Systems and methods for forming corrugated boards with ultrasound

An apparatus for forming corrugate boards, the system comprising:

• a single face unit configured to form a single face board having a fluted layer and an outer liner;
• a glue station configured to receive the single face board and another sheet material, the glue station being further configured to:
• selectively attach the another sheet material to the single face board to form a single wall board by applying an adhesive to the another sheet material or the single face board and press together the another sheet material and the single face board with the adhesive therebetween;
• and
• selectively advance the single face board therethrough without attaching the another sheet material to the single face board;
• and
• an ultrasonic unit configured to apply ultrasonic vibrations to the single face board or the single wall board, the ultrasonic vibrations being configured to remove moisture from the single face board or the single wall board and/or dry the adhesive used to attach layers thereof after the another sheet material is attached to the single face board at the glue station, and/or cause the fibers of the single face board or the single wall board to weave or intertwine together, the ultrasonic unit being positioned downstream of the glue station.

A method for forming corrugated boards, the method comprising:

• forming a fluted layer from a first sheet material;
• attaching the fluted layer to an outer liner to form a single face board, attaching the fluted layer to the outer liner comprising applying an adhesive to at least one of the fluted layer or the outer liner and pressing the fluted layer and the outer liner together;
• attaching a second outer liner to the single face board to form a single wall board, attaching the second outer liner to the single face board comprising applying an adhesive to at least one of the single face board or the second liner and pressing the single face board and the second outer liner together;
• and
• after attaching the second outer liner to the single face board to form the single wall board, applying ultrasonic vibrations to the first single wall board to release moisture therefrom.