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Title:
SYSTEMS AND METHODS FOR FORMING DUAL FLUTED CORRUGATED BOARD
Document Type and Number:
WIPO Patent Application WO/2022/060789
Kind Code:
A1
Abstract:
A method for making a dual fluted corrugated board includes providing a first single face corrugated board having a liner layer and a fluted layer attached to the liner layer and providing a second single face corrugated board having a liner layer and a fluted layer attached to the liner layer. The method also includes arranging the first single face corrugated board and the second single face corrugated board such that the fluted layers thereof face one another and attaching the first single face corrugated board to the second single face corrugated board.

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Inventors:
KIESSNER HANKO (US)
ALPINE JOHN PAUL (US)
Application Number:
PCT/US2021/050397
Publication Date:
March 24, 2022
Filing Date:
September 15, 2021
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
PACKSIZE LLC (US)
International Classes:
B23B29/08; B65D65/40; D21H11/02
Foreign References:
US4886563A1989-12-12
US5114509A1992-05-19
US8672825B22014-03-18
US5498304A1996-03-12
US20040234720A12004-11-25
US5894681A1999-04-20
US20110064926A12011-03-17
Attorney, Agent or Firm:
STRINGHAM, John C. et al. (US)
Download PDF:
Claims:
Docket No. 17705.190.1.1a

CLAIMS

1. A method for making a dual fluted corrugated board, the method comprising: providing a first single face corrugated board having a liner layer and a fluted layer attached to the liner layer; providing a second single face corrugated board having a liner layer and a fluted layer attached to the liner layer; arranging the first single face corrugated board and the second single face corrugated board such that the fluted layers thereof face one another; and attaching the first single face corrugated board to the second single face corrugated board.

2. The method of claim 1, wherein attaching the first single face corrugated board to the second single face corrugated board comprising applying ultrasonic vibrations to one or both of the first and second single face corrugated boards.

3. The method of claim 1 or 2, wherein: the fluted layer of the first single face corrugated board comprises a plurality of peaks and valleys facing the fluted layer of the second single face corrugated board; and the fluted layer of the second single face corrugated board comprises a plurality of peaks and valleys facing the fluted layer of the first single face corrugated board.

4. The method of claim 3, further comprising: aligning the peaks in the fluted layer of the first single face corrugated board with the valleys in the fluted layer of the second single face corrugated board; and aligning the valleys in the fluted layer of the first single face corrugated board with the peaks in the fluted layer of the second single face corrugated board.

5. The method of claim 4, wherein the alignment further comprising moving one of the first single face corrugated board or the second single face corrugated board relative to the other.

6. The method of claim 5, wherein moving one of the first single face corrugated board or the second single face corrugated board relative to the other comprised moving one of the first single face corrugated board or the second single face corrugated board faster than the other.

7. The method of any of claims 3-6, further comprising nesting the peaks in the fluted layer of the first single face corrugated board in the valleys of the fluted layer of the second single face corrugated board.

8. The method of any of claims 3-7, further comprising nesting the peaks in the fluted layer of the second single face corrugated board in the valleys of the fluted layer of the first single face corrugated board. Docket No. 17705.190.1.1a

9. The method of any of claims 1-8, wherein attaching the first single face corrugated board to the second single face corrugated board comprises attaching the fluted layer of the first single face corrugated board to the fluted layer of the second single face corrugated board.

10. The method of any of claims 1-9, wherein attaching the first single face corrugated board to the second single face corrugated board comprises applying water, glue, or adhesive to the fluted layer of the first single face corrugated board and/or the fluted layer of the second single face corrugated board.

11. The method of claim 10, wherein applying water, glue, or adhesive to the fluted layer of the first single face corrugated board and/or the fluted layer of the second single face corrugated board comprises applying water, glue, or adhesive to substantially an entire surface of the fluted layer of the first single face corrugated board and/or the fluted layer of the second single face corrugated board.

12. The method of claim 10, wherein applying water, glue, or adhesive to the fluted layer of the first single face corrugated board and/or the fluted layer of the second single face corrugated board comprises applying water, glue, or adhesive to only the peaks of the fluted layer of the first single face corrugated board and/or the fluted layer of the second single face corrugated board.

13. The method of claim 10, wherein applying water, glue, or adhesive to the fluted layer of the first single face corrugated board and/or the fluted layer of the second single face corrugated board comprises applying water, glue, or adhesive to only the valleys of the fluted layer of the first single face corrugated board and/or the fluted layer of the second single face corrugated board.

14. The method of claim 10, wherein applying water, glue, or adhesive to the fluted layer of the first single face corrugated board and/or the fluted layer of the second single face corrugated board comprises applying water, glue, or adhesive to only the peaks and the valleys of the fluted layer of the first single face corrugated board and/or the fluted layer of the second single face corrugated board.

15. The method of any of claims 10-14, wherein the water, glue, or adhesive is applied with a nozzle.

16. The method of any of claim 10-14, wherein the water, glue, or adhesive is applied with a roller.

17. The method of any of claims 10-16, wherein attaching the first single face corrugated board to the second single face corrugated board further comprises applying ultrasonic vibrations to the Docket No. 17705.190.1.1a first single face corrugated board and/or the second single face corrugated board to activate, heat, and/or dry the water, glue, or adhesive.

18. The method of any of claims 1-17, further comprising compressing the first single face corrugated board and the second single face corrugated board together.

19. The method of any of claims 1-18, wherein attaching the first single face corrugated board to the second single face corrugated board comprises applying pressure and ultrasonic vibrations to the first single face corrugated board and/or the second single face corrugated board to bond together the first single face corrugated board and the second single face corrugated board.

