller and enables two opposed cutting rollers 7001 and 7002 to cut upper and lower edges of the SVAFM simultaneously.
  • FIG 10 there is shown a cutting assembly 7000 which has vertically opposed first and second cutting rollers 7001 and 7002 respectively.
  • the first and second cutting rollers 7001 and 7002 rotate in the direction of arrows A and B respectively.
  • the rollers 7001 and 7002 cut notches 7003 into SVACM 7004 as is most clearly seen in enlargement bubble.
  • the SVACM 7004 is supported as it enters and exits the cutting assembly 7000 via first and second clip bridges 7005 of which only one is shown.
  • FIG. 1 1 there is shown a pair of cutting rollers forming a cutting assembly
  • the cutting assembly has a first cutting roller 10001 and associated squeeze roller 10002 and a second cutting roller 10003 and associated squeeze roller 10004.
  • the cutting rollers and squeeze rollers are fabricated from stainless steel.
  • the cutting assembly cuts notches into the top edge 10005 of the SVAFM 10006 which is bonded on the bottom edge to liner sheet 10007.
  • the SVAFM travels in the direction of arrow A.
  • the individual strips 10008 of SVACM 10006 already present a flat bottom edge as they are bonded to liner sheet 10007.
  • the same is not true for the top edge of the SVAFM where the top edge of each strip is not aligned and instead forms a stepped top edge of the SVACM.
  • FIG. 12 there is shown a first cutting roller 10001 which has corrugations having ridges 12001 which form the cutting edge.
  • the corrugations are formed from a single right handed (clockwise) helical groove when looked at from the direction of arrow B.
  • FIG 13 there is shown a second cutting roller 10003 which has corrugations having ridges 12002 which form the cutting edge.
  • the corrugations are formed from a single left handed (anti-clockwise) helical groove when looked at from the direction of arrow C.
  • This form of closed cell coreboard has a SVACM core made from layers of single face paperboard.
  • the SVACM has a 5mm core in height (thickness) from top edge surface to bottom edge surface.
  • the SVACM core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick and cut into sheets.
  • the top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 1 1 to a depth of 2.0mm.
  • a tri-laminate is formed from two 275gsm Kraft liner sheets which are 250 microns thick and an outer liner sheet of SBS (solid bleached sulphate) board which is 500 microns thick.
  • SBS solid bleached sulphate
  • This tri-layer laminate is left to dry and then is bonded to the top edge surface SVACM so the SBS board forms the outer facing sheet of the art board.
  • Another tri-layer laminate of Kraft board and SBS board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the SVACM. Again the SBS board forms the outer facing sheet.
  • the final step is to press the art board to assist with lamination and this also compresses the art board to a thickness of 5mm.
  • This form of closed cell coreboard has a SVACM core made from layers of single face paperboard.
  • the SVACM has 9.3mm core in height (thickness) from top edge surface to bottom edge surface.
  • the SVACM core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick and then cut into sheets.
  • the top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 11 to a depth of 1.3mm.
  • a tri-laminate is formed from two 275gsm Kraft liner sheets which are 250 microns thick and an outer liner sheet of SBS (solid bleached sulphate) board which is 500 microns thick.
  • SBS solid bleached sulphate
  • Another tri-layer laminate of Kraft board and SBS board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the SVACM. Again the SBS board forms the outer facing sheet.
  • the final step is to press the art board to assist with lamination and this also compresses the art board to a thickness of 10mm.
  • This form of closed cell coreboard has a SVACM dual core made from layers of single face paperboard.
  • the two SVACM cores are 9.3mm in height (thickness) from top edge surface to bottom edge surface.
  • the two SVACM cores are bonded to each other before the bottom edge surface of the resulting double core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick before being cut into sheets.
  • the top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 11 to a depth of 1.3mm.
  • a tri-laminate is formed from two 275gsm Kraft liner sheets which are 250 microns thick and an outer liner sheet of SBS (solid bleached sulphate) board which is 500 microns thick.
  • This tri-layer laminate is left to dry and then is bonded to the top edge surface dual core SVACM so the SBS board forms the outer facing sheet of the art board.
  • Another tri-layer laminate of Kraft board and SBS board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the dual core SVACM. Again the SBS board forms the outer facing sheet.
  • the final step is to press the art board to assist with lamination and this also compresses the art board to a thickness of 20mm.
  • This form of closed cell coreboard has a SVACM core made from layers of single face paperboard.
  • the close cell coreboard is produced via the machine of Figure 8 to have one layer of 275gsm Kraft liner bonded to each side of the SVACM core following cutting of the top and bottom surface edges of the SVACM.
  • This form of closed cell coreboard has a SVACM core made from layers of single face paperboard.
  • the SVACM has a 5mm core in height (thickness) from top edge surface to bottom edge surface.
  • the SVACM core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick and cut into sheets.
  • the top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 11 to a depth of 2.0mm.
  • a tri-laminate is formed from three 275gsm Kraft liner sheets which are 250 microns thick.
  • This tri-layer laminate is left to dry and then is bonded to the top edge surface SVACM. .
  • Another tri-layer laminate of Kraft board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the SVACM.
  • the final step is to press the structural board to assist with lamination and this also compresses the structural board to a thickness of 5mm.
  • Example 6 Thin High Strength Box Close Cell Coreboard
  • This form of closed cell coreboard has a SVACM core made from layers of single face paperboard.
