Apparatus and method for making a corrugated product.

(54) Title: METHOD AND APPARATUS TO MAKE A CORRUGATED PRODUCT.

(54) Title: APPARATUS AND METHOD FOR MAKING A CORRUGATED PRODUCT.

(57) Summary

The present invention refers to an apparatus for preparing a corrugated product, characterized in that it comprises: (a) a first pair of drive rollers to drive the middle substrate, driven to have a speed V3; (b) a shape guide, wherein the shape guide provides an upper surface for guiding the upper substrate, and a lower surface for guiding the lower substrate; (c) a second pair of drive rollers driven to have a speed V1; (d) where V3 is higher than V1; and the first pair of drive rollers is configured to drive the middle substrate into a space delimited by the shape guide, such that the middle substrate loops and contacts in an alternating manner with the upper and lower substrates; (e) a bonding device positioned around the upper surface and lower surface of the shape guide, wherein the bonding device couples the middle substrate with the upper and lower substrates; where a corrugated product is prepared.

(57) Abstract

The invention describes a device and method for making corrugated products. The device can be used with any substrate and ineludes, at least, first and second drive rollers for driving a middle substrate and a single wall corrugated product. In other embodiments the invention includes upper drive rollers, lower drive rollers and middle drive rollers for driving an upper substrate, a lower substrate and a middle substrate. The middle substrate is driven between the upper and lower substrates at a higher velocity to form flutes that are anchored between the upper an lower substrates thereby forming a corrugated product. The invention also provides for customized corrugated products having multiple fluted substrates in various desirable arrangements. Examples of such products include mattress, partition panels, other furniture and construction products.

I Μ ΡI '

PATENT TITLE No. 348607

Holders): BJ2, LLC

Address: 2544 South Green Road, University Heights, Ohio, 44122, USA

Denomination: METHOD AND APPARATUS TO MAKE A CORRUGATED PRODUCT.

Classification:

CIP: B31F1 / 24

CPC: B31F1 / 24

Inventor (s):

JASON CIK

REQUEST

Number:

MX / a / 2015/016599

International Filing Date: (BfeO July 6, 2011 ....... Divisional Patent Number: 337726 .....

PRIORITY

Country:

US US US

Coot:

July 2010 November 9, 2010 June 2011

Number:

61/362,115 61/411,898 61/493,655

Validity: Twenty years.

Expiration Date: July 6, 2031 .......

Issue Date: June 21, 2017

The reference patent is granted based on articles 1^or, 2nd section V, 6th section M, and 59 of the Industrial Property Law.

In accordance with article 23 of the Industrial Property Law, this patent is valid for twenty years, non-extendable, starting from the filing date of the international application and will be subject to the payment of the fee to keep these rights in force.

Whoever signs this title does so based on the provisions of articles 6 "sections III and 7" bis 2 of the Industrial Property Law (Official Gazette of the Federation (OO.F) 06/27/1991, amended on 08/02/1994 10/25/1996, 12/26/1997, 06/17/1999, 01/26/2004, 06/16/2005, 01/25/2006, 05/06/2009, 06/01 / 2010,18 / 06/2010, 06/28/2010 01/27/2012 and 04/09/2012); items 1^or, 3 «fraction V subsection a), 4^or and 12^or Sections I and III of the Regulation of the Mexican Institute of Industrial Property (D OF. 12/14/1999, amended ef 01/07/2002, 15/07/2004, 28/07/2004 and 7/09/2007); items 1^or, 3^or, 4^or, 5^or Section V subsection a), 16 sections l and III and 30 of the Organic Statute of the Mexican Institute of Industrial Property (DOF 12/27/1999, amended on 10/10/2002, 07/29/2004, 08/04/2004 and 09/13/2007); 1^or, 3rd and 5th paragraph a) of the Agreement that delegates powers to the Deputy General Directors, Coordinator, Divisional Directors, Heads of ..... Regional Offices Divisional Subdirectors, Departmental Coordinators and other subordinates of the Mexican Property Institute industrial (DOF 12/15/1999, amended on 02/04/2000, 07/29/2004, 08/04/2004 and 09/13/2007). "I

This document is signed with an advanced electronic signature (FIEL), based on articles 7 BIS 2 of the Industrial Property Law; 3 of its Regulations, and 1 section III, 2 section V, 26 BIS and 26 TER of the Agreement establishing the guidelines for the use of the Payment and Electronic Services Portal (PASE) of the Mexican Institute of Industrial Property, in the procedures indicated.

THE DIVISIONAL DIRECTOR OF PATENTS

NAHANNY CANAL REYES

<img file="MX348607B_D0001.tif" />

Original string;

NAHANNY MARISOL CANAL REYES | 00001000000403252793 | Administration Service

Tax | 1695 || MX / 2017/51031 ¡MX / a / 2015/016599 | Normal patent title with divisional PCT | 1027 | RGZ | Page (s) | NFJo4LwwmVHqrlybMgBbn5IOZ3l =

Digital stamp:

SZZ92t9XLjYFpxMitV55kJPNjrKuFMOvaDEffGZLfjOIRc4bou6jYk / tn6uY / BX9Vk / f60cUx45Pqt8g6AMAQ / Gj3g

C0ybtZa7 + 2UfJxnpcDakX / P9HOdgt7cAI3ZEvOu4aiVCYP9onPNiphErTI7r2Ua4St5jRRtl / 67wYc7tNx6hubNL / E aCVrBMI3CRqCGDi1qDS6ZVkO2q / UXmCmpz + 17fUvKBArxaAfkwhdyByfkSrYB6l8A2syy8eaGeelgBWP9kLswp4YWq zY + KDtu1j42eb4tfl2wKjUsnmmb47aK23Q4SSUnOk9HrUtCrpjS18UnTiSenuacjcmdqkufQ ==

Arenal No. 550. Floor 1, Pueblo Santa Mana Tepepan, Xochimilco. 16020, Mexico City.

(55) 53340700 www.gob.mx/impi

IM

MX / 2017/51031

Uxlakoisj

METHOD AND APPARATUS TO MAKE A PRODUCT

<img file="MX348607B_D0002.tif" />

Cross Reference with Related Requests

This application claims the benefit pursuant to 35 USC § 119 (e) of the United States of America Provisional Patent Application Serial No. 61 / 362,115, filed on July 7, 2010 and Serial No. 61/41 1,898, filed on November 9, 2010 and Serial No. 61 / 493,655, filed on June 6, 2011, the contents of which are incorporated herein by reference in their entirety.

Field of Invention

The invention relates generally to a process and apparatus for manufacturing a corrugated material.

Background of the Invention

Corrugated materials are extremely useful due to their low cost and high strength compared to weight and their ability to form into finished materials ranging from boxes, spacers, structural elements, etc. However, while corrugated cardboard is extremely useful, it has several disadvantages. First, the appearance of the cardboard may be less than desirable. Second, the surface is rough and rigid and prone to wrinkles. Third, corrugated board is relatively heavy for its weight, but lacks the necessary support for heavy jobs that tend to bend and curl. _____. . ..___,,. 1ΜΓ1 when placed under pressure on the sides. Ijm &amp; r ^ rJós^J OF THE MOFIF.DAD 'Oí-JTSi -T'7

INDUSTRIAL X. g. · »Corrugated paper materials have poor resistance to water, they become pulp after exposure to moisture, whether environmental or direct.

The current technology used for corrugating includes the following process. In order to mold a medium into the required shape, the medium is typically pressed between two rollers that resemble two wide gears. Gear teeth fit tightly together. When the media is fed between the two rollers, the grooves force the media into the desired waveform, forming gutters. The frequency and amplitude of the waveform is determined by the frequency of the grooves in the rollers and the depth of the grooves. Glue is often used to bond the corrugated layer to the flat layers. A different corrugation process is often used to corrugate sheet metal and plastic, where the gutters are oriented parallel to the direction of the material's path. The gutters are forced into the material by rollers stacked at the bottom and top of the material. In this way, the corrugation of different substrates requires different types of technologies adapted for each substrate.

Limitations of the conventional corrugation process include:

(1) The frequency and amplitude of the resulting wave cannot be adjusted easily and certainly not in real time. This is because the exact frequency and amplitude of the wave is determined by the dimensions of the rollers used. In order to perform any

IΜ ΡI change, the rollers must be changed with a tipSnftífetóéi! ^^^ INUUSTUIAl

This requires hang times during the shift. (2) Roller sets are expensive, therefore temperature manufacturers have a limited number of them. This limits the production of a fixed number of frequencies and amplitudes. (3) This conventional method is appropriate for smaller corrugations that have an amplitude within the range of 0.31 cm to 0.63 cm. However, it becomes more difficult for larger corrugations within the 2.54 cm range up to several meters. Corrugation of larger amplitudes will require rollers that have to be so large that their cost is prohibitive. (4) The conventional method is suitable only for materials that keep their shape after being molded by the corrugating rollers. Typically, the paper must be heated and steam treated prior to corrugation in order for it to hold its shape well. Materials with low plasticity and high mmr, such as rubber or certain plastics, may not hold their shape after passing through the corrugating rollers and will therefore be difficult to corrugate using conventional methods.

Therefore, there is a need for an apparatus and a process that provides a corrugated material that overcomes one or more of the current disadvantages mentioned above.

Brief Description of the Invention

Surprisingly, the present invention provides an apparatus and a process

IΜ PI;

to make a corrugated material that has ^ aiOE ^ si! improved industrial and pressure resistance from all directions, which can be waterproof and can be adapted to have a more pleasing aesthetic appearance, while at the same time providing greater ease of manufacture, more energy efficiency and use and production of fewer toxic chemicals. The invention describes a device and method for manufacturing corrugated products. The device can be used with any substrate and includes upper and lower drive rollers to drive the upper and lower substrate and drive rollers to drive the middle substrate. When the middle substrate is driven between the upper and lower substrates it forms gutters that are anchored between the upper and lower substrates to form a three-layer product.

In one embodiment, the invention provides a method of preparing a corrugated product, which comprises the steps of: providing an upper substrate and a lower substrate, at a rate of Vi and V₂, wherein the upper and lower substrates are kept at a distance Si from each other and provide a middle substrate, interposed between the upper substrate and the lower substrate, at a speed of V₃ in a trajectory to impact the lower substrate or the upper substrate, where the velocity V₃ is higher than the velocities Vi and V₂, so that the middle substrate alternately forms gutters, which make contact with the upper and lower substrates, where the corrugated product is formed. In the exemplary modalities, Vi and V₂ will be the same. However, in several exemplary embodiments of the invention, ν_Ί Y ., . ... 1Μ P i

V₂ they may be different from each other.

In another embodiment, an apparatus is provided for preparing a corrugated product. The device includes:

a first pair of drive rollers to drive the middle substrate through a feed guide and driven to have a speed V₃;

a shape guide positioned after the first pair of drive rollers, wherein the shape guide provides an upper surface to guide the upper substrate and a lower surface to guide the lower substrate;

a second pair of drive rollers driven to have a speed where V₃ is higher than V &lt;

a joining device positioned around the upper surface and the lower surface of the form guide, wherein the joining device couples the middle substrate with the upper and lower substrates, where the corrugated product is prepared.

The invention provides another exemplary embodiment of an apparatus for preparing a corrugated product, which comprises:

a first pair of drive rollers for feeding a medium substrate at a speed V3;

a shape guide positioned to accept the middle substrate from the first pair of drive rollers, the shape guide comprises a top surface and a bottom surface separated by a distance Sn where the shape guide accepts the top substrate on its top surface and the lower substrate on its lower surface;

<img file="MX348607B_D0003.tif" />

a second pair of drive rollers placed - the INSTITUTO MEXICANO on the property _ r_______. . . . ..... INDUSTRIAL, .-- shapes and pulls the corrugated product through the apparatus, where the corrugated article is produced.

