What type of laminate is corrugated cardboard

In this printing process our in-house graphics teams will help you increase the visual impact of your product by optimising your design and creating a photographic quality printed sheet, laminated onto corrugated board. Litho laminated printing is economical, producing large volume printed packages at the highest quality available.

A photographic quality printed sheet is laminated to the corrugated board in this process providing maximum visual impact. In its fundamental form, corrugated paper board is composed of a fluted paper core sandwiched between and bonded to inner and outer paper face liners.

Corrugated paper board is usually fabricated of natural brown-color Kraft paper, although some boards include an outer liner of white or coated paper, or other suitable material, depending on the finish desired. The choice of a finish liner must take into account that it is often the practice to label the board with printed data, or to apply decorative graphics thereto; hence the outer face liner must be receptive to printing inks.

It is also desirable that the outer face liner render the board water resistant. The manner in which corrugated paper board is manufactured is described in U.

In this patent the outer face liner of the board is identified as a "single liner," the face inner liner is referred to as the "double liner," while the fluted core is called the "corrugated medium.

As noted in the Lang patent, the conventional technique for manufacturing corrugated paper board makes use of a single facer unit and a double backer glue machine. In the take-off roll is fed into the unit. A web of the medium to be corrugated is drawn from another take-off roll and fed through cooperating corrugator rolls. The resultant fluted or corrugated medium has adhesive applied to hereto before it is combined with the single face liner. Thus coming out of the single facer unit is a laminate web formed by the single face liner combined with the fluted medium.

This laminate web is fed into the double backer glue machine where it is glued to a web of double liner drawn from a take-off roll. Hence emerging from the double backer glue machine is a continuous web of corrugated paper board in which the fluted medium or core is sandwiched between and bonded to inner and outer face liners. This web immediately goes through a curing step which cures the adhesive bond between the outer face liner and the fluted medium.

The corrugated paper board web is then slit, scored and cut to provide corrugated paper board having the desired carton specifications. The structural strength and wearing properties of corrugated paper board is in part determined by the face liners.

Thus when a shipping carton is made of corrugated paper board whose outer face liner is Kraft paper, this carton will not be water resistant and exposure to rain and snow in the course of shipment may weaken the carton.

Corrugated paper board is likewise used to form inexpensive furniture items, such as storage units, shelving and tables. Although these items have the advantage of being light-weight and inexpensive, they are subject to damage such as bending, creasing and tearing. When such products are used in or near an area where water is present, water damage tends to destroy the appearance, and eventually the structural integrity, of the furniture item.

There is thus a need for a cardboard material that can be used to form strong structures and containers wherein the cardboard also has the ability to resist water and other fluid damage. Plastic film may be laminated to the outside surface of the finished cardboard in order to make it water resistant and also to enhance the appearance of the cardboard, such as, for example, by the application of decorative plastic film.

The typical prior art method of laminating plastic film to corrugated paper board is to attach the film to the outer face liner of the finished corrugated paper board, during an off-line process on separate laminator equipment. That is, lamination does not take place at the "process end" of the production line where the inner and outer face liners are adhered to the fluted medium.

Instead, prior art methods of applying a plastic film laminate layer wait until after the fluted core has been sandwiched between paper face liners and the adhesive holding this "sandwich" has cured. The separate steps involved in such lamination processes add greatly to the cost of the laminated product, by increasing scheduling difficulties in the manufacture of different production runs, and by producing a higher percentage of waste material. Additionally, flexible plastic film material is slippery and tends to shrink when heated, making it more difficult--and therefore more costly--to work with.

Furthermore, the nature of the film may be such as to preclude printing of the outer liner with standard printing inks. Prior art attempts to apply plastic film laminates to cardboard face liners have met with the most success by applying the laminate after the corrugated paper board has been fully formed, such as in the Lang patent.

Unsuccessful attempts have been made to make outer face liners out of plastic film laminates and to apply these laminated outer face liners directly to the fluted medium. These attempts have been unsuccessful, as noted in Lang col. The heat and pressure degrade the plastic film laminate's appearance and other properties. In particular, the fresh, wet adhesive between the plastic film laminate and the fluted medium tends to cause slippage as the corrugated web enters the curing step.

Slippage causes unwanted misalignment and unevenness in the surface texture of the finished product. Additionally, the heat that is applied in the curing step tends to cause the plastic film layer of the laminate to shrink. These problems of slippage and shrinkage of the plastic film, which have not been overcome in the prior art, are addressed and resolved by this invention.

Additionally, this invention addresses the need for a low-cost cardboard material that is used to form containers and other structural members that are inexpensive, light-weight, and capable of withstanding heavy loading and impact forces as well as direct contact with water and other fluids. By associating a plastic film with the outer face liner, the exterior surface of the container formed therefrom is capable of resisting water and other fluids.

The cardboard layer may be made of corrugated cardboard having a plurality of flutes attached to an inner surface of the cardboard layer. The plastic film can be present on the outer surface of the container.

By forming the container with the plastic film on the inner surface, the container is protectively lined on the inside to hold items that may leak during storage or shipping. The plastic film may be biaxially oriented to further enhance the strength of the laminate.

When a thick corrugated layer is also used, or when the corrugated layer is comprised of multiple fluted layers, such container is adaptable for use as an inexpensive coffin. An additional embodiment of the invention relates to a container as described above wherein the exterior surface of the plastic film is corona-discharge treated to render it wettable and receptive to inks, coatings and adhesives, so that decorative graphics and other printed matter may be applied thereto.

An advantage of this structure is that it provides a container whose outer surface is made of plastic film that is not only impermeable to water but also wettable by printing inks. If desired, a second paper layer may be adhesively joined to the corona-discharge treated second surface of the plastic film with a water-based adhesive at room temperature.

The exterior surface of the second paper layer may be metallized to enhance its appearance. A further embodiment of the invention relates to a structural member for use in making furniture. The supporting member may be comprised of particle board, corrugated paper board, sheet rock or some other type of wall board. The supporting member may be laminated to the second surface of the plastic film with a water based adhesive, and in this arrangement, the second surface of the plastic film is corona-discharge treated to render it wettable and receptive to the adhesive at room temperature.

The resulting structural member is easily formed into shapes for making different types of furniture, such as cabinets, cupboards, tables, desks, shelves, etc. If desired, the exterior surface of the structural member may have decorative graphics applied thereto. Preferred features of the present invention are disclosed in the accompanying drawings, wherein similar reference characters denote similar elements throughout the several views, and wherein elements shown are not drawn to scale, and wherein:.

The corrugated board B is composed of a fluted core 10 formed by passing a web of Kraft paper through corrugating rolls in the manner described in the above-identified Lang patent. The fluted core is adhered to an inner face liner 11 of Kraft paper. This is because with bulk printing the quality of graphics, using laminated process upholds premium quality graphics at large scales. Corrugated packaging is a very thick and offers superior protection for its continents through the shipping process, ensuring that products arrive in perfect condition.

Additional features to packaging will make your business stand out from its competitors, enhanced packaging increases customer engagement as customers have been proven to consider a unique looking product over a basic one. Litho-laminated corrugated pieces can range in customisable features including;. Contact our Sydney office on 02 or Melbourne office on 03 , for a FREE premium packaging print consultation.

Litho-Laminated — Premium Corrugated Packaging Solution Are you looking for premium packaging to impress new customers and retain loyal clients? What is Litho-laminated packaging? Corrugated cardboard is a thicker and more durable version of traditional cardboard. Product Packaging Protection is essential for all kinds of product packaging, the durable corrugated cardboard allows for secure transportation and handling; from the most fragile and breakable, to large and uniquely shaped products.

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