  • the thickness of the SVACM core is 6mm prior to being cut via the cutting rollers which are set to penetrate a depth of 2.5mm.
  • the close cell coreboard is produced via the machine of Figure 8 to have one layer of 275gsm Kraft liner 250 microns thick bonded to each side of the SVACM core following cutting of the top and bottom surface edges of the SVACM.
  • the resulting board has a thickness of substantially 4.25mm which is the same as C Flute paperboard.

Abstract

A closed cell coreboard which includes: at least one upper sheet and/or at least one lower liner sheet; a core layer, said core layer comprising a plurality of adjacently abutted end aligned strips of vertical axis flute material (SVAFM); characterised in that the SVAFM have at least one edge surface which include(s) a plurality of projections formed there along which are folded, or can become folded during lamination to an upper and/or lower liner sheet(s). Also disclosed is a cutting roller which can be rolled over the top and/or bottom surfaces of the SVAFM to provide notches which define the plurality of foldable projections.

Description

IMPROVEMENTS IN AND RELTING TO COMPOSITE SHEET MATERIAL
TECHNICAL FIELD
The present invention relates to improvements in and relating to composite sheet material. BACKGROUND ART
The production of composite sheet material now simply termed composite board from single or double face corrugated paperboard is well known in the art. For example Xanita board as manufactured by Xanita of South Africa is a composite board referred to as a close cell coreboard. This closed cell coreboard is manufactured from adjacent strips of single or double face corrugated paperboard which form a core which is sandwiched between two liner sheets so that the flutes/channels run vertically (i.e. the corrugations of the core intersect the liner sheets substantially orthogonally).
For the avoidance of doubt the terms 'corrugations', 'channels' and 'flutes' or grammatical variants thereof, should be considered equivalent to one another and may be used interchangeably throughout this specification.
The advantages of composite board include its strength and its relative flatness compared with the surface of corrugated paperboard or corrugated cardboard which contains undulations on the surface thereof caused by lamination of the liner sheets to the corrugated core. These undulations adversely affect the print quality of any graphic images applied thereto. Thus, the flat composite board offered by Xanita provides an ideal medium for applying high quality graphic images for high end marketing purposes, such as point of sale displays and billboards: to name a few. However, the production of Xanita board as is detailed in WO2007052228 is very labour intensive and expensive. It would therefore be useful if there was provided a more cost effective alternative to Xanita board or like products. A further drawback with Xanita board is the fact it uses a hot melt adhesive which requires 150 degrees of heat and is very dangerous to handle due to the chemicals involved. Moreover, the use of hot melt adhesive makes recycling difficult as hot melt adhesives are difficult to recycle
In addition to the above, no-one has to date, been able to produce via a single continuous automated process, a composite board which is, to the naked eye, dead flat. Thus, there is a need for a composite board providing a flat surface similar or superior to that offered by Xanita board produced via a single continuous automated process.
A further drawback with Xanita board is that it is typically around 5mm, 10mm or 16mm thick compared with only 3-4mm thickness for standard corrugated paperboard/cardboard. Thus, whilst Xanita board is a lot stronger than standard corrugated paperboard/cardboard, this strength comes at a price in terms of the relative space occupied by the material. The extra space occupied by Xanita board is of concern to any exporters who might want to use packaging made from Xanita board for its additional strength. As exporters typically pay for transportation based upon the volume or weight being shipped, carted, or air freighted.
It would therefore be useful if there could be provided a slim line alternative to Xanita board but one which retains the increased strength characteristics of Xanita board over standard corrugated boxes.
All references, including any patents or patent applications cited in this specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.
Throughout this specification, the word "comprise", or variations thereof such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
It is an object of the present invention to address the foregoing problems or at least to provide the public with a useful choice.
Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only. DEFINITIONS
The term 'closed cell coreboard' as used herein refers to composite paper board which has at least one first liner sheet and at least one second liner sheet which respectively sandwich a core having a plurality of cells there between. Thus, closed cell coreboard includes honeycomb paper board which has a honeycomb core, or X-board as is manufactured by Xanita of South Africa, or 3C™ board as manufactured by Corcel. X- board and 3C™ board are composite boards comprising a core manufactured from adjacent strips of laminated layers of single or double face corrugated paperboard sandwiched between two liner sheets so that the flutes run orthogonally (i.e. the flute channels extend from the top liner sheet to the bottom liner sheet). The term 'edge surface' as used herein with reference the strips of vertical axis channel material (SVACM) refers to the face of strips where the top or bottom edge of the cells of each layer are visible.
The terms 'strips of vertical axis channel material' and 'SVACM ,as used herein interchangeably, refers to a plurality of strips of material made from either:
• laminated layers of single or double face board wherein the axis of the corrugations/channels (which run transverse to the longitudinal axis of the strip) are vertically oriented when the strip is horizontally oriented along its longitudinal axis; or · laminated layers of honeycomb paperboard wherein the axis of the cells/channels (which run transverse to the longitudinal axis of the strip) are vertically oriented when the strip is horizontally oriented along its longitudinal axis.
DISCLOSURE OF THE INVENTION According to a first aspect there is provided a closed cell coreboard which includes: upper and lower liner sheets each bonded so as to sandwich a core layer said core layer comprising a plurality of adjacently abutted end aligned strips of vertical axis flute material (SVACM); characterised in that the SVACM have at least one edge surface which include(s) a plurality of projections formed there along which are: folded; or can become folded during lamination, to the upper and lower liner sheets. According to a second aspect there is provided a closed cell coreboard substantially as described above wherein the SVACM is bonded to at least one upper, and at least one lower, liner sheet, wherein the respective upper and lower liner sheets are bonded on opposite edge surfaces of the SVACM so as to sandwich the core there between.