In this embodiment, the shape guide is a set of essentially parallel plates, parallel rollers, or combinations thereof. In other aspects, in the apparatus according to the invention a shape guide is provided to accept the middle substrate from the drive rollers and feed the middle substrate into the shape guide. In some embodiments, the shape guide comprises two plates separated by a distance that can be varied to accept the middle substrate.

In another embodiment, the invention provides a method of manufacturing a corrugated product, which comprises:

(a) provides an upper substrate and a lower substrate, the upper substrate moves at a speed Vi and the lower substrate moves at a speed V₂, the upper substrate and the lower substrate are essentially parallel to each other and are separated by a distance "Si";

(b) provide a middle substrate, the middle substrate is located between the upper substrate and the lower substrate and moves at a speed V₃, Where v₃ is higher than Vi or V₂;

(c) propelling the middle substrate in a path to make contact with the upper substrate or the lower substrate, wherein after contact with the upper substrate or the lower substrate, the middle substrate bounces in an opposite direction to make contact with the opposite substrate, where after contact with the opposite substrate, the substrate

IΜ ΡI medium bounces to make contact with another substrate;

(d) coupling the point of contact of the middle substrate with the upper substrate or with the lower substrate, so that the middle substrate forms channels between the upper substrate and the lower substrate;

where the corrugated product is provided.

In another embodiment, the invention provides a cec comprising a first corrugated product, the first corrugated product includes:

a superior substrate;

a medium substrate;

a lower substrate;

two side perimeter pieces; and two end perimeter pieces;

wherein the middle substrate is ribbed and the gutters are attached to the upper and lower substrates to form a single wall corrugated product; and wherein the two side pieces are attached to the sides of the corrugated product and the two end pieces are attached to the ends of the foam product to enclose the inside of the mattress.

In some exemplary embodiments, the mattress also provides a second corrugated product adhered to the upper or lower substrate, wherein the second corrugated product comprises a second upper substrate, a second lower substrate, and a second corrugated middle substrate between the second upper and lower substrates and two side perimeter pieces and two end perimeter pieces.

In another embodiment, the invention provides a method of manufacturing a foam mattress comprising a primer which includes:

preparing a corrugated single wall foam product having a top substrate, a middle substrate and a bottom substrate;

wherein the middle substrate is ribbed and the gutters of the middle substrate are engaged with the upper and lower substrates; and mating the foam perimeter pieces around the exterior of the single wall corrugated product to form the foam mattress.

In several exemplary embodiments, the method of manufacturing a mattress also includes: a second corrugated product adhered to the upper substrate or to the lower substrate, wherein the second corrugated product comprises a second upper substrate, a second lower substrate, and a second corrugated middle substrate between the second top and bottom substrates and two side perimeter pieces and two end perimeter pieces.

Although multiple embodiments are described, other embodiments of the invention will be apparent to those of ordinary skill in the art upon reading the following detailed description. As will be apparent, the invention has the ability to be modified in several respects, all without departing from the spirit and scope of the present invention. Accordingly, the detailed description should be considered illustrative rather than restrictive in nature.

WICKED

INSTITUTO MEXICANO fa '***' * # ^ * '

OF THE INDOSWAII PTOOPISTY Brief Description of Drawings

Figure 1 is a schematic drawing illustrating an exemplary embodiment of a corrugated product apparatus in accordance with the invention.

Figure 2 is a schematic diagram illustrating a second exemplary embodiment of the invention, where adhesives are used to secure the gutters to the upper substrate and to the lower substrate.

Figure 3 is a schematic diagram illustrating a third exemplary embodiment of the invention, wherein ultrasonic welding is used to secure the gutters with the upper and lower substrates.

Figure 4 is a schematic diagram illustrating a fourth exemplary embodiment of the invention, where V! and V₂ they may vary one from another.

Figure 5 is a schematic diagram illustrating an embodiment of the apparatus in accordance with the invention, having a set of rollers forming a guide as shown in the embodiment illustrated in Figure 1. In this embodiment, the substrate Medium is fed directly into the drive rollers.

Figure 6 is a schematic diagram illustrating another exemplary embodiment of the invention, wherein the corrugating apparatus does not include a shape guide or a feed guide.

Figure 7 is a schematic diagram of an embodiment of the invention used to manufacture a double corrugated product. In this mode, a fourth and a fifth media are used to provide a

-..__________

X - τ। u- - τ,,_π.

ΙΜΡΙ® ^ _ .__._ _ .____. , ____,. , INSTITUTE ΜΚΧΙΟΝ ·, --7.-μ external substrate of the corrugated product. oela «οπεγ> *_γ>

^σ INDUSTRIAL

Figure 8 is a schematic diagram illustrating an embodiment of the invention used to make a double-walled corrugated product. In this embodiment, a fourth substrate is used to provide a separate corrugated layer on the corrugated product.

Figure 9A is a schematic diagram illustrating an embodiment of the invention used to manufacture a single substrate corrugated product. Figure 9B is a diagram of Figure 9A.

Figure 10 is a perspective view of a CAD producing one embodiment of the corrugating apparatus illustrated in Figures 1-9.

Figure 11 is a perspective view of a CAD produced by Figure 10, where one of the support structures has been removed to better illustrate the internal rollers.

Figure 12 is a close-up of the internal rollers illustrated in Figure 11.

Figure 13 is a perspective, sectional view of one embodiment of the mattress made in accordance with the invention.

Figure 14 is a perspective, sectional view of another embodiment of a mattress made in accordance with the invention.

Figure 15 is a perspective view of a corrugated plastic panel made in accordance with one embodiment of the invention.

Figure 16 is a top plan perspective view of a corrugated plastic panel, as shown in Figure 14, but with the top substrate having a pre-printed image on it.

Figure 17 is a schematic diagram of a plastic panel

-,_______

Corrugated IMPI shown in Figure 14, which illustrates how plastic and panel dimensions can be used in accordance with one embodiment of the invention.

Figure 18 is a top plan perspective view of a corrugated stainless steel panel made using the corrugating apparatus, in accordance with one embodiment of the invention.

Figure 19 is a schematic diagram illustrating some usable sizes and dimensions of the stainless steel panel shown in Figure 23.

Figure 20 is a perspective view of a chair, according to an embodiment of the invention, made by varying only Vi and V₂ in real time with the use of the corrugation apparatus.

Figure 21 is a perspective view of a bookcase made using the corrugating apparatus, in accordance with an embodiment of the invention.

Figure 22 is a perspective view of a partition panel made using the corrugation apparatus, in accordance with one embodiment of the invention.

Figure 23 is a perspective view of a corrugated column made using the corrugating apparatus, in accordance with one embodiment of the invention.

Figure 24 is a perspective, top plan view of a building constructed with the use of corrugated wall panels, in accordance with one embodiment of the invention.

Detailed description of the invention

In the specification and in the claims, the terms "includes" and "comprises" are open terms and should be construed to mean "including, not limited to." These terms encompass the more restrictive terms such as “consists essentially of” or “consists of”.

It should be noted that as used herein and in the appended claims, the singular forms of "a", "an", "the", "the" include the plural reference, unless the context dictates otherwise. Also, the terms "a", "one", "the", "the", "one or more" and "at least one" can be used interchangeably. Also, it should be noted that the terms "comprises", "includes", "characterized in that" and "has" can be used interchangeably.

Unless otherwise defined, all technical and scientific terms used herein have the same meanings as those commonly understood by those of ordinary skill in the art. All publications and patents specifically mentioned are incorporated herein by reference in their entirety, for all purposes, including describing the chemicals, instruments, statistical analyzes, and methodologies that may be reported in the publications that may be used in connection with this invention. All references cited in this specification are to be taken as indicative of the skill of those skilled in the art. Nothing should be taken as an admission that the invention is not empowered to anticipate the

IMPI description by virtue of the previous invention. institu-> macano DELA FPOPIEPAD industrial

Traditional corrugated products, such as cardboard and paper, are made first by forming a wood pulp to make a thick paper called kraft paper. Such pulp and paper production is a high energy and chemical process. To make the cardboard, the kraft paper is then smoothed with high pressure steam. Although corrugated products can have multiple layers or substrates, they typically have a "liner board" layer to which the corrugated "corrugated" middle layer is glued. After the corrugated layer is fixed with the first layer of the liner board, a second liner board is glued on top of the corrugated layer. Then the corrugated product is processed by pressurized rollers and undergoes another heat treatment. The finished cardboard product can then be cut into different sizes. In the production of corrugated paper products, it is necessary to pre-treat the paper before the corrugation process. This is because the paper is rigid and does not thermally "bend" when the gutters are formed, as opposed to folding and folding and thus loses its strength and protective ability. Therefore, the pre-treatment of the paper material with chemical and physical processes, including pressure and steam, is required to make the corrugated paper product.

In conventional corrugated products a "single sided" product refers to a corrugated one comprising a single sheet of liner board with the corrugated middle layer engaged only with that side. “A single wall” refers to a building where the middle —_________

ΙΜ ΡI ¿53 ^^ corrugated is sandwiched between two sides of the cardboard of q ^^^ íeM &amp; · ^

INDUSTRIAL double wall corrugated refers to a corrugated product that has 3 layers of liner board alternated with two layers of corrugated media. Similarly, a "triple wall" corrugation will have five layers of liner board separated by three layers of corrugated media. It should be understood that the present invention is not limited to a single wall product or any other product can be optimized to make any type of conventional or unconventional corrugated product.

The present invention provides alternative methods of making corrugated products from various types of media with the use of various substrates. Referring now to Figure 1, there is illustrated an embodiment of an apparatus for making a single wall corrugated product 16 in accordance with the invention. As shown, apparatus 10 includes a feed guide 20 for feeding a medium substrate 22 of a medium to be corrugated. The apparatus 10 also includes an upper portion and a lower portion of the shape guide 30 for guiding the upper substrate 32 and the lower medium substrate 34 for the corrugated product 16. As illustrated, the middle substrate 22 is fed into the form guide between the upper substrate 32 and the lower substrate 34. The upper substrate 32 is fed onto the upper roller 36 of the shape guide and the lower substrate 34 is fed onto the lower roller 38 of the shape guide. After passing over the guide rollers 36 and 38, the upper substrate 32 and the lower substrate 34 are bent towards the middle substrate 22, where they come into contact with the upper and lower feed rollers 40,

IMPI

INSTITUTE MfXXANo · --— that feed the upper substrate 32 and the substrate 34

30. Furthermore, the apparatus is designed so that the middle substrate 22 is fed into the shape 30 equidistant between the first substrate 32 and the second substrate 34.

The middle substrate 22 is fed into a first set of drive rollers 42 at a speed V₃. After passing through the drive rollers 42, the middle substrate 22 passes through the feed guide 20 which directs the middle substrate 22 to be fed, into the space S1 between the upper substrate 32 and the lower substrate 34. Away from form 30 is an upper drive roll 46 and a lower drive roll 47 that rotate at the desired speeds, which drives the substrates 32 and 34 at speeds V! and V₂, respectively, heaters 48 are also shown that are opposite the upper and lower substrates 32, 34 as they enter form 30. Those skilled in the art will appreciate that when V₃ is higher than Vt and than V₂, the middle substrate 22 will bend as it contacts the upper and lower substrate 32, 34. When the medium (e.g., substrates 22, 32, and / or 34) can be melted, heaters 48 heat the surface of the medium, such that as the middle substrate 22 contacts either of the upper substrate 32 or the substrate 34 bottom is fixed or bonded in place, thus forming a complete corrugated sandwich as it passes through the shape guides 30.

