Abstract: A machine for converting a sheet stock material into a relatively less dense dunnage product includes both (a) a helical pre-form assembly having a cylindrical mandrel with a longitudinal axis and a guide member for guiding the sheet stock material from a supply thereof into a helical path along and around the mandrel so as to form a helical pre-form that rotates around the longitudinal axis and advances parallel to the longitudinal axis; and (b) a restriction in the path of the pre-form that slows the advance and rotation of the pre-form past the restriction, the restriction causing the pre-form to retard longitudinal advancement, to twist upon itself, and to permanently deform as it moves past the restriction, thereby longitudinally and helically crumpling the pre-form.

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 machine and method for the continuous folding of sheet material into difference three-dimensional patterns is featured. The innovative machine and method folds sheet material by force converging the sheet to a final stage that imparts a final fold or pattern. Unique programming allows for the change of convergence sequencing and change of materials.

Abstract: This invention relates to an improved flame retardant honeycomb comprising high modulus fiber and a flame retardant thermoplastic binder having a melt point of from 120° C. to 350° C. and a limiting oxygen index of 26 or greater, methods for making the honeycomb, and articles comprising the honeycomb. In a preferred embodiment the paper in the honeycomb has a flame classification of UL-94 V-0.

Abstract: A three-dimensional support structure is provided and includes a single sheet of material that is folded into a repeating pattern of cells. Each of the cells is formed by first and second spaced-apart endwalls and first and second sloped sidewalls spanning between the endwalls. Each endwall comprises two plies of material while each sidewall comprises a single ply of material. The first and second sidewalls are adjoined at a folded edge. The cells are aligned such that the first endwall of one cell from the repeating pattern abuts the second endwall of an adjacent cell of the repeating pattern to form a four-ply wall of the material. A first liner may be attached to a first side of the folded material and a second liner may be attached to a second side of the folded material.

Abstract: A ripple bottom pizza box and the method of creating a pizza box with such a ripple bottom. A pizza box blank is provided that is made of corrugated cardboard. The corrugated cardboard has parallel corrugation waves that traverse a flat bottom section pf the pizza box blank in a first direction. A roller is provided that has multiple parallel roller heads. The flat bottom section of the pizza box blank is advanced under the rollers. The parallel roller heads press parallel depressions into the flat bottom section in a direction perpendicular to the first direction of the corrugation waves. The result is that when the pizza box blank is folded into a pizza box, the bottom of the pizza box is contoured with parallel depression lines.

Abstract: A three-dimensional object folded from a flat work piece, particularly a filter element folded from a nonwoven fabric, characterized in that the three-dimensional object (20) is made up of several rows (5, 6, 7) of hollow pyramid elements (30) that are joined in rows and nested into one another.

Abstract: One or more sheet material layers in a multi-layer laminated structure is reinforced by adhesive bridges that extend through openings in the layer and tie together the layers on either side of the reinforced layer. A plurality of openings are provided in the layer or layers to be reinforced. The openings are spaced apart and distributed over the surface of the layer. Accordingly, when the layer is incorporated into a multi-layer structure, the adhesive applied to the layer, or to the layers on either side thereof, is forced through the openings so that a continuous adhesive connection is formed between the layers on opposite sides of the reinforced layer via the adhesive bridges that extend through the openings.

Abstract: A method for manufacturing a paper core material is described. The paper core material has uses such as in the building industry and has the advantage that no toxic home syndrome is caused in a newly built house or office. The paper core material has a continuous geometric pattern such as rectangular or hexagonal cells and is made by the method of providing a plurality of base paper strips, bending and gluing the base paper strips to form the paper core material having a continuous geometric pattern, treating the paper core material with a charcoal solvent comprising activated carbon dust, wood vinegar and a flame-resisting agent, and drying the paper core material. An alternate method is provided which involves treating the base paper strips with the charcoal solvent, drying the base paper strips, and then bending and gluing the base paper strips to form the paper core material having a continuous geometric pattern.

Abstract: In the manufacture of a noise attenuation panel for an aeroengine nacelle an adhesive film is applied to a front face of a cellular component of the panel. The adhesive film is caused to reticulate to the ends of the walls of the cells at the front face of the cellular component. A perforate facing component of the panel is bonded to the front face of the cellular component by adhesive flow from the cell walls to the facing component. To avoid unpredictable adhesive flow giving rise to cosmetic spots on the front face of the facing component the two components are brought together with the interposition of an adhesive flow control sheet and the reticulated adhesive caused to bond the two components together by adhesive flow under the control of the adhesive flow control sheet.