According to a third aspect there is provided a closed cell coreboard which includes:
- a liner sheet bonded to a core layer, such that said core layer comprises a plurality of adjacently abutted, end aligned, strips of vertical axis channel material (SVACM); characterised in that the SVACM have at least one edge surface which includes a plurality of projections formed there along which are:
- folded; or
- can become folded, during lamination to a liner sheet. In general the liner sheets and SVACM may preferably be made from Kraft paper. However, the liner sheets and SVACM can be made from recycled paper or cardboard. It should also be appreciated that the liner sheets could be made from other sheet materials. It will be appreciated that where a high strength board is required virgin Kraft paper will be used as opposed to recycled paper. Additionally, in some embodiments as discussed below multiple layers of liner sheets may be bonded to one or both edge surfaces of the SVACM.
In general the SVACM may be formed by cutting pre-laminated corrugated sheet material or pre-laminated honeycomb board into strips and re-orienting so the channels are vertically positioned. According to a further aspect of the present invention there is provided a strip of vertical flute material (SVACM) which includes:
- a strip formed from either: a laminate of corrugated single or double face board, or a laminate of honeycomb board; wherein at least one opposed edge surface of the strip include(s) a plurality of projections there along which are:
- folded; or
- can become folded during lamination to the liner sheet(s).
In one preferred embodiment the SVACM prior to being cut by the cutting roller(s) (i.e. SVACM which is sans projections) may be substantially 5 -7mm in height from top edge surface to bottom edge.
It will be appreciated the projections can become flaps when folded/flattened during the lamination process to liner sheets and this has the effect of increasing the effective surface area of the core layer which is available to be bonded to the liner sheets.
The projections may preferably extend substantially 0.5mm to 2.5mm from a putative fold line. Preferably, the projections may span substantially 2.5mm across.
In general the composite closed cell coreboard of the present invention may be considered a type of: paperboard or cardboard product, depending on the grade of sheet material being used. However, other types of sheet material may be used.
In one preferred embodiment the adhesive used with the present invention may be a water-based dispersion containing vinyl acetate copolymer. Although this should not be seen as limiting the scope of the present invention. A water-based adhesive containing vinyl acetate copolymer in dispersion is a non- hazardous substance, and can therefore be used safely provided normal ventilation is provided.
Vinyl acetate copolymer dispersions can be relatively quick setting at room temperature and do not require a high activation temperature - unlike starch based glues. Vinyl acetate copolymer dispersions have a low viscosity, good adhesion and a long open time. A relatively low viscosity is required to allow the adhesive to flow readily, (e.g., when being transferred from an applicator to the fluted sheet) while a good adhesion provides the ability to adhere quickly to a surface. The open time is a measure of the time, under normal temperature and pressure that the adhesive can have an exposed surface before it loses its ability to wet the opposing surface and penetrate into the opposing surface fibres. This wetting and penetration is required to form an effective bond between the fluted paper and the liner. An adhesive having a relatively long open time is preferred as the adhesive may be open to the atmosphere for some time prior to application to the flutes.
Preferably the adhesive is Adhesin™ Z9129W or Z9040, a vinyl acetate copolymer supplied by Henkel New Zealand Limited. The applicant has found that Adhesin™ Z9129W or Z9040 has the required viscosity, and long open time required for use with the present invention. For example, Adhesin™ Z9129W or Z9040 has a viscosity in the range 2100-2200 m.Pa.S and an open time of between 0.5 to 1 minute. However, it is envisaged that other adhesives having similar properties may also be used.
According to a further aspect there is provided a cutting roller which includes radial corrugations over the surface thereof wherein said ridges of the radial corrugations are configured to form cutting edges.
The radial corrugations may be created in a variety of different ways. In some embodiments the corrugations may be created via a single helical groove.
In one preferred embodiment the cutting roller has radial corrugations in the form of a right handed helical groove.
In another preferred embodiment the cutting roller has radial corrugations in the form of a left handed helical groove.
In preferred embodiments the corrugations may be created by a plurality of radial grooves which are spaced apart.
The cutting edge may come in a variety of different forms.
In one preferred embodiment the cutting edge may be in the form of a thin flat edge. Preferably the thin flat edge may be substantially 0.5mm -1.0mm wide.
In one preferred embodiments adjacent cutting edges are spaced between substantially 3mm-5mm apart. Preferably the cutting edges may be substantially 3.5mm apart.
In another preferred embodiment the cutting edge may be a tapered point. The tapered point may be formed by one or both sides of the ridge.
Preferably the grooves have a depth of substantially 0.5mm to 3.5mm. Most preferably, the grooves have a depth of substantially 3.5mm.
According to a still further aspect of the present invention there is provided a machine for making a closed cell coreboard from SVACM wherein the machine includes: a first cutting roller which presses down against an edge surface of SVACM oriented with the channels running vertically and wherein the SVACM is supported by a first squeeze roller which has a rotational axis vertically aligned with said first cutting roller; a second cutting roller which presses up against an edge surface of SVACM oriented with the channels running vertically and is supported by a second squeeze roller which has a rotational axis vertically aligned with said second cutting roller; wherein the first and second cutting rollers have radial corrugations over the surfaces thereof wherein said ridges of the radial corrugations form a cutting edge and wherein the machine is configured so the SVACM moves relative to the first and second cutting rollers.