Of course, those skilled in the art will appreciate that and V₂, are generally the same when driven by drive rollers 47 and 48 that make contact with substrate 32

Upper IMPI and lower substrate 34 after it fixes with upper and lower substrates 32, 34. However, in alternative embodiments, illustrated for example in Figures 4 and 7, drive rollers 62 and 64 make contact with the upper 32 and lower 34 substrates, respectively, before the middle substrate 22 is attached thereto. As illustrated in this embodiment, the faster the feeding of the upper substrate 32 or lower substrate 34 into shape 56 or 58 will result in a complete corrugated product that is curved in the direction of the slower moving substrate, such as shown in Figure 4.

Furthermore, it should be understood that the process can be automated by driving the drive rollers with a motor. In some modes, when V is equal to V₂, the drive rollers 46 and 47 and 62 and 64 may be driven together in any conventional manner. For example, a chain on the motor drive shaft will drive the sprockets engaged with rollers 46 and 47 or 62 and 64 together, so that V! and V₂ they are the same. In addition, the same motor can drive the medium substrate at speed V₃ desired with the use of a sprocket of a different size, so that the drive rollers 42 rotate at a higher speed. Of course, those skilled in the art will recognize that separate motors can be used to drive each of the pairs of drive rollers, such that the speed ν_Ί, V₂ and V₃ it can be adjusted separately without the need to "mesh" each of the drive rollers at a particular speed. Also, when using multiple motors, the speeds

Relative IΜ ΡI of V₂ and V₃ they can be individually adjusted '^^^ industrially so that they vary from one another over time during the course of manufacture. In this mode, a product, such as 16 shown in Figure 7, can be made by altering the speed of V, and V₂ in real time, as a single wall corrugated product 16 is produced.

Of course, those skilled in the art will appreciate that when V! and V₂ can be adjusted in time, a corrugated product can be made in any shape. For example, cylindrical shapes and / or square shapes can be generated. For example, Figure 23 illustrates a cylindrical cylinder made using the present invention, where the ratio of V! to V₂ (or V₂ a VJ is constant and always higher, which provides a constant curvature with the substrate having a higher V on the outside and a lower V on the inside of the cylinder. Those skilled in the art will appreciate that the motors for each of the drive rolls can be controlled by a programmable computer system, so that manual control is not necessary. Furthermore, it will be appreciated that each of the rollers of the pair of drive rollers must rotate in an opposite direction. For example, as shown in Figure 7y, the upper drive roller of the pair 42 of drive rollers will rotate in a clockwise rotating direction, while the lower drive roller will rotate in the counterclockwise rotating direction. Similarly, as shown in Figure 1, the drive roller 46 will rotate to the right while the drive roller 47 will rotate to the left.

Those skilled in the art will appreciate that

IMPI when making a medium substrate 22, grooved from wílmércfl

INDUSTRIAL such as for example foam, the substrate is resilient and malleable. Therefore, the substrate 22 bends upon impact of the upper substrate 32 and the lower substrate and allows an instantaneous bond of the middle substrate 22 to the upper and lower substrates after impact. Those skilled in the art will appreciate that the rebound of the middle substrate 22 after impact with the upper substrate 32 is due to its malleability, which drives the middle substrate in the opposite direction to impact the lower substrate 34 and vice versa. Furthermore, the point of impact of the middle substrate 22 on the upper and lower substrates 32 and 34 after exiting the shape guide 20, affects the shape of the gutter and the attachment of the middle substrate 22 to the upper and lower substrates 32, 34 and lower. Thus, in some embodiments, the middle substrate 22 can impact the upper and lower substrates 32/34, while the substrates are still in contact with the shape rollers 40. In this regard, the present invention provides much greater utility compared to conventional corrugating techniques in that with paper the middle substrate is first treated and then pressed into the desired shape with the use of grooved rollers. Once removed from the rollers, the corrugated paper sticks with the opposing liner boards.

In various exemplary embodiments, the invention also comprises cutting blades 50 that terminate the sides of the corrugated product with a smooth, uniform edge. In various other exemplary embodiments, a cutting apparatus 60 is also included in the invention.

IMPI ^ which cuts the corrugated product to the desired length? '

However, those skilled in the art will appreciate that the cutting blades 50 need not be located after the end of the apparatus. In various embodiments, the cutting blades 50 need not cut all 3 layers at once. Those skilled in the art will appreciate that in various embodiments, it may be desirable to cut each layer of the substrate to a different width. In these modes, there will need to be three separate cutting blades. In accordance with these modalities, multiple knives are located anywhere throughout the corrugating process. In addition, when multiple cutting blades are used, they can be distributed in different places throughout the process. For example, the middle substrate 22 can be cut before entering the shape 20, while the outer substrates 32 and 34 can be cut after the shape, but before the drive rollers 46 and 47.

Figure 2 illustrates another exemplary embodiment of an apparatus used to make corrugated products 10 in accordance with the invention. In the embodiment shown, the general design is the same as that shown in Figure 1, however, Figure 2 illustrates that in this embodiment, the fixation of the gutters 24 with the upper and lower substrates 32 and 34 is achieved with the use of an adhesive 52 that is applied to the apex of each gutter 24, which binds it together are the upper and lower substrates 32 and 34 and results in a single wall corrugated product 16.

Figure 3 illustrates another exemplary embodiment of the invention, where the gutters are joined with substrates 32 and 34 upper and

WICKED

INSTITUTO MEXICANA ».____. __. . , ....., - OF THE lower PROPERTY with the use of 54 ultrasonic welding. Ultrasonic ^ elOacraF ^^ can be incorporated into the oí form (Pigwo 3}_;—E-eto-eo · can be applied more when the medium comprising the substrates is going to be bonded to metal or polymer films.

It should be understood that the drive rollers shown in Figures 1 through 4 can be substituted with any other mechanical means to drive the substrates, such as, without limitation, a conveyor belt, track, etc.

In an alternative embodiment of the invention, instead of feeding substrates 32 and 34 into form 30 in sync with middle substrate 22, upper and lower substrates 32 and 34 can be fed into apparatus 10 at the end of the run. form 20 after substrate 22 has been corrugated and passed through form 20 (seen in Figures 2 and 3). The substrate 22 will maintain its corrugated shape until it comes out of the shape 20 as long as the gutters slide along the inside walls of the shape 20. An advantage of this method is that an adhesive or solvent can be easily applied on the ridges. wave through the interior of shape 20, as illustrated in 52 (Figure 2).

It should be understood that each gutter can be joined as a continuous joint along the full width of the wave or it can be spot welded. For example, in these embodiments, several spot welds on the top and bottom of the ribbed layer, for example 4 on the top and 4 on the bottom, are usually sufficient depending on the width of the ribs. substrates and the properties of the substrate material.

IΜ PI

INSTITUTO MÉXICANt 'n · _____ _ · OEM MOHEDAL ·

However, experienced people ^ n

<img file="MX348607B_D0004.tif" />

They will recognize that the width can vary Hrr-f> ¡n? ™ (q ·· ^ caria a wire) up to a theoretical limit of the width of the available substrate. In several exemplary embodiments, most applications will be within the 30.48 cm to 2.43 m range. However, it should be appreciated that any limitation with respect to the width of the substrates results only from the widths of the veneer sheet available. The ability to easily cut foam sheets to any desired size, either before or after corrugating adds to the utility of the invention.

Those skilled in the art will appreciate that the present invention can be used to make corrugated products from many types of media or substrates. For example, although the medium can be cardboard or paper, the medium can also be a polymer product. Such polymer products can be in the form of foam products. Such foam products can be made of polyethylene and / or they can be polylactic acid foam products, such as those available for sale from, for example, VEX Protective Packaging Inc., Bridgeview, IL; Sealed Air, Elmwood Park, NJ. Other media that can be used for corrugated products include plastic films, such as polypropylene, and metals, such as steel, aluminum, and the like. Therefore, it should be appreciated that in various embodiments, appropriate materials for the upper substrate, the lower substrate and / or the corrugated product include poly (lactide-co-glycolide) (PLGA); polylactide (PLA), polyglycolide (PGA), D-lactide, D, L-lactide, L-lactide, D, L-lactide-epsilon22

ΙΜΡΙ ^> ^

INSTITUTO MEXICANO r caprolactone, DL-lactide-glycolide-epsilon-caprolactof ^^^ &amp; plift ^^ caprolactone-glycolide-caprolactone or combinations thereof.

Other non-biodegradable polymers useful in the present invention include, without limitation, various cellulose derivatives (carboxymethyl cellulose, cellulose acetate, cellulose acetate propionate, ethyl cellulose, hydroxypropyl methyl cellulose, hydroxyalkyl methyl cellulose, and alkyl -cellulose), silicon, silicon-based polymers (such as polydimethylsiloxane), polyethylene-co- (vinyl-acetate), poloxamer, polyvinylpyrrolidone, poloxamine, polypropylene, polyamide, polyacetal, polyester, poly-ethylenechlorotrifluoroethylene, polytetrafluoroethylene (PTGE or "Teflon ™"), styrene-butadiene rubber, polyethylene, polypropylene, polyphenylene oxidepolystyrene, poly-alpha-chloro-p-xylene, polymethylpentene, polysulfone, vinyl ethylene-degradable acetate (for example, vinyl-ethylene-acetate and poly (ethylene-co-vinyl-acetate) discs, methacrylates, poly (N-isopropylacrylamide) and other related polymers.

Additional polymers may also include, but are not limited to, delrin, polyurethane, silicone and polyurethane copolymers, polyolefins (such as polisobutylene and polyisoprene), acrylamides (such as polyacrylic acid and poly (acrylonitrile-acrylic acid), neoprene, nitrile, acrylates ( such as polyacrylates, poly (2-hydroxy-ethyl-methacrylate), methacrylates, methyl-methacrylate, 2-hydroxyethyl-methacrylate, and copolymers of acrylates with N-vinyl pyrrolidones), N, vinyl-lactams, polyacrylonitrile , glucomannan gel, vulcanized rubber, poly (3-hydroxybutyrate), and combinations thereof. Examples of polyurethanes include thermoplastic polyurethanes, aliphatic polyurethanes, segmented polyurethanes. Polyurethanes

IMPI

INSTITUTO MtXICAN., Ji hydrophilic, polyether-urethane, polycarbonate-urethane and urethane.

Other suitable materials include, but are not limited to, highly or poorly crosslinked biocompatible homopolymers and copolymers of hydrophilic monomers, such as 2-hydroxyalkyl acrylates and methacrylates, N-vinyl monomers and ethylenically unsaturated acids and bases, polycyanoacrylate, polyethylene oxide block copolymers. polypropylene glycol, polygacturonic acid, polyvinyl-pyrrolidone, polyvinyl acetate, polyalkylene glycols, polyethylene oxide, collagen, sulfonated polymers, vinyl ether monomers and polymers, alginate, polyvinyl amines, polyvinyl pyridine and polyvinyl imidazole.

