SYSTEM AND METHOD FOR PRODUCING A MULTI-LAYERED BOARD HAVING A MEDIUM WITH IMPROVED STRUCTURE
A system and method for producing a board product made from paper products that have embossed medium that features an improved structural profile. The improved structural profile may include a triangular flute pattern wherein each flute may exhibit a first linear leg support and a second linear leg support that each support a center apex structure. The apex may have a substantially flat portion that is configured to engage a facing. As such, the board product may further include one or more facings that are adhesively coupled to the embossed medium. Further, the apex of each “triangle” may also have a groove or channel for receiving an adhesive in a continuous and uniform manner.
1 . A board product, comprising:
a paper medium having a plurality of flutes, wherein at least a set of the plurality of flutes each comprise a first linear leg support structure, a second linear leg support structure and an apex structure; and
a paper facing coupled to the tip support structure.
2 . The board product of claim 1 , further comprising a second facing affixed with respect to the paper medium.
3 . The board product of claim 1 , further comprising a second paper medium affixed with respect to the paper facing.
4 . The board product of claim 1 , wherein the first linear leg structure and the second linear leg structure are affixed with respect to the paper facing at an angle between approximately 30 degrees and 60 degrees.
5 . The board product of claim 1 , herein each apex structure comprises a flat portion parallel to the paper facing.
6 . The board product of claim 1 , wherein each apex structure further comprises a flat portion having a groove configured to channel an adhesive for coupling each apex structure to the paper facing.
7 . The board product of claim 1 , further comprising a continuous adhesive line coupled between each apex structure and the paper facing.
8 . The board product of claim 1 , wherein the plurality of flutes further comprise:
a first plurality of flutes each having an apex structure coupled to the paper facing such that the paper facing is affixed to the paper medium on a first side; and
a second plurality of flutes each having an apex structure coupled to a second paper facing such that the second paper facing is affixed to the paper medium on a side opposite the first side.
9 . A board-making method, comprising:
embossing a paper product to include a plurality of flutes, wherein at least a second plurality of the plurality of flutes each comprise a first linear leg support structure, a second linear leg support structure and an apex structure; and
coupling a paper facing to at least a third plurality of the apex structures of the second plurality of flutes.
10 . The board-making method of claim 9 , further comprising embossing a groove in each apex structure.
11 . The board-making method of claim 9 , further comprising heating the paper medium prior to embossing.
12 . The board-making method of claim 9 , further comprising wetting the paper medium prior to embossing.
13 . The board-making method of claim 12 , further comprising drying the paper medium after embossing.
14 . The board-making method of claim 9 , further comprising curing the paper medium after embossing.
15 . The board-making method of claim 9 , further comprising gluing the paper medium to the paper facing.
16 . The board-making method of claim 9 , further comprising affixing a second facing with respect to the paper medium.
17 . The board-making method of claim 9 , wherein the embossing further comprises embossing a first set of apex structures facing a first direction and second set of apex structures facing second direction that is opposite the first direction.
18 . A board-making machine, comprising:
an embosser configured to emboss a paper product o include a plurality of flutes, wherein at least a second plurality of the plurality of flutes each comprise a first linear leg support structure, a second linear leg support structure and an apex structure; and
a combiner configured to couple a paper facing to at least a third plurality of the linear tip support structures of the second plurality of flutes.
19 . The board-making machine of claim 18 , further comprising a conditioner configured to condition the paper medium prior to embossing.
20 . The board-making machine of claim 18 , wherein the combiner further comprises an adhesive applicator configured to locate each apex structure and to apply a continuous line of adhesive to each apex structure.