HK1261662B - System and method for producing a facing for a board product with strategically placed scores - Google Patents

Description

System and method for generating a facing for a paperboard product with strategically placed score lines

Technical Field

The present disclosure relates to a system and method for producing a paperboard product from a paper product.

Background Art

Modern papermaking technology uses paper machines in paper mills to produce paper rolls, which in turn can be used by paperboard manufacturers to produce paperboard products (i.e., corrugated paperboard). As a result, paper rolls can be produced by continuously operating machines. Modern paper machines typically produce paper from a number of substances, including wood pulp comprising wood fibers (although other fibers can also be used). These fibers tend to stretch and are suitable for aligning adjacent to each other. The fibers begin in the form of a slurry that can be fed from the mixing box of the paper machine onto a moving screen. In modern paper machines, the fibers tend to align with each other and with the direction in which the screen moves. This alignment of the underlying fibers is called the principal direction of the paper and is consistent with the machine direction. Therefore, the principal direction is often referred to as the machine direction (MD), and the produced paper has an associated MD value.

When paper is used to make paperboard products, portions or layers of the paperboard product may be corrugated. Conventional corrugators corrugate the underlying paper product in the cross-direction (CD) of the paper, failing to take advantage of the paper's natural strength variations in the machine direction. Furthermore, the paper's greater natural strength in the machine direction is not exploited by cross-corrugation technology in paperboard manufacturing solutions. Furthermore, conventional corrugated media contains sinusoidal grooves due to the shape of the protrusions in conventional corrugating roller pairs. As a result, companies producing conventional paperboard products remain stuck in outdated production procedures that limit the strength of their paperboard products.

Summary of the Invention

The purpose of the present disclosure is to provide a new paperboard product, a paperboard making method and a paperboard making machine.

The objectives of the present disclosure are achieved by adopting the following technical solutions. The paperboard product proposed in the present disclosure includes: a top layer having a plurality of score lines, the score lines being embossed into the paper before the top layer is combined with any other paper product; and a relief printing medium, the relief printing medium comprising fibers arranged in a direction, the relief printing medium further comprising a plurality of grooves whose axes are arranged in the direction, the relief printing medium being coupled to the top layer such that the score lines are aligned in parallel with respect to the grooves; wherein the score lines are aligned with the grooves such that each score line is equidistant from each groove.

The purpose of this disclosure can also be further achieved by adopting the following technical measures.

The aforementioned paperboard product further comprises a second surface layer fixed relative to the relief printing medium.

The aforementioned paperboard product, wherein the second facing layer includes a plurality of score lines, the plurality of score lines being embossed into the paper before the facing layer is combined with any other paper product.

The aforementioned paperboard product further comprises a second paper medium fixed relative to the surface layer.

The aforementioned paperboard product, wherein the relief media further comprises linear relief media.

The aforementioned paperboard product, wherein the plurality of score lines substantially covers the entire area of the surface layer.

The aforementioned paperboard product, wherein the plurality of score lines are aligned with the plurality of grooves, respectively, so that the paperboard product can be precisely coupled in a plane perpendicular to at least one score line.

The objectives of the present disclosure are also achieved by the following technical solutions. The paperboard manufacturing method proposed in the present disclosure includes: before combining a paper surface layer with any other paper product, scoring a paper surface layer with a plurality of score lines at a first interval; embossing the paper medium with a plurality of grooves at a second interval, such that fibers of the embossed medium are aligned with the plurality of grooves; combining the paper surface layer with the embossed medium, such that the score lines at the first interval are set at the second interval relative to the grooves; wherein the plurality of score lines are aligned with the plurality of grooves, such that each score line is equidistant from each groove.

The purpose of this disclosure can also be further achieved by adopting the following technical measures.

The aforementioned cardboard manufacturing method, wherein the first interval and the second interval are equal and offset relative to each other.

In the aforementioned cardboard manufacturing method, the first interval includes a distance that is several times the second interval.

The aforementioned paperboard manufacturing method, wherein the combination further includes bonding the embossing medium to the paper surface layer.

The aforementioned paperboard manufacturing method, wherein scoring the paper surface layer with the plurality of score lines at a first interval further comprises embossing the score lines at intervals of approximately five millimeters.

The aforementioned paperboard manufacturing method, wherein the groove is embossed to show a C-shaped groove profile.

The aforementioned cardboard manufacturing method further includes gluing the paper medium to the paper surface layer.

The aforementioned paperboard manufacturing method further includes fixing a second paper surface layer relative to the paper medium.

In the aforementioned paperboard manufacturing method, the embossing further comprises embossing a first group of vertex structures facing a first direction and embossing a second group of vertex structures facing a second direction opposite to the first direction.

