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Aug. 20, 1.946. G, wElss 2,406,051 APPARATUS FOR -PRODUCING CORRUGATED STRUCTURES Filed June 26, v1943 5 Sheets-Shea?f 1 A y Fig. 2 /2 INVENTOR. Ger-)fart Zréz'ss . BY ai ATTÜR/VEYS Aug. 20, 1946. _ 2,406,053 'ca_ wElss APPARATUS FOR PRODUCING CORRUGATED STRUCTURES Filed June 26, 1945 s sheetœsheet 2 _ VEN TOR. 6er/uff 7/6/ s ` A - Aug; 2o, 194e. ~ ’ G. WE1-ss ì 2,406,051 APPARATUS FOR PRODUCING CORRUGATED STRUCTURES Filed June 26, 1945- ' /07/ s sheèts-sheet s ' /03 104 80 IN VEN TOR. Gerhart Zt/ez'ss 'BY /íèáßám I ATTORNEYS Patented Aug. 20, 1946 „2,406,051 À'rr‘r OFFICE UNITED STATES 2,406,051 APPARATUS FOR PRODUCING CORRÚGATED STRUCTURES Gerhart Weiss, Sunnyside, N. Y., assignor of twenty-five per cent to Paul Porzelt, New York, and twenty-five per cent to Fritz Lunzer, Kew Gardens, N. Y. Application June 26, 1943, Serial No. 492,409 1. Claim. (o1. 154-30) 2 1 Figure 10 is a partial cross section showing the sealing of the tubular corrugated structure by the tape as shown in Figure 9. Figure l1 is another modified forming of my apparatus in which I show an apparatus for con tinuously producing a corrugated structure. YMy invention relates to certain novel corru gated structures and the apparatus for producing the same, and more particularly my invention re lates to certain novel corrugated structures com prising resin impregnated fibrous materials and certain apparatus for continuously forming such structures. Certain problems arise in connection with the manufacture of corrugated structures from resin impregnated ñbrous materials because of the. particular properties of the resin impregnated component parts in the structure and operations involved in forming .and maintaining the corru gated shape of the structure. It is a further object of the present invention to 15 provide a novel apparatus for continuously form- _ ing resin impregnated corrugated structures of tubular shape. It is a further object of the present invention to provide a continuous apparatus for forming ‘Y .resin impregnated corrugated structures which , It is a further object of the present invention to provide a continuous process for shaping resin example vinyl acetate, vinyl chloride or copoly mers thereof lor polyvinyl acetal, butyral etc. support 4. »The shaping elements 2 comprise long rods which extend longitudinally along the `apparatus and which rods may terminate at the end 5 of the upper element 6 of the pressing ap paratus which presses the upper liner element ‘I on to the corrugated element.> impregnated fibrous sheets to corrugated form . and `enclosing in the continuation of the same operation, said corrugated structure within the resin impregnated liner elements. ` The core members 2 may have a shape dic tated t by the shape of the corrugations to be formed and here are in the form of curved mem bers so that the conventional curved or sine wave Further objects will be apparent from a con corrugation is formed. The support 5 and the supporting elements 3 firmly hold the shaping rods 2 in position so that sideration of the drawings and a specific descrip tion thereof which here follows. Referring now more specifically to Figure 1, Figure 2 and Figure 4, I show a roll I of resin im pregnated fibrous material such as paper, which has been impregnated with aurea or phenol formaldehyde condensation product or a thermo plastic resin such as a vinyl compound, as for The resin impregnated paper I passes ñrst under lshaping elements 2 supported by rods 3 from a ' contain metal inserts or core elements. Figure 12 is a cross section of a modified form of my invention. , Figure 1 is a side schematic View ofthe appa-A the corrugations are formed in proper space rela ratus for forming a corrugated structure. tion with one another._ From an adhesive tank 9 adhesive is supplied 2-2 of Figure 1 showing the Ycorrugated forming 35 through a doctor element I0 on to the upper por tions of the corrugated sheet I so that whenthe Figure 3 is a cross section of the corrugated resin >impregnated corrugated liner element ‘I element formed according to my invention. is fed down onto the corrugatedsheeting I and Figure 2 is a cross section taken along the line elements. ' n Figure 4 is a perspective end view of the cor rugated structure forming apparatus of my inven tion. pressed thereon by the upper pressing element 6, 40 adhesion is effected between