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Title:
LOAD-BEARING HONEYCOMB STRUCTURES MADE FROM FOLDED MULTILAYER CORRUGATED CARDBOARD
Document Type and Number:
WIPO Patent Application WO/2015/082977
Kind Code:
A4
Abstract:
The invention relates to weight-bearing honeycomb structures from folded multi-flute corrugated cardboard, and the process and system for the industrial manufacturing of the structures. A load-bearing honeycomb structure is made from a plurality of sheets of folded corrugated cardboard with at least an upper and a lower cover layer. The honeycomb structure includes a length given by the distance between substantially equally spaced cuts through the corrugated cardboard along the direction of flutes, a width given by the width of the cardboard web and by the distance of substantially equally spaced cuts substantially perpendicular to the flutes, and a thickness given by the distance of the substantially equally spaced cuts perpendicular to the flutes.

Inventors:
ISELI ALFRED (CH)
Application Number:
PCT/IB2014/002635
Publication Date:
July 30, 2015
Filing Date:
December 03, 2014
Export Citation:
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Assignee:
ISELI ALFRED (CH)
International Classes:
B31D3/00
Attorney, Agent or Firm:
MOETTELI, John (Rathausgasse 1, Arbon, CH)
Download PDF:
Claims:
AMENDED CLAIMS

received by the International Bureau on 26 May 2015 (26.05.2015)

1 . A load-bearing honeycomb structure (360, 554, 654) made from sheets (210, 410, 512, 612) of folded corrugated cardboard strips (216, 316, 416) with at least an upper cover layer (230, 330, 430) and a lower cover layer (238, 338, 438), the honeycomb structure comprising:

a. a length defined by a distance (21 1 , 41 1 , 51 1 , 61 1 ) between first substantially equally spaced cuts (220, 420) through the corrugated cardboard along the direction of flutes,

b. a width substantially given by the product of a thickness (215, 315, 415) of the corrugated cardboard and a number of the folded cardboard strips (216, 316, 416) which are folded together,

c. a thickness given by the distance (217, 317, 417, 517, 617) of the substantially equally spaced cuts oriented substantially perpendicular to the flutes.

2. The structure of claim 1 wherein the corrugated cardboard is at least a double-flute corrugated cardboard with an upper cover layer (230, 330, 430), a middle cover layer (234, 334, 434) and a lower (238, 338, 438) cover layer.

3. The structure of claim 1 wherein the folded strips (216, 316, 416) have a dimension defined by a distance (217, 317, 417, 517, 617) between the substantially equally spaced cuts (224, 228, 324, 328, 422) oriented substantially perpendicular to the flutes, and wherein pairs of strips of double width (219, 319, 419) are alternatingly folded upwards and downwards along the cuts at an angle (326) of about 180 degrees whereby sheets (210, 410) are folded in a substantially accordion-like manner such that the cover layers supplied with glue are in intimate contact with each other.

4. The structure of claim 1 wherein the second substantially equally spaced cuts perpendicular to the flutes do not extend through both the upper cover layer and the lower cover layer, and wherein the cuts are executed alternatingly from above and from below the cardboard sheet.

5. The structure of claim 1 wherein the substantially equally spaced cuts (224, 228, 324, 328, 526, 528) are oriented perpendicular to the flutes and extendifKj through both the upper cover layer and the lower cover layer, and wherein strips of the upper cover layer and lower cover layer are alternatingly connected by at least one connection selected from a connection selected from the group of connections consisting of:

a. an aluminum foil adhered onto the upper cover layer and the lower cover layer connection;

b. adhesive tapes connection (440, 442);

c. adhesive label connections made from at least one material, selected from the group comprising a paper material, a woven fabric material and a plastic material (444, 446, 623, 625);

d. a threads glued across the cuts connection; and,

e. a plurality of drops of fast-drying glue connection (450, 452).

6. The structure of claim 1 , wherein the length of the honeycomb is in the range from about 2 cm to about 30 cm.

7. The structure of claim 1 , wherein the length of the honeycomb is in the range from about 1 .00 m to about 8.00 m.

8. A process for the production of a load-bearing honeycomb structure, the process comprising the steps of:

a. cutting a multi-flute web of corrugated cardboard having at least an upper cover layer (230, 330, 430) and a lower cover layer (238, 338, 438) into cardboard sheets (210, 410, 512, 612) along flutes at a selected performance speed of a cardboard manufacturing machine, the selected performance speed optionally being a full speed; b. cutting the cardboard sheets into substantially equally wide strips (216, 316, 416) within a tolerance of about 0.1 mm oriented substantially perpendicular to the flutes at a given performance speed of the cardboard manufacturing machine;

c. applying adhesive to both sides of the cardboard strips (216, 316, 416); d. folding connected cover layer strips (218, 318, 418) under substantially stationary conditions alternatingly downwards and upwards by a folding angle (326) of about 180 degrees around axes oriented along the cuts (224, 228, 324, 328, 422) and perpendicular to the flutes, thereby folding the cardboard sheets in a substantially accordion-like manner and bringing the cover layers of adjacent strips into intimate contact for gluing; and,

e. curing the glue under pressure applied to a substantially stationary honeycomb.