The object of the present disclosure is also achieved by adopting the following technical solutions. According to the paperboard making machine proposed in the present disclosure, it includes: a scoring device, which is configured to emboss at least one scoring line in a paper surface layer at a first interval; an embossing device, which is configured to emboss the paper product to include a plurality of grooves at a second interval, so that the fibers are aligned with the plurality of grooves; and a combiner, which is configured to couple the paper surface layer to the embossed paper product so that the first interval is aligned with the second interval; wherein the plurality of scoring lines are respectively aligned with the plurality of grooves, so that each scoring line is equidistant from each groove.

The purpose of this disclosure can also be further achieved by adopting the following technical measures.

The aforementioned paperboard making machine further comprises a plurality of feed rollers configured to feed paper to the scorer and the embosser.

The aforementioned paperboard making machine, wherein the combiner is further configured to align the at least one score line with one or more of the plurality of grooves so that the coupling of the combined paper facing and embossed paper product is biased to a precise position relative to the at least one score line.

BRIEF DESCRIPTION OF THE DRAWINGS

The various aspects of the claims and the many attendant advantages will become more readily apparent and likewise better understood when reference is made to the following detailed description taken in conjunction with the accompanying drawings, in which:

1A-1B are views of a corrugated single wall conventional paperboard product before and after primary fold joints without utilizing score lines in one or more facing plies.

2A-2C show various states of a blank having a slot cut and conventional coining lines so that it can be manipulated into a container.

3 is an isometric cross-sectional view of a scored facing that can be part of one or more paperboard products according to one or more embodiments of the subject matter disclosed herein.

4 is an isometric cross-sectional view of relief media that can be part of one or more paperboard products according to one or more embodiments of the subject matter disclosed herein.

5 is an isometric cross-sectional view of a paperboard product having the scored facing of FIG. 3 and the media of FIG. 4 according to an embodiment of the subject matter disclosed herein.

6A-6C are a series of views of the paperboard product of FIG. 5 coupled with score lines in one or more facing layers according to an embodiment of the disclosed subject matter.

FIG. 7 shows a side-by-side comparison of a coupled conventional paperboard product and the coupled paperboard product of FIG. 5 .

8A-8B are views of a paperboard product before and after joining using score lines in one or more facing layers according to an embodiment of the disclosed subject matter.

9 is a diagram of aspects of a machine configured to produce the paperboard product of FIG. 3 according to an embodiment of the subject matter disclosed herein.

DETAILED DESCRIPTION

The following discussion is presented to enable one skilled in the art to make and use the subject matter disclosed herein. The general principles described herein may be applied to embodiments and applications other than those described in detail herein without departing from the spirit and scope of the detailed description. The present disclosure is not intended to be limited to the embodiments shown, but is to be accorded the broadest scope consistent with the principles and features disclosed or suggested herein.

By way of overview, the subject matter disclosed herein may relate to a system and method for producing a paperboard product made from a paper product that has a pre-scored topsheet in addition to the media (sometimes referred to as fluting) to enable precise joining. Conventional paperboard products may have a cross-corrugated media and a topsheet that does not have one or more score lines imprinted (at least prior to assembly with the corrugated media). Such conventional paperboard products may be inferior because any imprinted score lines will somehow damage the underlying corrugated media. When the final paperboard product is scored, cut, and folded, the reduced strength of the underlying media results in reduced precision. This lack of precision in the folded container can lead to gap variations and tailing because any joined portions of the paperboard product cannot maintain a precise joining plane when folded. As a result, the joined portions "fishtail" out of alignment.

With a pre-scored facing (sometimes called a wall or liner) having strategically placed score lines (e.g., strategically placed relative to the final attachment point and/or relative to the underlying grooves in the attachment media), the problem of tailing is eliminated. This is because the pre-scored lines bias the facing away from the score lines when attached. As a result, the fold lines on the facing are precisely aligned along the pre-scored lines (aligning any folds with the desired box corner pattern) and precisely placed relative to any underlying grooves (aligning any folds with the groove pattern). The effect of the pre-scored lines in the facing is enhanced when used in conjunction with embossed media that exhibits superior structural features compared to traditional cross-corrugated media. This advantage and additional aspects of various embodiments of the subject matter disclosed herein are discussed below with reference to Figures 1-8.