20. A system for producing dual fluted corrugated boards, the system comprising: a first supply of single face corrugated board having a liner layer and a fluted layer attached to the liner layer, the fluted layer comprising a plurality of peaks and valleys; a second supply of single face corrugated board having a liner layer and a fluted layer attached to the liner layer, the fluted layer comprising a plurality of peaks and valleys; an adhesive applicator configured to apply water, glue, or an adhesive to the fluted layer of the first supply and/or the fluted layer of the second supply; first and second merger guides configured to guide the single face corrugated boards of the first and second supplies, respectively, into engagement with one another, such that the peaks of the first supply nest within the valleys of the second supply and the peaks of the second supply next within the valleys of the first supply; and a sensor to detect proper engagement and nesting of the single face corrugated boards of the first and second supplies with one another.

21. The system of claim 19, further comprising an ultrasonic device configured to apply ultrasonic vibrations to one or both of the single face corrugated boards of the first and second supplies, the ultrasonic vibrations being configured to activate, heat, and/or dry the water, glue, or adhesive.

22. The system of claim 20 or 21, further comprising a feed wheel configured to guide the single face corrugate board of the first supply to the first merger guide and maintain a separation between the single face corrugated boards of the first and second supplies.

23. The system of any of claims 20-22, wherein the adhesive applicator comprises a glue wheel or a nozzle.

24. The system of any of claims 20-23, wherein the sensor comprises a photoelectric sensor.

17 Docket No. 17705.190.1.1a

25. The system of any of claims 20-24, further comprising first and second feed wheels configured to engage and advance the single face corrugate boards of the first and second supplies, respectively.

26. The system of claim 25, wherein the first and second feed wheels are configured to selectively advance the single face corrugate boards of the first and second supplies, respectively, at different rates or at the same rate.

27. The system of claim 25 or 26, wherein first and second feed wheels are configured to press the single face corrugate boards of the first and second supplies together to facilitate attachment therebetween.

28. The system of any of claims 20-27, further comprising one or more crossheads or one or more longheads configured to perform one or more conversion functions on the dual fluted corrugated boards.

29. A method for making a dual fluted corrugated board, the method comprising: providing a first single face corrugated board having a liner layer and a fluted layer attached to the liner layer, the fluted layer comprising a plurality of peaks and valleys facing away from the liner layer; providing a second single face corrugated board having a liner layer and a fluted layer attached to the liner layer, the fluted layer comprising a plurality of peaks and valleys facing the fluted layer of the first single face corrugated board; applying water, glue, or an adhesive to the fluted layer of the first single face corrugated board and/or to the fluted layer of the second single face corrugated board; aligning the fluted layer of the first single face corrugated board with the to the fluted layer of the second single face corrugated board such that: the peaks in the fluted layer of the first single face corrugated board are aligned with the valleys in the fluted layer of the second single face corrugated board; and the valleys in the fluted layer of the first single face corrugated board are aligned with the peaks in the fluted layer of the second single face corrugated board; and pressing together the first single face corrugated board and the second single face corrugated board.

30. The method of claim 29, further comprising applying ultrasonic vibrations to the first single face corrugated board and/or the second single face corrugated board to activate, heat, and/or cure the water, glue, or adhesive.

18 Docket No. 17705.190.1.1a

31. The method of claim 29 or 30, wherein aligning the fluted layer of the first single face corrugated board with the to the fluted layer of the second single face corrugated board comprising monitoring the relative positions of the peaks and valleys to ensure a nesting relationship.

32. The method of any of claims 29-31, wherein aligning the fluted layer of the first single face corrugated board with the to the fluted layer of the second single face corrugated board comprising advancing one of the first single face corrugated boards faster or slower than the other.

33. A system for producing dual fluted corrugated boards, the system comprising: a first supply of single face corrugated board having a liner layer and a fluted layer attached to the liner layer, the fluted layer comprising a plurality of peaks and valleys; a second supply of single face corrugated board having a liner layer and a fluted layer attached to the liner layer, the fluted layer comprising a plurality of peaks and valleys; first and second merger guides configured to guide the single face corrugated boards of the first and second supplies, respectively, into engagement with one another, such that the peaks of the first supply nest within the valleys of the second supply and the peaks of the second supply next within the valleys of the first supply; and a sensor to detect proper engagement and nesting of the single face corrugated boards of the first and second supplies with one another.

34. The system of claim 33, further comprising an ultrasonic device configured to apply pressure and ultrasonic vibrations to one or both of the single face corrugated boards of the first and second supplies to bond together the single face corrugated boards of the first and second supplies.

35. The system of claim 33 or 34, further comprising a feed wheel configured to guide the single face corrugate board of the first supply to the first merger guide and maintain a separation between the single face corrugated boards of the first and second supplies.

36. The system of any of claims 33-35, wherein the sensor comprises a photoelectric sensor.

37. The system of any of claims 33-36, further comprising first and second feed wheels configured to engage and advance the single face corrugate boards of the first and second supplies, respectively.

38. The system of claim 37, wherein the first and second feed wheels are configured to selectively advance the single face corrugate boards of the first and second supplies, respectively, at different rates or at the same rate.

19 Docket No. 17705.190.1.1a

39. The system of any of claims 33-38, further comprising one or more crossheads or one or more longheads configured to perform one or more conversion functions on the dual fluted corrugated boards.

40. A dual fluted corrugated board, comprising: a first single face corrugated board having a liner layer and a fluted layer attached to the liner layer; and a second single face corrugated board having a liner layer and a fluted layer attached to the liner layer, wherein the first single face corrugated board and the second single face corrugated board are arranged such that the fluted layers thereof face one another and are attached to one another.