Preferably, the cutting rollers and squeeze rollers have a gap between their respective outer circumferential surfaces which allows the cutting edge to penetrate the edge surface of the SVACM the desired depth. For example if the SVACM has a height of 6mm the gap between the cutting roller and the squeeze roller is adjusted so the cutting edge will penetrate substantially 2.5mm into the top edge surface of the SVACM. If the sheet material from which the SVACM is made is 250 microns thick this results in a SVACM having a height of substantially 3.75mm following cutting and folding of the projections formed on the SVACM via the cutting rollers. According to a further aspect there is provided a closed cell coreboard made in accordance with present invention substantially as described herein wherein the sheet material is substantially between 4mm - 4.5mm thick.
The squeeze roller may come in a variety of different forms without departing from the scope of the present invention. In general the squeeze roller may be made from a steel, plastic or other hard wearing material. The squeeze roller has substantially the same length as the cutting roller and is position so that the cutting roller can press down upon the SVAFM to perform the cutting action. According to a further aspect there is provided a machine substantially as described above wherein the first cutting roller has a left handed helix and the second cutting roller has a right handed helix or vice versa and wherein the first cutting roller is positioned upstream of the second cutting roller relative to the direction in which the SVACM moves past the respective first and second cutting rollers.
According to a still further aspect there is provided a machine substantially as described above wherein the first and second cutting rollers are positioned to cut a one edge of the SVACM following the bonding of a first liner sheet to the other edge of the SVACM.
In general the cutting rollers may be driven directly or indirectly by a motor. Typically the cutting rollers are driven to rotate at twice the speed of the conveyor bringing SVACM core.
According to a still further aspect of the present invention there is provided a machine for making a closed cell coreboard from SVACM wherein the machine includes: a first cutting roller assembly which causes a first cutting roller to press down against an edge surface of SVACM oriented with the channels of the SVACM running vertically; a second cutting roller assembly which causes a second cutting roller to press up against an edge surface of SVACM; wherein the first and second cutting rollers have radial corrugations over the surfaces thereof wherein said ridges of the radial corrugations form a cutting edge and wherein the machine is configured so that the SVACM moves relative to the first and second cutting rollers and wherein the machine includes: - a glue applicator station where glue is applied to the top and bottom edge surfaces of the SVACM which now include a plurality of projections thereon created by the first and second cutting rollers; and
- a laminating station for bonding sheet material to the top and bottom edge surfaces of the SVACM.
According to a further aspect of the present invention there is provided a method of manufacturing a closed cell coreboard from SVACM comprising the step of: a) cutting top and/or bottom edges of the SVACM oriented with the channels (cells) of the SVACM running vertically, via an upper cutting roller and a lower cutting roller; wherein the upper and lower cutting rollers have radial corrugations over the surface thereof wherein said ridges of the radial corrugations form a cutting edge such that when the ridges are brought into contact with the edge surface(s) of the SVACM the ridges produce cuts along the edge surface(s) which in turn create a plurality of projections.
According to a further aspect of the present invention there is provided a method of making a closed cell coreboard from SVACM comprising the step of using pair of cutting rollers to cut into an edge SVACM wherein the cutting rollers each have radial corrugations over the surface thereof wherein ridges of the radial corrugations form a cutting edge and wherein one cutting roller has radial corrugations forming a right handed helix and the other roller has radial corrugations forming a left handed helix.
According to a further aspect there is provided a method of making a closed cell coreboard substantially as described above including the extra step of gluing an edge surface of the SVACM which has been cut by the pair of rollers to at least one liner sheet.
In preferred embodiments, the upper and/or lower cutting rollers are separated from corresponding squeeze rollers by a gap that is adjusted to produce the depth of cut required. According to a still further aspect of the present invention there is provided a method of making a closed cell coreboard comprising the steps of: a) cutting top and bottom edge surfaces of the SVACM oriented with the corrugations of the SVACM running vertically via an upper cutting roller and a lower cutting roller, wherein the upper and lower cutting rollers have radial corrugations over the surface thereof wherein said ridges of the radial corrugations form cutting edges; b) applying glue to the top and bottom edge surfaces of the SVACM which now include a plurality of projections thereon created by the first and second cutting rollers; c) bonding sheet material to the top and bottom edge surfaces of a plurality of SVACM which collectively form a continuous array/bed of adjacently abutted SVACM.
According to yet another aspect of the present invention there is provided a closed cell coreboard which includes: • a first sheet of material which is selected from particle board, mdf or other wood chip derived composite; and
• a second sheet of material which is a closed cell coreboard of the present invention substantially as described above. According to another aspect of the present invention there is provided a box made with a closed cell coreboard substantially as described above.
In one preferred embodiment the box has ventilation channel-cut outs which extend from the base of a side wall to the top thereof wherein the coreboard has a thickness of substantially between 4mm-4.5mm. Preferably the ventilation channel-cut outs may be similar to that disclosed in the Applicants' earlier filed PCT specification published as WO2010/056137.
Preferably, the box is made from closed cell coreboard material in accordance with the present invention. Most preferably, the box is made from a closed cell coreboard having a thickness of substantially 4mm -4.5mm. The box being constructed from SVACM made of laminated layers of single face paperboard comprising 150gsm corrugating medium and a 125gsm liner sheet.