In one aspect, closed-cell, low-density polyethylene (LDPE) foam is used for the upper substrate, the lower substrate, and the corrugated substrate. In use, corrugated articles made using the present invention can use any size of substrate as long as it is flexible. Thus, the width, height and thickness of the substrate can vary depending on the desired use of the corrugated product. For example, more rigid structural corrugated products may require stiffer, but thinner substrates, as thin as about 0.15 cm, while a product used in the manufacture of furniture, for example, cushions and mattresses may require thicker substrates, such as about 1.27cm thick, but it can be about 0.31cm to 2.54cm thick. Closed cell polyethylene foam has a good balance between stiffness and memory (meaning it will return to its original shape

INSTITUTO MU ICAN ^ after bending) at a lower density than other^{1 L}e ^ tímas> * 3! Spd® forms a good support for the corrugated design. —-----.

Also, closed cell low-density polyethylene is suitable for use in furniture items, as long as it is non-toxic. Polyethylene is known as a safe and stable material. It does not degrade or react with its environment, even after many years. It does not require additives, like other plastics. It will not “perspire” chemicals after its useful life. This makes polyethylene a unique material to use in a baby product as it is important that it does not leak from chemicals due to the baby's environment. Other foams, such as polyurethane foam, are made of different materials and can degrade and alter more easily than polyethylene.

Those skilled in the art will appreciate that the stiffness and resilience of the corrugated product made using the present invention can be modified depending on the intended use. For example, by varying the relations of Vi, V₂ and V₃, a greater or lesser periodicity is allowed with respect to the channels of the corrugated substrate. When the relation of V₃ a ν_ή and V₂ is very high, there will be an increased number of gutters per linear meter of corrugated product. However, when the ratio is low, there will be a decreased number of gutters per linear meter of corrugated product. Furthermore, those skilled in the art will appreciate that although Vt and V₂ they can be the same, it can be convenient to V, or V₂ higher (or lower) than the other. See, for example, Figures 4 and 7. Such cases may arise when it is desirable to have non-linear exit corrugation.

WICKED. ,,,. ,. . MSXICAN INSTITUTE

Furthermore, by varying the space between the substrates ^^^ ffiité ^ a ^^ optimization of the corrugated product. When the space S1 between the upper and lower substrates is too large, the gutters will be large and the corrugated product will have higher elasticity and less rigidity. Conversely, when the gap is small, the corrugated product will be stiffer and have less elasticity.

Figure 4 illustrates an embodiment of the invention where V! and V₂They are different. As shown in this embodiment, a separate pair 62 of upper drive rolls and a pair 64 of lower drive roll are added to the apparatus 10 prior to feeding the upper and lower substrates 32 and 34 into the upper and upper 56 and 58 forms. lower separated. By having drive rollers 62 and 64 separated, actuation of substrates 32 and 34 prior to engaging the middle substrate channels 22 with upper and lower substrates 32, 34, V! and V₂ may differ and the corrugation achieved can be adapted by changing the ratios from Vi to V₂as well as with V₃, as shown in Figure 4. Depending on the difference between V! and V₂, the corrugation can be curved or wavy and therefore will not slide through a straight shape. Thus, to advantage, the invention provides a curved corrugation to come out of shape in a compliant manner.

In addition, when foam is used to make the corrugated product, an outer side of the foam can often be cured to provide a hard covering for the exterior of the corrugated product. Thus, when the present invention is used to make corrugated containers, the interior of the container may be foam type.

KSTITUTO MtXICANO as long as the exterior of the container may have a covering andfJX ^ I ^

In other embodiments, the corrugated product according to the invention can be used to make furniture. In these cases, depending on the type of substrate used, the V- | / V ratio₂ to V₃ and the distance Sn the strength, plasticity, resilience and stiffness of the corrugated product can be adapted.

Other methods are contemplated to optimize and / or adapt the apparatus 10. For example, as shown in Figure 5, the corrugating apparatus 10 can be simplified to omit the shape guide 30 (shown in Figure 1) and in its Instead, form rollers 66 are used. In this embodiment, a shape guide 30 is not necessary, as the rollers direct the middle substrate 22 directly to the upper substrate 32 and the lower substrate 34. As with the mode illustrated in Figure 1, in the mode illustrated in Figure 5, V₃ is higher than Vi and V₂ and V, and V₂they are the same. Heaters 48 are also shown. Those skilled in the art will appreciate that the increased velocity of V₃ compared to V! and Vi will result in a medium substrate 22 that is alternately and automatically directed toward the alternate substrate 32 or 34, due to its winding from contact with the substrate to which it is attached by the heaters 48. Additionally, the use of rollers 66 shape makes the apparatus 10 simpler, which offers easier adjustment of the apparatus 10.

Figure 6 is a schematic diagram illustrating another embodiment of the invention, which does not have a shape guide 30 nor a feed guide 20, as shown in Figures 1 and 2. As shown in iMPi ^ n

INSTITUTO MEXICANO Λ],. _Λ OF THE FRvFíEUAU í &lt;

Figure 6, a drive roll 42 feeds the substrate 22 ^ (^ 3 ^ 3846 ^ to form shape rolls 68. As with the other embodiments of the invention, the periodicity of the channels 24 depends on the ratio of the velocities Vi and V₂ to V₃.

Figure 7 is a schematic diagram showing an exemplary embodiment of the invention used to make a modified double-walled corrugated product 18. In this embodiment, the corrugating apparatus 10 provides an internal, single-walled corrugated product 16 sandwiched between an upper substrate 78 or fourth substrate and a lower substrate 80 or fifth substrate. As with the embodiment illustrated in Figure 4, the single-walled corrugated product 16 is prepared by providing an upper substrate 32, a lower substrate 34, and a middle substrate 22, wherein the velocities Vi and V₂ they are not the same. In the mode shown in Figure 7, the speeds \ Λ and V₂ they alternate with respect to their magnitudes with each other. Thus, for example, when Vt is higher than V₂, process 16 will be forced down while when V₂ is higher than V_1t product 16 will be forced up. In this embodiment, the fourth substrate 78 is driven by drive rollers (not shown) that drive the fourth substrate 78 at a speed V₄. Similarly, the fifth substrate 80 is also driven by the drive rollers (not shown) at a speed V₅.

In the mode shown, V₄ and V₅ They are equal. However, those skilled in the art will appreciate that V₄ and V₅ may not be the same in the case where the double-walled corrugated product 19 will sag depending on the difference in velocities of V₄

WICKED

INSTITUTO mXICand A, · -'- ® '«* ^ 1 FROM THE FKOFIEOAD to V₅. In the mode shown in Figure 7, the single-wall product is made with the use of a control roller for¹ the middle substrate 34 and the upper drive roller pair 62 and the lower drive roller pair 64 that drive the upper substrate 32 and the lower substrate 34 through the upper 56 and lower 58 form feeders, respectively, and around guide rollers 76. Similarly, the fourth substrate 78 and the fifth substrate 80 are driven around the guide rollers 86. Furthermore, in the embodiment shown, the upper and lower bonding elements 84 and 82 positioned at the location of the fourth 78 and fifth 80 substrates, where the single-walled product 16 contacts the apparatus, which seals the product 16 single wall corrugated, alternating with fourth 78 and fifth 80 substrates. Of course, those skilled in the art will appreciate that the joining elements 78 and 80 can use any appropriate method to join the single wall product 16 with the fourth 78 and fifth 80 appliances, such as, for example, the connecting elements. heating, adhesive application, spot welding or the like.

Figure 8 is a schematic diagram depicting another exemplary embodiment of the corrugating apparatus 10 in accordance with the invention for making a second modified type of the double corrugated product 14. In this embodiment, a single wall corrugated product is made essentially as described above. However, as with the embodiment of Figure 3, once the single-wall product exits the shape guides 30, it is driven by the upper and lower drive rollers 46 and 47, forming a torque that drives product 16

IMPI INSTI FUTO MEXICANO through a trajectory to make contact with the

As shown in Figure 8, the fourth suirarate. 78 ...... S¡, g.ua ..... Mna ,. „path around guide roller 86 and through drive rollers 88 driving substrate 78 at speed V₄. As it exits drive rollers 88, substrate 78 is fed into a feed guide 90 in a path to make contact with the double-walled product 16, where it is attached to the top surface of the product by an element 92 of heating represented in Figure 8 as a heating element. As illustrated, upon contact with the top substrate 32 of the single wall product 16, the fourth substrate 78 bounces to collide with the guide 94 at a desirable distance from the top substrate 32 to provide the size and desired periodicity to provide a single-sided corrugated surface on top of product 16 to produce product 14.

In the embodiment illustrated in Figure 8, the single-sided portion formed by the substrate 78 may be a different material depending on the intended use. For example, in the case of furniture and crib mattress padding, the top ribbed layer will be thinner and easier to compress. Its function will be to provide a softer cushion close to the surface of the article. When used for a mattress, the single wall layer 16 can be used to cushion the top layer or can be used to add structural strength or both.

Figure 9A is a schematic diagram illustrating an embodiment of the invention adapted to produce only the half-corrugated substrate 102. In this embodiment, the middle layer 102 is fed

IMPI

INSTITUTE mF.xíCan) Λ

i. &lt;i. . । . . . . ΠΕ THE ΓΛ PIETY.

within drive rollers 104 driving the subtracted velocity V3 through shape guide 106, poMo or I, path, of substrate 102 results in substrate 102 making contact with the upper or lower portions of shape guide 110. As shown, heaters 108 are positioned to heat the portion of substrate 102 that contacts itself when trough 24 is formed. The path of the substrate 102 is alternately directed to the upper or lower portion of the shape guide 110 by rewinding the substrate 102 as it alternately bounces from the upper or lower portions of the shape guide 110. As shown Illustrated, the grooved substrate 102 is then driven by a second set of drive rollers 112 to advance for finishing, as desired. Figure 9B is a diagram of Figure 9A illustrating the ribbed substrate 102 formed by bonding the gutters 24 to themselves rather than to a top and / or bottom substrate, such as liner board used in corrugated cardboard techniques. conventional cardboard.

It should be appreciated that the embodiments of the present invention described in the above specification and Figures 1 through 9 can be combined in different ways as required. For example, although Figure 8 polishes a single single wall corrugated product 16 with a single sided corrugated product formed on one side, the product 14 can be manufactured to have a single sided corrugated product on both sides of the product. 16. Furthermore, in such a design, the size of the single face on the upper and lower sides of the product 16 may have different sizes and have different periodicities.

IMPI

INSTITUTE MFX'Cano

Dfc LA FROUFOAU

Furthermore, through the different modalities of the 'ThK / gHtiórT- ^ rur described, each substrate of the corrugated product can¹ They are in a different · »medium depending on the desired uses of the corrugated product. In this embodiment, forcing the substrate 102 through from the 110 at a faster speed, resulting in a higher input / output speed ratio, the wave crests (gutters 24) will begin to compact together until they are touch. The crest of each gutter is then joined with another at its point of contact as illustrated by heaters 108 (or any other appropriate method, such as adhesive) at the point of contact.

The ability to adapt the size, stiffness, thickness and resilience of the corrugated product achieved by the present invention makes it ideal for making furniture. In some embodiments, the invention comprises furniture cushion elements. For example, metal and / or wooden supports are often included in the article to provide strength and support for the needs of the individual, such as in the upright position. However, the use of metal in particular adds to the weight of the article. Often times, metal components do not always flex to accommodate the person and can be a source of discomfort after a period of time. For example, bed springs are often a source of pressure points for the person and diminish the therapeutic, restorative, and rejuvenating effects of sleep.

Additionally, most furniture items are made from polymeric materials which can be a source of concern.

MEXICAN INSTITUTE. Environmental, especially for children. For example '^ M ^ &amp; h mattress constructions using matsrialps gnp p_nr themselves or due to certain impurities in the material, they can cause or aggravate allergic reactions in humans and / or can result in other potentially dangerous conditions. For example, materials that incorporate polyurethanes, polyvinyl chlorides, polystyrenes, or polycarbonates all contain water-soluble and / or volatile chemicals that are potentially harmful to human health and safety and to the environment.

