A system and method for producing a board product characterized by having two corrugated mediums and at least one embossed mediumin the board product. The board product may further include one or more facings that are adhesively coupled to either the corrugated medium, the embossed medium, or both. Generally speaking, a corrugated medium may be characterized as a paper product that exhibits flutes induced by a cross-corrugating process such that the induced flutes are perpendicular (or at least not congruent) with the machine direction of the paper product. An embossed medium may be characterized as a paper product that exhibits flutes induced by a linear-embossing process such that the induced flutes are aligned with the machine direction of the paper product. A resultant board product is stronger and more efficiently produced because of the linearly-embossed medium harnessing the natural strength of the paper in the machine direction.

A non-fibrous film has at least one film body that is non-fibrous, and at least one film element that is non-fibrous. The film element is coupled to the film body at an interface that is non-continuous across a film width of the non-fibrous film. The non-fibrous film has at least one of the following characteristics: the interface has at least one mechanical property having a value that is different than the value of the mechanical property of at least one of the film element and the film body, and/or the film element has at least one mechanical property having a value that is different than the value of the mechanical property of the film body.

A system and method for producing a board product made from paper products that have a pre-scored facing in addition to a medium (sometimes called fluting). Conventional corrugated board may feature a cross-corrugated medium and one or more facing that have no score lines that are imprinted (at least prior to assembly with the corrugated medium). Such a conventional board product may be inferior because any score lines that are imprinted will damage the underlying corrugated medium in some manner. A breakdown in the strength of the underlying medium leads to poor precision when the eventual board product is scored, cut, and bent. A lack of precision in folding a board product is known as fishtailing as any articulated portion of the board product may not maintain a precise plane of articulation when bent. Hence, the articulated portion “fishtails” out of alignment. Having precisely located impression lines in register to underlying flutes of a medium ensures correct and precise articulation.

A system and method for producing a board product made from paper products that have a pre-scored facing in addition to a medium (sometimes called fluting). Conventional corrugated board may feature a cross-corrugated medium and one or more facing that have no score lines that are imprinted (at least prior to assembly with the corrugated medium). Such a conventional board product may be inferior because any score lines that are imprinted will damage the underlying corrugated medium in some manner. A breakdown in the strength of the underlying medium leads to poor precision when the eventual board product is scored, cut, and bent. A lack of precision in folding a board product is known as fishtailing as any articulated portion of the board product may not maintain a precise plane of articulation when bent. Hence, the articulated portion “fishtails” out of alignment. Having precisely located impression lines in register to underlying flutes of a medium ensures correct and precise articulation.

A method of manufacturing an activated composite web includes laminating a film layer to a nonwoven web to form a composite web, forming a plurality of apertured protuberances in the film layer, and passing the composite web through intermeshing elements to form an activated composite web. The intermeshing elements form a plurality of first lanes, with first widths, substantially unaffected by activation, and a plurality of second lanes, with second widths. The second widths are less than the first widths. Portions of the plurality of apertured protuberances define first apertures in the first lanes and second apertures in the second lanes. The cross-sections of the second apertures are larger than the first apertures. The first apertures have their major axes substantially aligned in the first direction while the second apertures have their major axis substantially aligned in the second direction. An activated composite web also is provided.

Patterned substrates having a first substrate region that is incrementally mechanically stretched with corrugations and a second substrate region having a plurality of discrete unstretched portions completely surrounded by the first substrate region.

A system and method for producing a board product made from paper products that have a pre-scored facing in addition to a medium (sometimes called fluting). Conventional corrugated board may feature a cross-corrugated medium and one or more facing that have no score lines that are imprinted (at least prior to assembly with the corrugated medium). Such a conventional board product may be inferior because any score lines that are imprinted will damage the underlying corrugated medium in some manner. A breakdown in the strength of the underlying medium leads to poor precision when the eventual board product is scored, cut, and bent. A lack of precision in folding a board product is known as fishtailing as any articulated portion of the board product may not maintain a precise plane of articulation when bent. Hence, the articulated portion “fishtails” out of alignment. Having precisely located impression lines in register to underlying flutes of a medium ensures correct and precise articulation.

A system and method for producing a board product characterized by having two corrugated mediums and at least one embossed medium in the board product. The board product may further include one or more facings that are adhesively coupled to either the corrugated medium, the embossed medium, or both. Generally speaking, a corrugated medium may be characterized as a paper product that exhibits flutes induced by a cross-corrugating process such that the induced flutes are perpendicular (or at least not congruent) with the machine direction of the paper product. An embossed medium may be characterized as a paper product that exhibits flutes induced by a linear-embossing process such that the induced flutes are aligned with the machine direction of the paper product. A resultant board product is stronger and more efficiently produced because of the linearly-embossed medium harnessing the natural strength of the paper in the machine direction.

A panel includes a corrugated base with base corrugations configured from first base segments and second base segments. A first of the base corrugations includes a first of the first base segments and a first of the second base segments that is non-parallel to the first of the first base segments. The first of the base corrugations forms a first channel that extends laterally between and longitudinally along the first of the first base segments and the first of the second base segments. A corrugated stringer includes a plurality of stringer corrugations arranged longitudinally along and within the first channel. The stringer corrugations are configured from first stringer segments and second stringer segments. A first of the stringer corrugations includes a first of the first stringer segments and a first of the second stringer segments that is non-parallel to the first of the first stringer segments.

A core layer suitable for a multilayer composite including at least one surface layer and one core layer, the surface layer arranged to at least partially cover the core layer and be fixedly connected thereto, wherein the core layer has elements composed of wood, which elements have plate-like regions arranged in zig-zag-shaped fashion, wherein a plate-like zig region of an element with an adjoining plate-like zag region of the element form a common edge between them, in such a way that the wood element of zig-zag-shaped form is formed, wherein elements of zig-zag-shaped form are arranged in the core layer such that two such edges of two different elements cross one another at a non-zero angle, and wherein the two elements are fixedly connected to one another at the crossing point. In one embodiment, a wood element of zig-zag-shaped form may be adhesively bonded to a planar wood element.