CHOI JEONG HEON (KR)
KIM JUN SOO (KR)
CHOI JEONG HEON (KR)
| US4239593A | 1980-12-16 | |||
| US4153304A | 1979-05-08 | |||
| US5584967A | 1996-12-17 |
| 1. | An apparatus for producing a multilayered product, the apparatus comprising: a first section including a base roller for supplying a base layer prerolled on the base roller; and at least one second section receiving at least one additional layer of material and applying the at least one additional layer onto the base layer to produce a multilayered product, wherein the first section and the at least one second section are arranged in a transport direction for transporting a product from one section to another section. |
| 2. | The apparatus of claim 1, wherein the at least one second section includes: a first guide roller supplying the additional layer of an additional layer forming material; a first absorbing roller rotating to receive the additional layer from the first guide roller; and a first pressing roller applying the additional layer onto the base layer. |
| 3. | The apparatus of claim 2, wherein the first pressing roller includes: a first shell having first openings; and a first absorption controller disposed in the first shell and controlling adherence of the additional layer onto the base layer. |
| 4. | The apparatus of claim 3, wherein the first pressing roller further includes a first mesh cover having second openings smaller than the first openings of the first shell. |
| 5. | The apparatus of claim 1, wherein the at least one second section includes a plurality of second sections, and each of the second sections includes: a first guide roller supplying the additional layer of an additional layer forming material ; a first absorbing roller rotating to receive the additional layer from the first guide roller; and a first pressing roller applying the additional layer onto a supplied product, the supplied product being either the base layer or the base layer having at least one additional layer thereon. |
| 6. | The apparatus of claim 1, further comprising: at least one dryer disposed in the transport direction and drying the multilayered product from the at least one second section. |
| 7. | The apparatus of claim 6, further comprising: a cutting roller rolling the dried multilayered product thereon. |
| 8. | A method of producing a multilayered product, the method comprising: (a) providing a base layer at a first station; and (b) providing at least one additional layer of material at at least one second station and applying the at least one additional layer onto the base layer at the at least one second station to produce a multi layered product, wherein the first station and the at least one second station are arranged in a transport direction for transporting a product from one station to another station. |
| 9. | The method of claim 8, wherein the providing step (a) is performed by using a base roller having the base layer prerolled thereon. |
| 10. | The method of claim 8, wherein the providing step (b) includes: transporting the additional layer through at least one guide roller; supplying the additional layer onto a surface of a first absorbing roller; and applying the produced additional layer onto the base layer. |
| 11. | The method of claim 10, wherein the applying step is performed by a first pressing roller, wherein the first pressing roller includes, a first shell having first openings, and a first absorption controller disposed in the first shell and controlling adherence of the additional layer onto the base layer. |
| 12. | The method of claim 11, wherein the first pressing roller further includes a first mesh cover having second openings smaller than the first openings of the first shell. |
| 13. | The method of claim 8, further comprising: (c) drying, by at least one dryer disposed in the transport direction, the multilayered product produced from the producing step (b). |
| 14. | The method of claim 13, further comprising: (d) rolling, by a cutting roller disposed in the transport direction, the dried multilayered product thereon. |
| 15. | A multilayered product produced by the method of claim 8. |
RELATED APPLICATION The present application claims the benefit of Korean Patent Application No. 10-2001-39864 filed on July 4,2001, under 35 U. S. C.
ยง119, which is herein fully incorporated by reference.
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to multi-layered papers and a method and apparatus for producing the multi-layered papers and associated products.
2. Description of Related Art Various types of multi-layered paper products and methods and apparatuses for producing the same are known in the art. Generally, a hard paper having a multi-layered structure such as pasteboard is manufactured by stacking and pasting multiple layers of paper materials. The stacking and pasting of multiple layers of paper materials increases the hardness of the pasteboard which is suitable for use as packaging boxes, binders, or file covers.