It will be appreciated by those skilled in the art that:
• the thickness of the sheet material used to manufacture the SVACM; and
• the thickness of the liner sheets bonded to the top and bottom edges of the SVACM; will depend on the end use of the closed cell coreboard. For most applications the SVACM may be made from 175gsm -275gsm Kraft paper and the liner sheets may be 175gsm - 275 gsm Kraft paper. In general the thicker the paper or board used the stronger the resulting close cell coreboard.
According to further aspect of the present invention there is provided a sign made with a closed cell coreboard substantially as described above.
According to another aspect of the present invention there is provided a display stand made with a closed cell coreboard substantially as described above.
According to another aspect of the present invention there is provided a closed cell coreboard substantially as described above or as made by the methods or machines substantially as described above.
Preferred embodiments of the present invention provide a number of advantages over the prior art which can include: providing a composite board which has increased strength; providing a composite board which is relatively thin (i.e. substantially
4mm -4.5mm thick). providing a composite board which has a flatter/smoother looking surface; providing a composite board which has increased strength relative to the thickness of the board; providing a core having an increased effective bonding surface area; providing a composite board which is more environmentally friendly than existing comparable products; providing boxes with increased strength which can be easily and cheaply recycled; providing a renewable resource for manufacturing building products; providing a method of making composite board which does not require a hot melt adhesive.
BRIEF DESCRIPTION OF DRAWINGS
Further aspects of the present invention will become apparent from the following description which is given by way of example only and with reference to the accompanying drawings in which: Figure 1 shows a schematic partial perspective exploded view of a sheet of closed cell coreboard (composite board) in accordance with one preferred embodiment of the present invention;
Figure 2 shows a side view of the composite board of Figure 1 looking along line A; Figure 3 shows a schematic plan view of a bed of end aligned strips of vertical axis channel material forming the core in the composite board in Figure 1 ;
Figure 4 shows a schematic side view of a strip of vertical axis channel material (SVACM) showing what the core looks like viewed along line B in Figure 1 ;
Figure 5a shows a schematic perspective view of the abutted strips of vertical channel material (SVACM) as depicted in Figure 4; Figure 5b shows a schematic top view of the abutted strips of vertical channel material (SVAF ) as depicted in Figure 4;
Figure 6 shows a partial perspective view of the SVACM depicted in Figures
4 and 5; Figure 7 shows a partial view of a cutting roller in accordance with one preferred embodiment of the present invention; shows a machine for making a composite corrugated sheet material as depicted in Figures 1 and 2; shows a partial view of a cutting roller in accordance with a further preferred embodiment of the present invention; shows a cutting roller assembly utilising cutting rollers as depicted in Figure 9; shows a portion of a machine for making composite sheet material in accordance with another preferred embodiment of the present invention;
Figure 12 shows a partial view of the first cutting roller in Figure 11 having corrugations formed via a right handed helical groove in accordance with a preferred embodiment of the present invention; and
Figure 13 shows a partial view of the second cutting roller in Figure 11 having corrugations formed via a left handed helical groove in accordance with a preferred embodiment of the present invention. BEST MODES FOR CARRYING OUT THE INVENTION
Figures 1 and 2 broadly illustrate the nature of the closed cell coreboard (composite board) of the present invention which is indicated by arrow 1. Figure 3 shows in greater detail the unique SVACM core of the present invention. In Figures 1 and 2, the composite board 1 is made from Kraft paper and has an upper liner sheet 2 and lower sheet 3 which are bonded to a core layer 4 comprised of a plurality of abutted end aligned strips of vertical channel axis material (SVACM) 5a, 5b, and 5c. The SVACM 5a - 5c are made up of four layers of single face paperboard 5' - 5IV bonded together which can be seen clearly in Figure 2 and Figure 6. Figure 2 shows the vertical axis line A-A that extends along the channels which in this embodiment are formed between the fluted medium and liner sheets of the single face paperboard forming the layers.
The nature of the SVACM core layer is shown in Figure 3. As can be seen the strips (individual SVACM) 5a - 5c are abutted together to form a bed upon which liner sheet 2 and then liner sheet 3 can be bonded. The ends 101 and 102 of the strips 5a - 5c are end aligned to match the edge of the upper and lower liner sheets (not shown). The corrugations shown by the zig-zag line can clearly be
In Figures 4 - 6 the SVACM generally indicated by arrow 100 have ends 101 and 102. The view shown in Figure 4 is along line B in Figures 1 and. The SVACM has a number of projections 103 on the top and bottom edges thereof. The projections are formed by a roller discussed later in relation to Figure 7 which forms cuts 104 into the top and bottom edge surfaces. The projections 103 become folded /flattened during lamination roughly along putative fold line 105 shown by the dotted lines. When the projections 105 become folded/flattened - refer Figure 5 - the projections 103 effectively increase the available surface area for bonding to the liner sheets 2 and 3 shown in Figures 1 and 2. The projections are initially folded/flattened when they come into contact with a glue roller as is discussed in more detail below in relation to Figure 8.
In Figure 7 there is shown a cutting roller generally indicated by arrow 1000. The cutting roller has radial corrugations generally indicated by arrow 1001 made up of ridges 1002 and grooves 1003. The ridges have a tapered cutting edge 1004.
In Figure 8 there is provided a machine for making a composite sheet material from strips of vertical axis channel material (SVACM) generally indicated by arrow 5000.