41. The dual fluted corrugated board of claim 40, wherein the fluted layers of the first single face corrugated board and the second single face corrugated board are attached to one another within mating peaks and troughs thereof.

42. The dual fluted corrugated board of claim 40 or 41, wherein the fluted layers of the first single face corrugated board and the second single face corrugated board are attached to one another along substantially the entire lengths thereof.

43. A dual fluted corrugated board, comprising: a first liner layer a first fluted layer attached to the first liner layer; a second fluted layer attached to the first fluted layer; and a second liner layer attached to the second fluted layer.

44. The dual fluted corrugated board of claim 43, wherein the first and second fluted layers each have alternating peaks and valleys.

45. The dual fluted corrugated board of claim 44, wherein the peaks of the first fluted layer mate with the valleys of the second fluted layer and the peaks of the second fluted layer mate with the valleys of the first fluted layer.

46. The dual fluted corrugated board of claim 44 or 45, wherein the first and second fluted layers are attached to one another within mating peaks and valleys thereof.

47. The dual fluted corrugated board of any of claims 43-46, wherein the first and second fluted layers are attached to one another along substantially the entire lengths thereof.

48. A method for making a single face corrugated board, the method comprising: forming a fluted layer from a first sheet material, the fluted layer comprising a series of peaks and valleys; and

20 Docket No. 17705.190.1.1a attaching a liner layer to the fluted layer, wherein attaching the liner layer to the fluted layer comprises: pressing the fluted layer and the liner layer together; and applying ultrasonic vibrations to one or both of the fluted layer and the liner layer.

49. The method of claim 48, wherein attaching the liner layer to the fluted layer further comprises applying water, glue, or another adhesive to the fluted layer or the liner layer before pressing the fluted layer and the liner layer together.

50. The method of claim 49, wherein applying ultrasonic vibrations to one or both of the fluted layer and the liner layer releases the water from the fluted layer or the liner layer.

51. The method of claim 49 or 50, wherein applying ultrasonic vibrations to one or both of the fluted layer and the liner layer activates, dries, or cures the water, glue, or adhesive.

21

Description:
Docket No. 17705.190.1.1a

SYSTEMS AND METHODS FOR FORMING DUAL FLUTED CORRUGATED BOARD CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to United States Patent Application Serial No. 17/474,869, filed September 14, 2021, and entitled Systems and Methods for Forming Dual Fluted Corrugated Board, which claims priority to and the benefit of United States Patent Application Serial No. 63/150,899, filed February 18, 2021, and entitled Systems and Methods for Forming Dual Fluted Corrugated Board with Ultrasound, and United States Patent Application Serial No. 63/079,350, filed September 16, 2020, and entitled Systems and Methods for Forming Dual Fluted Corrugated Board, the disclosures of which are incorporated herein by this reference in their entireties.

1. Technical Field

[0002] Exemplary embodiments of the disclosure relate to systems, methods, and devices for forming corrugated board. More specifically, exemplary embodiments relate to systems, methods, and devices for forming dual fluted board from two single face corrugated boards.

BRIEF SUMMARY

[0003] Exemplary embodiments of the disclosure relate to systems, methods, and devices for forming corrugated board. More specifically, exemplary embodiments relate to systems, methods, and devices for forming dual fluted corrugated board from two single face corrugated boards. In some embodiments, the two single face corrugated boards are joined together using ultrasound.

[0004] For instance, one embodiment is directed to a method for making a dual fluted corrugated board. The method includes providing a first single face corrugated board having a liner layer and a fluted layer attached to the liner layer and providing a second single face corrugated board having a liner layer and a fluted layer attached to the liner layer. The first single face corrugated board and the second single face corrugated board are arranged such that the fluted layers thereof face one another. The first single face corrugated board is attached to the second single face corrugated board. In some embodiments, the first and second single face corrugated boards are attached together using an adhesive. In some embodiments, the adhesive is activated, heated, and/or dried using ultrasound. The ultrasonic vibrations may be configured to remove moisture from the single face corrugate boards, activate, heat, and/or dry the adhesive, and/or cause the paper fibers of the single face corrugated boards to weave, intertwine, or otherwise stick together to achieve the bonding. Docket No. 17705.190.1.1a

[0005] According to another embodiment, a system for producing dual fluted corrugated boards includes a first supply of single face corrugated board having a liner layer and a fluted layer attached to the liner layer and a second supply of single face corrugated board having a liner layer and a fluted layer attached to the liner layer. Each of the fluted layers has a plurality of peaks and valleys. The system also includes an adhesive applicator configured to apply an adhesive to the fluted layer of the first supply and/or the fluted layer of the second supply. First and second merger guides are configured to guide the single face corrugated boards of the first and second supplies, respectively, into engagement with one another such that the peaks of the first supply nest within the valleys of the second supply and the peaks of the second supply nest within the valleys of the first supply. A sensor can detect proper engagement and nesting of the single face corrugated boards of the first and second supplies with one another. An ultrasonic device can activate, heat, and/or dry the adhesive and/or cause the fibers of the first and second single face corrugated boards to weave, intertwine, or otherwise stick or bond together.