Figures 1A-1B illustrate a conventional paperboard product 100 before and after primary folding without the use of score lines in one or more facing layers. As briefly discussed in the overview, score lines facilitate paperboard joining, ensuring precise joining of the paperboard product. To illustrate the issues with conventional paperboard product 100, the views in Figures 1A-1B are shown, and then various issues with the final container are illustrated in Figures 2B-2C to illustrate the impact of the issues with conventional paperboard product 100. Conventional paperboard product 100 may have some form of media 103 attached to a first facing layer 101 and a second facing layer 202. Of course, these facing layers do not have any pre-set score lines. Therefore, there are no score lines to align with the grooves in media 103. Furthermore, media 103 may also be conventional cross-corrugated media with grooves aligned in the cross-sheet direction (discussed further below) of the media 103.

When it is desired to join the paperboard products 100 (which is typically the case when the paperboard products are ultimately used for containers and boxes), the machine may generate a score line (or sometimes an indentation, embossing, or some other form of marking to create a fold line) at the line used for joining (e.g., used as a corner or fold point without reference to the underlying groove). Thus, when looking at FIG. 1B , it is desired to fold at point 104. As can be seen, the paperboard products 100 are being joined (at approximately 180 degrees in this view). The 180-degree fold is sometimes referred to as a primary fold and may be a requirement of the manufacturer producing the folding box blank. The blank is an unfolded container in a flat, open state (as shown in FIG. 2A ) that is manufactured to be ultimately manipulated into a container or box. Conventional conventional slotted container (RSC) blanks are discussed below with reference to FIG. 2A-2C .

When a machine makes an impression in a paperboard product during production of a blank, a mechanical embossing collar can be used to emboss the crease line at a specific location. This location is relative to the edge of the blank (e.g., as just one example, 36 inches from the edge of the blank); in conventional methods, this location is independent of the underlying grooves of the media. Therefore, when the mechanical embossing collar embosses the fold line, any underlying grooves that happen to be within the embossed area are crushed. By crushing the internal grooves, a significant localized amount of the paperboard structure is centering. As a result, the fold point 104 begins to bend inward, and the outer fold points begin to stretch around the fold. As the two legs begin to converge, the inner grooves around the fold begin to narrow.

FIG1B shows a conventional paperboard product with a full 180-degree connection. The first surface layer 101 has been folded in half so as to contact itself. The second surface layer 102 has been stretched sufficiently at point 104 to accommodate the additional distance around the 180-degree fold point 104. As can be seen, the internal grooves of the media 103 lose structure when the local grooves are significantly damaged. Furthermore, the second surface layer 102 may often break at the 180-degree fold point 104. Such a break significantly weakens the paperboard product at point 104. Due to the damage in the media structure caused by the fold point 104 and the possible break in one or more surface layers, the final container or box product will exhibit additional undesirable changes. This undesirable change is discussed next with reference to FIG2A-2C.

2A-2C show various states of a blank with slots 106 cutouts and conventional embossed lines 108b, 108c, 108d, and 108e, so that the blank 105 can be manipulated into a container. In FIG2A , the blank 105 is shown as a paperboard product in which desired features, such as slots and embossed lines, can be modified. Thus, the paperboard product can have a pair of slots 106 cut along final fold lines 108b, 108c, 108d, and 108e. For the desired purpose, the slots 106 should be precisely aligned and sized, and the dimensions shown in FIG2A are for illustrative purposes only and serve only as an example of a flat blank 105. As a typical requirement of the end user of the blank, the leftmost panel 107a can be folded 180 degrees (at fold line 108b) to lie flat on top of panel 107b. This 180-degree fold is referred to as the primary fold. Similarly, the rightmost panel 107d can be folded 180 degrees (at fold line 108d) to lie flat on top of the facing 107c. Once folded, the ends 108a and 108e of the blank 105 can then be positioned adjacent to each other with the glue pad 109 positioned in an overlapping manner so that the edge 108a can be adhered to the glue pad 109. When precisely aligned, the edge 108a is positioned adjacent to the edge 108e so that the distance between the edges 108a and 108e is the same as the width of the other slots 106 in the blank 105.

When coupled in this manner, the disassembled container blanks 105 can be in a folded state to be fed into a machine for erecting boxes or containers from the blanks. This coupling can be used to package and ship the resulting disassembled container blanks 105 before erecting them into boxes or containers. As shown in Figures 2B-2C, this coupling often results in undesirable variations when performed on conventional paperboard products.

