Abstract: A panel structure having a low-density core that can withstanding loads normal to a first primary surface, and a first facing of high-density sheet material that can extend along the first primary surface. The high-density sheet material can be laminated on the core such that the laminated core and facing cooperatively resist bending loads and loads along the primary surface. The first facing can extend from the first primary surface on a side of the core along a secondary surface, which can be non-parallel to the first primary surface. The first facing can bend along a score line between the first primary surface and the secondary surface.

Abstract: The present disclosure relates to methods and devices for securing cylindrical goods in containers during transportation. Some embodiments include void fillers configured to restrain motion of objects in freight containers. Some embodiments include methods of fabricating void fillers for use in freight containers. Some embodiments include methods of using void fillers to restrain object motion in freight containers. In some cases, a void filler is fabricated from a honeycomb-style cardboard materials. In some cases, a void filler is used to restrain an upright cylindrical item such as an upright paper roll in a freight container.

Abstract: A sandwich construction including a core having inner and outer surfaces and comprising a sheet material oriented extending between the inner and outer core surfaces in a configuration providing resistance to crushing in a direction between the inner and outer surfaces. The formable protector further includes an outer facing layer of a sheet material adhered to the outer surface of the core layer; and an inner facing layer adhered to the core inner surface and being sufficiently deformable to conform to a sharp edge of a protected object when the protector is bent therearound, and being substantially more compressible or stretchable than the outer facing layer. The core has sufficient resistance to crushing and the outer facing layer is sufficiently durable for causing the core to partially crush when the protector is bent around the sharp edge while partially retaining crushing resistance for protecting the sharp edge against impact.

Abstract: A panel structure having a low-density core that can withstanding loads normal to a first primary surface, and a first facing of high-density sheet material that can extend along the first primary surface. The high-density sheet material can be laminated on the core such that the laminated core and facing cooperatively resist bending loads and loads along the primary surface. The first facing can extend from the first primary surface on a side of the core along a secondary surface, which can be non-parallel to the first primary surface. The first facing can bend along a score line between the first primary surface and the secondary surface.

Abstract: A panel structure having a low-density core that can withstanding loads normal to a first primary surface, and a first facing of high-density sheet material that can extend along the first primary surface. The high-density sheet material can be laminated on the core such that the laminated core and facing cooperatively resist bending loads and loads along the primary surface. The first facing can extend from the first primary surface on a side of the core along a secondary surface, which can be non-parallel to the first primary surface. The first facing can bend along a score line between the first primary surface and the secondary surface.

Abstract: An airflow pad is disclosed that includes first and second external facings of paper material extending between edge portions of the panel and having interior portions disposed remotely from the edge portions. A low-density core of paper material disposed between and associating the external facings to provide stiffness to the panel. The pad defines a network of channels open at least one of the edge portions and at the interior portion of the first facing allowing airflow therebetween.

Abstract: A product-stacking structure that holds a plurality of products on a horizontal base and includes a plurality of side sections extending generally upright from the horizontal base section (e.g., walls). The walls are configured and dimensioned for retaining bottom features of the products within. The horizontal base includes a horizontal base surface and a void region creating a boundary that restricts movement of upper features of the products in at least one horizontal direction. The product-stacking structure also includes a supportive pad affixed to the first portion over the horizontal bottom section and within the plurality of side sections to cover the void region and configured for supporting products stacked thereon.

Abstract: An apparatus for forming a resilient prestressed honeycomb structure from a honeycomb structure having opposed hollow-ell faces defining opposed planar surfaces. The apparatus comprises a conveyor for conveying the honeycomb structure and a compression apparatus for compressively deforming at least a portion of the honeycomb structure. When the honeycomb structure is conveyed past the compression apparatus, the compression apparatus compressively deforms one of the planar surfaces of the honeycomb structure to form a resilient prestressed cushioned face portion. The compression apparatus comprises a plurality of parallel and elongate compression rolls for compressively deforming the honeycomb structure to form the resilient prestressed cushioned face portion.