The machine has a first conveyor belt assembly 5001 which transports SVACM 5002 in the direction of arrow A. The SVACM 5002 are then delivered onto a slip bridge 5003 which is made of polypropylene (or other low friction surface) over which the SVACM 5002 slide as they are pushed to a first cutting roller assembly 5004. The first cutting roller assembly has a first cutting roller 5005 and a squeeze roller 5006. The gap between the first cutting roller 5005 and squeeze roller 5006 is slightly smaller than the thickness of the SVACM 5002 which passes therethrough. The first cutting roller 5005 cuts notches into the top edge of the SVAFM which creates the projections as previously described and shown in Figures 4 - 6.The SVACM 5002 are then moved by the rotation of the rollers 5005 and 5006 and onto a second slip bridge 5007, before being conveyed by a second conveyor belt assembly 5008 to a first glue application station 5009.
The first glue application station 5009 has a doctor roller 5010 and a glue applicator roller 5011 which are counter rotate with respect to one another. Adhesive is pumped from a reservoir (not shown) via conduits (not shown) to deliver adhesive to the region shown by arrow 5200 between the top portion of two rollers 5010 and 5011. The distance the doctor roller 5010 is separated from the glue applicator roller 5011 determines the thickness of the adhesive layer applied by the glue applicator roller 5011. As the glue applicator roller 5011 contacts the top edge surface of the SVACM and applies a layer of adhesive thereto. Any excess adhesive not applied falls off the end of the rollers and is collected by a tray (not shown) and returned to the reservoir and recirculated. Following glue application station 5009 the SVACM then passes to a first laminating station 5012 where sheet material in the form of Kraft paper 500 is laminated to the SVACM via nip rollers 5013 to form single face SVACM board.
The single face SVACM board then passes to a second cutting roller assembly 5014 having a second cutting roller 5015 and squeeze roller 5016. The second cutting roller 5015 cuts notches into the bottom edge of the SVACM which creates the projections as previously described and shown in Figures 4 - 6.
The cutting rollers 5005 and 5015 are driven by motors not shown that rotate the others at the same speed as the SVACM travels along the first conveyor 5001.
The newly formed single face SVACM board then passes a second glue application station 5017 wherein a doctor roller 5018 transfers adhesive to a glue applicator roller 5019. The second glue station operates in substantially the same manner as the first glue application station 5009 discussed above. The glue applicator roller 5019 contacts the bottom edges of the SVACM and applies a layer of adhesive thereto. The single face SVACM board then passes to a second laminating station 5020 where a second sheet material in the form of Kraft paper 501 is laminated to the single face SVACM board via nip roller 5021 and opposed pressure belt assemblies 5022 and 5023: to thereby create composite corrugated sheet material (composite board) 5024.
In Figure 9 there is provided a cutting roller generally indicated by arrow 6000. The cutting roller 6000 has radial projections 6001 which extend above the circumferential surface 6002 of the cutting roller 6000. The ridges have a tapered cutting edge 6003. The height of the radial projections substantially corresponds to the depth of cut (and hence height of the projections) which will be formed on the SVACM core. The advantage of this configuration of cutting roller is shown in Figure 10. As can been this cutting roller assembly 7000 obviates the need for a squeeze roller and enables two opposed cutting rollers 7001 and 7002 to cut upper and lower edges of the SVAFM simultaneously.
In Figure 10 there is shown a cutting assembly 7000 which has vertically opposed first and second cutting rollers 7001 and 7002 respectively. The first and second cutting rollers 7001 and 7002 rotate in the direction of arrows A and B respectively. The rollers 7001 and 7002 cut notches 7003 into SVACM 7004 as is most clearly seen in enlargement bubble. The SVACM 7004 is supported as it enters and exits the cutting assembly 7000 via first and second clip bridges 7005 of which only one is shown.
In Figure 1 1 there is shown a pair of cutting rollers forming a cutting assembly
10000. The cutting assembly has a first cutting roller 10001 and associated squeeze roller 10002 and a second cutting roller 10003 and associated squeeze roller 10004. In this embodiment the cutting rollers and squeeze rollers are fabricated from stainless steel. The cutting assembly cuts notches into the top edge 10005 of the SVAFM 10006 which is bonded on the bottom edge to liner sheet 10007. The SVAFM travels in the direction of arrow A. As can be seen the individual strips 10008 of SVACM 10006 already present a flat bottom edge as they are bonded to liner sheet 10007. However, the same is not true for the top edge of the SVAFM where the top edge of each strip is not aligned and instead forms a stepped top edge of the SVACM. The combined action of the two cutting rollers
10001 , 10003 and associated squeeze rollers 10002,10004 smooth out the top edge of the SVACM to create a flat top edge ready for bonding to a second liner sheet not shown. The pair of cutting rollers 10001 and 10003 both rotate at twice the speed of the SVACM which helps flatten out the top edge of the SVAFM and fold the projections.
The gap between the cutting rollers and squeeze rollers depends on the desired cutting edge depth of penetration In Figure 12 there is shown a first cutting roller 10001 which has corrugations having ridges 12001 which form the cutting edge. The corrugations are formed from a single right handed (clockwise) helical groove when looked at from the direction of arrow B.
In Figure 13 there is shown a second cutting roller 10003 which has corrugations having ridges 12002 which form the cutting edge. The corrugations are formed from a single left handed (anti-clockwise) helical groove when looked at from the direction of arrow C.
Example 1 - Art Board
This form of closed cell coreboard has a SVACM core made from layers of single face paperboard. The SVACM has a 5mm core in height (thickness) from top edge surface to bottom edge surface.
