# US 11,078,629 B1 · Thick-caliper laminated paperboard and methods for making the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,078,629 B1 - Document ID: US11078629B1 - Status: Granted - Kind: B1 - Application number: 16/265,278 - Filed: 2019-02-01 - Granted: 2021-08-03 - Earliest claimed: 2018-02-01 - Assignees: Caraustar Industrial and Consumer Products Group, Inc. - Applicants: Caraustar Industrial and Consumer Products Group, Inc. - Inventors: Josh Wolfenbarger; Don Ervin - Web page: https://patentgrep.com/patent/US11078629B1 ## CPC - D21H 27/34: Continuous materials, e.g. filaments, sheets, nets - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 29/08: Corrugated paper or cardboard - D21H 11/14: Secondary fibres (working-up waste paper D21C5/02) - D21H 27/38: at least one of the sheets having a fibrous composition differing from that of other sheets - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - B32B 29/005: {next to another layer of paper or cardboard layer} - B32B 2250/26: All layers being made of paper or paperboard - B32B 2262/067: Wood fibres - B32B 2307/732: Dimensional properties - B32B 2309/105: Thickness - B32B 2317/12: Paper, e.g. cardboard - B32B 2439/62: Boxes, cartons, cases - B32B 2479/00: Furniture - D21F 11/04: paper or board consisting on two or more layers - D21F 11/08: paper or board consisting of two or more layers - D21H 25/04: Physical treatment, e.g. heating, irradiating (D21H25/18 takes precedence; dryer section of machines for making continuous webs of paper D21F5/00) - D21H: PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - D21F: PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON ## Abstract Methods of making laminated paper sheets include winding paper around a flat-sided mandrel to form a flat-sided convolute tube and cutting from the flat-sided convolute tube one or more laminated paper sheets. The laminated paper sheets are alternatives to plastic, wood, and wood-like materials, such as plywood, medium-density fiberboard (MDF), and oriented strand board (OSB). ## Claims ### Claim 1 A method of making a laminated paper sheet, comprising: winding paper around a mandrel having a plurality of flat sides to form a convolute tube having a plurality of paper layers and a plurality of substantially flat sides, wherein lengthwise edges of the convolute tube are respectively defined between adjacent substantially flat sides of the convolute tube's plurality of substantially flat sides; applying adhesive to the paper to bond the convolute tube's adjacent layers of paper; and removing from the convolute tube one or more substantially flat laminated paper sheets. ### Claim 2 (depends on 1) The method according to claim 1, wherein: the step of winding paper around a mandrel comprises winding paper having a caliper of at least 10 mils to form a convolute tube having a thickness of at least 125 mils; and the step of removing from the convolute tube one or more substantially flat laminated paper sheets comprises removing the lengthwise edges of the convolute tube to yield a plurality of substantially flat laminated paper sheets. ### Claim 3 (depends on 1) The method according to claim 1, wherein: the step of winding paper around a mandrel comprises winding paper around a substantially rectangular mandrel; and the step of removing from the convolute tube one or more substantially flat laminated paper sheets comprises removing the lengthwise edges of a substantially rectangular convolute tube to yield four substantially flat laminated paper sheets. ### Claim 4 (depends on 1) The method according to claim 1, wherein: the step of winding paper around a mandrel comprises winding paper around a polygonal mandrel having five or more substantially flat sides; and the step of removing from the convolute tube one or more substantially flat laminated paper sheets comprises removing the lengthwise edges of a convolute tube having five or more substantially flat sides to yield at least five substantially flat laminated paper sheets. ### Claim 5 (depends on 1) The method according to claim 1, comprising laminating two or more of the substantially flat laminated paper sheets to form a thicker laminated paper sheet or board. ### Claim 6 (depends on 5) The method according to claim 5, wherein the step of laminating two or more of the substantially flat laminated paper sheets yields a laminated paper sheet or board having a thickness of at least 15/32 inch. ### Claim 7 (depends on 1) The method according to claim 1, wherein the step of winding paper around a mandrel comprises winding a continuous paper web to form the convolute tube. ### Claim 8 (depends on 1) The method according to claim 1, wherein the step of applying adhesive to the paper comprises applying adhesive to at least one side of a paper web as the paper web is unwound from a paper roll. ### Claim 9 (depends on 1) The method according to claim 1, wherein the step of removing from the convolute tube one or more substantially flat laminated paper sheets comprises cutting one or more laminated paper sheets from the convolute tube's substantially flat sides, each laminated paper sheet comprising a plurality of paper layers. ### Claim 10 (depends on 1) The method according to claim 1, wherein the step of removing from the convolute tube one or more substantially flat laminated paper sheets comprises removing the lengthwise edges of the convolute tube to yield one or more laminated paper sheets. ### Claim 11 (depends on 1) The method according to claim 1, wherein the step of winding paper around a mandrel comprises winding paper to form a convolute tube having a wall thickness of 100 mils to 2000 mils. ### Claim 12 (depends on 1) The method according to claim 1, wherein: the step of winding paper around a mandrel yields a convolute tube having a wall thickness of at least 500 mils; and the step of removing from the convolute tube one or more substantially flat laminated paper sheets yields one or more laminated paper sheets each having a thickness of at least 500 mils. ### Claim 13 A method of making a laminated paper sheet, comprising: applying adhesive to at least one side of a paper web as the paper web is unwound from a paper reel; rewinding the paper web on a mandrel having a plurality of flat sides to form a convolute tube having (i) a plurality of paper plies, (ii) a plurality of flat sides, and (iii) a plurality of lengthwise rounded corners respectively between each pair of adjacent flat sides; and cutting from the convolute tube one or more laminated paper sheets. ### Claim 14 (depends on 13) The method according to claim 13, wherein the steps of (i) applying adhesive to at least one side of a paper web and (ii) rewinding the paper web on a mandrel adhesively bonds adjacent plies of the paper web. ### Claim 15 (depends on 13) The method according to claim 13, comprising laminating two or more of the laminated paper sheets to form a thicker laminated paperboard sheet or board. ### Claim 16 (depends on 13) The method according to claim 13, wherein the step of cutting from the convolute tube one or more laminated paper sheets comprises removing the convolute tube's lengthwise rounded corners to yield a plurality of laminated paper sheets. ### Claim 17 (depends on 13) The method according to claim 13, wherein: the step of rewinding the paper web on a mandrel comprises rewinding the paper web around a rectangular mandrel; and the step of cutting from the convolute tube one or more laminated paper sheets comprises removing the convolute tube's lengthwise rounded corners to yield four laminated paper sheets. ### Claim 18 (depends on 13) The method according to claim 13, wherein: the step of rewinding the paper web on a mandrel comprises rewinding the paper web around a mandrel having five or more flat sides; and the step of cutting from the convolute tube one or more laminated paper sheets comprises removing the convolute tube's lengthwise rounded corners to yield at least five laminated paper sheets. ### Claim 19 (depends on 13) The method according to claim 13, wherein the step of rewinding the paper web on a mandrel comprises rewinding a paper web having a caliper of 10 mils to 50 mils to form a convolute tube having a wall thickness of 100 mils to 2000 mils. ### Claim 20 (depends on 13) The method according to claim 13, wherein: the step of rewinding the paper web on a mandrel comprises rewinding paper to form a convolute tube having a thickness of at least 250 mils; and the step of cutting from the convolute tube one or more laminated paper sheets yields one or more laminated paper sheets each having a thickness of at least 250 mils.