Apparatus and method for production of a two-ply paperboard panel

A method of fabricating a two-ply paperboard panel, the method comprising the steps of:

• running a first paperboard ply into a labyrinth defined by a rotating synchronized roll set comprised of a roll with raised nubs and a second roll with recessed pockets wherein spacer flaps are created as the nubs of one of the rolls of the roll set force through the first paperboard ply with such spacer flaps folded into the pockets of the second roll as the rolls mesh,
• pulling the first paperboard ply with the formed spacer flaps from the roll set and suitably adhering the spacer flaps to a second paperboard ply to create a two-ply paperboard panel;
• pulling the first paperboard ply with the formed spacer flaps under tension from the roll set by a tension roll that is run at slight over speed to that of the rotating roll set with the first paperboard ply having a significant wrap around the tension roll;
• and
• employing the tension roll as a backup roll with exposed spacer flaps emerging from the second roll having recessed pockets, further having adhesive applied by a glue roll as the first paperboard ply with the exposed spacer flaps passes through a gap between the backup roll and the glue roll.