Generally, a conventional method and apparatus for producing multi-layered paper such as pasteboard involves the use of paper material layers of different qualities and a plurality of rollers for rolling these paper material layers. Particularly, an adhesive is applied on a surface of a first paper material layer and then a second paper material layer is pasted on top of the first paper material layer. This process is repeated until a predetermined number of paper material layers have been pasted on top of each other. Then the final product is rolled up on a cutting roller and cut appropriately to produce a multi-layered paper of desired shape and size.
However, such conventional methods and apparatuses suffer from many problems. For example, since each paper material layer must be manufactured first through a process and device separate from the process and device for pasting and layering the paper material layers, the conventional methods and apparatuses require a large scaled facility and manufacturing expense. Further, even after the paper is manufactured, the waste water generated through the process must be disposed properly, which requires a waste water disposal plant and scheme. This increases the manufacturing cost significantly.
SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide improved multi-layered paper products, and an improved method and apparatus for producing multi-layered paper products, which eliminate
the above and other problems associated with conventional multi- layered paper products and conventional methods and apparatuses for producing the multi-layered paper products.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description and specific examples, which indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, wherein reference numerals designate corresponding parts in the various drawings and wherein: Fig. 1 is a diagram of an apparatus for producing a multi-layered paper product according to an embodiment of the present invention; Fig. 2 is an exploded sectional view of the apparatus of Fig. 1 according to the present invention; Fig. 3 is a sectional view of an example of a multi-layered paper product produced according to the present invention; and
Fig. 4 is a sectional view of another example of a multi-layered product produced according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In the drawings, like reference numerals represent like elements.
Referring now in detail to the drawings for the purpose of illustrating preferred embodiments of the present invention, an apparatus 1 for producing a multi-layered paper or similar product according to an embodiment of the present invention as shown in Fig. 1 includes: at least one container or source (not shown) providing a layer 28 of a paste paper material or any other layer-forming material; sets of guide rollers 4 each set delivering the layer 28 onto the outer surface of a corresponding absorbing roller 15; a plurality of absorbing rollers 15 (15a, 15b, 15c, 15d) being arranged along a transport medium such as a conveyor in an assembly line fashion or the like, each absorbing roller receiving at its outer surface the layer 28 of a paste paper material being supplied through the corresponding set of guide rollers 4 from the container or any other source and thereby forming an additional layer 28a of paste paper material on its outer surface (Fig. 2); a plurality of pressing rollers 11 (1 la, llb, l lc, lld) operating against the absorbing rollers 15; a plurality of dryers 30 positioned along the assembly line for drying a layered product 24 being formed along the assembly line; a dryer 30a for drying the product 24 from the last pressing roller 15d to produce a final multi-
layered product 25; and a cutting roller 40 for rolling the final product 25 thereon.
All the absorbing rollers 15 (15a, 15b, 15c, 15d) rotate in one direction whereas all the pressing rollers 11 (1 la, 1 lb, 11c, 1 ld) rotate in the opposite direction. In this example, the absorbing rollers 15 rotate in the clockwise direction, and the pressing rollers 11 rotate in the counterclockwise direction. As the rollers 15 and 11 rotate, any item produced therefrom is moved along the transport medium in the transporting direction. Any existing technique or mechanism can be used to rotate selectively the rollers 15 and 11 and to move the item produced therefrom to desired locations.
The apparatus 1 according to the embodiment of the present invention can be functionally divided into a base paper forming section 10 for providing a base paper layer 23 from a base roller 39, and one or more pasting sections 20 (20a, 20b, 20c, 20d) to apply additional layers 28a of paste paper materials 28 to an outer surface of the base paper layer 23 (Fig. 2). The materials used to produce the additional layers 28a are preferably a mixture of paper materials and paste materials, such that no separate adhesive is needed to be adhere the multiple layers to each other. In this example, there are four pasting sections 20 (20a, 20b, 20c, 20d).
