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Патент USA US2406051

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Aug. 20, 1.946.
G, wElss
Filed June 26, v1943
5 Sheets-Shea?f 1
y Fig. 2
Ger-)fart Zréz'ss .
Aug. 20, 1946.
'ca_ wElss
Filed June 26, 1945
s sheetœsheet 2
6er/uff 7/6/ s ` A
Aug; 2o, 194e.
G. WE1-ss
Filed June 26, 1945-
s sheèts-sheet s '
Gerhart Zt/ez'ss
/íèáßám I
Patented Aug. 20, 1946
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)
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
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
Figure 4 is a perspective end view of the cor
rugated structure forming apparatus of my inven
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.
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.
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. `
this precise corrugated structure is’maintained
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.
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
`~'I-‘he«central rodTSB iis’ßsupported ‘by a support
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
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
VFigure Gis a cross vsectional View, taken along
theline‘íì-S` o‘f Figure 5.
Figure ’7,is across section taken-along‘the vline
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
‘Figures 6 and v7 Vare cross sectional views -that
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.
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
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.
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
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
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
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.
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