the liner element 'I and the corrugated sheeting I. The corrugated ‘ Figure 5 is a perspective view of another form sheeting passes over the table I2 where it may be of my invention showing the apparatus and heated to first effect the softening of the thermo means by which tubular corrugated structures plastic resin with which the corrugated and liner 45 elements have been impregnated. can be continuously formed. Figure 6 is a cross section of the apparatus of From an adhesive tank I3, adhesive is fed Fig. 5 along the line ‘ô-G of Figure 6. through a tube I4 and `a doctor applicator I5 through the bottom of the corrugated sheeting Figure 7 is a cross section taken along the line I whereupon a bottom liner element I6 is pressed l-l of Figure 5. . 50 Figure 8 is a perspective of the tubular corru- . _on to the bottom of the corrugated sheeting I by a pressure element I'I. By means of this ap paratus I can lcontinuously f-orm a corrugated gated structure formed by the apparatus shown in Figure 5. ` l sheeting in_wh'ich'the corrugations are properly molded into the resin impregnated sheeting I and Figure 9 is a detailed perspective showing the application of the sealing strip to the joint of the tubular corrugated structure. ` 55 this precise corrugated structure is’maintained 2,406,051 4 by rod inserts While the liner elements are being applied under pressure to the corrugated sheeting. In Figure 3 I show a corrugated sheeting formed by the process here set forth in which between and 7, and which comprises the inner liner 25, ~‘the resin-Which impregnatesîthelpaperÍis thermo plastic or heat Vsoftenable. Upon beingso‘soitened, eral vcorrugated shape to the plastic strip ‘89 and the paper as Áfit passesïbetWeen-the shaping mem "ber-s ‘22 and 123 AvformsY to a corrugated shape. ~impart a block shaping to the strip material. The block shaped corrugated strip material is carried along 'between rods ûß'and 89 Which are the outer liner «tl and the corrugated element 2 l ’. The inner liner 25 is overlapped at ¿i4 and the outer liner ¿ii is overlaped at 45, this overlapping the upper liner l and the lower liner i6 is dis of the liner elements as well as of the corrugated posed the y.corrugated element ~l. Aelement 2i’ being effected to secure a firm ad The shaping members 2 may eitherbe solid >core hesive end joint. or they may comprise a three-part sectional eie In Figure 9 I show a modification of my in ment that can be spread by pressure downwardly ’ ’ Y‘vention in which the end joining of the liner ele applied thereto. v Y fment is-eiì-“ected by the application of an adhesive In Figure 5 I show an apparatus an'd a'metho tape Eîì to the joint Where the outer liner element by means of which I can continuously form tu- ` meets and a pressure member 5| firmly applies bular corrugated resin impregnated structures. theadhesive tape 5@ -to the joint. From a roll 20 a sheet of resin impregnatedpaper >In Figure l0 I show a cross section of a cor 2i is fed between an external-corrugated shaping rugated structure so formed in which the adhesive Y element 22 and an internal corrugated shaping tape “dii is applied over the outer liner element 4I. element 23 made up of a series of "rods havingfa AIn Figure 11 I show the apparatus for con shape that conforms to the inside shape oí the tinuously forming a corrugated structure in shaping member 22. The resin impregnated paper n which a strip of resinimpregnated ñbrous Ina 2l passes between the shaping elements 22 and 23 20 terial 86 is fed from «a roll 3l through a first vand may Ebe ~preiirninarily softened by heating if ’set-of shaping rolls S2~an`d 33 «which apply agen a second »set of shaping rolls 8'4 and 85 which A resin impregnated ïliner sheet 25Vis îfed `from va roll 528 and -`adhesive is applied to the _outer surface thereof from an adhesive tank?! îthrough an adhesive applicator ring ‘28; "The adhesive ‘coatedïliner material Jv25 @is ‘then lled overa-sec- z fed by means of tracks Si) and 9| into the open ings »in the corrugated strip 8B -so that a rod in sert fallsinto each opening as shown. The rods »are disposed in opposed relation to one another tional s'hell‘âû (see Figure@ Wherebyïit ispressed into adhesive vcontact :With the resin impregnated paper 2'! -Wliich has ïbeen :shaped fto l corrugated form. The sectional »shells "39 are supported >by arms'EïZ whicharesupported'centrallyßby»a i=od`33. ' I 1A steamilinelîi?iïrunslthrough