9. The process of claim 8, wherein a connection between the strips is established by a connection step, the connection step selected from one or more of the group of connection steps consisting of :

a. alternatingly providing cuts (224, 324) from above and cuts (228, 328) from below to alternatingly leave the lower cover layer (238, 338) and the upper cover layer (230, 330) intact, whereby adjacent strips are connected alternatingly by uncut upper and lower cover layers; and, b. alternatingly connecting upper cover layer (430) and lower cover layer (438) by at least one alternating connection, the at least one alternating connection selected from one or more of the group of connections consisting of:

i. gluing an aluminum foil onto the upper cover layer and the lower cover layer, and cutting the aluminum foil to alternatively connect the upper and the lower cover layer;

ii. attaching adhesive tapes (440, 442) above the cuts, alternatingly on the upper cover layer and the lower cover layer;

iii. attaching adhesive labels (444, 446, 623, 625) made from at least one material from a list of materials, comprising paper, woven fabrics and plastic alternatingly on the upper and the lower cover layer;

iv. attaching threads across the cuts alternatingly on the upper cover layer and the lower cover layer; and v. applying drops (450, 452) of fast-drying glue alternatingly on the cuts through the upper cover layer and the lower cover layer.

10. The process of claim 8 wherein the honeycomb has a length between about 2 cm and about 30 cm.

1 1 . A system for the industrial production of weight-bearing honeycomb structures, the system comprising:

a. at least one first apparatus configured to run at a selected speed, preferably an optimal speed, of a cardboard manufacturing machine, the cardboard manufacturing machine producing a web of multi-flute corrugated cardboard with at least one upper cover layer and one lower cover layer; and,

b. at least one second apparatus configured to run at a slower speed for the production of honeycombs from sheets of corrugated cardboard.

12. The system of claim 1 1 , wherein the at least one first apparatus comprises at least one first apparatus station, the at least one first apparatus station selected from one or more of the group of stations consisting of::

a. a station (510) for cutting the web along the flutes into rectangular sheets or quadratic sheets (512, 612) by substantially equally spaced knives (515);

b. a station (520, 620) for cutting the web substantially perpendicularly to flutes into strips by substantially equally spaced knives (524, 528, 624, 628); and,

c. a station for substantially precisely stacking the sheets into vertical stacks.

13. The system of claim 1 1 , wherein the at least one second apparatus comprises a second apparatus station, the second apparatus station selected from one or more of the group of stations consisting of:

a. a connecting strip station (620') for connecting the strips into double strips by at least one connecting strip station step, the at least one connecting strip station step selected from one or more of the group of stations consisting of :

i. gluing an aluminum foil onto the upper cover layer and the lower cover layer, and cutting the aluminum foil to alternatively connect the upper cover layer and the lower cover layer; ii. attaching adhesive tapes (440, 442) above the cuts, alternatingly on the upper cover layer and the lower cover layer;

iii. attaching adhesive labels (444, 446, 623, 625) made from at least one adhesive label material, the at least one adhesive label material selected from the group of label materials consisting of a paper material, a woven fabric material, and a plastic material, alternatingly on the upper cover layer and the lower cover layer;

iv. attaching threads across the cuts alternatingly on the upper cover layer and the lower cover layer; and,

v. applying drops (450, 452) of fast-drying glue alternatingly on the cuts through the upper and the lower cover layer; and, b. a gluing device station (530, 630) comprising a first gluing device (536, 636) arranged above the upper cover layer (230, 330, 430) and a second gluing device (534, 634) arranged below the lower cover layer (238, 338, 438) to alternatingly apply glue on the upper cover layer and the lower cover layer connecting the cardboard strips;

c. a stationary station (540, 640) comprising: a pressure exerting manifold (544, 644) to exert downward pressure on connected strips of the upper cover layer along cuts (228, 328, 529) and upward pressure on connected strips of the lower cover layer along cuts (224, 324, 526) with a control and feedback mechanism maintaining distance (542, 642) between one or more pressure manifolds precisely at the distance (342, 342', 342") required to fold connected cover layers (218, 318, 418) alternatingly downward and upward through a folding angle (326) of about 180 degrees thereby folding cardboard sheets (512, 612) in a substantially accordion-like manner and bringing the cover layers of adjacent strips into intimate contact for gluing; and,

d. a stationary pressing station for compacting the honeycomb and curing of glue.

14. The system of claim 12, wherein the station for cutting the web into strips comprises at least one web strip cutting device, the at least one web strip cutting device selected from one or more of the group of devices consisting of:

a. a device for precisely adjusting the distance between the knives to within a tolerance of 0.1 mm;

b. a device for maintaining the cardboard in a constant vertical position by providing a counter force to the force exerted by the knives; c. a device for continuous sharpening of the knives; and,

d. a device for continuously monitoring and adjusting the cutting depth of the knives.

15. The system of claim 1 1 , wherein the honeycombs are manufactured to have a length and or width in the range from about 2 cm to about 30 cm.

16. The system of claim 1 1 , wherein the honeycombs are manufactured to have a length in the range from about 1 .00 m to about 8.00 m.