[0006] In still another embodiment, a method for making a dual fluted corrugated board includes providing a first single face corrugated board having a liner layer and a fluted layer attached to the liner layer and providing a second single face corrugated board having a liner layer and a fluted layer attached to the liner layer. Each of the fluted layers includes a plurality of peaks and valleys facing one another. Adhesive is applied to the fluted layer of the first single face corrugated board and/or to the fluted layer of the second single face corrugated board. The fluted layer of the first single face corrugated board is aligned with the fluted layer of the second single face corrugated board such that (i) the peaks in the fluted layer of the first single face corrugated board are aligned with the valleys in the fluted layer of the second single face corrugated board, and (ii) the valleys in the fluted layer of the first single face corrugated board are aligned with the peaks in the fluted layer of the second single face corrugated board. The first single face corrugated board and the second single face corrugated board are pressed together such that the fluted layers thereof are nested together. Ultrasound is used to activate, heat, and/or dry the adhesive and/or cause the fibers of the first and second single face corrugated board to weave or intertwine to securely bond the first and second single face corrugated boards together.

[0007] These and other objects and features of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the disclosure as set forth hereinafter. Docket No. 17705.190.1.1a

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0009] Figure 1 A illustrates a single face corrugated board;

[0010] Figure IB illustrates a single wall corrugated board;

[0011] Figure 1C illustrates a double wall corrugated board;

[0012] Figure ID illustrates a triple wall corrugated board;

[0013] Figure 2 illustrates an example system for forming single face corrugated boards; [0014] Figure 3 A illustrates an example system for forming dual fluted corrugated boards;

[0015] Figure 3B illustrates another example system for forming dual fluted corrugated boards using ultrasound; and

[0016] Figure 4 illustrates an example embodiment of a dual fluted corrugated board.

DETAILED DESCRIPTION

[0017] While the present disclosure will describe details of embodiments with reference to specific configurations, the descriptions are illustrative and are not to be construed as limiting the scope of the present invention. Various modifications can be made to the illustrated configurations without departing from the spirit and scope of the invention as defined by the claims. For better understanding, like components have been designated by like reference numbers throughout the various accompanying figures.

[0018] Shipping and packaging industries frequently use corrugate board to create boxes and other packaging materials, including protective inserts that are placed inside of boxes to further protect items packaged therein. As shown in Figures 1A-1D, there are various of types of corrugated boards. The most basic type of corrugated board is referred to as a single face board. As shown in Figure 1A, a single face board 100 has only two layers, a corrugated or fluted layer 102 and a liner layer 104. Single face boards are not as durable as the other types of corrugated boards. As a result, single face boards are often used inside of boxes to add extra cushioning or protection to items packaged therein.

[0019] Figure IB shows a more common type of corrugated board, which is referred to as a single wall board 106. A single wall board 106 includes two outer liners 108a, 108b and a middle Docket No. 17705.190.1.1a corrugated or fluted layer 110 attached to the outer liners 108a, 108b. A single wall board provides far superior strength and rigidity compared to single face boards. As a result, single wall boards are commonly used to form shipping boxes.

[0020] Figure 1C shows a double wall board 112. Double wall board 112 includes two outer liners 114a, 114b, two corrugated or fluted layers 116a, 116b, and a middle liner 118. As can be seen in Figure 1C, the fluted layer 116a is positioned between and attached to the outer liner 114a and the middle liner 118 and the fluted layer 116b is position between and attached to the outer liner 114b and the middle liner 118. The middle liner 118 also separates the fluted layers 116a, 116b from each other. The multi-layered nature of the double wall board 112 makes it highly rigid and durable. As a result, double wall boards are often used to form industrial strength cartons.

[0021] Figure ID shows a triple wall board 120. Triple wall board 120 includes two outer liners 122a, 122b, three corrugated or fluted layers 124a, 124b, 124c, and two middle liners 126a, 126b. As can be seen in Figure ID, the fluted layer 124a is positioned between and attached to the outer liner 122a and the middle liner 126a, the fluted layer 124b is positioned between and attached to the middle liner 126a and the middle liner 126b, and the fluted layer 124c is position between and attached to the outer liner 122b and the middle liner 126b. The middle liner 126a separates the fluted layers 124a, 124b from each other and the middle liner 126b separates the fluted layers 124b, 124c from each other. The multi-layered nature of the triple wall board 120 makes it highly rigid and durable. As a result, triple wall boards are often used in place of wood to create shipping crates.

[0022] Figure 2 illustrates one example embodiment of a system 130 that can be employed to form single face boards, such as single face board 100 from Figure 1 A. As can be seen in Figure 2, system 130 includes first and second streams of sheet material 132a, 132b. Sheet material 132a will become the fluted layer (e.g., fluted layer 102, Figure 1A) and sheet material 132b will become the liner layer (e.g., liner layer 104, Figure 1 A) of the single face board.

[0023] Sheet material 132a is fed partially around/through fluting rollers 134a, 134b to fold sheet material 132a into the fluted configuration shown. More specifically, the fluting rollers 134a, 134b include alternating and nesting/mating peaks and valleys formed on the exterior surfaces thereof. As the fluting rollers 134a, 134b rotate, sheet material 132a is compressed between the nesting/mating peaks and valleys, thereby folding sheet material 132a into the fluted configuration.

[0024] As sheet material 132a rotates about fluting roller 134b, a liquid (e.g., water), glue, or another adhesive (water, glue, and adhesive may be generally referred to herein as an adhesive) is Docket No. 17705.190.1.1a applied thereto. In the illustrated embodiment, a glue wheel 136 rotates through a reservoir 135 of water, glue, or another adhesive. As the glue wheel 136 rotates, it picks up water, glue, or another adhesive from reservoir 135. With further rotation of the glue wheel 136, the water, glue, or another adhesive thereon is brought into contact with the peaks on one side of the fluted sheet material 132a and is transferred thereto.

[0025] With the water, glue, or another adhesive applied thereto and further rotation of fluting roller 134b, the fluted sheet material 132a is brought into contact with the sheet material 132b. A pressure roller 138 and the peaks of the fluted roller 134b apply pressure between the peaks of the fluted sheet material 132a and the sheet material 132b with the water, glue, or adhesive therebetween to help bond the sheet materials 132a, 132b together.