the rod 33 y"to sup «iply Eheat to" soften -the vresin impregnated ¿cor rugated liner 'elements "for theirI shaping `and for> the purposes explained hereinafter. When the rod is to remain in place after man ufacture as in the manufacture of armor plat ing, then the rod is coated with an adhesive. When the rod simply-actsïas aïcore ‘to ïfacilitate in proper shaping of the corrugated element, then the `rod is coated with alubricating com positionrwhich may be either a lubricant'bypits 'adherence' and '_infthe case- ofthe 'use of a'thermo fownïcharacteristic or a substance which upon ’ setting»resinftoapplyïheat thereto‘to efîectialcur 40 Aapplication of heat adjacent thereto becomes ’ing‘oî these :elements when :their proper shaping soft and the rod can thus beV disengaged there vhasï'been effected. ' " ' ' `~'I-‘he«central rodTSB iis’ßsupported ‘by a support 35. The resin impregnated «sheet »21 .with the 'inner ‘liner 25 ¿attached îthereto ¿emergesirom fthe shaper -ZZÍandi-islindicated asïîïl’. A‘From an ad -hesive tank T38 .and through- an adhesive îfeed vring B9 'the corrugatedsheeting‘Zl" is Y:coated-With an adhesive. From a roll liüÍa lsheetÍoi resin im- l -pregnated paper "42| ¿is >led over the "corrugated sheeting land-by means 'of ya `pressing „element ’112, the «resin impregnated outer 'liner .element ufl ïis Vadhesively secured over the `corrugated«sheeting 21’. Thus; ‘by continuous operation »"I shape a resin impregnated sheet to corrugated ïformv'and while lin such '"corrugated'fform' 1I ëattac'h iin fad hesive relation A.thereto an inner'liner element 25 and anouter î'liner `element I4 I . " V"IThe n‘application of -heat is so controlled thatin the case o'f ja’therino plastic >resin îbeing used, ‘the heat lis-applied to soften the resin and after shaping ATis leiiected'ïthe structure iis-‘coolerd either by the nonïuse of Èheat or by theuse of cooling means ïto set the thermo Yplastic resin impregnated sÍheet Ain 'the structure formed. ' ' ‘ VFigure Gis a cross vsectional View, taken along theline‘íì-S` o‘f Figure 5. p ' . Figure ’7,is across section taken-along‘the vline from..` Willa'ssïist in ‘the understanding of theßperation _ _ _- a higher speed than the roller members next en countered in the apparatus. and accordingly press Ythe corrugations so as to'close the corruga `tionsabout the core elementsandrform -triangu lar-enclosures aboutsaid core members l88 and 8.9. Y From Van adhesive ’tank such as_éltl, adhesive 'is applied by means of doctor elements 9S and 91 to the externalrportions of the Vcorrugations 8i). f’I'he adhesive coated. corrugated resin Aimpreg nated strip 8% With'the cores contained therein then passes between two chromium plated con tinuous belts IQll and lill which are rotated over rolls m2 andr‘llJS by a suitable driving mecha nism. The chromium plated belts 1D0 and 10i (il) come in smooth and slipping contact with the liner elements i634 and 105 which are applied upon the adhesive coated corrugated strip ele ment Sil. A pair of continuously rotating end less plate blcck chains IBS and |01 rotating Y about wheels H18, |09, H0, HI, yact to transmit pressure vfrom the hydraulic press H3 through theV ball bearing surface IM thereon and ‘from stationary platen-H5 and the ball bearing sur face ‘Figures 6 and v7 Vare cross sectional views -that ,y The corrugated strip 80 with the rods 88 and 89 new positioned lin adjacent corrugations there s‘ ‘of »pass ,throughgrollsQZ and 93 >which operate at lll thereon. ‘ Y ` Pressuretrarismitted >from the hydraulic rpress ÑH3 is applied 'through ball bearingsjl I4 seated inîthat surface on to the heavy plates V'H36 and ¿In-Figure 8` Ishow the resin impregnated cor similar pressure is applied trom the table 'H6 rugated ‘tubular structure ‘which is a 'product of below to the ball bearings H1 ‘to the 'track lill, the apparatus and method shown in `Figures '5, 6 75 the tracks H36 and` iûl' applying fpressure't'hrough orf’theapparatus/shown'in Figureâ. 1` f l . 