Moving articles, such as the mattresses described herein, can use polyethylene foam with densities from about .60 kg per cubic meter to about 1.5 pounds per cubic meter. A combination of densities can be used. For example, a material made of .60 kg per cubic meter can be used for the corrugated product, and a material made of .85 kg per cubic meter and for the top and bottom substrates in order to give the outer surfaces more rigidity and uniformity.

These low-density substrates result in less material used, lower costs, and lower weight. For example, the finished corrugated product of a child's mattress weighs approximately 1.5 kg, while comparable weights are 5 to 6 kg.

US Food &amp; Drug Administration (FDA) standards for plastic resins used in product packaging are of higher purity than plastics used for non-food packaging. This commonly refers to a food grade plastic. Plastics

WICKED

INSTITUT '. » MiXICANO ______ ...______... .. W- LA F * WfOAp. food grade that do not contain dyes or plastic^NPIr®wJaw? li ^ considered harmful to humans. -------—.............

Furniture items made from a food grade low-density polyethylene (LDPE) or polylactic acid (PLA) and its compliant copolymers or homopolymers have been found to offer a very low level of toxicity and can eliminate or reduce reactions allergies in humans or other potentially dangerous conditions due to construction materials or their impurities. Even when food grade LDPE or PLA is used for the food containers, it is well known that no water soluble chemicals permeate, which are supposed to cause the allergic reaction or the potentially harmful conditions.

Also within the scope of the present invention is the use of a polylactic acid, starch source biopolymer, or other biopolymeric films and laminates to optimize the container of renewable and recyclable materials.

Also, it is within the scope of the invention to construct an article of furniture with the use of an organically grown cotton wadding, in order to eliminate any possible contamination by agricultural pesticide or chemical fertilizer. This cotton wadding can be treated with ozone or another sanitizing process to clean, oxygenate, and remove other volatile contaminants. Other non-toxic materials can be used in place of the cotton wadding, for example, polyester or densified polypropylene.

The invention will also be described with reference to the following

IMPJ »to ^{, Ν}’^τοΙ '^{τ &lt;}· Non-limiting examples. It will be evident to 11 that I know^w,^ e ^ n changes in the modalities described without apart * »» ^ dni niranrp. of the present invention. Thus, the scope of the present invention should not be limited to the embodiments described herein, but only by the embodiments described by the language of the claims and the equivalents of those embodiments. Unless otherwise indicated, all percentages are by weight.

Figures 10, 11 and 12 are CAD diagrams of an exemplary embodiment of the corrugating apparatus illustrated in Figures 1-9. Figure 10 is a perspective view of apparatus 10 showing the placement of the upper 32, middle 22, and lower 34 substrates as they are fed into the corrugated apparatus and a single wall corrugated product 16 exiting the apparatus 10. Figure 11 is a perspective view of the embodiment of the apparatus shown in Figure 10, but with a wall of the apparatus 10 removed to show the internal rollers. Illustrated is the middle substrate 22 drive roller 26 which guides the middle substrate 22 within the drive rollers 42. The upper substrate 32 passes over the guide roller 36 and the lower substrate 34 passes under the lower guide roller 38. It is also shown that after passing under the guide roller 26, the middle substrate 22 then passes through the pair 42 of drive rollers while the upper and lower substrates 32 and 34 pass through the shape rollers 66. After corrugating, the single-walled product 16 then passes through drive rollers 46, which pulls product 16 through corrugating apparatus 10. Figure 12 is a view in

IMPI ^ tMSTm &lt;Tn_WPXIC,_N&lt;,

,. . .... DF the «ΟΜίΓΙΛΠ close-up perspective of the interior of the corrugated coating mode shown in Figures 10 and 11. In this w *» *, * i mir-ti-un_RRsample passing under guide roller 26 and passing between drive roller pair 42 to be fed at speed V3 within the apparatus. As shown, the heaters 48 are arranged above and below the feed guide 20 to thereby heat the middle substrate 22 and the upper substrate 32 and the middle substrate 22 and the lower substrate 34 when they impact each other on the rollers 66. so. After joining the middle substrate22 with the upper substrate 32 and the middle substrate 22 with the lower substrate34, the corrugated single-walled product exits the form rollers 66 and passes between the drive rollers 4 6 that pull the product 16 attached to through the corrugating apparatus 10.

In an exemplary embodiment, corrugated products, such as 16, 14, and 18 (Figures 1, 8, and 7, respectively) are constructed of a food-grade polymer, a food-grade polylactic acid, or a low-density polyethylene grade. (LDPE) in accordance with FDA 21 CRF177 standards.

Also, in accordance with the present invention, the polyethylene film has a density of 0.85 to 1.0 grams per cubic centimeter, a maximum extraction fraction (expressed as a percentage by weight of the polymer) in N-hexane at specific temperatures at 5.5%. at 50 ° C), and a maximum extraction fraction (expressed as a polymer pass-through percentage) in xylene at specific temperatures is 11.3% at 25 ° C.

Example 1 - Manufacture of mattress

IMPI »3 mlxion institute '·' A. ΜΐΛ8ΚΟ?! ΊϋΑΠ

In various embodiments, the invention comprises a mattress, after these embodiments, the mattress comprises an inner wrapped core XT, a cushion layer, and an outer cover layer. In these embodiments, the corrugated foam core can be made as described above for Figures 1, 2 and 3. The middle cushion layer may comprise a second corrugated foam product, a layer of cotton wadding, polyester or densified foam such as polyurethane, polyester, polypropylene or polylactic acid and the like. The outer cover layer may comprise cotton or laminated foam, wherein the foam comprises polyurethane, polyethylene, polyester, polypropylene, or polylactic acid and the like and the laminate comprises a film independently selected from polyurethane, polyethylene, polyester, polypropylene, or acid. polylactic and the like. Furthermore, in various embodiments, the mattress may comprise a flame retardant layer between the middle cushion layer and the outer cover layer. However, those of skill in the art will appreciate that in various embodiments, the flame retardant may not be necessary, such as when the materials themselves are not flammable, such as with polyester, or because the Flame retardant is added to one of the other layers. In these embodiments, the flame retardant can be added in the outer cover layer or in the cushion middle layer. For example, when cotton wadding is used for the middle layer of cushioning, boric acid (usually 15%) or another retardant can be mixed with the cotton and so on, or another flame retardant is needed. In several

INSTITUTO MEXICAN ') exemplary modalities, the internal foam core'míwíreclo Figures 1, 2 and 3 is a corrugated product, as oo describe-agi.i! Y. uses one or more of the polymers identified above. The corrugated product 16 may include an upper substrate 32, a lower substrate 34, and a ribbed medium substrate 22, as described herein.

Figure 13 illustrates one embodiment of a mattress 220 manufactured in accordance with the present invention. As shown, the mattress core includes a single wall corrugated product, as shown at 16 in Figure 1 and Figures 10-12. As shown in Figure 13, the middle substrate 222, the upper substrate 224, and the lower substrate 226 are cut to the desired size. In various embodiments, a projection, or outer perimeter of the upper and lower substrates 224/226 is retained and a side perimeter side piece 228 and an end perimeter piece 230 are added and sealed on both sides and at the ends of the mattress. , which provides support for the edges of the mattress. In various embodiments, those skilled in the art will appreciate that the perimeter pieces are not required for the foam mattress 220. Next, a layer of cushioning material 232, such as a cotton polyester or polypropylene 244 is wrapped around the corrugated foam core 238 followed by a flame barrier 234. Then, a surface or cover layer 236 is added. In some embodiments, the cover layer is a woven cotton, polyester, or polypropylene fabric, while in some embodiments, the woven cotton polyester or polypropylene is coated with a low-density polyethylene that can be food grade.

IΜ ΡI

INSTITUTO MEXICANO -1 (see, for example, 21 CFR 177.1520). Without packaging¹^? ^^ those skilled in the art will appreciate that the cover layer can be any comfortable fiber or polymer cover. In some embodiments, the cover can be a thin foam with a film laminated thereon. In various embodiments, the plate can be polyethylene, polypropylene, polyurethane, or the like. It should be appreciated that with the use of the described methods, a mattress or cushion can be manufactured in any desired size.

Figure 14 illustrates another embodiment of mattress 240 in accordance with the invention. In this embodiment, the mattress 240 includes a single-wall corrugated product 238, such as the one illustrated in Figure 13. In this embodiment, the single-wall corrugated product includes a top substrate 224, a middle substrate 222, and a lower substrate 226. The first single wall product 238 can be finished with the end perimeter pieces (not shown) and two side perimeter pieces 228 joined with the sides and ends of the corrugated product. In addition to closing the interior of the mattress, the end pieces act to provide support for the edges of the mattress. In the mattress embodiment 240, there is also a second single wall product 258 fixed with the first single wall product. Also, in this embodiment, there are two side perimeter pieces 248 and two end perimeter pieces (not shown). In this embodiment of mattress 240, the middle substrate 242 and optionally the top 244 and bottom 246 substrates may be made of a thinner foam to provide a more resilient top layer that provides greater cushioning for the mattress.

IMPI user of the mattress. In addition, the second single wall product easily attaches to the first single wall product 238 by heating the opposing substrates (eg, 224 and 246) before they are stacked so that they are bonded together. After the first corrugated product 238 and the second corrugated product 258 are bonded together, the composite product is wrapped in the cover 252.

In various embodiments, the mattress cover 236 and 252 comprises a layer of cotton or thin foam with a polymer film laminated thereto. For example, when mattress cover 236/252 is foam, the foam can be 0.07 cm / 0.31 cm, composed of polyurethane, polyethylene, polyester, polypropylene, or polylactic acid. In these embodiments, the polymer film can be independently selected from polyurethane, polyethylene, polyester, polypropylene, or polylactic acid. Furthermore, although in some embodiments the cover can wrap around the mattress to contain it on all sides and have an open end to accept the insertion of the mattress. In other embodiments, the cover can only cover the upper portion of the mattress and can be joined with the sides of the first corrugated product to thus cover the underlying cushion layer or the second corrugated product. Those skilled in the art will appreciate that the cushion layer, for example the second corrugated product, does not need to be bonded to the first corrugated product when the cover is used. For example, when the cover is bonded to the sides of the first corrugated product, such as by heat sealing the cover with the sides or with adhesives, the cover will hold the cushion layer in place.

WITCH your place. Similarly, when the cover is illuminated, for example, a pillow, the cover stretches over the communication and holds the component parts together, which simplifies mattress construction. In some embodiments, the open end of the cover can be sealed. Of course, those skilled in the art will appreciate that the cover can be used in mattress embodiments, where the cushion layer is not a second corrugated product. For example, the cover is equally useful when the cushion layer comprises cotton, densified polyester, or polypropylene cushion.

In addition, although the mattress 240 is "single sided", for example, it has only the second single wall product 258 engaged with one of the surfaces of the first single wall product 238, it is contemplated that the mattress may be one side with a second single wall cushion product attached to the other side of the 238 product. Additionally, those skilled in the art will appreciate that although the mattress embodiment 240 shown comprises two separate single wall products 238 and 258 joined together, the mattress may comprise a hybrid product 13, as shown in Figure 8. , with another piece or foam substrate attached to the fourth substrate 78. Those skilled in the art will appreciate that mattress 240 can be any mattress size ranging from a baby crib mattress to any desired size. Furthermore, those skilled in the art will appreciate that although Figures 13 and 14 illustrate the gutters of the corrugated layer aligned with the long axis of the

IMPI »Mexican institute

OF THE nonCDAD mattress, in some modalities in accordance with the invéTFdlW, corrugated may be arranged in such a way that the flaps are quetlawalineated with the short axis of the mattress.