The first undesirable variation is shown in FIG. 2B and is referred to as gap variation. Gap variation can occur when edges 108a and 108e are not precisely aligned with one another, resulting in a gap the same width as the other slots when glue pad 109 is bonded to panel 107a. If the primary folds at fold lines 108b and 108d are rolled inward, the gap may be too narrow, and if the primary folds at fold lines 108b and 108d are rolled inward, the gap may be too wide. In this view, it can be seen that panel 107a has been joined 180 degrees along primary fold line 108b, and panel 107d has been joined 180 degrees along primary fold line 108d. However, glue pad 109 does not significantly overlap panel 107a, and edges 108a and 108e are too far apart. Without a precise overlap, edges 108a and 108e with glue pad 109 may not be properly bonded to one another in the proper position. This gap variation can occur due to a lack of fold line precision, such as with the centrally located major fold lines 108b and 108d. Another variation, not shown, can occur when the edges 108a and 108e are too close together or even overlap. Gap variation can be characterized by excessive or insufficient overlap (or even no overlap) in the glue pads and is a variable that can lead to undesirable problems in the finished container.

The second undesirable variation is shown in FIG2C and is referred to as "wagtail." Wagtail occurs when a fold causes one or more panels to be non-parallel to the other panels. In the example shown in FIG2C , panel 107a is not parallel to panel 107d. As such, edge 108a is also not parallel to edge 108e, and the glue pad will not engage with panel 107a in a precise manner. Here, primary fold 108b may be precise enough, but primary fold 108d is imprecise and causes panel 107d to fold out of alignment. This causes problems for the setting machine that erects the RSC blanks into boxes or containers.

The problems shown in Figures 2A-2C often occur when conventional paperboard products are scored and folded without considering the location of any underlying grooves in the media. Furthermore, post-assembly scoring (e.g., scoring that occurs after the paperboard product is assembled) causes damage to the grooves because the side grooves become partially or completely crushed, preventing the grooves from following the fold lines on either side of the desired fold location. This not only reduces board/box strength but also allows for irregular folding (rolling scoring), resulting in side-to-side gap variations as measured at the manufacturer's union. This and other problems can be overcome by pre-scoring the topsheet and then assembling the paperboard product with the score lines aligned with the underlying grooves in the media.

Before discussing various embodiments, a brief discussion of cross-corrugation and linear embossing is provided. As briefly mentioned above, conventional paperboard products include conventionally produced corrugated media (sometimes referred to as fluted corrugation), such as cross-corrugated media. Cross-corrugated media has flutes formed perpendicular to the underlying fibers of the paper product. This results in the flutes being misaligned with the majority of the underlying fibers and, therefore, not utilizing the paper's natural strength in the MD (when compared to the CD). Failure to utilize the paper's MD results in lost opportunities when manufacturing paperboard products when achieving a specific board strength. That is, more paper (heavier paper, larger flutes, etc.) must be expended to achieve the desired paperboard strength.

Linear embossed media differs from cross-corrugated media in that the flutes produced are aligned with the MD of the paper product. This results in the flutes being aligned with the majority of the underlying fibers and, therefore, utilizing the natural strength of the paper's MD (as compared to CD). Utilizing the paper's MD can improve paperboard product manufacturing efficiency when achieving a specific paperboard strength. That is, less paper (lighter paper, smaller flutes, etc.) must be used to achieve the desired paperboard strength. Aspects of making, generating, and using linear embossed media are discussed in greater detail in U.S. Patent Application No. 15/077,250, filed on March 22, 2016, entitled "SYSTEM AND METHOD FOR INDUCING FLUTING IN A PAPER PRODUCT BY EMBOSSING WITH RESPECT TOMACHINE DIRECTION," the entire contents of which are incorporated herein by reference for all purposes. Aspects of linear embossed media are discussed below with reference to FIG. Next, aspects of a pre-scored liner are discussed with reference to FIG.

FIG3 is an isometric cross-sectional view of a scored facing layer 110, which may be part of one or more paperboard products, according to one or more embodiments of the subject matter disclosed herein. In this embodiment, the facing layer may be generated with an MD value in the MD direction 122 and with a weight and material commonly used for facing layers of paperboard products. The facing layer 110 is sometimes referred to as a liner or wall, as this layer of the paperboard product is typically the innermost layer of the paperboard product. As briefly discussed above, the facing layer 110 is often scored to induce a joint along a specific line. However, if the facing layer is already coupled to one or more additional layers of the paperboard product (e.g., corrugated media, embossed media, another facing layer, etc.), the scoring process will leave an impression not only on the facing layer 110, but also on any other layers of the paperboard product. As shown in FIG2B-2C , this post-assembly scoring can result in undesirable changes and structural damage to the additional layers of the paperboard product, which in turn significantly weakens the paperboard product at the joint point.