2,406,051 6 -5 89 as `by-electric current orlby heat by conduc the chromium belts lill to the corrugated strip 80 positioned between the liner elements |04 and which is impregnated into the fibrous material, tion to cause the coatings thereon to'soften and lose their adhesive qualitie'sL- The rods may thereuponv be withdrawn from the corrugations. In making an armorplating or other building structure in Which the rods or tubular inserts 83 and 89 are to be left in place, no such means of to be cured and to firmly bond all parts ofV the withdrawal need be provided- m5. Thus I lirmly apply pressure to the cor rugated structure to `cause the thermo plastic to flow and set, or in the case of a thermosetting compound, to cause the thermosetting compound, - I may also employ as the limpregnated agent 'In Figure 12 I show the corrugated structure formed according to the apparatus shown and described above in which the corrugated strip ele ment 8E! is ñrmly bonded between the upper liner element lili vand the lower liner element |85. Vinsol, sold by the Hercules Powder Co. and which is an extract of yellow pine trees, certain silicates, such as sodium and potassium silicate, and described hereinabovel can be varied by those skilled in the art without departing -from the corrugated structure together. , By the heat application set out herein, a hard strong resin impregnated corrugated structure is obtained. n It will be understood that -the apparatus shown spiritcf myinvention. For example, in Figure ll -the crimping orcorrugating rolls 32, 33, 84 preferably treated with an acid so that the sili cate is set in place'in the fibrous material, vinyl idine chloride and chlorinated para?ñns. These resins may also be applied tothe fibrous mate rial by dipping, spraying, brushing or any other suitable applicator meansv and heat and subse and 85, maybe modified in shape to produce a curved corrugati'on instead'of the rectangular corrugation >shown herein. In that case curved cores or inserts 88 and 89 would be employed.I The mechanisms involved would still be substan quently -cold is applied to take advantage of the thermo plastic nature of the materials employed. tially the same. Various types of ‘resins may be used for impreg It is also within the scope of my invention to nating the ñbrous material to form the corru-> form the corrugated middle elements, such as gated stru’ctures ‘described herein.' For example element l shown in Figure 3, or the element` 8u reference is made to my copending application ` shown in Figure' 12, by extruding a plastic mass Serial No. 484,503 which described certain ther comprising sawdust, or wood ñour in a mix ccm prising an adhesive, the mix being extruded 30 ino-setting resins vwhich are applied to the fibrous material and which are set by heat and pressure. through a die having a cross section depending I have found that I may obtain a very strong on the type of corrugatiou involved. In other words the corrugated element is extruded in its corrugated form through the die and the plastic resin impregnated corrugated structure by using mass that forms the corrugated element sets as tion of which is accelerated by the use of a perox ide as a catalyst. Whereas it is necessary in the case of the phenol formaldehyde condensation resins to employ pressure, in the curing there of, it is unnecessary to use‘pressure in curing the it emerges from the die. diethylene chloride-polystyrene resin, the reac ' Hot air or other suitable heating means may assist in the setting and drying of the extruded corrugated material. I may employ as the composition to be eX 40 diethylene chloride-polystyrene resin. The resin is ñrst heated to a range of ’l0-80° C. and sec truded in the form of a corrugated structure ondly to a range of 10G-120° C. The fibrous ma a mass comprising excelsior or Wood wool and a teria] may be impregnated with the resin either binder whichmay comprise lignin or alterna by dipping, spraying, brushing or the like. tively a suitable thermosetting or a thermoplastic It is much more dimcult from an operating resin such as for example phenol formaldehyde standpointto employ core elements which must condensation product or any of the well known be withdrawn and pressure apparatus in forming vinyl compounds or other suitable adhesive' corrugated structures than to use simple joining resincus or plastic compositions well known in means, It is the object of the present invention this art. The excelsior is boiled in dilute sulphuric acid, then drained, and neutralized, , to form a corrugated structure impregnated with a- hard resin without the necessity for using pres whereupon it may be molded, pressed or extruded sure apparatus and core members. It is a fur with the addition of aniline or furfural if a ther object of the present invention to make a resinous combination is