Processes for manufacturing a structural member

Abstract

A fabrication machine is disclosed herein. In various aspects, the fabrication machine includes a brake adapted to mechanically cooperate with a wrapper to impart a longitudinal tension to the wrapper by controlling the force required to advance the wrapper, the wrapper comprised of a cellulose-based material. The brake is adjustable to allow selection of longitudinal tension in the wrapper, in various aspects. Various aspects may include a wrapper roll in mechanical cooperation with the brake, the wrapper being drawn from the wrapper roll as the wrapper is advanced. The fabrication machine secures the wrapper at the selected tension about the core to form a structural member, in various aspects. Methods of use of the fabrication machine are disclosed herein. This Abstract is presented to meet requirements of 37 C.F.R. §1.72(b) only. This Abstract is not intended to identify key elements of the apparatus and methods disclosed herein or to delineate the scope thereof

The invention claimed is: 
     
         1 . A structural member for a pallet manufactured by a process comprising the steps of:
 advancing a wrapper with a core emplaced thereupon through a fabrication machine in a direction of material flow, the wrapper being formed of a flexible sheet of cellulose based material, the core being formed of laminated fiberboard sheets;   engaging the wrapper and the core with the fabrication machine as the core and the wrapper advance in the direction of material flow between side rollers, the side rollers engaging the wrapper and imparting a peripheral tension to the wrapper around the core, the peripheral tensioning of the wrapper about the core is in directions orthogonal to the direction of material flow; and   securing the wrapper in tension to the core with adhesive interposed between the core and the wrapper.   
     
     
         2 . The structural member for a pallet manufactured by a process as in  claim 1 , further comprising the steps of:
 tensioning the wrapper to a longitudinal tension; and   securing the wrapper in longitudinal tension to the core.   
     
     
         4 . The structural member for a pallet manufactured by a process as in  claim 2 , further comprising the steps of:
 using a brake in mechanical cooperation with the wrapper to impart a selected longitudinal tension in the direction of material flow to the wrapper by controlling the force required by a mechanism to advance the wrapper along the track.   
     
     
         5 . The structural member for a pallet manufactured by a process as in  claim 1  further comprising the steps of:
 using a compression table for holding the wrapper in tension about the core as adhesive interposed between the wrapper and the core cures while performing the step of securing the wrapper in tension to the core. 
 
     
     
         6 . A structural member for a pallet manufactured by a process comprising the steps of:
 advancing a wrapper with a core emplaced thereupon through a fabrication machine in a direction of material flow, the wrapper being formed of a flexible sheet of cellulose based material, the core being formed of laminated fiberboard sheets;   engaging the wrapper and the core with the fabrication machine as the core and the wrapper advance in the direction of material flow, tensioning the wrapper to impart a longitudinal tension; and   securing the wrapper in longitudinal tension to the core with adhesive interposed between the core and the wrapper.   
     
     
         7 . The structural member for a pallet manufactured by a process as in  claim 6 , further comprising the steps of:
 the side rollers engaging the wrapper and imparting a peripheral tension to the wrapper around the core, the peripheral tensioning of the wrapper about the core is in directions orthogonal to the direction of material flow; and   securing the wrapper in peripheral tension to the core with adhesive interposed between the core and the wrapper.   
     
     
         8 . The structural member for a pallet manufactured by a process as in  claim 6 , further comprising the steps of:
 using a brake in mechanical cooperation with the wrapper to impart a selected longitudinal tension in the direction of material flow to the wrapper by controlling the force required by a mechanism to advance the wrapper along the track.   
     
     
         9 . The structural member for a pallet manufactured by a process as in  claim 6 , further comprising the steps of:
 using a compression table for holding the wrapper in longitudinal tension about the core as adhesive interposed between the wrapper and the core cures while performing the step of securing the wrapper in tension to the core.