Abstract: A laminator for applying pre-printed labels to a single face corrugated web to form double face corrugated sheets utilizes a control system including accurate leading and trailing edge detection of the labels to custom cut the corrugated web to match the label length in a manner which assures complete and uniform coverage of the glued flute tips of the corrugated web by the labels. The labels are fed non-stop as a series of spaced sheets into a laminating nip to join the leading edge of the traveling single face corrugated web. A positioning nip upstream of the laminating nip varies the speed of the incoming sheets to accurately match sheet leading edge to web leading edge. Detection of the sheet trailing edge triggers operation of the web cut-off knife to accurately match the corresponding cut trailing edge.

Abstract: An industry standard width composite paper web includes one layer comprising a plurality of narrow web portions derived from trim rolls of paper which are laminated to a second carrier web of the selected standard width. In an alternate embodiment, the carrier web itself may comprise a plurality of narrow trim roll web portions. The web portions comprising each layer may be spaced from one another slightly, and the gaps between web portions in both layers must offset laterally with respect to one another to maintain composite web integrity.

Abstract: A double backer for curing the web bonding adhesive and drying the corrugated paperboard web utilizes a web holddown apparatus for maintaining the web in intimate drying contact with the lower heating units which does not require the use of a driven holddown belt. The web is pulled through the double backer by a downstream vacuum conveyor section comprising a single full width belt to the upper surfaces of which a vacuum is applied. The vacuum drive belt has low friction strips on the underside by which the belt is supported on vacuum plenum support surfaces and a unique pattern of vacuum distribution channels on the other side of the belt which together reduce friction and drive power requirements.

Abstract: A double backer for curing the web bonding adhesive and drying the corrugated paperboard web utilizes a web holddown apparatus for maintaining the web in intimate drying contact with the lower heating units which does not require the use of a driven holddown belt. The holddown is provided instead by a series of parallel, flexible, closely spaced strips suspended above the web in the heating section and extending in the direction of web travel. Supplemental holddown force may be provided by banks of spring fingers supported above and in contact with the holddown strips on a transverse support rod which may be rotated to vary the amount of supplemental holddown force. Alternately, the holddown strips may comprise continuous cables in which one run of the cables rests upon the moving web to provide the web holddown and a second run includes high friction cable portions which are movable into driving contact with the upper surface of the web to pull it through the heating section, as for initial web thread up.

Abstract: A double backer for curing the web bonding adhesive and drying the corrugated paperboard web utilizes a web holddown apparatus for maintaining the web in intimate drying contact with the lower heating units which does not require the use of a driven holddown belt. The holddown is provided instead by a series of parallel, flexible, closely spaced strips suspended above the web in the heating section and extending in the direction of web travel. Supplemental holddown force may be provided by banks of spring fingers supported above and in contact with the holddown strips on a transverse support rod which may be rotated to vary the amount of supplemental holddown force. Alternately, the holddown strips may comprise continuous cables in which one run of the cables rests upon the moving web to provide the web holddown and a second run includes high friction cable portions which are movable into driving contact with the upper surface of the web to pull it through the heating section, as for initial web thread up.

Abstract: A double backer for curing the web bonding adhesive and drying the corrugated paperboard web utilizes a web holddown apparatus for maintaining the web in intimate drying contact with the lower heating units which does not require the use of a driven holddown belt. The web is pulled through the double backer by a downstream vacuum conveyor section comprising a single belt or a series of transport belt sections to the upper surfaces of which a vacuum is applied. The vacuum drive belt may have portions which are unsupported between laterally spaced vacuum slots, supported on a reduced friction support surface, or supported by air bearings to reduce friction and drive power requirements.

Abstract: A method and apparatus for manufacturing recyclable paper pallets utilizes spool-shaped laminated supports which are wound on a spool-shaped mandrel utilizing adhesive coated paper strips. In one aspect of the invention, the spool-shaped laminated supports can be glued to conventional upper and lower pallet skin sheets also made of paper material, such as corrugated paperboard. In another aspect of the invention, the spool-shaped pallet supports are utilized in a system in which the pallet is integrated directly into a pre-strapped load. In this system, a slip sheet is strapped directly to the bottom of a load and the slip sheet is glued directly to the upper faces of an array of pallet supports, sufficient to support the load and to provide the spacers or standoffs for subsequent insertion of lifting equipment, such as a lifting fork, beneath the load. The inherent rigidity of the strapped load may be sufficient to compensate for the lack of rigidity of the thin paper slip sheet.

Abstract: A control system is established wherein, when there is a flow of continuous web material (2), an identification phase is provided by increasing the torque signal to a pull roll motor (13) until slippage between the pull roll (12) and continuous web is created at a breakaway torque point, the value of which is measurable. The pull roll motor is then caused to be driven by a signal which creates a motor torque output which is of a value less than the breakaway torque point. Thus, no slippage can occur. As the motor is driven at the lower torque value, a calibration phase is entered wherein an encoder output of the pull roll is properly equated with that of a measuring wheel (9), this phase occuring at a time when there can be no slip between the web-roll interface. The identification-calibration process can be repeated as often as desired.

Abstract: A method and apparatus for manufacturing recyclable paper pallets utilizes spool-shaped laminated supports which are wound on a spool-shaped mandrel utilizing adhesive coated paper strips. In one aspect of the invention, the spool-shaped laminated supports can be glued to conventional upper and lower pallet skin sheets also made of paper material, such as corrugated paperboard. In another aspect of the invention, the spool-shaped pallet supports are utilized in a system in which the pallet is integrated directly into a pre-strapped load. In this system, a slip sheet is strapped directly to the bottom of a load and the slip sheet is glued directly to the upper faces of an array of pallet supports, sufficient to support the load and to provide the spacers or standoffs for subsequent insertion of lifting equipment, such as a lifting fork, beneath the load. The inherent rigidity of the strapped load may be sufficient to compensate for the lack of rigidity of the thin paper slip sheet.