desired. Alternatively to resin impregnated corrugated structure having using excelsior as the base material, I may em ploy cotton ñock. 55 relatively high impact strength and substantial The complete corrugated structure compris tensile strength. ing upper and lower liners and the centrally at tached corrugated element is extruded. The apparatus used is an extrusion die with upper, and lower slots and a central sine curve slot that meets the upper and lower slots, the central slot being formed for example by a series of curved blocks set in the die head. When the composition extruded is thermo plastic, it is heated prior to extrusion and cooled after extrusion. Suitable heat may be applied by hot air or steam or hot water pipes and cooling means by suitable cooling and refrigerating devices in Zones so « The resin such as the diethylene chloride-poly styrene condensation product which can be cured by heat alone and without the use of pressure is therefore extremely valuable in making a resin impregnated corrugated structure of high impact and high tensile» strength without the necessity for using pressure apparatus. ' It will be understood that the apparatus and method herein described can be used not only for the manufacture of corrugated structures from resin impregnated sheeting, but may also be used for the manufacture of corrugated sheet ing from plain coated or resin impregnated 1i which are determined by the particular nature 70 brous material such as paper or cardboard, since the shaping and forming apparatuses are believed of the thermosetting or thermoplastic resin to be novel. employed. < . In addition to employing paper or cardboard, If the rods 88 and 89 are to be withdrawn hav I may form corrugated structures from cloth, as ing simply been used as core elements, then I may apply heat directly through the rods 88 and 76 for example cotton duck, or from cloth woven 7 2,406,951 from glass fibre, such cloths being impregnated with a thermoplastic or thermoadhesive com pound, such as phenol formaldehyde or vinyl acetate so that such cloth has when set suñi In the case of the use of certain thermcsetting impregnated resins adhesion will be induced dur ing the curing of the impregnated sheets when pressed into contact With one another. In other cient rigidity and structural strength to main "il instances added adhesives will be necessary de tain the corrugated structure. pending upon the strength of the joint required. By employing different resins of the type set Various modiñcatio-ns of my invention will sug forth above, I may vary the properties of the ñnal gest themselves to those skilled in the art. I ac corrugated structure produced so that I may pro cordingly desire that in construing the breadth duce a ñreproof, Water resistant, resin impreg of the appended claim that they shall not be lim nated corrugated structure having either hard ited to the specific details shown and described ness or resilient strength or I may com-bine vari in connection with the above explanation. ous compositions to obtain for example a cor I claim: rugated structure having an external coating giv An apparatus 4for continuously producing co-r ing high impact strength„ and an internal im rugated material which comprises means for pre pregnating resin which gives toughness and re shaping ñbrous sheet material, a second means silience to the corrugated structure. for shaping said sheet material into rectangular The application of adhesives in forming the corrugated form, means for introducing core corrugated structuresshown hereinabove will be mem-bers into the corrugations formed in said covered of course by the nature of the material 20 corrugated material, means for advancing said employed. When plain sheet «material is em corrugated material containing said core mem ployed, then adhesives are necessary to induce adhesion between the liner elements and the cor bers, means for pressing liner elements in contact rugated element. When resin impregnated sheet material is employed, the use of added adhesives core members, said means for advancing said cor rugated material moving at a greater rate of speed than said means for pressing liner elements will depend on whether adhesion can be induced between adjacent sheets by the use of heat and pressure alone as in the case of thermoplastics. with said corrugated material containing said onto said corrugated material. GERHART WEISS.