The SVACM core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick and cut into sheets. The top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 1 1 to a depth of 2.0mm. Then a tri-laminate is formed from two 275gsm Kraft liner sheets which are 250 microns thick and an outer liner sheet of SBS (solid bleached sulphate) board which is 500 microns thick. This tri-layer laminate is left to dry and then is bonded to the top edge surface SVACM so the SBS board forms the outer facing sheet of the art board. Another tri-layer laminate of Kraft board and SBS board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the SVACM. Again the SBS board forms the outer facing sheet.
The final step is to press the art board to assist with lamination and this also compresses the art board to a thickness of 5mm. Example 2- Art Board
This form of closed cell coreboard has a SVACM core made from layers of single face paperboard. The SVACM has 9.3mm core in height (thickness) from top edge surface to bottom edge surface.
The SVACM core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick and then cut into sheets. The top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 11 to a depth of 1.3mm. Then a tri-laminate is formed from two 275gsm Kraft liner sheets which are 250 microns thick and an outer liner sheet of SBS (solid bleached sulphate) board which is 500 microns thick. This tri-layer laminate is left to dry and then is bonded to the top edge surface SVACM so the SBS board forms the outer facing sheet of the art board. Another tri-layer laminate of Kraft board and SBS board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the SVACM. Again the SBS board forms the outer facing sheet. The final step is to press the art board to assist with lamination and this also compresses the art board to a thickness of 10mm.
Example 3- Art Board
This form of closed cell coreboard has a SVACM dual core made from layers of single face paperboard. The two SVACM cores are 9.3mm in height (thickness) from top edge surface to bottom edge surface. The two SVACM cores are bonded to each other before the bottom edge surface of the resulting double core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick before being cut into sheets. The top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 11 to a depth of 1.3mm. Then a tri-laminate is formed from two 275gsm Kraft liner sheets which are 250 microns thick and an outer liner sheet of SBS (solid bleached sulphate) board which is 500 microns thick. This tri-layer laminate is left to dry and then is bonded to the top edge surface dual core SVACM so the SBS board forms the outer facing sheet of the art board. Another tri-layer laminate of Kraft board and SBS board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the dual core SVACM. Again the SBS board forms the outer facing sheet.
The final step is to press the art board to assist with lamination and this also compresses the art board to a thickness of 20mm. Example 4 - Industrial Board
This form of closed cell coreboard has a SVACM core made from layers of single face paperboard. The close cell coreboard is produced via the machine of Figure 8 to have one layer of 275gsm Kraft liner bonded to each side of the SVACM core following cutting of the top and bottom surface edges of the SVACM. Example 5 - Structural Board
This form of closed cell coreboard has a SVACM core made from layers of single face paperboard. The SVACM has a 5mm core in height (thickness) from top edge surface to bottom edge surface.
The SVACM core is bonded to a 275gsm Kraft paper bottom liner sheet which is 250 microns thick and cut into sheets. The top edge surface of the SVACM liner sheet is then cut via a pair of cutting rollers as shown in Figure 11 to a depth of 2.0mm. Then a tri-laminate is formed from three 275gsm Kraft liner sheets which are 250 microns thick. This tri-layer laminate is left to dry and then is bonded to the top edge surface SVACM. . Another tri-layer laminate of Kraft board is also prepared at the same time and left to dry before being bonded to the liner sheet on the bottom edge surface of the SVACM.
The final step is to press the structural board to assist with lamination and this also compresses the structural board to a thickness of 5mm.
Example 6 - Thin High Strength Box Close Cell Coreboard This form of closed cell coreboard has a SVACM core made from layers of single face paperboard. The thickness of the SVACM core is 6mm prior to being cut via the cutting rollers which are set to penetrate a depth of 2.5mm. The close cell coreboard is produced via the machine of Figure 8 to have one layer of 275gsm Kraft liner 250 microns thick bonded to each side of the SVACM core following cutting of the top and bottom surface edges of the SVACM.
The resulting board has a thickness of substantially 4.25mm which is the same as C Flute paperboard.
Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope of the appended claims.

Claims

What we claim is:
1. A closed cell coreboard which includes: at least one upper sheet and/or at least one lower liner sheet; a core layer, said core layer comprising a plurality of adjacently abutted end aligned strips of vertical axis flute material (SVAFM); characterised in that the SVACM have at least one edge surface which include(s) a plurality of projections formed there along which are: folded; or can become folded during lamination, to an upper and/or lower liner sheet(s).
2. A closed cell coreboard as claimed in claim 1 wherein the SVACM is bonded to at least one upper, and at least one lower, liner sheet wherein the respective upper and lower liner sheets are bonded on opposite edge surfaces of the SVACM so as to sandwich the core there between.
3. A closed cell coreboard which includes: a liner sheet bonded to a core layer, such that said core layer comprises a plurality of adjacently abutted, end aligned, strips of vertical axis channel material (SVACM); characterised in that the SVACM have at least one edge surface which includes a plurality of projections formed there along which are: folded; or can become folded, during lamination to a liner sheet.
4. A strip of vertical channel material (SVACM) comprising a strip formed from a laminate of: corrugated single or double face board, or a laminate of honeycomb board;
wherein at least one edge surface of the strip include(s) a plurality of projections there along which are:
folded; or
can become folded during lamination to the liner sheet(s).
