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 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.