Certainteed Corporation

Tom Cuthbertson

David I Suda

Larry Clevenstine

Mark Buscher

A backing sheet, and a system and method of manufacturing a backing sheet with stapling tabs. The system includes a roller device configured to apply an adherent material to a first side of the backing sheet continuously fed from a feed roll. The sheet is then fed to a first pair of folders configured to fold the backing sheet along the edges such that the adherent material holds the first fold in place. The sheet passes through a second pair of folders that form a second fold along the edges of the sheet by folding in the opposite direction as in the first fold. Advantageously, an applicator device is configured to apply a tacky substance, such as a starch solution, between the contacting portions of the second fold, prior to the formation of the second fold. The tacky substance maintains the second fold and prevents the stapling tab from opening during further manufacturing and packaging processes. Alternatively, the system includes a piercing device configured to piece a hole through the backing sheet in order to allow a portion of adherent material to leak through the hole and contact a portion of the backing sheet. Once the second fold is made, the portion of adherent material extending through the hole will contact a portion of the backing sheet and will adhere to the portion of the backing material it contacts, and thereby prevent the stapling tab from opening during the remaining manufacturing and packaging processes.

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Royersford, PA, United States of America

Tom Cuthbertson