SYSTEMS AND METHODS FOR FORMING CORRUGATED BOARDS WITH ULTRASOUND

Abstract

Systems and methods for forming corrugated boards are disclosed. The system includes a single face unit configured to form a single face board having a fluted layer and an outer liner. The system also includes a single face buffer configured to store or hold a length of the single face board. The system has a glue station configured to attach a second outer liner to the single face board to form a single wall board. The system also has an ultrasonic unit configured to apply ultrasonic vibrations to the single wall board. The ultrasonic vibrations are configured to remove moisture from the single wall board, activate, heat, and/or dry an adhesive used to attach the fluted layer and the outer liners, and/or cause the fibers of the fluted layer and the outer liners to weave, intertwine, or otherwise stick together.

Description

Claims

1. A system for forming corrugated boards, the system comprising: a glue station configured to attach a single face board and an outer liner together with a liquid to form a single wall board;an ultrasonic device configured to apply ultrasonic vibrations to the single wall board, the ultrasonic vibrations being configured to remove moisture from the single wall board;a creasing unit configured to form creases in the single wall board; anda folding unit configured to fold the single wall board into a stack or bale.

2. The system of claim 1, wherein the glue station is configured to apply glue to the single face board or the outer liner.

3. The system of claim 1, wherein the glue station is configured to press the single face board and the outer liner together with the liquid therebetween to form the single wall board.

4. The system of claim 1, wherein the ultrasonic device is positioned downstream of the glue station.

5. The system of claim 1, further comprising a cutting unit configured to cut the single wall board along a length or width thereof.

6. The system of claim 5, wherein the cutting unit is positioned between the ultrasonic device and the creasing unit.

7. The system of claim 1, wherein the creasing unit is configured to form creases in a first side of the single wall board and creases in a second side of the single wall board.

8. The system of claim 7, wherein the creases formed in the first side and the creases formed in the second side alternated with one another.

9. The system of claim 1, further comprising a single face unit configured to form the single face board, the single face board having a fluted layer and an outer liner.

10. The system of claim 9, wherein the single face unit comprises: first and second fluting rollers configured to fold a sheet material into the fluted layer, the first and second fluting rollers comprising mating peaks and valleys that are configured to fold the sheet material such that the fluted layer has alternating peaks and valleys; andan adhesive applicator that is configured to apply an adhesive to the fluted layer while the fluted layer is at least partially wrapped around the second fluting roller.

11. The system of claim 10, wherein the single face unit further comprises a pressure roller, the pressure roller and the second fluting roller being configured to press the fluted layer and the outer liner together to form the single face board.

12. An apparatus for forming corrugate boards, the apparatus comprising: a single face unit configured to form a single face board having a fluted layer and an outer liner, the single face unit comprising: first and second fluting rollers configured to fold a sheet material into the fluted layer, the first and second fluting rollers comprising mating peaks and valleys that are configured to fold the sheet material such that the fluted layer has alternating peaks and valleys; andan adhesive applicator that is configured to apply an adhesive to the fluted layer while the fluted layer is at least partially wrapped around the second fluting roller.

13. The apparatus of claim 12, wherein the single face unit further comprises a pressure roller, the pressure roller being configured to press the fluted layer and the outer liner together to form the single face board.

14. The apparatus of claim 13, wherein the pressure roller and the second fluting roller are configured to cooperate press the fluted layer and the outer liner together to form the single face board while the fluted layer is at least partially wrapped around the second fluting roller.

15. The apparatus of claim 12, further comprising an ultrasonic device configured to apply ultrasonic vibrations to the single face board, the ultrasonic vibrations being configured to remove moisture from the single face board.

16. A system for forming corrugated boards, the system comprising: a single face unit configured to form a single face board having a fluted layer and an outer liner, the single face unit comprising: first and second fluting rollers configured to fold a sheet material into the fluted layer, the first and second fluting rollers comprising mating peaks and valleys that are configured to fold the sheet material such that the fluted layer has alternating peaks and valleys; andan adhesive applicator that is configured to apply an adhesive to the fluted layer while the fluted layer is at least partially wrapped around the second fluting roller;a glue station configured to attach the single face board and another outer liner together with a liquid to form a single wall board;an ultrasonic device configured to apply ultrasonic vibrations to the single wall board, the ultrasonic vibrations being configured to remove moisture from the single wall board;a creasing unit configured to form alternating creases in the single wall board; anda folding unit configured to fold the single wall board along the alternating creases and into a stack or bale.

17. The system of claim 16, wherein the single face unit further comprises a pressure roller, the pressure roller and the second fluting roller being configured to cooperate press the fluted layer and the outer liner together to form the single face board while the fluted layer is at least partially wrapped around the second fluting roller.

18. The system of claim 16, wherein the glue station is downstream of the single face unit, the ultrasonic device is downstream of the glue station, the creasing unit is downstream of the ultrasonic device, and the folding unit is downstream of the creasing unit.

19. The system of claim 16, further comprising a cutting unit configured to cut the single wall board to width or length, the cutting unit being disposed downstream of the ultrasonic device and upstream of the creasing unit.

20. The system of claim 16, wherein the glue station is configured to apply pressure to the single face board and the another outer liner to attach the single face board and the another outer liner together.