[0026] It will be appreciated that the system and process shown and described in connection with Figure 2 for forming single face corrugate boards is merely exemplary. Other systems, processes, and devices for forming single face corrugate boards may be used in connection with the disclosed embodiments.

[0027] Attention is now directed to Figure 3 A, which illustrates a system 150 for making dual fluted corrugated boards and boxes therefrom. As can be seen, system 150 includes first and second supplies 152a, 152b of single face corrugate boards 154a, 154b. The single face corrugate board 154a includes a liner 156a and a fluted layer 158a and the single face corrugate board 154b includes a liner 156b and a fluted layer 158b.

[0028] The supplies 152a, 152b may be premanufactured and folded into fanfold bales or rolled into cylindrical bales, as shown in Figure 3 A. The premanufactured supplies 152a, 152b may be positioned and used in system 150 to form dual fluted corrugate boards, as described below. Alternatively, the supplies 152a, 152b may not be premanufactured. Rather, the supplies 152a, 152b may include first and second systems similar to system 130 from Figure 2. Such systems may produce single face corrugate boards 154a, 154b on demand or as needed by system 150.

[0029] Whether the single face corrugate boards 154a, 154b are premanufactured or made on demand, system 150 can use the single face corrugate boards 154a, 154b to form a dual fluted corrugate board 160. The dual fluted corrugate board 160 includes opposing outer layers formed from liners 156a, 156b from the single face corrugate boards 154a, 154b. The dual fluted corrugate board 160 also includes a dual fluted layer formed from fluted layers 158a, 158b from the single face corrugate boards 154a, 154b. As will be described in more detail below, the fluted layers 158a, 158b are glued or otherwise attached to one another. Attaching the fluted layers 158a, 158b Docket No. 17705.190.1.1a together attaches the single face corrugate boards 154a, 154b together and forms a corrugated board with opposing outer layers and an inner fluted layer that is two layers thick.

[0030] As can be seen in Figure 3 A, the single face corrugate boards 154a, 154b are spaced apart from one another and fed along merging guides 162a, 162b. A feed wheel 164 may guide/advance the single face corrugate board 154a towards the merging guide 162a. The feed wheel 164 may also maintain a desired space or separation between the single face corrugate boards 154a, 154b during an initial phase of the process.

[0031] As the single face corrugate boards 154a, 154b advance along the merging guides 162a, 162b, water, glue, or another adhesive may be applied to one or both of the fluted layers 158a, 158b. For instance, as shown in Figure 3A, glue wheels 166a, 166b may apply water, glue, or another adhesive to the peaks of the fluted layers 158a, 158b that face one another. Alternatively, or additionally, as shown in Figure 3 A, one or more nozzles 168 may spray water, glue, or another adhesive onto one or both of the surfaces of the fluted layers 158a, 158b that face one another. In some embodiments, the one or more nozzles 168 may apply water, glue, or another adhesive to substantially the entire surfaces of the fluted layers 158a, 158b that face one another. In other embodiments, the one or more nozzles 168 may apply water, glue, or another adhesive to only portions of the surfaces of the fluted layers 158a, 158b that face one another. For instance, the one or more nozzles 168 may only apply water, glue, or another adhesive to the peaks of the fluted layers 158a, 158b that face one another.

[0032] Once water, glue, or another adhesive has been applied to the fluted layers 158a, 158b, the merging guides 162a, 162b may guide the single face corrugate boards 154a, 154b together. More specifically, the distance between the merging guides 162a, 162b may decreases so as to bring the single face corrugate boards 154a, 154b closer together and ultimately into contact with one another. The single face corrugate boards 154a, 154b may be brought into contact with one another such that the fluted layers 158a, 158b nest or mate within each other. That is, for example, the peaks on the fluted layer 158a may nest or mate within the valleys in the fluted layer 158b and the peaks on the fluted layer 158b may nest or mate within the valleys in the fluted layer 158a.

[0033] The system 150 also include feed wheels 170a, 170b. The feed wheels 170a, 170b may assist with advancing the single face corrugate boards 154a, 154b/dual fluted corrugate board 160. As noted below, the feed wheels 170a, 170b may advance the single face corrugate boards 154a, 154b at different rates and/or at the same rate. Additionally, in some embodiments, the feed wheels 170a, 170b may also press the single face corrugate boards 154a, 154b together to facilitate a Docket No. 17705.190.1.1a strong attachment between the fluted layers 158a, 158b and the water, glue, or another adhesive applied thereto.

[0034] As noted above, the merging guides 162a, 162b bring the single face corrugate boards 154a, 154b closer together and into contact with one another. It is important to ensure that the single face corrugate boards 154a, 154b are properly aligned when they are brought together. In particular, it is important to ensure that the fluted layers 158a, 158b are aligned with one another in mating or nesting fashion (e.g., so the peaks of one fluted layer will nest in the valleys of the other fluted layer). If the fluted layers 158a, 158b are not properly aligned with one another, the fluting layers 158a, 158b may not properly attach to each other. Additionally, the peaks of the fluting layers 158a, 158b may compress against one another, thereby deforming the peaks and reducing the strength of the dual fluted corrugate board 160.

