Recyclable signage

Abstract

Manufacturing signage assemblies, systems, and devices are shown and described. Recyclable signage intended for outdoor use may include a medium with a coated unactivated striped front and rear face, an adjacent liner sheet, and wherein the fluted medium and the liner are adhered with an adhesive to form the signage.

Claims

1. A layered outdoor signage consisting of: a. a corrugated medium having a plurality of ridges; b. a first layer liner adjacent said corrugated medium, wherein said first layer liner having a moisture barrier and a graphic print; c. a polyvinyl acetate adhesive binding said first layer liner and said corrugated medium; d. a second layer liner adjacent said corrugated medium, wherein said second layer liner having a moisture barrier and a graphic print; and e. a starch adhesive binding said second layer liner and said corrugated medium.

2. The signage in claim 1, wherein said signage being repulpable and recyclable.

3. The signage in claim 1, wherein said signage comprises two opposing printable exterior surfaces.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the disclosure will be better understood by a reading of the Description of Embodiments along with a review of the drawings, in which:

(2) FIG. 1 is a schematic front overview of one embodiment of a process assembly according to the present disclosure;

(3) FIG. 1A is a schematic overview of the embodiment introduced in FIG. 1;

(4) FIG. 2 is schematic product material flow overview along the embodiment introduced in FIG. 1;

(5) FIGS. 3A and 3B are perspective views of isolated segments shown in FIG. 1;

(6) FIGS. 4A and 4B are perspective views of isolated segments shown in FIG. 1;

(7) FIGS. 5A, 5B, and 5C are perspective views of isolated segments shown in FIG. 1;

(8) FIG. 6 is a perspective view of isolated segments shown in FIG. 1, showing flute tips creating a fluted medium;

(9) FIG. 7 is a perspective view of isolated segments shown in FIG. 1;

(10) FIG. 8 is a perspective view of isolated segments shown in FIG. 1;

(11) FIG. 9 is a perspective view of isolated segments shown in FIG. 1;

(12) FIG. 10 is a perspective view of isolated segments shown in FIG. 1;

(13) FIGS. 11A and 11B are perspective views of isolated segments shown in FIG. 1;

(14) FIG. 12 is a perspective view of one embodiment of a signage medium according to the present disclosure; and

(15) FIG. 13 is an exploded view of the embodiment introduced in FIG. 1.

DESCRIPTION OF EMBODIMENTS

(16) In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as forward, rearward, left, right, upwardly, downwardly, and the like are words of convenience and are not to be construed as limiting terms.

(17) Referring now to the drawings in general and FIG. 1 in particular, it will be understood that the illustrations are for the purpose of describing embodiments of the disclosure and are not intended to limit the disclosure or any inventions thereto. As best seen in FIGS. 1 and IA, the signage process and masterflute assembly, generally designated 100, are shown embodied according to the present disclosure to assemble and manufacture any of the signage shown and described herein. Applicant has discovered unexpected advantages of the process flow embodiments for critical orientation, activation, and heating procedures. For instance, typical embodiments to produce the unique, recyclable signage include specific manipulations of medium, liner, and adhesives as shown and described herein at wet-end assemblies, pre-print assemblies, central laminating assemblies, and completed in a delivery section assembly.

(18) FIG. 1 is an overview of an in-line laminator comprising process stations to provide any of the signage having the corrugated support shown and described herein. FIGS. 1A-11B introduce useful elements and product flow for the conveying, activating, heating, crimping, and adhering of the mediums, liners, and adhesives.

(19) As introduced in FIGS. 1 and 2, the assembly may include a wet end 102, 104, 106, 108, and 110; a pre-print section 112; a central laminating section 114 and 116; and a delivery section 118. As illustrated in FIGS. 1-2, assembling the recyclable signage shown and described herein having a corrugated support includes conveying a medium along a longitudinal direction. In particular examples, the medium having a coated unactivated striped front face and an opposing coated unactivated striped rear face is conveyed through the wet-end of the conveying process, i.e. station 102, station 104, station 106, and station 108. As shown, the medium is conveyed through a corrugator. In particular examples, the corrougator includes at least one pair of heated drums that concurrently heat, i.e. thereby activate, the medium's stripes. The corrugator further crimps the medium to define a barrier. As shown in FIG. 6, the assembly then generates flute tips along the medium to define a fluted medium. In particular examples, the medium is then conveyed around a secondary heated drum to activate unactivated stripes, thereby creating a full wrap. Typically, a liner sheet is then conveyed along an asitrade in a direction adjacent the medium. In certain examples the liner sheet has activated elements and unactivated elements on a front side, as well as activated elements and unactivated elements on a rear side. However, alternative embodiments and examples include additional liner sheets, including activated elements and/or unactivated elements. The fluted medium is then adhered about the liner. Applicant has unexpectantly discovered advantages of a starch adhesive to adhere the fluted medium about the liner. In certain examples, the starch adhesive is treated along peaks and ridges of the fluted medium.

(20) In some examples, the medium is conveyed through an asitrade heating, for instance Applicant has discovered improved activation during asitrade heating between about one hundred and seventy degrees to about one hundred and eighty degrees, to heat the stripes and penetrate the coating in-between the stripes. In this way, the asitrade heating encloses the penetrated stripes to produce the medium shown and described herein.

(21) In certain examples, the coating may be devoid of activation until the strips are concurrently heated and activated, followed by downstream compressing the medium, the liner, and the adhesive. Further, the medium may have a bleached sheet and be coated prior to activating the stripes. For instance, the coated medium may have a plurality of heat-activated coatings, for instance for water repellant characteristics and the like. The method may include coating the medium prior to adhering the medium with the liner sheet. The method may include coating the liner sheet prior to adhering the medium with the liner sheet.