However, the embodiment of FIG. 3 may be a face layer 110 that has undergone a pre-scoring process, such that score lines 115 are embossed into the face layer 110 before the face layer 110 is combined with any other paper product (e.g., any other layer of a paperboard product). In the embodiment shown in FIG. 3 , the pre-scored lines 115 are spaced relative to one another and may be strategically spaced to align with the final relief printing medium (not shown in FIG. 3 ), which may ultimately have grooves of a similarly specified pitch size. Further, the score lines may be continuous embossings in the face layer 110. However, a "scored" line may be any localized weakening of the face layer 110 at a fold point in the paperboard product that is strategically placed relative to the underlying grooves. However, in other embodiments, the score lines may be fold impressions (continuous linear or discontinuous), partial slits (continuous linear or discontinuous) through the face layer 110, perforations in the face layer 110, and the like.

In other embodiments (not shown), the pre-scored lines 115 may be slightly less uniform across the face layer 110. For example, two score lines 115 may be grouped together approximately 5 mm apart, then separated from another grouping of the two with the same 5 mm spacing. In another example, there may be only a single grouping of score lines on a face layer, or even on a single score line. While a 5 mm spacing is given as an example, any spacing width is feasible, and a common spacing will match a common groove profile, such as a C-shaped groove, a B-shaped groove, an R-shaped groove, etc. This grouping may correspond to the intended connection points for a particular carton machine. However, to efficiently produce a consistent face layer 110, the score lines 115 may be impressed by the scorer at strategically selected intervals (e.g., every five millimeters) so that any portion of the pre-scored face layer 110 can be combined with other layers of the final paperboard product. The relief printing medium 130 of FIG. 4 may be one such additional layer.

FIG4 is an isometric cross-sectional view of a relief medium 130 that can be part of one or more paperboard products according to one or more embodiments of the subject matter disclosed herein. This figure shows an isometric view of a portion of relief medium 130 that can be formed by a relief printing process. That is, grooves 131 are formed by passing a starting paper product through an embossing roller using a linear embossing technique, such that the grooves 131 are formed to align with the majority of the underlying fibers 125 of the paper. The grooves 131 are also formed to align with the machine direction 122. The linear relief medium 130, when forming the grooves 131 in the machine direction 122 of the paper (e.g., aligning with the majority of the underlying fibers 125), takes advantage of the paper's natural strength in the machine direction 122. Thus, the linear relief medium 130 takes advantage of the paper's natural strength in the machine direction 122. This relief medium 130 can be a component/layer of a paperboard product, as discussed below with reference to FIG5 .

Further, as shown in FIG4 , when viewed from a cross-sectional perspective, the grooves 131 may form a triangular pattern. This groove pattern having a triangular, repeating shape is referred to as a groove profile. This groove profile provides an improvement in the structural integrity of the embossed media 130 when compared to groove profiles exhibiting curved or sinusoidal groove profiles. Such curved or sinusoidal groove profiles are common in conventional cross-corrugated media. Therefore, the triangular groove profile shown in FIG4 also offers advantages over corrugated media in terms of paperboard strength and structural integrity. The groove profile exhibits vertices 132 that can be bonded to a facing layer (not shown). The vertices can be spaced apart in a repeating manner at a specific distance (such as, for example, 5 mm). As will be discussed below, when coupled to the matching pre-scored facing layer 110 of FIG3 , the vertices 132 of the embossed media 130 can be precisely aligned in a desired manner to produce a precise and less destructive connection to any resulting paperboard product.

FIG5 is an isometric, cross-sectional side view of a paperboard product 300 having the scored face layer 110 of FIG1 and the media 130 of FIG4 , according to an embodiment of the disclosed subject matter. In this embodiment, the paperboard product 300 comprises three layers: a first face layer 110, the media 130, and a second face layer 140. As shown, the first face layer 110 may form an inner wall that couples to one side of the embossed media 130 (although the top/bottom orientation reference to alignment with the paperboard product 300 is arbitrary). Coupling may be achieved by applying adhesive to the apex of each groove on the top side of the media 130, such that the face layer 110 is glued to the media 130 where the adhesive is applied. In other embodiments, glue may be applied to the entire face layer 110 before coupling to the media 130.

Likewise, the second facing layer 140 can form a bottom outer wall coupled to the opposite side of the embossed medium 130 (again, the top/bottom directional reference is arbitrary). The coupling can be through adhesive applied to the apex of each groove on the bottom side of the medium 130, such that the facing layer 140 is glued to the embossed medium 130 where the adhesive is applied. In other embodiments, glue can be applied to the entire facing layer 140 before being coupled to the embossed medium 130.