The base paper forming section 10 includes the base roller 39 having the base paper layer 23 rolled thereon. The first pasting section 20a includes the first pressing roller 1 la, the first absorbing roller 15a,
the layer 28 of paste paper material, and the set of guide rollers 4 (not shown) for supplying the layer 28. The second pasting section 20b includes the second pressing roller 1 lb, the second absorbing roller 15b, the layer 28 of paste paper material, and the set of guide rollers 4 (not shown) for supplying the paste paper material 28. The third pasting section 20c includes the third pressing roller lie, the third absorbing roller 15c, the layer 28 of paste paper material and the set of guide rollers 4 (not shown) for supplying the layer 28. The fourth pasting section 20d includes the fourth pressing roller lld, the fourth absorbing roller 15d, the layer 28 of paste paper material and the set of guide rollers 4 (not shown) for supplying the layer 28. Although only four pasting sections 20 (20a, 20b, 20c, 20d) are illustrated, the present invention is not limited to such and the apparatus of the present invention can include any number of pasting sections as needed.
Fig. 2 shows a detailed sectional diagram of the first pasting section 20a of the apparatus 1 in Fig. 1. The rest of the pasting sections 20 (20b, 20c, 20d) operate in the same or similar manner with the same construction as the first pasting section 20a.
Referring in detail to Figs. 1 and 2, in the first paste section 20a, the base paper layer 23 is supplied by the base roller 39 as the base roller 39 rotates in the counterclock direction to unravel the base paper layer 23 rolled thereon. The layer 28 of paste paper material or any other layer-forming material is supplied to the outer surface of the absorbing roller 15a through the guide rollers 4 so that an additional layer 28a of
the paste paper material is provided onto the outer surface of the absorbing roller 15a as the absorbing roller 15a rotates.
On the other hand, the first pressing roller 1 la includes a shell 13a in the shape of a roller or rollable item, a wire mesh cover 14a optionally disposed on the outer surface of the shell 13a, and an absorption controller 12a disposed in the shell 13a. The absorption controller 12a can be used to enhance or control absorption or adherence of the additional layer 28a onto the outer surface of the base paper layer 23 as the pressing roller 1 la rotates against the absorbing roller 15a. For example, the absorption controller 12a disposed in the shell 13a can be configured to create a suction force for increasing or adjusting adherence of the additional layer 28a onto the outer surface of the base paper layer 23. In one example, the absorption controller 12a includes any means <BR> <BR> (e. g. , pump, etc. ) to create the suction force. This allows the additional layer 28a of paste paper material to adhere to the outer surface of the base paper layer 23 so as to produce a layered product 24. The absorption controller 12a can also include, optionally, any means to <BR> <BR> effectively circulating pressure air in the first pressing roller l la (e. g. , a vacuum pump).
The first shell 13a has a plurality of slits or openings 26a that are used by the first absorption controller 12a to adjust adherence of the additional layer 28a onto the outer surface of the base paper layer 23.
The first wire mesh cover 14a disposed on the outer surface of the shell 13a has a plurality of orifices that further enhance the adherence control
of the first absorption controller 12a. In this effort, the size of the orifices of the mesh cover 14 may be preferably much smaller than the size of the openings 26a of the first shell 13a.
Once the layered product 24 is produced by the operation of the first pressing roller 1 la and the first absorbing roller 15a, this product 24 is passed to the next pasting section 20b, 20c or 20d so that additional layers 28a, 28a, 28a of the paste paper material can be formed on the base paper layer 23.
The first pasting section 20a and the rest of the pasting sections 20b, 20c, 20d have the same structure and configuration as the paper forming section 10 discussed above.
Referring to Figs. 1 and 2, the method for producing a multi-layered paper 25 according to an embodiment of the present invention includes producing the base paper layer 23 in the base paper forming section 10, and applying an additional layer 28a of paste paper material onto a surface of the base paper layer 23 in each of the pasting sections 20 (20a, 20b, 20c, 20d) to produce a layered product 24. Each layered product 24 is dried by the dryer 30. At the last pasting section 20d, the layered product 24 is finally dried by the dryer 30a to produce a final product 25 of multiple layers. This final product 25 is rolled onto the cutting roller 40 for future use.
