SYSTEMS AND METHODS FOR FORMING DUAL FLUTED CORRUGATED BOARD

1 . A method for making a dual fluted corrugated board, the method comprising:

providing a first single face corrugated board having a liner layer and a fluted layer attached to the liner layer;

providing a second single face corrugated board having a liner layer and a fluted layer attached to the liner layer;

arranging the first single face corrugated board and the second single face corrugated board such that the fluted layers thereof face one another; and

attaching the fluted layer of the first single face corrugated board to the fluted layer of the second single face corrugated board.

2 . The method of claim 1 , wherein attaching the fluted layer of the first single face corrugated board to the fluted layer of the second single face corrugated board comprises applying ultrasonic vibrations to one or both of the first and second single face corrugated boards.

3 . The method of claim 1 , wherein:

the fluted layer of the first single face corrugated board comprises a plurality of peaks and valleys facing the fluted layer of the second single face corrugated board; and

the fluted layer of the second single face corrugated board comprises a plurality of peaks and valleys facing the fluted layer of the first single face corrugated board,

and the method further comprises:

aligning the peaks in the fluted layer of the first single face corrugated board with the valleys in the fluted layer of the second single face corrugated board; and

aligning the valleys in the fluted layer of the first single face corrugated board with the peaks in the fluted layer of the second single face corrugated board.

4 . The method of claim 3 , wherein the alignment further comprises moving one of the first single face corrugated board or the second single face corrugated board relative to the other.

5 . The method of claim 4 , wherein moving one of the first single face corrugated board or the second single face corrugated board relative to the other comprised moving one of the first single face corrugated board or the second single face corrugated board faster than the other.

6 . The method of claim 3 , further comprising:

nesting the peaks in the fluted layer of the first single face corrugated board in the valleys of the fluted layer of the second single face corrugated board; and

nesting the peaks in the fluted layer of the second single face corrugated board in the valleys of the fluted layer of the first single face corrugated board.

7 . The method of claim 1 , wherein attaching the first single face corrugated board to the second single face corrugated board comprises attaching the fluted layer of the first single face corrugated board to the fluted layer of the second single face corrugated board.

8 . The method of claim 1 , wherein attaching the first single face corrugated board to the second single face corrugated board comprises applying water, glue, or adhesive to the fluted layer of the first single face corrugated board and/or the fluted layer of the second single face corrugated board.

9 . The method of claim 1 , wherein attaching the first single face corrugated board to the second single face corrugated board further comprises applying ultrasonic vibrations to the first single face corrugated board and/or the second single face corrugated board to activate, heat, and/or dry the water, glue, or adhesive, and/or cause fibers thereof to weave, intertwine, or otherwise stick to one another.

10 . The method of claim 1 , further comprising compressing the first single face corrugated board and the second single face corrugated board together.

11 . The method of claim 1 , wherein attaching the first single face corrugated board to the second single face corrugated board comprises applying pressure and ultrasonic vibrations to the first single face corrugated board and/or the second single face corrugated board to bond together the first single face corrugated board and the second single face corrugated board.