The score lines 115 are aligned in the direction of the underlying grooves of the embossed medium. Both the score lines and the grooves are also aligned with the machine direction 122 of the score surface layer 110, the surface layer 140, and the underlying paper in the medium 130. Furthermore, in this embodiment, the score lines 115 of the score surface layer 110 are aligned so that the score lines are equidistant from the corresponding vertex positions of the fixed embossed medium. For example, if the top side vertices of the embossed medium 130 are spaced 5 mm apart, the score lines 115 are also spaced 5 mm apart, but offset by 2.5 mm. In other words, for each pair of top side vertices that are 5 mm apart, the fixed surface layer 110 has a score line 115 midway between each pair of top side vertices that are spaced approximately 2.5 mm apart.

By precisely placing score lines in a facing layer secured to a media having linear grooves, precise join lines can be created. That is, if the paperboard product 300 were to be folded, the scored facing layer would precisely follow one or more score lines. That is, the fold would lie precisely in a single plane perpendicular to the joined score lines. This folding can be precise and will serve to prevent the joining direction from veering off the normal to the plane of the score lines. In other embodiments (not shown), the bottom side layer 140 can also be pre-scored with a similar pattern of score lines that precisely align with the bottom vertices of the embossed media 130. Furthermore, the pre-scored lines in any facing layer can cover substantially all areas of the facing layer (e.g., score lines only in the intended join points).

When all three layers are assembled and secured, the resulting paperboard product 300 is superior to conventional paperboard products due to several factors. First, because the grooves of the embossed medium 130 are strategically aligned relative to the score lines of the pre-scored face layer 110, any joining of the paperboard product will be precise, resulting in precision in the finished box container. This precision prevents gap variations and tail swinging. Further, the linear embossed medium 130 includes a groove profile that exhibits excellent strength due to the leg structure of the triangular nature of each groove. Still further, adhesive can be applied continuously and evenly to each vertex in a more precise and predictable manner because portions of the adhesive will not overflow onto the legs as would be the case with sinusoidal vertices that do not have flat receiving areas. Finally, when using conventional paperboard scoring techniques, the pre-scored face layer 110 prevents a scoring step after the paperboard is assembled that would cause damage to the underlying layer (e.g., the embossed medium 130).

Figures 6A-6C are a series of views of the paperboard product 300 of Figure 5 , joined using score lines in one or more face layers, according to an embodiment of the disclosed subject matter. In Figure 6A , the paperboard product 300 is shown from an edge view to better illustrate what occurs when the paperboard product 300 is joined. As shown, the paperboard product 300 includes a first face layer 110, a second face layer 140, and a medium 130. The medium 130 is positioned between the first face layer 110 and the second face layer 140. The first face layer may also include score lines 115. In this example view of Figure 6A , the first face layer 110 is shown facing downward for illustrative purposes only. Furthermore, for ease of illustration, only two score lines 115 are shown, as there could be more score lines that align with the grooves of the medium 130 that also include score lines on the second face layer 140. Furthermore, the medium 130 is shown as having a sinusoidal groove profile, but it should be understood that any groove profile shape may be used.

In the next view, FIG6B , paperboard product 300 has begun to join. Here, the fold line will precisely follow score line 115 in facing layer 110. Thus, first fold point 603 corresponds to first score line 115, and second fold point 604 corresponds to second score line. As can be seen in this view of FIG6B , the joining that will result in a final 180-degree joint will include two distinct folds, each approximately 90 degrees. Furthermore, first fold point 603 is located directly between two vertices of media 130 (the vertices facing the lower groove—i.e., the two vertices secured to first facing layer 110), causing the legs of this groove to begin to move toward each other. As a result, first stretch point 601 of second facing layer 140 begins to form directly above first fold point 603. Similarly, second fold point 604 is located directly between two vertices of media 130 (the vertices facing the lower groove—i.e., the two vertices secured to first facing layer 110), causing the legs of this groove to also begin to move toward each other. As a result, a second stretch point 602 of the second panel 140 begins to form directly over the second fold point 604 .

In FIG6C , the paperboard product 300 is shown fully coupled to a 180-degree position. Thus, the first and second stretch points 601, 602 are each approximately 90 degrees. Unlike the conventional example of FIG1A-1B , where the stretch points fold a full 180 degrees, this embodiment achieves a full 180-degree coupling of the paperboard product while only having approximately a 90-degree fold, thereby causing stretch at any given location. Having a full 180-degree coupling at any given point while only having a 90-degree stretch results in less stress at the pull point on the underlying fibers in the facing layer 140. This, in turn, results in greater strength at the corners of the box and container due to less damage to the facing layer 140 from stretching and no loss of groove structure in the media 130.