In the step of forming the base paper layer 23, the base roller 39 stores therein the base paper layer 23 in somewhat solid state.
Preferably, the base paper layer 23 is pre-rolled on the base roller 38.
According to the number of pasting sections 20, the distance between the base and cutting rollers 39 and 40 can be adjusted appropriately.
In the first pasting section 20a, as the first absorbing roller 15a having the additional layer 28a rotates as discussed above, the first absorbing roller 15a operating with the rotating first pressing roller 1 la applies the additional layer 28a onto the base paper layer 23 sandwiched between the rollers 15a and 1 la as the base paper layer 23 arrives at the first pasting section 20a. As a result, a two-layered product 24 is produced which is dried by the corresponding dryer 30. This two-layered product 24 is moved to the next pasting section 20b in which another layer 28a of paste paper material or the like is applied on a surface of the two-layered product 24. This process is repeated in the subsequent pasting sections 20 until the last pasting section 20d produces the layered product 24.
The thickness of the additional layer 28a depends on the spacing between the corresponding absorbing roller 15 and the corresponding pressing roller 11 and/or the suction force controlled by the corresponding absorption controller 12a.
The layered product 24 has multiple layers composed of the base paper layer 23 and four additional layers 28a of the paste paper materials 28. The layered product 24 then passes through the dryer 30a and is dried to become the final product 25. Fig. 3 shows an example of the final product 25. Optionally, then the final product 25 is rolled onto the cutting roller 40. This completes the process of forming the multi-
layered paper product 25 according to an embodiment of the present invention.
In another embodiment, multiple additional layers of paste paper material may be applied simultaneously onto a surface of the base paper layer 23 at one pasting section.
According to the present invention, the rotation of any one of the absorbing rollers 15 and pressing rollers 11 and the movement of any item produced from each of the sections 10 and 20 can be selectively controlled to synchronize application of the additional layer 28a onto an appropriate portion of the base paper layer 23.
Fig. 4 shows another example of a multi-layered product 25'which can be produced by the apparatus of the present invention. As shown in Fig. 4, a carbon paper product 25'is composed of a base paper layer 23' and three additional layers 28a'of carbon materials. The carbon paper <BR> <BR> product 25'can be used for different purposes, e. g. , as a wall-paper since the carbon layers 28a'have a high shelter rate against electronic waves.
If a non-woven or film paper is used as the paste paper material 28, the product 25'may be produced of a carbon fiber or carbon film.
In the present invention, one or more layers of any material or substance, preferably in solid state, can be supplied to the plurality of guide rollers 4 to produce a multi-layered product of desired material (s), and the position and operation of the elements of the apparatuses of the present invention can be controlled to vary the thickness of each layer in the multi-layered product.
Moreover, although Fig. 1 shows that additional layers 28a are applied to one same side of the base paper layer 23, the apparatus 1 according to the present invention can be configured to apply the additional layers 28a to one and/or the other side of the base paper layer 23, either simultaneously or selectively. For instance, the apparatus 1 can be configured such that one or more of the pasting sections 20 apply the additional layer (s) onto one side of the base paper layer 23, whereas the other pasting sections 20 apply the additional layer (s) to the other opposite side of the paper layer 23. As a result, the final product 25 would include the base paper layer 23 sandwiched between the additional layers 28a. In another example, the additional layers may be applied simultaneously on both sides of the base paper layer 23. This may be accomplished by replacing the pressing roller with another absorbing roller. Obviously, other variations are possible and the present invention encompasses all such variations.
In addition, the dryers 30 and 30a can be installed optionally. The dryers 30 and 30a are attached to the apparatus 1 to simplify the present invention. The dryers 30 and 30a can be any known dryers such as IR (infrared) dryers, Yankee dryers, etc.
Accordingly, the methods, apparatuses and products of the present invention are simple in structure, inexpensive to manufacture, durable in use, and refined in appearance.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.