Also, in accordance with the present invention, the outer layer of the furniture item can be heat melted with a non-toxic substrate within the article, thereby providing improved tensile strength and tear strength with the layer. external of the article. The non-toxic fabric substrate can be constructed of materials including cotton, polyester, polypropylene, and others or combinations thereof.

The inner end component of the moving article is constructed of a corrugated, polymeric support system that offers the necessary strength, maintains the desired shape of the article, provides most of the cushioning requirements, and provides the required weight support.

The corrugated support system includes a top layer, where the top layer has a length, width and thickness, an optional bottom layer, where the bottom layer has a length, width and thickness, and a corrugated middle layer placed between the top and bottom layer. The ribbed layer has a length, a width and a thickness, wherein the ribbed layer is fixed to the upper and lower layers at points of contact of the ribbed layer with the upper and lower layers. In general, the polymeric medium comprising the upper layer, the lower layer and the middle layer is heated for softening and passed through a series of rollers to effect the shape.

IM pi iNSTrruTOM¡.-_XICANO 3

M LA R »IPIEIMD corrugated. Cooling of the polymer provides an ar &lt;i6O^{To the}corFtr ^ 4? r final. ...........

Example 2 - Use of plastic sheet type sheet for the Manufacture of Corrugated Plastic.

Figure 15 illustrates a panel 300 made of corrugated plastic. As shown, panel 300 includes upper substrate 332, lower substrate 334, and middle substrate 322. Figure 16 illustrates a plastic panel 300 such as that shown in Figure 15, but with a printed surface 336. Using the described technique, printed substrates such as 336 can be pre-formed prior to the corrugating process. Figure 17 illustrates a plastic panel, such as that shown in Figures 15 and 16, showing the dimensions that can be used for this embodiment. Plastic substrates, such as those depicted at 332, 334, and 322 are available for sale from, for example, Blueridge Films, Inc., (http://www.blueridqefilms.com/). In these embodiments, the union of the gutters with the upper and lower substrate is achieved with ultrasonic welding.

Example 3 - Use of Sheet Metal in Roll for the Manufacture of Corruga ted steel

In some embodiments, in accordance with the invention, as shown in Figure 18, a corrugated steel panel 400 may be made with the use of rolled sheet steel for one or more of the substrates 432, 433, 422 In this mode, the sheet metal sheet in

IMPI

PROPERTY ROLL MAY BE ANY OF THE AVAILABLE FOR SALE '^' ^ L illustrates some dimensions that can ^{| ie}nr paria el punol Ί00 d ° corrugated steel. In these modalities, the union of the gutters with the upper and lower substrate is achieved with ultrasonic welding.

Example 4 - Manufacture of Corrugated Furniture

Figures 20 and 21 depict various exemplary embodiments of furniture that can be constructed in accordance with the present invention. Figure 20 is a cutaway of a streamlined chair 260 that can be constructed using the present invention and showing the interior gutters of the middle substrate. As shown, the chair can be constructed by varyi ng the relationship from \ Λ to V₂ in real time. In the embodiment of the chair 260 shown, the perimeter or projection of the upper and lower substrate relative to the middle substrate is provided so that edge pieces 262 can be inserted to seal the chair. Figure 21 illustrates a bookcase 270 using the corrugated products of the invention, in accordance with another exemplary embodiment. In the embodiment shown, six flat, single-walled corrugated pieces are assembled as shown, to comprise two side pieces, two shelves, and a top and bottom of the bookcase. In addition, a backing piece is provided on the bookcase, which is optional and can be corrugated product, if desired or just a single piece of substrate. In this mode, the corrugated products are produced with a “wood grain” finish that comprises a wood grain preprinted by the process used in Figure 15. In this mode, a

IΜ ΡI iNSTrruTOMRxioN.-, Standard wood veneer sticks with the corrugated extem &amp; ^ f ^ surface. Such veneers are available for sale from, for example, WiseWood Veneer (http://www.wisewoodveneer.com/index.html).

Those skilled in the art will appreciate that when making furniture in accordance with the present invention, different substrates can be used as desired. For example, chair 260 may have a rigid plastic, load bearing plastic as the bottom substrate, while soft foam may be desirable as the top substrate. The average substrate can vary in accordance with the rigidity of the cushion desired by the user. Of course, those skilled in the art will appreciate that the substrates can be the same, such as, for example, a load-bearing plastic and a foam of the cushion piece that can be applied to the upper surface of the chair 260, when desired. Also, although foam pieces are generally available from the manufacturer in white, foam pieces can be inked in any desired color.

Figure 22 illustrates partition panels in accordance with one embodiment of the invention. In this embodiment, partitions, such as those used to form "office cubicles" can be made with the use of any desired material for the top, middle and bottom substrates and can provide any suitable finish. For example, for interior office spaces, it may be desirable to have an external surface that is hard and durable, such as a rigid plastic. The inner surface of the partition, the substrate can be made of a closed cell foam, dense so that the user of the office cubicle can

ΙΜΡΙ $ ^ use tacks or other fastening device for peg-aT ^ pe ^^^^ and the like on the substrate surface. In some r¹ ? *; ilidnd?⁰, it may be desirable for the middle substrate to be a noise absorbing foam, so that the noise is absorbed by the partition. Additionally, the buyer can select to have the outer surface printed with any decoration such as wood grain, a forest scene, or the like. Divider panels 280 can be any appropriate size and can be fitted within a frame that has flanges. 282/284 alternate male and female.

Example 5 - Manufacture of Corrugated Columns

Figure 23 illustrates a column made of a single wall corrugated product in accordance with the invention. As illustrated, the corrugated column is made by maintaining a constant ratio of V₁> V₂ (or Those skilled in the art will appreciate that the diameter of the column can be controlled simply by using a desired ratio of V! to V₂. For example, for a small diameter column, Vi will be much larger than V₂while a larger diameter column will require less difference between the two speeds. Similarly, an oblong column can be made by having V, = \ /₂, in shape, symmetrical, on either side of the curved portion (for example, V!> V₂). Those skilled in the art will appreciate that the column can be any size and, like other products, can be composed of any required substrate. Thus, column 290 can be made of foam, plastic or metal and is

IMPI can be used to form the legs of a table when s ^ 'Oopl ^^ Slcafr flat corrugated product, such as the one shown p ^ r ··? Lp? Mol dt parad _nthe legs of a chair, etc., when coupled with a product such as 260, shown in Figure 20. Similarly, the column can be used for the structural component when fabricated from sheet metal type sheet in roll and used as the support of the building. In addition, when manufactured, the ends of the column can be clamped together by leaving a protrusion of the upper and lower substrates relative to the middle substrate and joining the ends, such as by sonic welding to comprise a circular, fully closed column.

Example 6 - Manufacture of Building Materials

In another exemplary embodiment, shown in Figure 24, the corrugated apparatus can be used to construct building materials, such as walls and roofs (not shown) for houses. These building panels can be used for the construction of a wall that has weight bearing capabilities. In this embodiment, the upper and lower substrates can be more robust, such as for example plastic, metal rolls such as copper or steel. Furthermore, the middle substrate can be any suitable substrate, such as a sound absorbing foam, or plastic or metal. In general, when used for wall panels, the corrugated product of the invention is approximately 8 "by 35.56" or larger. The panels can be adjusted together with the use of any medium. For example,

IMPI

INSTITUTO MÍXICAN · • t INDUSTRIAL MOPIEUAD panels may have supplementary rails comprising a male flange similar to that shown in Figure 22 or a tongue and groove coupling that can be secured with a convenient device such as screws (not shown). Furthermore, conduits can be provided in the space defined by the gutters so that the corrugated building panels do not need to be altered to accept electrical cables and the like. Furthermore, it should be appreciated that when the building panels of the present invention can be substituted for conventional building components, such as veneer lumber and / or 2 "by 10" building panels can also be formed to encompass the materials. Finishing. In this way, the external substrate of the corrugated product can be cured and / or smoothed so that the building panel also incorporates the smoothness and finish of the dry wall. Furthermore, it should be appreciated that the corrugated material may be a polymer or cellulose-based or mixtures of the two.

The following paragraphs consecutively number 1 through 69 and provide various aspects of the present invention. In one embodiment, in the first paragraph (1), the present invention provides:

1. A method of preparing a corrugated product, comprising the steps of:

provide an upper and lower substrate at a velocity of Vi and V₂ where the upper and lower substrates are kept at the distance S! between each other and provides a middle substrate, interposed between the upper substrate and the lower substrate, at a speed of V₃, in a trajectory to impact the upper and lower substrates, where the velocity V₃

IMPI

INSTITUTO MÍMICAΝ.Ί is higher than the speeds of V, and V₂ so that^{D £}éU & S ^ ht (> J ^^ forms gutters that make alternative contact mn i ^ c gnctratns upper and lower, where the corrugated product is formed.

two. The method in paragraph 1, where the distance Si is delimited by a shape guide.

3. The method of paragraph 2, wherein the shape guide comprises an upper surface and a lower surface.

Four. The method of paragraph 3, wherein the upper and lower surfaces comprise plates or rollers.

5. The method of paragraphs 1-4, wherein the middle substrate is directed between the upper substrate and the lower substrate by the shape guide.

6. The method of any of paragraphs 1 to 5, further comprising drive rollers positioned prior to the shape guide to activate the middle substrate.

7. The method of any of paragraphs 1 to 6, further comprising a second set of drive rollers after the shape guide to pull the corrugated product through the apparatus.

8. The method of any of paragraphs 1 through 7, further comprising engaging the middle substrate gutters with the upper and lower substrates.

9. The method of paragraph 8, wherein the channels of the middle substrate are coupled with an adhesive, a suitable solvent to partially dissolve the substrates, infrared heat, heat, laser welding or ultrasonic welding.

IMPI

INSTITUT »MEXICAN» LA FROFIFILAD in »ustwial

<img file="MX348607B_D0005.tif" />

10. The method of any of the paragraphs -i ni η nn ηλπΚρ y. and V₂ They are equal.

eleven. The method of paragraphs 1 to 10, wherein the substrates are independently selected from poly (lactide-co-glycolide) (PLGA); polylactide (PLA), polyglycolide (PGA), D-lactide, D, L-lactide, L-lactide, D, Llactida-epsilon-caprolactone, D, L-lactide-glycolide-epsilon-caprolactone, polyepsilon- caprolactone-glycolide-caprolactone or combinations thereof, carboxymethyl cellulose, cellulose acetate, cellulose acetate propionate, ethyl cellulose, hydroxypropyl methyl cellulose, hydroxyalkyl methyl cellulose and alkyl cellulose, polydimethylsiloxane, polydimethylsiloxane ( vinyl acetate), poloxamer, poly vi ni I p¡rrol idone, poloxamine, polypropylene, polyamide, polyacetal, polyester, polyethylene-chlorotrifluoroethylene, polytetrafluoroethylene (PTGE or “Teflon ™”), styrene-butadiene rubber, polyethylene, polypropylene, polyphenylene oxide-polystyrene, poly-alpha-chloro-p-xylene , polymethylpentene, polysulfone, non-degradable vinyl-ethylene acetate (for example, vinyl ethylene acetate and poly (ethylene-co-vml-acetate) discs, methacrylates, poly (Nisopropylacrylamide) and delrin, polyurethane, copolymers silicone and polyurethane, polyolefins (such as polysobutylene and polyisoprene), acrylamides (such as polyacrylic acid and poly (acrylonitrilo-acrylic acid), neoprene, nitrite, acrylates (such as polyacrylates, poly (2-hydroxy-ethylmethacrylate), methacrylates, methyl methacrylate, 2-hydroxyethyl methacrylate and copolymers of acrylates with N-vinyl pyrrolidones), N, vinyl-lactams, polyacrylonitrile, glucomannan gel, vulcanized rubber, poly (3-hydroxybutyrate) and combinations thereof.