Further, fold points 603 and 604 are folded all the way into the corresponding grooves, so that secondary grooves are formed to provide additional corner structure from the liner 110. That is, at the first fold point 603, a first secondary fold groove 610 is formed by the facing 110 on the inside of the first primary fold groove 605. Similarly, a second secondary fold groove 611 is formed by the facing 110 on the inside of the second primary fold groove 606. The secondary grooves 610 and 611 provide additional corner strength in boxes and containers.

FIG7 shows a side-by-side comparison of a coupled conventional paperboard product 100 and the coupled paperboard product 300 of FIG5 . As can be seen, conventional paperboard 100 exhibits distortion in the media structure at and near the 180-degree coupling point. Here, the underlying grooves are centered because the fold point does not perfectly align with the corresponding grooves in the media. This corner exhibits significantly less predictable folding. In contrast, the embodiment of the paperboard product with precisely positioned score lines exhibits additional secondary grooves, as discussed above with reference to FIG6C . This coupling point in paperboard product 300 exhibits superior strength compared to conventional example 100.

Figures 8A-8B illustrate a paperboard product before and after joining one or more facing layers using a score line, according to an embodiment of the disclosed subject matter. In Figure 8A, paperboard product 800 is shown from an edge view to better illustrate what occurs when paperboard product 800 is joined. As shown, paperboard product 800 includes a first facing layer 810, a second facing layer 840, and a medium 830. Medium 830 is positioned between first facing layer 810 and second facing layer 840. The first facing layer may further include a score line 815. In this example view of Figure 8A, first facing layer 810 is shown facing downward for illustrative purposes only. Furthermore, only one score line 815 is shown, located precisely below the apex of a groove in medium 830. Further still, medium 830 is shown as having a sinusoidal groove profile, but it should be understood that any groove profile shape may be used, and medium 830 may be embossed or corrugated.

In the next view, FIG8B , the paperboard product 300 has begun to be joined. Here, the fold line will precisely follow the score line 815 in the facing layer 810 . Thus, the first fold point 804 corresponds to the first score line 815 . As can be seen in this view of FIG8B , the joining will result in a final approximately 90-degree join without damaging the underlying groove. Further, the fold point 804 is located directly between two vertices of the media 830 (the vertices facing the lower groove—i.e., the two vertices fixed to the first facing layer 810 ), causing the legs of this groove to begin to move toward each other. As a result, the stretch point 805 of the second facing layer 840 begins to form directly on the fold point 804 . With the precisely positioned score line 815 , a 90-degree fold can be achieved without causing undesirable damage to the groove of the media 830 . Next, additional aspects of various embodiments of the paperboard product are discussed with reference to the machine of FIG9 .

FIG9 is a diagram of various aspects of a machine 500 configured to produce the paperboard product 300 of FIG5 , according to an embodiment of the subject matter disclosed herein. The machine 500 can produce other embodiments, including the embodiment of the paperboard product 800 of FIG8A . The machine 500 includes three paper feed rollers 510, 530, and 540 for producing the paperboard product. These feed rollers include a first facing feed roller 510, an embossing medium feed roller 530, and a second facing feed roller 540. It should be noted that the paper wound around the first facing feed roller 510 is wound before scoring, and the paper wound around the embossing medium feed roller 530 is wound before embossing. The weight and composition of the paper for each respective feed roller can vary and be specifically designed for the respective purpose.

The paper from each roll can be unwound from each respective roll and fed toward a combiner 550 configured to combine the various layers of paper together to form the resulting paperboard product. Before entering the combiner 550, at least some of the paper from the feed rolls can pass through one or more stations to score the paper. Thus, the first facing feed roll 510 can feed the paper into a scoring station 590, which scores the paper in a precise manner. In other embodiments, the lines impressed on the facing 110 can be perforations along precise lines, intermittent cuts, or some other form of localized weakening of the facing 110. When the paper leaves the scoring station 590, it becomes the scored facing 110 as discussed above with reference to FIG3 . The scored facing 110 is then fed to the combiner 550 to be combined with other materials.

Furthermore, also before entering the combiner 550, at least some of the paper from the feed roller may pass through one or more stations for forming the paper into media. As used herein and in the industry, media may refer to a paper product that has been formed into a sheet of paper having grooves. Thus, the embossed media feed roller 530 may feed the paper into a first embossing roller 531a and a second embossing roller 531b that are aligned with each other. When the paper leaves the embossing stations (e.g., embossing rollers 531a and 531b), it becomes the embossed media 130 discussed above with reference to FIG. 4. The embossed media 130 is then fed into the combiner 550 to be combined with other materials.