Abstract: A method is disclosed of folding a honeycomb panel, the panel preferably comprising a honeycomb core having opposing face sheets. A slit is preferably cut through one face sheet and the underlying honeycomb core and a wedge is driven into the honeycomb panel at the location of the slit. The wedge crushes the honeycomb core to a preselected depth with a preselected angle whereby the crushed honeycomb core forms a hinge. The honeycomb panel can then folded along the hinge in a direction opposite the intact face sheet. Adhesives can be used to hold the hinge in the folded position.

Abstract: A honeycomb protector for protecting the corners, edges or other surfaces of articles during shipping of such articles comprising self-locking honeycomb panels. In one embodiment, the protector includes first and second unitary panels separated by a channel about which the panels are foldable. The first panel includes a lip which fits into a slit in the second panel to connect and lock the first and second panels in position.

Abstract: A spacer is provided for supporting and cushioning a roll of web material during shipment comprising a pad including a honeycomb core sandwiched between opposite face sheets. The pad includes a curved recess formed therein which is conformed to receive and cushion the rolls of web material. The recess is defined by a portion of the pad in which the honeycomb core and one of the face sheets has been compressively deformed to a predetermined depth. The face sheet which is compressively deformed includes an elongate slit located in the region overlying the recess for preventing the tearing of the face sheet when the pad is compressively deformed.

Abstract: A resilient prestressed honeycomb structure is disclosed in which at least one of its defined planar surfaces is cushioned along its lateral length by substantially continuously deforming it under compression to a preselected depth. Also disclosed is a one-step method for simultaneously cutting and forming a resilient prestressed paper honeycomb structure and apparatus therefor. One preferred embodiment of the resilient prestressed paper honeycomb structure is sufficiently strong and lightweight to use as an inner packaging for providing cushioning protection of articles having a fragility factor rating of less than about 85 G's against multiple impacts.

Abstract: A method is disclosed of folding a honeycomb panel, the panel preferably comprising a honeycomb core having opposing face sheets. A slit is preferably cut through one face sheet and the underlying honeycomb core and a wedge is driven into the honeycomb panel at the location of the slit. The wedge crushes the honeycomb core to a preselected depth with a preselected angle whereby the crushed honeycomb core forms a hinge. The honeycomb panel can then folded along the hinge in a direction opposite the intact face sheet.

Abstract: A honeycomb protector for protecting the corners or edges of articles during shipping of such articles comprising a flat panel including first, second, third and fourth portions which are foldable to form the protector. In one embodiment, the fourth portion includes a finger which fits within a notch in the third portion for connecting the third and fourth portions together co-planarly when the protector is folded. The portions are preferably foldably connected to each other by crush slit scores. The crush slit score foldably connecting selected portions has a bevel angle in a preselected range providing a spring-biasing action between the selected portions when the panel is folded. The spring biasing action causes the finger to lock in the notch to assure that the protector does not unfold while the article is being packaged for shipment.

Abstract: A method is disclosed of folding a honeycomb panel, the panel preferably comprising a honeycomb core having opposing face sheets. A slit is preferably cut through one face sheet and the underlying honeycomb core and a wedge is driven into the honeycomb panel at the location of the slit. The wedge crushes the honeycomb core to a preselected depth with a preselected angle whereby the crushed honeycomb core forms a hinge. The honeycomb panel can then folded along the hinge in a direction opposite the intact face sheet. Adhesives can be used to hold the hinge in the folded position.

Abstract: A shipping carton includes a plurality of generally rectangular panels with a hinge between at least each two adjacent panels. The panels can be extended and placed at about right angles from each other to form a sidewall having an open top portion and an open bottom portion. A pair of support trays each comprising a panel member and four side members that extend therefrom fit over the portion bottom and top portion of the sidewall to enclose the carton. In a preferred embodiment, spaced-apart inserts and liner members can be provided which fit within each support tray. The panels and the support trays are secured to prepare the carton for shipping.