[0035] To monitor whether the fluted layers 158a, 158b are properly aligned with one another and ensure that the peaks and valleys thereof are properly nesting together, the system 150 may include a sensor 172, such as a photoelectric sensor or photo eye. The sensor 172 may be positioned along the side of the single face corrugate boards 154a, 154b/dual fluted corrugate board 160. The sensor 172 may be positioned to “see” through the nested peaks and valleys of the combined fluted layers 158a, 158b. However, if the fluted layers 158a, 158b are not aligned and properly nesting, the fluted layers 158a, 158b may become deformed. The deformed fluted layers 158a, 158b may block the vision of the sensor 172, thereby indicating that the fluted layers 158a, 158b are misaligned.

[0036] When the fluted layers 158a, 158b are misaligned, the rotational speed of one or both of the feed wheels 170a, 170b may be adjusted. For instance, the speed of feed wheel 170a may be (at least temporarily) increased to advance the single face corrugate board 154a faster than the single face corrugate board 154b. By at least temporarily advancing the single face corrugate board 154a faster than the single face corrugate board 154b, the fluted layers 158a, 158b may be aligned with one another. Once the fluted layers 158a, 158b are aligned with one another, the peaks and valleys thereof will properly nest or mate together. When the peaks and valleys properly nest together, the sensor 172 will be able to “see” through the combined peaks and valleys and the speeds of the feed wheels 170a, 170b may be synchronized.

[0037] Once formed, the dual fluted corrugate board 160 may be converted into a box template. For instance, as shown in Figure 3 A, one or more crossheads 174 and/or one or more longheads 176 may perform one or more conversion functions on the dual fluted corrugate board Docket No. 17705.190.1.1a folds, bend, and the like. The box template may then be erected into a box. The one or more crossheads 174 and/or one or more longheads 176 may be part of a box making machine 178.

[0038] As is well known in the art, fanfold or z-fold corrugate material is often used by box making machines to form box templates therefrom, and particularly box making machines that form custom sized box templates. Fanfold or z-fold corrugate material is corrugate material that has been folded back and forth on itself to form a stack or bale of corrugate material. Such stacks or bales of corrugate material allow for the corrugate to be stored and transported (e.g., on pallets) in an efficient manner. However, there are some potential drawbacks to fanfold or z-fold corrugate material. For instance, the folds or creases formed in the corrugate material when making the stacks or bales remain in the corrugate material even after the corrugate material is unfolded or removed from the stack or bale. The folds or creases can pose challenges for processing the corrugate material, including feeding the corrugate material through box making machines, etc. Additionally, the folds or creases can also be undesirable in a finished box. For instance, if the folds or creases are located in certain areas of a finished box, the box may have slightly less strength or may be visually less appealing.

[0039] Using the disclosed corrugate making systems in conjunction with a box making machine can avoid the potential drawbacks associated with fanfold or z-fold corrugate material. That is, the corrugate making systems disclosed herein may be associated with a box making machine such that the newly formed corrugate material can be fed into the box making machine without having the corrugate material first formed into a fanfold or z-fold bale. Feeding the newly formed corrugate material (that does not have fanfold or z-fold creases) directly into a box making machine reduces the challenges of processing the corrugate material (e.g., by the box making machine, etc.) and allows for boxes to be formed that are free of the fanfold or z-fold creases.

[0040] Nevertheless, the corrugate making systems disclosed herein are not required to be used directly with a box making machine. Rather, for instance, the disclosed corrugate making systems may be associated with a fanfold system that is configured to fold the newly formed corrugate into a fanfold or z-fold stack or bale.

[0041] Attention is now directed to Figured 3B, which illustrates a system 150’ for making dual fluted corrugated boards and boxes therefrom. In many respects, the system 150’ is similar or identical to the system 150 from Figure 3 A. Accordingly, the discussion of the system 150’ will focus on those aspects that are particularly unique compared to the system 150.

[0042] The system 150’ includes one or more ultrasonic devices 180. In the illustrated embodiment, the ultrasonic device 180 is positioned between the sensor 172 and the feed wheels Docket No. 17705.190.1.1a

170a, 170b. However, the ultrasonic device 180 may be positioned at other locations within the system 150’. For instance, the ultrasonic device 180 may be positioned between the feed wheels 170a, 170b and the crosshead 174.

[0043] The ultrasonic device 180 may be used to facilitate bonding of the single face corrugate boards 154a, 154b. For instance, as the single face corrugate boards 154a, 154b pass by or through the ultrasonic device 180, the ultrasonic device 180 may activate the water, glue, or other adhesive that was previously applied to the fluted layers 158a, 158b. In some embodiments, the water, glue, or other adhesive affects the fibers of the single face corrugate boards 158a, 158b in a way that facilitates bonding between the fibers and, thus, the single face corrugate boards 158a, 158b. For instance, the water, glue, or other adhesive may soften an outer fiber layer from the fibers of the single face corrugate board 158a, 158b or/or cause the fibers to loosen from one another. As the water, glue, or other adhesive dries, sets, or cures, the fibers of the single face corrugate boards 158a, 158b that are contacting one another may weave, intertwine, or otherwise stick together to bond the single face corrugate boards 158a, 158b together.

[0044] With the water, glue, or other adhesive activated, the ultrasonic device 180 and/or the feed wheels 170a, 170b may presses the single face corrugate boards 154a, 154b together (with the activated water, glue, or other adhesive therebetween) and the activated water, glue, or other adhesive may bond the single face corrugate boards 154a, 154b together.

[0045] In some embodiments, activating the water, glue, or other adhesive may include heating the water, glue, or other adhesive. The ultrasonic device 180 may produce ultrasonic vibrations (and optionally pressure) that heat the water, glue, or other adhesive enough to enable the water, glue, or other adhesive to bond with another surface. In such embodiments, the ultrasonic device 180 is likely to be positioned upstream of the feed wheels 170a, 170b, such that the ultrasonic device 180 is able to activate the water, glue, or other adhesive before the feed wheels 170b, 170b press the single face corrugate boards 154a, 154b together.