--------— IMPIí ^

INTHTUTO MÉXICANO,

12. The method of any of paragraphs 1 to ^^^ A'boTt ^^ upper, lower and middle substrates comprise polyatilancu.-.- -, .......

13. The method in paragraph 8, wherein the polyethylene is closed-cell, low-density polyethylene foam.

14. The method in paragraphs 1 through 13, wherein the polyethylene is a food grade polyethylene.

fifteen. An apparatus for preparing a corrugated product, which comprises:

a first pair of drive rollers to drive the medium substrate at a speed V₃;

a shape guide positioned after the drive rollers, wherein the shape guide provides an upper surface to guide the upper substrate and a lower surface to guide the lower substrate; a second pair of drive rollers driven to have a speed Vi, where V₃ higher than Vl is a bonding device placed around the upper surface and the lower surface of the form guide, wherein the bonding device couples the middle substrate with the upper and lower substrates, where the corrugated product is prepared.

16. The apparatus of paragraph 15, wherein the shape guide is a set of essentially parallel plates, parallel rollers, or a combination thereof.

17. The apparatus of paragraphs 15 to 16, wherein the shape guide is positioned after the first pair of drive rollers and comprises two plates separated by a distance that can be varied to accept the middle substrate.

ΙΝΤΠ-Πσο MEXICAN

OF LA «ΟΗΕΠΑ0 'Μ β. _. iNpu.mtiAi Χ · 1

18. The apparatus of any of paragraphs 15 to 17, wherein the bonding device is a heater, a solvent, a sonic weld, a laser weld, or an adhesive that bonds the channels of the middle substrate to the upper and lower substrates.

19. The apparatus of any of paragraphs 15 to 18, further comprising a cutting apparatus.

twenty. The apparatus of paragraphs 15 to 19, further comprising one or more guide rollers for guiding the upper substrate within the shape guide and the lower substrate within the shape guide.

twenty-one. The apparatus of paragraphs 15 to 20, wherein the second pair of drive rollers is located in the apparatus after the corrugated product exits the shape guide.

22. The apparatus of paragraphs 15 to 20, wherein the second pair of drive rollers is located before the form guide and drives only the higher substrate at a speed of

2. 3. The apparatus of paragraphs 15 to 20 and 22, wherein a third set of drive rollers is located before the shape guide and drives only the lower substrate at a speed V₂.

24. The apparatus of paragraphs 15 to 23, wherein the drive rollers are activated separately.

25. The apparatus of paragraphs 15 to 23, wherein the drive rollers are activated together.

26. An apparatus for preparing a corrugated article, which comprises:

a first pair of drive rollers to feed a medium substrate

INSTITUTE Μ LAICA NO at speed V₃, through the shape guide;

a shape guide positioned after the primar, pac ri ^ mriiiing hp knob, and comprises an upper surface and a lower surface separated by a distance Si, wherein the shape guide accepts the upper substrate on its upper surface and the lower substrate on its lower surface;

a bonding device positioned around the upper surface and lower surface of the shape guide, wherein the bonding device couples the channels of the middle substrate with the upper and lower substrates to provide a corrugated product;

a second pair of drive rollers positioned after the form guide and pulls the corrugated product through the apparatus;

where the corrugated article is produced. .

27. The apparatus of paragraph 26, wherein the shape guide is a set of essentially parallel plates, parallel rollers, or combinations thereof.

28. The apparatus of paragraphs 26 and 27, which also includes a shape guide, wherein the shape guide is two plates separated by a distance that can be varied to accept the middle substrate.

29. The apparatus of any of paragraphs 26 to 28, wherein the bonding device is a heater, sonic weld, laser weld, or adhesive that bonds the middle substrate gutters to the upper and lower substrates.

30. The apparatus of any of paragraphs 26 to 29, further comprising a cutting apparatus.

IΜ ΡI

MEXICAN INSTITUTE

31. A method of making a corrugated product? \ U ^ Wtnp «! ^ (A) To provide an upper substrate and a lower substrate, the ....... upper substrate moves at a speed V, and the lower substrate moves at speed V₂, the upper substrate and the lower substrate are essentially parallel to each other and are separated by the distance "Si";

(b) provide a middle substrate, the middle substrate is located between the upper substrate and the lower substrate and moves at a speed V₃, Where v₃ is higher than \ Λ or V₂;

(c) propelling the middle substrate in a path to make contact with the upper substrate or the lower substrate, wherein after contact with the upper substrate or the lower substrate, the middle substrate bounces in an opposite direction to make contact with the substrate opposite, wherein after contact with the opposite substrate, the middle substrate bounces to contact another substrate; and (d) coupling the contact point of the middle substrate with the upper substrate and the lower substrate, such that the middle substrate forms channels between the upper substrate and the lower substrate;

where the corrugated product is provided.

32. The method in paragraph 31, where V! and V₂ They are equal.

33. The method in paragraph 31, where V₁ and V₂ they are not the same.

3. 4. The method in paragraphs 31 to 33, where the first, second, and third substrates independently comprise:

polyethylene derivatives, polylactic acid derivatives, cellulose derivatives, silicon and silicon-based polymers, and methacrylates.

35. The method in paragraphs 31 to 34, where the first,

IΜ ΡI

ΙΝΠΤΠ ΙΤΟ Μ EX ICA NO second and third substrates comprise independently mefffé ^ T ^

<img file="MX348607B_D0006.tif" />

poly (lactide-co-glycolide) (PLGA); nnlilantide (Pl A), polyglycolide (PGA), D-lactide, D, L-lactide, L-lactide, D, L-lact¡da-epsilon-caprolactone, DX-lactide-glycolide-epsilon-caprolactone, polyepsilon -caprolactone glycolide-caprolactone or combinations thereof, carboxymethyl cellulose, cellulose acetate, cellulose acetate propionate, ethyl cellulose, hydroxypropyl methyl cellulose, hydroxyalkyl methyl cellulose and alkyl cellulose, polydimethylsiloxane), polyethylsiloxane) l-acetate), poloxamer, polyvinylpyrrolidone, poloxamine, polypropylene, polyamide, polyacetal, polyester, polyethylene-chlorotrifluoroethylene, polytetrafluoroethylene (PTFE or “Teflon ™”), styrene-butadiene rubber, polyethylene, polypropylene, polyphenylene oxide-polystyrene, poly-alpha-chloro-p-xylene, polymethylpentene , polysulfone, vinyl ethylene acetate not degradable (for example, vinyl ethylene acetate and poly (ethylene co-vinyl acetate) discs, methacrylates, poly (Nisopropylacrylamide), delrin, polyurethane, silicone and polyurethane copolymers, polyolefins (such as polysobutylene and polyisoprene), acrylamides (such as polyacrylic acid and poly (acrylonitrilo-acrylic acid), neoprene, nitrile, acrylates (such as polyacrylates, poly (2-hydroxy-ethylmethacrylate), methacrylates, methyl-methacrylate) , 2-hydroxyethyl-methacrylate, and copolymers of acrylates with N-vinyl pyrrolidones), N, vinyl-lactams, polyacrylonitrile, glucomannan gel, vulcanized rubber, poly (3-hydroxybutyrate) and combinations thereof.

36. The method in paragraphs 31 to 35, where the polyethylene is a closed-cell, low-density foam.

37. The method in paragraphs 31 to 36, where the substrates l NSTITUT Ο Μ F XIC Α Μ -> βίΜ & ι # upper, middle and lower are selected in the form of a food grade polymer, a food grade polylactic acid or a low polyethylene Food grade density (LDPE) in accordance with FDA standards.

38. The method of paragraphs 24 to 30, wherein the coupling is achieved with the use of adhesive, an appropriate solvent to partially dissolve the substrates, infrared heat, heat, laser or ultrasonic welding.

39. A corrugated mattress comprising a first corrugated product, the first corrugated product includes:

a superior substrate;

a medium substrate; and a lower substrate;

wherein the middle substrate is ribbed and the gutters are attached to the upper and lower substrates to form a single wall corrugated foam mattress.

40. The corrugated mattress of paragraph 39, which also comprises a next layer of cotton, densified polyester or polypropylene covering the corrugated foam product.

41. The corrugated mattress of paragraphs 39 and 40, where the flame barrier covers the polyester or polypropylene cotton cover.

42. The corrugated mattress of paragraphs 39 to 41, further comprising a surface layer.

43. The corrugated mattress in paragraphs 39 to 42, where the

INSTITUTO MEXICANA Ρ ^{M LA}.

upper, middle and lower substrates independently corff ^^ tlen * '- ^ - polyethylene derivatives, p'011 laulluu acid derivatives,' dci'ivaduade cellulose, silicon and silicon-based polymers, and methacrylates.

44. The corrugated mattress of paragraphs 39 to 43, where the first, second and third substrates independently comprise:

poly (lactide-co-glycolide) (PLGA); polylactide (PLA), polyglycolide (PGA), D-lactide, D, L-lactide, L-lactide, D, L-lactide-epsilon-caprolactone, D, L-lactide-glycolide-epsilon-caprolactone, polyepsyl-caprolactoneglycolide- caprolactone or combinations thereof, carboxymethylcellulose, cellulose acetate, cellulose acetate propionate, ethylcellulose, hydroxypropylmethylcellulose, hydroxyalkylmethylcellulose and alkylcellulose, polydimethylsiloxane), polyethylene-co-), vinyl-acetyl polyvinylpyrrolidone, poloxamine, polypropylene, polyamide, polyacetal, polyester, polyethylene-chlorotrifluoroethylene, polytetrafluoroethylene (PTFE or "Teflon ™"), styrene-butadiene rubber, polyethylene, polypropylene, polyphenylene oxide-polystyrene, poly-alpha-chloro-p-xylene, polymethylpentene , polysulfone, non-degradable vinyl ethylene acetate (for example vinyl ethylene acetate and poly (ethylene co-vinyl acetate) discs, methacrylates, poly (Nisopropylacrylamide), delrin, polyurethane, silicone and polyurethane copolymers, polyolefins (such as polysobutylene and polyisoprene), acrylamides (such as polyacrylic acid and poly (acrylonitrile-acrylic acid), neoprene, nitrile, acrylates (such as polyacrylates, poly (2-hydroxy-ethylmethacrylate), methacrylates, methyl-methacrylate) -hydroxyethyl-methacrylate, and copolymers of acrylates with N-vinyl pyrrolidones), N, vinyl-lactams, polyacrylonitrile, glucomannan gel, vulcanized rubber, poly (357

IMPI hydroxybutyrate) and combinations thereof. .Xsfí *?

Four. Five. The mattress of paragraphs 39 to 45, wherein the polyethylene is a closed-cell, low-density foam.

46. The cushion of paragraphs 39 to 45, where the upper, middle and lower substrates are independently selected from: a food grade polymer, a food grade polylactic acid or a food grade low density polyethylene (LDPE) of compliance with FDA regulations.