(22) In some examples, the liner sheet may be conveyed through an asitrade for heating between about one hundred and fifty degrees to about one hundred and sixty degrees, or the like.

(23) In certain examples shown in FIGS. 12 and 13, the signage 10 produced by any of the processes and methods herein includes a care layer 20, a top liner 30, and a bottom liner 40. Top liner 30 and bottom liner 40 typically comprise magazine stock paper, but may be ofany other substantially flat material as understood by one skilled in the art having the benefit of this disclosure. As further described herein, the signage 10 includes a semi-impermeable coating to provide the structural integrity and characteristics suitable for printing shown and described herein.

(24) As illustrated in the figures, the core layer 20 typically comprises a fluted corrugated sheet defined by a plurality of ridges. Each ridge has a peak and may be separated from a neighboring ridge with a trough. Core layer 20 has a first side and a second side. In particular examples, the peaks of the ridges are defined as crests 22 on the first side of core layer 20. The troughs 24 between the ridges define the peaks of the ridges on the second side of core layer 20. Core layer 20 may be of any flute size. In one example, core layer 20 is a B flute. In another example, core layer 20 is a C flute. Yet in another example, core layer 20 is an E flute. Still in other examples, core layer 20 is a non-fluted medium.

(25) In particular examples, top liner 30 has an inner face and an outer face. Outer face is exposed facing away from core layer 20. Inner face includes an adhesive that binds to crests 22. In one example, the adhesive comprises polyvinyl alcohol. The adhesive may further include additives. In embodiments where core layer 20 comprises a non-fluted medium, then inner face may bind to at least a portion of first side of core layer 20.

(26) Bottom liner 40 also comprises an inner face and an outer face 44. Outer face 44 is exposed facing away from core layer 20. Inner face includes an adhesive that binds to troughs. In one example, the adhesive comprises corn starch, or similar adhesive as understood by those skilled in the art having the benefit of this disclosure. The adhesives may further include additives. In embodiments where core layer 20 comprises a non-fluted medium, then inner face 42 may bind to at least a portion of second side 28 of core layer 20. As seen in FIG. 13, bottom liner 40 may further include striping 46 to provide enhanced connection between elements shown and described herein. In one particular example, the inner face 42 of bottom liner 40 includes striping 46.

(27) One benefit for using a corrugated medium is recycling properties after use. Signage 10 also includes a semi-permeable coating that may serve to increase its stability when used outdoors; for instance, weatherproofing, withstanding humidity, wind, precipitation, and the like. Semi-permeable coating may comprise a wax alternative, such as FluteSHIELD? coating, to retain improved recycling capabilities after use. Application of semi-permeable coating may give signage 10 various Cobb values.

(28) In one embodiment, the semi-permeable coating is applied to outer faces 34 and 44 of top liner 30 and bottom liner 40, respectively. In another embodiment, the semi-permeable coating is applied to both faces of top liner 30 and bottom liner 40. Core layer 20 may also include a semi-permeable coating. In one example, the semi-permeable coating is applied to at least a portion of either the first side 26 or second side 28. In another example, the semi-permeable coating is applied to both sides of core layer 20.

(29) The semi-permeable coating may be applied before, during, or after application of any adhesive to any layer. More than one type of semi-permeable coating may be applied on one or more layers of signage 10. Signage 10 may also include additional coatings, such as a SurfSHIELD? coating. For example, signage 10 may include SurfSHIELD? SuperCobb as an additional coating. These additional coatings may be used to modify any characteristic of signage 10, such as its Cobb value or color.

(30) Semi-permeable coatings may interact with one or more adhesives used to adhere core layer 20 onto top liner 30 and bottom liner 40. For example, the semi-permeable coating may form chemical bonds with a polyvinyl alcohol adhesive used to adhere the top liner 30 onto core layer 20. In another example, the semi-permeable coating may form chemical bonds with a corn starch adhesive used to adhere the bottom liner 40 onto core layer 20. Various additives may be included with one or more adhesives to strengthen the bonding between the adhesive and semi-permeable coating.

(31) In operation, signage 10 typically includes one or more graphics 50 printed on an outer face. Graphics 50 may comprise text, icons, images, or a combination thereof. Applicants have unexpectedly discovered the systems shown and described herein enhance the ability of signage 10 to receive graphics 50. Certain embodiments of the present inventions may be adapted to receive print being free of a clay coating. For example, top liner 30 and bottom liner 40 may comprise magazine stock paper with graphics 50 printed in the absence of a clay coating. Graphics 50 may be printed using a solvent-based ink. More than one solvent-based ink may be used to print graphics 50. In other examples, top liner 30 and bottom liner 40 may include a clay coating with graphics 50 printed on top. Alternatively, other coatings may be used to prime outer faces 34, 44 for printing. Clay coatings or other priming coats may also be used with top liner 30 and bottom liner 40 without a graphic 50 printed.

(32) Numerous characteristics and advantages have been set forth in the foregoing description, together with details of structure and function. Many of the novel features are pointed out in the appended claims. The disclosure, however, is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts, within the principle of the disclosure, to the full extent indicated by the broad general meaning of the terms in which the general claims are expressed. It is further noted that, as used in this application, the singular forms a, an, and the include plural referents unless expressly and unequivocally limited to one referent.

(33) Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, the present disclosures may be applied to corrugated mediums other than those having a single wall. For instance, the corrugated medium may comprise a double or triple wall board. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.