Once passed through the embossing rollers 531a and 531b, the embossed medium 130 can proceed to the applicator 570 to apply adhesive to the newly formed vertices. The applicator may include a device for identifying the position of each vertex and then aligning a series of adhesive dispensers with the identified vertices. In other embodiments, the adhesive can be transferred to the groove tips using (multiple) adhesive rollers in which the paper contacts the adhesive film and adheres to the groove tips. In this way, the adhesive can be accurately applied in a continuous and uniform manner. Then, various techniques such as bonding, curing, wetting, drying, heating and chemical treatment are used to combine the first surface layer 110, the embossed medium 130 and the second surface layer 140 in the combiner. The resulting paperboard product 300 has at least one scored surface layer that is precisely aligned with at least one linear embossed medium 130 in which the paperboard product can be precisely connected.

While the subject matter discussed herein is susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and have been described above in detail. However, it should be understood that there is no intention to limit the claims to the precise forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the claims.

Claims (19)

1. A cardboard product comprising: A surface layer having multiple serrations, wherein the multiple serrations are embossed in the paper before the surface layer is combined with any other paper product; and A relief printing medium comprising fibers arranged in one direction, the relief printing medium further comprising a plurality of grooves, each with its own axis arranged in that direction, the relief printing medium being coupled to the surface layer such that the plurality of scribed lines are respectively aligned in a parallel manner with respect to the plurality of grooves. The plurality of scribed lines are respectively aligned with the plurality of grooves, such that each scribed line and each groove are equidistant. 2. The paperboard product according to claim 1, further comprising a second surface layer fixed relative to the embossed printing medium. 3. The paperboard product of claim 2, wherein the second surface layer comprises a plurality of serrations, the plurality of serrations being embossed in the paper before the surface layer is combined with any other paper product. 4. The paperboard product according to claim 1, further comprising a second paper medium fixed relative to the surface layer. 5. The paperboard product according to claim 1, wherein the letterpress printing medium further comprises a linear letterpress printing medium. 6. The cardboard product of claim 1, wherein the plurality of serrations substantially cover all areas of the surface layer. 7. The cardboard product according to claim 1, wherein the plurality of scribe lines are respectively aligned with the plurality of grooves, such that the cardboard product can be precisely joined in a plane perpendicular to at least one scribe line. 8. A method for making cardboard, comprising: Before combining the paper surface layer with any other paper product, score the paper surface layer with multiple scribe lines at a first interval. The paper medium is embossed with multiple grooves at a second interval, such that the fibers of the embossed medium are aligned with the multiple grooves. The paper surface layer is combined with the embossed medium such that the engraving line under the first interval is set with a second interval relative to the groove; The plurality of scribed lines are respectively aligned with the plurality of grooves, such that each scribed line and each groove are equidistant. 9. The method of making cardboard according to claim 8, wherein the first interval and the second interval are equal and offset relative to each other. 10. The method for making cardboard according to claim 8, wherein the first interval includes a distance that is several times the second interval. 11. The paperboard manufacturing method according to claim 8, wherein the assembly further comprises bonding the embossing medium to the paper surface layer. 12. The paperboard manufacturing method according to claim 11, wherein scribing the paper surface layer with the plurality of scribe lines at a first interval further comprises imprinting the scribe lines at intervals of about five millimeters. 13. The paperboard manufacturing method according to claim 8, wherein the groove is embossed to show a C-shaped groove outline. 14. The paperboard manufacturing method according to claim 8, further comprising bonding the paper medium to the paper surface layer. 15. The paperboard manufacturing method according to claim 8, further comprising fixing a second paper surface layer relative to the paper medium. 16. The paperboard manufacturing method according to claim 8, wherein the embossing further comprises embossing a first set of vertex structures facing a first direction and embossing a second set of vertex structures facing a second direction opposite to the first direction. 17. A cardboard making machine, comprising: A scribing device configured to imprint at least one scribing line in the surface layer of paper at a first interval; A letterpress printer configured to letterpress a paper product into a plurality of grooves spaced at a second interval, such that fibers are aligned with the plurality of grooves; and A combiner configured to couple the paper surface layer to the embossed paper product such that the first spacing is aligned with the second spacing. The plurality of scribed lines are respectively aligned with the plurality of grooves, such that each scribed line and each groove are equidistant. 18. The paperboard making machine of claim 17, further comprising a plurality of feed rollers configured to feed paper to the scriber and to the letterpress. 19. The cardboard making machine of claim 17, wherein the combiner is further configured to align the at least one scribe line with one or more of a plurality of grooves, such that the connection between the combined paper surface layer and the embossed paper product is biased to a precise position relative to the at least one scribe line.