[0046] In other embodiments, the ultrasonic device 180 may be used to dry or cure the previously applied water, glue, or another adhesive. For instance, if water is previously applied to the corrugate boards 154a, 154b, the ultrasonic device 180 may produce ultrasonic vibrations (and optionally pressure) that cause the corrugate boards 154a, 154b to release the water or moisture therefrom. In embodiments where glue or another adhesive has previously been applied to the corrugate boards 154a, 154b, the ultrasonic device 180 may produce ultrasonic vibrations (and optionally pressure) that cause the glue or other adhesive to release moisture, thereby facilitating drying or curing of the glue or other adhesive. In such embodiments, the ultrasonic device 180 is Docket No. 17705.190.1.1a likely to be positioned downstream of the feed wheels 170a, 170b, such that the ultrasonic device 180 is able to dry or cure the water, glue, or other adhesive after the feed wheels 170b, 170b press the single face corrugate boards 154a, 154b together.

[0047] It will be appreciated that embodiments may include a first ultrasonic device 180 that is used to activate the water, glue, or other adhesive and a second ultrasonic device 180 that is used to dry or cure the water, glue, or other adhesive. In such embodiments, the first ultrasonic device 180 may be positioned upstream of the feed wheels 170a, 170b and the second ultrasonic device 180 may be positioned downstream of the feed wheels 170a, 170b.

[0048] In still other embodiments, the ultrasonic device 180 may be used to bond the first and second single face corrugated boards 154a, 154b together without using glue or another adhesive. For instance, the ultrasonic device 180 or another device may press the first and second single face corrugated boards 154a, 154b together and the ultrasonic device 180 may produce ultrasonic vibrations that cause the materials of the first and second single face corrugated boards 154a, 154b to bond together.

[0049] Figure 4 illustrates a perspective view of the dual fluted corrugated board 160 created with either of the systems 150, 150’. As can be seen, the dual fluted corrugated board 160 includes first and second liners 156a, 156b on opposing sides thereof. Dispose between the first and second liners 156a, 156b are first and second fluted layers 158a, 158b. The first fluted layer 156a is attached to the first liner 156a and the second fluted layer 156b is attached to the second liner 156b (e.g., at outwardly facing peaks thereof). Additionally, the first and second fluted layers 156a, 156b are attached to one another. The first and second fluted layers 156a, 156b include alternating peaks and valleys. The peaks of one fluted layer mate with the valleys of the other fluted layer and vice versa. The first and second fluted layers 156a, 156b may be attached to one another along the entire or portions of the lengths thereof. For instance, the first and second fluted layers 156a, 156b may be attached to one another at the mating peaks and valleys or along the entire lengths thereof.

[0050] Notably, the strength of the dual fluted corrugate board 160 is significantly higher than a typical single wall corrugated board. The strength of corrugate boards is measured using the Edge Crush Test (“ECT”). A typical single wall corrugated board has an ECT value of about 32. In contrast, a dual fluted corrugate board as described herein has an ECT value of about 52. In other words, the extra fluting layer in the dual fluted corrugate board increases the strength/ECT value by about 62%. Docket No. 17705.190.1.1a

[0051] If such an increase in strength is not needed, a dual fluted corrugate board can be made that has similar strength/ECT value as a typical single wall corrugated board. To form such a dual fluted corrugated board, less sheet material is required. For instance, thinner sheet material may be used or the profile of the fluted layers may be changed (e.g., by making the peaks and valleys wider and/or shorter) to reduce the amount of sheet material used. As will be appreciated, using less material while providing the same or higher strength/ECT values is highly desirable.

[0052] In some embodiments, dual fluted corrugate boards as disclosed herein may provide similar strength/ECT values as common double wall corrugated boards. For instance, double wall corrugated boards typically have an ECT value of about 48. As noted above, a dual fluted corrugated board as described herein has an ECT value of about 52. Thus, the ECT value of the dual fluted corrugated boards disclosed herein is about 8% higher than a typical double wall corrugate board. This is particularly notable since the dual fluted corrugate boards require one less layer of sheet material to make compared to the double wall corrugated boards.

[0053] While the disclosed embodiments have focused on the formation of dual fluted corrugate boards, it will be appreciated that the disclosure is not limited to forming dual fluted corrugate boards. For instance, the disclosed embodiments may similarly be used to form single face, single wall, double wall, or triple wall corrugate boards. For instance, to form a single face corrugate board, the two sources of material (single face corrugate boards 154a, 154b) in Figures 3 A and 3B may be replaced by a source of liner material and a source of fluted material that can be joined together in a manner similar to that described above to form a single face corrugate board. Similar, to form a single wall corrugate board, one of the two sources of material (single face corrugate boards 154a, 154b) in Figures 3 A and 3B may be replaced with a source of liner material (without the attached fluted layer). The remaining single face corrugate board and the liner material may be joined together as described herein to form a single wall corrugate board.

[0054] According to one example embodiment, a system for producing dual fluted corrugated boards includes a first supply of single face corrugated board having a liner layer and a fluted layer attached to the liner layer, the fluted layer comprising a plurality of peaks and valleys; a second supply of single face corrugated board having a liner layer and a fluted layer attached to the liner layer, the fluted layer comprising a plurality of peaks and valleys; first and second merger guides configured to guide the single face corrugated boards of the first and second supplies, respectively, into engagement with one another, such that the peaks of the first supply nest within the valleys of the second supply and the peaks of the second supply next within the valleys of the Docket No. 17705.190.1.1a first supply; and a sensor to detect proper engagement and nesting of the single face corrugated boards of the first and second supplies with one another.

