Stock material or miscellaneous articles – Structurally defined web or sheet – Nonplanar uniform thickness material
Reexamination Certificate
2000-11-29
2003-05-06
Loney, Donald J. (Department: 1772)
Stock material or miscellaneous articles
Structurally defined web or sheet
Nonplanar uniform thickness material
C428S184000, C425S328000, C425S322000, C156S250000, C156S260000, C156S262000, C156S510000, C156S512000, C156S522000
Reexamination Certificate
active
06558777
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to corrugated cardboard plates, a method of and an apparatus for making the corrugated cardboard plates from corrugated cardboards that are excellent in heat insulation and sound insulation, and have a lightweight feature and a strength. The present invention also relates to the corrugated cardboard plates and architectural elements utilizing the corrugated cardboard plates.
2. Description of the Prior Art
The assignee of the present invention has applied for patent on an apparatus for and a method of continuously manufacturing a honeycomb structure that can be used as a material for furniture and architectures (the Japanese Laid-open Patent Publication No. 11-235773). This honeycomb structure is lightweight and has cells exhibiting an extremely high compressive strength and is excellent in heat insulation and sound insulation. However, the apparatus for making the honeycomb structure tends to become somewhat complicated.
More specifically, the honeycomb structure is prepared by laminating a plurality of paper materials for forming honeycomb cells to provide a honeycomb core material, then forming honeycomb units by cutting the laminate of the paper materials in a direction perpendicular to the honeycomb cells while the latter are closed, successively connecting the honeycomb units, with upper and lower faces bonded together, to provide an elongated honeycomb core, and bonding a sheet to a cut face (front and rear sides) of the elongated honeycomb core to provide the honeycomb structure. However, at the time the honeycomb units are formed by cutting the honeycomb core material, a relatively large cutting force is required since the cutting is performed while the honeycomb cells are closed. For this reason, a guillotine cutter comprising a single knife blade and capable of exerting a higher cutting force than a saw tooth is employed for cutting the honeycomb core material. However, the use of the guillotine cutter results in a smooth cut face (a face where an adhesive is to be applied) and, therefore, the adhesive applied will not be satisfactorily retained on the cut faces of the honeycomb units, with the consequence that the sheet will not be firmly bonded to the elongated honeycomb core. In view of this, while the cells of the honeycomb units are expanded by the use of an expander, the front and rear faces of each honeycomb units where the adhesive is to be subsequently applied is roughened by the use of a surface roughening device. As such, the manufacture of the honeycomb structure requires the use of the surface roughening device and the expander.
SUMMARY OF THE INVENTION
The present invention is intended to provide corrugated cardboard plates at a reduced cost, wherein corrugated cardboards are employed in place of the above discussed honeycomb core materials, wherein the sheet can be assuredly and firmly bonded with no surface roughening being required, and which has a performance comparable or higher than that exhibited when the honeycomb core materials are used.
Another important object of the present invention is to provide an architectural material wherein the corrugated cardboard plates are used so that it can be suitably and optimally used as a floor panel, a partition wall for use in restaurants and offices or an external wall for a temporary dwelling, all of which have an excellent lightweight feature and an excellent thermal insulation.
In order to accomplish these objects of the present invention, a method of making corrugated cardboard plates according to the present invention includes a step of laminating and bonding a plurality of corrugated cardboards to provide a corrugated cardboard laminate, each of the corrugated cardboards including a corrugated sheet and at least one liner sheet bonded to the corrugated sheet, the corrugated sheet having a plurality of cells and a corresponding number of ridges; a step of cutting the corrugated cardboard laminate along a plurality of cutting lines lying perpendicular to a direction in which the ridges of the corrugated sheet extend, to provide a plurality of corrugated blocks, each of the corrugated blocks having upper and lower faces opposite to each other; a step of arraying the corrugated blocks in a line to provide an elongated flat corrugated plank in which the top face of one of the corrugated blocks is bonded to the bottom face of the next adjoining corrugated block; a step of bonding at least one backing sheet, made of paper, to one of opposite surfaces of the elongated flat corrugated plank; and a step of cutting the elongated flat corrugated plank into a plurality of corrugated cardboard plates of a predetermined size. The corrugated sheet referred to above is a sheet corrugated at regular intervals so that cells can be formed in the corrugated cardboard, which cells may have a generally U-shaped (or sinusoidal) section, a generally V-shaped section or a trapezoidal section.
With the above described corrugated cardboard plate making method, when the corrugated cardboard laminate is to be cut along cutting lines lying perpendicular to ridge lines of the corrugated sheet into a plurality of corrugated blocks, not a guillotine cutter including a single knife blade, but a circular saw or a band saw including a body having its tip formed with rows of equally spaced saw teeth or a so-called raking saw having a plurality of equally spaced saw teeth that are alternately offset laterally relative to each other to provide two rows of alternating saw teeth, can advantageously be employed. In other words, since the corrugated cardboard laminate is of a design wherein corrugated cardboards are laminated together with the cells left open and does not require a relatively large force during the cutting thereof, the use of the circular saw, the band saw or the ranking saw is possible. For this reason, cut faces of each of the corrugated cardboard blocks resulting from cutting of the corrugated cardboard laminate can be suitably roughened and, therefore, by applying an adhesive to the cut faces of each of the corrugated cardboard blocks optimally, the sheet can be assuredly and firmly bonded. Accordingly, no surface roughening need not be performed with the use of the surface roughening device and the expander such as required in the previously suggested apparatus. Accordingly, it is possible to continuously manufacture at a reduced cost the corrugated cardboard plates having excellent heat and sound insulations and being lightweight and robust and, yet, capable of exhibiting a performance comparable to or higher than that exhibited by the use of the honeycomb core material.
An apparatus for making corrugated cardboard plates according to the present invention includes a laminating machine for making a corrugated cardboard laminate by laminating and bonding a plurality of corrugated cardboards, each of the corrugated cardboards including a corrugated sheet and at least one liner sheet bonded to the corrugated sheet, the corrugated sheet having a plurality of cells and a corresponding number of ridges; a corrugated block former for making a plurality of corrugated blocks by cutting the corrugated cardboard laminate along a plurality of cutting lines lying perpendicular to a direction in which the ridges of the corrugated sheet extend, each of the corrugated blocks having upper and lower faces opposite to each other; a corrugated plank preformer for making an elongated flat corrugated plank by arraying the corrugated blocks in a line, in which the top face of one of the corrugated blocks is bonded to the bottom face of the next adjoining corrugated block; a corrugated plank former for making a continuous strip of corrugated plank by bonding at least one backing sheet, made of paper, to one of opposite surfaces of the elongated flat corrugated plank; and a corrugated plate former for cutting the elongated flat corrugated plank into a plurality of corrugated cardboard plates of a predetermined size.
The corrugated cardboard plate making method
Daizen Kabushiki Kaisha
Loney Donald J.
LandOfFree
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