5. A closed cell coreboard or strip of vertical axis channel material (SVACM) as respectively claimed in claims 1-3 or claim 4 wherein the projections extend substantially 0.5mm to 2.5mm from a putative fold line.
6. A closed cell coreboard or strip of vertical axis channel material (SVACM) as respectively claimed in claimed in claims 1-3 or claim 4 wherein the projections are substantially 3.5mm across.
7. A cutting roller which includes radial corrugations over the surface thereof wherein ridges of the radial corrugations are configured to form cutting edges.
8. A cutting roller as claimed in claim 7 wherein the radial corrugations are in the form of a right handed helical groove.
9. A cutting roller as claimed in claim 7 wherein the radial corrugations are in the form of a left handed helical groove.
10. A machine for making a closed cell coreboard from SVACM wherein the machine includes:
a first cutting roller which presses down against an edge surface of SVACM oriented with the channels running vertically and wherein the SVACM is supported by a first squeeze roller which has a rotational axis vertically aligned with said first cutting roller;
a second cutting roller which presses up against an edge surface of SVACM oriented with the channels running vertically and is supported by a second squeeze roller which has a rotational axis vertically aligned with said second cutting roller; wherein the first and second cutting rollers have radial corrugations <&er the surfaces thereof wherein said ridges of the radial corrugations form a cu^ig edge and wherein the machine is configured so the SVACM moves relative iu the first and second cutting rollers.
1 1 . A machine as claimed in claim 10 wherein the first cutting roller has a left handed helix and the second cutting roller has a right handed helix or vice versa and wherein the first cutting roller is positioned upstream of the second cutting roller relative to the direction in which the SVACM moves past the respective first and second cutting rollers.
12. A machine as claimed in claim 1 1 wherein the first and second cutting rollers are positioned to cut a one edge surface of the SVACM following the bonding of a first liner sheet to the other edge of the SVACM.
13. A machine for making a closed cell coreboard from SVACM wherein the machine includes: a first cutting roller assembly which causes a first cutting roller to press down against an edge surface of SVACM which is oriented with the corrugations of the SVACM running vertically; a second cutting roller assembly which causes a second cutting roller to press up against an edge surface of SVACM; wherein the first and second cutting rollers have radial corrugations over the surfaces thereof wherein ridges of the radial corrugations form a cutting edge and wherein the machine is configured so that the SVACM moves relative to the first and second cutting rollers and wherein the machine includes: a glue applicator station where glue is applied to the top and bottom edge surfaces of the SVACM which now include a plurality of projections thereon created by the first and second cutting rollers; and a laminating station for bonding sheet material to the top and bottom edge surfaces of the SVACM.
14. A method of manufacturing a closed cell coreboard from SVACM comprising the step of: a) cutting top and/or bottom edge surfaces of the SVACM, which is oriented with the channels of the SVACM running vertically, via an upper cutting roller and a lower cutting roller; wherein the upper and lower cutting rollers have radial corrugations over the surface thereof wherein ridges of the radial corrugations form a cutting edge such that when the ridges are brought into contact with the edge surface(s) of the SVACM the ridges produce cuts along the edge surface(s) which in turn create a plurality of projections.
15. A method of making a closed cell coreboard from SVACM comprising the step of using pair of cutting rollers to cut into an edge surface of the SVACM wherein the cutting rollers each have radial corrugations over the surface thereof wherein-ridges of the radial corrugations form a cutting edge and wherein one cutting roller has radial corrugations forming a right handed helix and the other roller has radial corrugations forming a left handed helix.
16. A method as claimed in 15 including the extra step of gluing the edge surface of the SVACM which has been cut by the pair of rollers to at least one liner sheet.
17. A method of making a closed cell coreboard comprising the steps of: a) cutting top and bottom edge surfaces of the SVACM oriented with the corrugations of the SVACM running vertically via an upper cutting roller and a lower cutting roller, wherein the upper and lower cutting rollers have radial corrugations over the surface thereof wherein said ridges of the radial corrugations form cutting edges; b) applying glue to the top and bottom edges of the SVACM which now include a plurality of projections thereon created by the first and second cutting rollers; bonding sheet material to the top and bottom edges of a plurality of SVACM which collectively form a continuous array/bed of adjacently abutted SVACM.
18. A composite sheet of building material which includes a first sheet of material which is selected from particle board, mdf or other wood chip derived composite and a second sheet of material which is a closed cell coreboard as claimed in any one of claims 1-3 and 5-6.
19. A closed cell coreboard as: claimed in any one of claims 1-3 and 5-6, or made by the methods or machines as claimed in any one of claims 10-17.
20. A box made with a closed cell coreboard as claimed in claim 19.
21. A box as claimed in claim 20 wherein the box has ventilation channel-cut outs which extend from the base of a side wall to the top thereof wherein the coreboard has a thickness of substantially between 4mm-4.5mm.
22. A sign made with a closed cell coreboard as claimed in claim 19.
23. A display stand made with a closed cell coreboard as claimed in claim 19.
PCT/NZ2011/000156 2010-08-12 2011-08-12 Improvements in and relating to composite sheet material WO2012021073A1 (en)

Applications Claiming Priority (4)

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JP2014156037A (en) * 2013-02-15 2014-08-28 Kawakami Sangyo Co Ltd Sandwich structure
CN110091559A (en) * 2018-01-31 2019-08-06 成都天府轨谷科技有限公司 A kind of rail vehicle decorative floor composite material and preparation method
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