[0055] In some embodiments, the system includes an ultrasonic device configured to apply pressure and ultrasonic vibrations to one or both of the single face corrugated boards of the first and second supplies to bond together the single face corrugated boards of the first and second supplies.

[0056] In some embodiments, the system includes a feed wheel configured to guide the single face corrugate board of the first supply to the first merger guide and maintain a separation between the single face corrugated boards of the first and second supplies.

[0057] In some embodiments, the system includes first and second feed wheels configured to engage and advance the single face corrugate boards of the first and second supplies, respectively. [0058] In some embodiments, the first and second feed wheels are configured to selectively advance the single face corrugate boards of the first and second supplies, respectively, at different rates or at the same rate.

[0059] In some embodiments, the system includes an adhesive applicator configured to apply water, glue, or another adhesive to the fluted layer of the first supply and/or the fluted layer of the second supply.

[0060] In one embodiment, a system for producing dual fluted corrugated boards includes a first supply of single face corrugated board having a liner layer and a fluted layer attached to the liner layer, the fluted layer comprising a plurality of peaks and valleys; a second supply of single face corrugated board having a liner layer and a fluted layer attached to the liner layer, the fluted layer comprising a plurality of peaks and valleys; an adhesive applicator configured to apply water, glue, or an adhesive to the fluted layer of the first supply and/or the fluted layer of the second supply; first and second merger guides configured to guide the single face corrugated boards of the first and second supplies, respectively, into engagement with one another, such that the peaks of the first supply nest within the valleys of the second supply and the peaks of the second supply next within the valleys of the first supply; and an ultrasonic device configured to apply ultrasonic vibrations to one or both of the single face corrugated boards of the first and second supplies, the ultrasonic vibrations being configured to activate, heat, and/or dry the water, glue, or adhesive and/or cause fibers of the single face corrugated boards to weave, intertwine, or otherwise stick together.

[0061] In some embodiments, the system includes a sensor to detect proper engagement and nesting of the single face corrugated boards of the first and second supplies with one another. Docket No. 17705.190.1.1a

[0062] In some embodiments, the system includes a feed wheel configured to guide the single face corrugate board of the first supply to the first merger guide and maintain a separation between the single face corrugated boards of the first and second supplies.

[0063] In some embodiments, the adhesive applicator comprises a glue wheel or a nozzle.

[0064] In some embodiments, the system also includes first and second feed wheels configured to engage and advance the single face corrugate boards of the first and second supplies, respectively, wherein the first and second feed wheels are configured to: selectively advance the single face corrugate boards of the first and second supplies, respectively, at different rates or at the same rate; or press the single face corrugate boards of the first and second supplies together to facilitate attachment therebetween.

[0065] In one embodiment, a method for making a dual fluted corrugated board includes providing a first single face corrugated board having a liner layer and a fluted layer attached to the liner layer; providing a second single face corrugated board having a liner layer and a fluted layer attached to the liner layer; arranging the first single face corrugated board and the second single face corrugated board such that the fluted layers thereof face one another; and attaching the fluted layer of the first single face corrugated board to the fluted layer of the second single face corrugated board.

[0066] In some embodiments, attaching the fluted layer of the first single face corrugated board to the fluted layer of the second single face corrugated board comprises applying ultrasonic vibrations to one or both of the first and second single face corrugated boards.

[0067] In some embodiments, the fluted layer of the first single face corrugated board comprises a plurality of peaks and valleys facing the fluted layer of the second single face corrugated board; and the fluted layer of the second single face corrugated board comprises a plurality of peaks and valleys facing the fluted layer of the first single face corrugated board, and the method further comprises: aligning the peaks in the fluted layer of the first single face corrugated board with the valleys in the fluted layer of the second single face corrugated board; and aligning the valleys in the fluted layer of the first single face corrugated board with the peaks in the fluted layer of the second single face corrugated board.

[0068] In some embodiments, the alignment further comprises moving one of the first single face corrugated board or the second single face corrugated board relative to the other.

[0069] In some embodiments, moving one of the first single face corrugated board or the second single face corrugated board relative to the other comprised moving one of the first single face corrugated board or the second single face corrugated board faster than the other. Docket No. 17705.190.1.1a

[0070] In some embodiments, the method nesting the peaks in the fluted layer of the first single face corrugated board in the valleys of the fluted layer of the second single face corrugated board; and nesting the peaks in the fluted layer of the second single face corrugated board in the valleys of the fluted layer of the first single face corrugated board.

[0071] In some embodiments, attaching the first single face corrugated board to the second single face corrugated board comprises attaching the fluted layer of the first single face corrugated board to the fluted layer of the second single face corrugated board.

[0072] In some embodiments, attaching the first single face corrugated board to the second single face corrugated board comprises applying water, glue, or adhesive to the fluted layer of the first single face corrugated board and/or the fluted layer of the second single face corrugated board.

[0073] In some embodiments, attaching the first single face corrugated board to the second single face corrugated board further comprises applying ultrasonic vibrations to the first single face corrugated board and/or the second single face corrugated board to activate, heat, and/or dry the water, glue, or adhesive, and/or cause fibers thereof to weave, intertwine, or otherwise stick to one another.

[0074] In some embodiments, the method includes the first single face corrugated board and the second single face corrugated board together.

[0075] In some embodiments, attaching the first single face corrugated board to the second single face corrugated board comprises applying pressure and ultrasonic vibrations to the first single face corrugated board and/or the second single face corrugated board to bond together the first single face corrugated board and the second single face corrugated board.

[0076] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. Thus, the described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.