47. The cushion of paragraphs 39 to 43 and 46, which also comprises a second corrugated product adhered to the upper or lower substrate, wherein the second corrugated product comprises a second upper substrate, a second lower substrate and a second corrugated middle substrate between the second top and bottom substrates and two side perimeter pieces and two end perimeter pieces.

48. The cushion of paragraphs 39-43 and 47, where the second corrugated product is adhered to the first corrugated product with the use of heat or adhesive.

49. The mattress of paragraphs 39 through 43 and 48, wherein the second corrugated product is made of substrates that are thinner and more resilient to provide a cushion type than the substrates used to make the first corrugated product.

fifty. The cushion of paragraphs 39 and 43 to 49, where the second upper substrates, the second middle and the second lower substrates independently comprise:

polyethylene derivatives, polylactic acid derivatives, derivatives

IMPIOS. &lt;_ ......... - ...,. ..... MEXICAN INSTITUTE of cellulose, silicon and silicon-based polymers, and mefai ^^ fift ·

51. The cushion of paragraphs 39 to 43 to 50, where the second upper, second middle and second lower substrates independently comprise:

poly (lactide-co-glycolide) (PLGA); polylactide (PLA), polygI icolide (PGA), D-lactide, D, L-lactide, L-lactide, D, L-lactide-epsilon-caprolactone, D, L-lactide-glycolide-epsilon -caprolactone, polyepsilon-caprolactone-glycolide-caprolactone or combinations thereof, carboxymethylcellulose, cellulose acetate, cellulose acetate propionate, ethylcellulose, hydroxypropyl-methyl-cellulose, hydroxyalkyl-methyl-cellulose and Iloxyl cellulose, Iloxyl-cellulose ), polyethylene-co- (v¡n¡l-acetate), poloxamer, polyvinylpyrrolidone, poloxamine, polypropylene, polyamide, polyacetal, polyester, polyethylene-chlorotrifluoroethylene, polytetrafluoroethylene (PTFE or “Teflon ™”), styrene-butadiene rubber, polyethylene, polypropylene, polyphenylene oxide-polystyrene, poly-alpha-chloro-p-xylene , polymethylpentene, polysulfone, non-degradable vinyl ethylene acetate (for example, vinyl ethylene acetate and poly (ethylene co-vinyl acetate) discs, methacrylates, poly (Nisopropylacrylamide), delrin, polyurethane, silicone and polyurethane copolymers, polyolefins (such as polysobutylene and polyisoprene), acrylamides (such as polyacrylic acid and poly (acrylonitrile-acrylic acid), neoprene, nitrile, acrylates (such as polyacrylates, poly (2-hydroxy-ethylmethacrylate), methacrylates, methyl-methacrylate) -hydroxyethyl-methacrylate, and copolymers of acrylates with N-vinyl pyrrolidones), N, vinyl-lactams, polyacrylonitrile, glucomannan gel, vulcanized rubber, poly (3-hydroxybutyrate) and combinations thereof.

IMPI,. ,. , INSTITUTO MEXICANO '* 2 Z

52. The mattress of paragraphs 39 and 43 to the polyethylene is a closed cell low density foam.

53. The method of paragraphs 39 and 42 to 52, where the second upper substrate, the second middle substrate and the second lower substrate are independently selected from: a food grade polymer, a food grade polylactic acid or a polyethylene Low Density Food Grade (LDPE) in accordance with FDA standards.

54. The mattress of paragraphs 39 to 53, further comprising: two side perimeter pieces, and two end perimeter pieces, wherein the two side pieces are attached to the sides of the corrugated foam product and the two end pieces are attached to the ends of the foam product to enclose the inside of the mattress.

55. A method of making a foam mattress comprising a first corrugated product including:

preparing a corrugated single wall foam product having a top substrate, a middle substrate, and a bottom substrate, wherein the middle substrate is ribbed and the gutters of the middle substrate are engaged with the top and bottom substrates to make a mattress of foam.

56. The method in paragraph 55, which also includes mating foam perimeter pieces around the outside of the foam mattress.

57. The method of paragraph 55, which further comprises wrapping the enclosed corrugated product with a layer of cotton, densified polyester, or polypropylene.

IMPI Mexican institute Λ

58. The method in paragraphs 55 to 57, which provides a flame barrier on top of cotton, densified pniiÁ ^ tAr or polypropylene layer.

59. The method in paragraphs 55 to 58, which also includes an outer layer on top of the flame barrier.

60. The method in paragraphs 55 through 59, where the top, middle, and bottom substrates independently comprise:

polyethylene derivatives, polylactic acid derivatives, cellulose derivatives, silicon and silicon-based polymers, and methacrylates.

61. The method in paragraphs 55 through 60, where the top, middle, and bottom substrates independently comprise:

poly (lactide-co-glycolide) (PLGA); polylactide (PLA), polyglycolide (PGA), D-lactide, D, L-lactide, L-lactide, D, L-lactide-epsilon-caprolactone, D, L-lact¡da-glycol¡da-epsiion- caprolactone, polyepsilon-caprolactone glycolide-caprolactone or combinations thereof, carboxymethylcellulose, cellulose acetate, cellulose acetate propionate, ethylcellulose, hydroxypropylmethylcellulose, hydroxyalkylmethylcellulose and alkylmethylcellulose, polydyethylene) -acetate), poloxamer, polyvinylpyrrolidone, poloxamine, polypropylene, polyamide, polyacetal, polyester, polyethylene-chlorotrifluoroethylene, polytetrafluoroethylene (PTFE or "Teflon ™"), styrene-butadiene rubber, polyethylene, polypropylene, polyphenylene oxide-polystyrene, poly-alpha-chloro-p-xylene, polymethylpentene , polysulfone, non-degradable vinyl ethylene acetate (for example vinyl ethylene acetate and poly (ethylene co-vinyl acetate) discs, methacrylates, poly (N isopropylacrylamide), delrin, polyurethane, silicone copolymers and

ΙΜΡΙ ^ 5 «NsrmjTo MtxiCANo„

,. ,, ...... tH THE HHWDAP. C¹^ - a 4 polyurethane, polyolefms (such as polysobutylene and ^ 'pO'hisopfeffG ^ acrylamides (such as polyacrylic acid and po # faerHonitrile acrylic acid), neoprene, nitrile, acrylates (such as polyacrylates, poly (2-hydroxy-ethylmethacrylates) , methacrylates, methyl methacrylate, 2-hydroxyethyl methacrylate, and copolymers of acrylates with N-vinyl pyrrolidones), N, vinyl lactams, polyacrylonitrile, glucomannan gel, vulcanized rubber, poly (3-hydroxybutyrate) and combinations thereof.

62. The method in paragraphs 55 to 61, wherein the polyethylene is a closed-cell, low-density foam.

63. The method of paragraphs 55 to 62, wherein the upper, middle, and lower substrates, second upper substrate, second middle substrate, and second lower substrate, are independently selected from: a food grade polymer, a grade polylactic acid Food grade low density polyethylene (LDPE) in accordance with FDA regulations.

64. The method of paragraphs 55 to 63, wherein the coupling is achieved with the use of an adhesive, a suitable solvent to partially dissolve the substrates, infrared heat, heat, laser and ultrasonic welding.

65. The mattress of paragraphs 55 and 58 to 64, which further comprises a second corrugated product adhered to the upper o r lower substrate, wherein the second corrugated product comprises a second upper substrate, a second lower substrate and a second medium corrugated substrate between the second top and bottom substrates and two side perimeter pieces and two end pieces.

MEJtlON INSTITUTE '·

66. The mattress of paragraphs 55 and 58 to 65, éTi ^^ í ^ el ^ Sg ^^ or corrugated product is adhered to the first corrugated product with the use of heat or adhesive.

67. The mattress of paragraphs 55 and 58 to 66, wherein the second corrugated product is made of substrates that are thinner and more resilient to provide a cushion type than the substrates used to make the first corrugated product.

68. The cushion of paragraphs 55 and 58 to 67, wherein the second upper substrate, the second middle substrate and the second lower substrate independently comprise:

polyethylene derivatives, polylactic acid derivatives, cellulose derivatives, silicon and silicon-based polymers, and methacrylates.

69. The method in paragraphs 55 and 58 through 68, where the top, middle and bottom substrates independently comprise:

poly (lactide-co-glycolide) (PLGA); polylactide (PLA), polyglycolide (PGA), D-lactide, D, L-lactide, L-lactide, D, L-lactide-epsilon-caprolactone, D, L-lactide-glycolide-epsilon-caprolactone, polyepsilon-caprolactoneglycolide- caprolactone or combinations thereof, carboxymethyl cellulose, cellulose acetate, cellulose acetate propionate, ethyl cellulose, hydroxypropyl methyl cellulose, hydroxyalkyl methyl cellulose and alkyl cellulose, polydimethylsiloxane), polyethylene co- (vinyl acetate), poloxamer, polyvinylpyrrolidone, poloxamine, polypropylene, polyamide, polyacetal, polyester, polyethylene-chlorotrifluoroethylene, polytetrafluoroethylene (PTFE or “Teflon ™”), styrene-butadiene rubber, polyethylene, polypropylene, polyphenylene oxide-polystyrene, poly-alpha-chloro-p-xylene, polymethylpentene ,

<img file="MX348607B_D0007.tif" />

polysulfone, vinyl-ethylene-acetate not degradable (for example, '3? ^^ de'Vtmf ^ ethylene-acetate and poly (ethylene-co-vinyl-acetate), methacnlate; - proli (N ^ isopropylacrylamide), delrin, polyurethane, silicone and polyurethane copolymers, polyolefins (such as polysobutylene and polyisoprene), acrylamides (such as polyacrylic acid and poly (acrylonitrile-acrylic acid), neoprene, nitrite, acrylates (such as polyacrylates, poly (2-h) droxy-ethylmethacrylate), methacrylates, methyl-methacrylate, 2-hydroxyethyl-methacrylate, and copolymers of acrylates with N-vinyl pyrrolidones), N, vinyl-lactams, polyacrylonitrile, glucomannan gel, vulcanized rubber, poly (3-hydroxybutyrate) and combinations thereof.

70. The method of paragraphs 55 and 58 to 69, where the polyethylene is a closed-cell, low-density foam.

71. The method of paragraphs 55 and 58 to 70, wherein the second upper substrate, the second lower substrate and the middle substrate are independently selected from: a food grade polymer, a food grade polylactic acid or a polyethylene of Low Density Food Grade (LDPE) in accordance with FDA standards.

72. A mattress cover, the mattress cover comprises a laminated foam that covers at least one surface of the mattress.

73. The mattress cover of paragraph 72, wherein the foam comprises polyurethane, polyethylene, polyester, polypropylene, and polylactic acid.

74. The mattress cover of paragraphs 72 to 73, where the foam is approximately 0.079 cm to 0.31 cm.

75. The mattress cover of paragraphs 72 to 74, where the ιμρι MsxicANlaminated institute is a polyurethane, polyester, polylactic polyurethane film. - - .....

76. The mattress cover of paragraphs 72 to 75, where the cover meets the sides of the mattress.

77. The mattress cover of paragraphs 72 to 76, wherein the cover wraps around the mattress to contain it having an open end to accept the mattress.

Although this invention has been described in conjunction with the various exemplary embodiments noted above, several substantial alternatives, modifications, variations, improvements, and / or equivalents, whether known or to be known, may be apparent by 1211. Pursuant to this, the exemplary embodiments in accordance with this invention, as set forth, are intended to be illustrative and not limiting, various changes can be made without departing from the spirit and scope of the invention. Therefore, the invention is intended to encompass all substantial alternatives, modifications, variations, improvements, and / or equivalents of these exemplary embodiments.