Abstract: Honeycomb forms can be held in an expanded or compressed state by the use of a lengthwise device such as a cord or similar lengthwise material threaded through holes in the honeycomb plies. This cord has a frictional surface to hold the honeycomb from unintended movement. Additionally, a semi rigid lengthwise device, such as a twisted, stranded wire may be used with the separated strands preventing the return of the end plies.

Abstract: A method of imparting directional permanency of folding to a sheet, and an apparatus therefor, which is suitable for manufacturing frame bodies, cushioning members and other block products for packaging, from a sheet of paper and other recyclable materials. The method includes a step of moving respective folding working tools, disposed on one or both surfaces of a sheet, required amounts so as to fold the sheet along respective folding ruled lines, and a step of shortening spacings between the respective folding working tools in a uniform ratio in accordance with an apparent amount of shortening in a longitudinal dimension caused by the shifting, while synchronizing with the moving step. Directional permanency of folding can be accurately imparted to the sheet along the folding ruled lines.

Abstract: An acoustically significant composite panel having a general sound-absorbing face (or a general sound-diffusing face) and a tuned sound-absorbing face. Such a panel includes a sandwich or composite of a first layer of molding media, a honeycomb of cells and a second layer of molding media. The first layer has at least one or more apertures in it that convert the corresponding cells into Helmholtz resonators. These Helmholtz resonators can be tuned to the same or different frequencies. The second layer is generally sound-absorbing. A general diffuser structure can be attached to the second layer. These panels can be attached to the walls and/or ceilings of a room to control its sonic quality. Also, these panels can be suspended vertically below a ceiling to control noise.

Abstract: A method of making a pleat in a sheet-like material comprising the steps of feeding a flexible and thin sheet-like material having a flat surface in a direction of an extended line of an imaginary straight line which is perpendicular to its one end and along the surface, left and right parts of the sheet-like material being conveyed at a substantially same speed at both sides of the straight line, the one end of the sheet-like material being of a flat form at a start of the feeding, the left and right parts of the sheet-like material being gradually reduced in distance therebetween and drawn near toward the straight line at the middle portion of the extended line so as to face with each other and diagonally cross the surface, and coming in contact with each other perpendicularly to the surface at the forward portion of the extended line, thereby to form the pleat, conveying the sheet-like material through the middle portion to the forward portion with the left and right parts gradually twisted in a direction

Abstract: A reinforced box-like structure for forming a void area in a concrete formation. The structure includes a bottom panel having a plurality of spaced apart, parallel base partitions and a top panel having a plurality of spaced apart, parallel top partitions. The base partitions extend across the bottom panel and in a direction normal to the bottom panel, and the top partitions extend across the top panel and in a direction normal to the top panel. Each of the base partitions and top partitions include a plurality of double-thickness walls with a plurality of slots therein and flat top edges between the slots. The structure is assembled by superimposing the top panel over the bottom panel such that the base partitions extend transversely relative to the top partitions.

Abstract: A method for splitting up a honeycomb panel, preferably for use as a separator for sheets and, particularly, breakable sheets such as glass sheets, starts with a sheet of honeycomb material with a cover layer on both sides. During the splitting up, each cover layer is cut from outside of the honeycomb toward the inside in order to flange the cover layer in situ to the inside.

Abstract: An apparatus for sequentially forming folds in a sheet of paper which is continuously moving substantially in a single plane. A first fold is formed in the center of the continuously-moving sheet of paper and subsequent pairs of folds are sequentially formed, one on each side of the previously-formed folds, until the entire continuously-moving sheet is folded. Guide wires retain each folded section until the entire sheet is folded by the cyclic upward movement of a continuous flexible wire loop held for free movement on a pair of spaced apart pulley assemblies. Each pulley assembly includes a plurality of evenly spaced pulleys each of which are held for free rotation on a support frame. Each support frame is driven in rotation about a central axis of rotation. Each individual pulley includes a freely rotatable ring surrounding the periphery of the pulley around which the flexible wire loop is held.

Abstract: A method for forming 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 variety of sheet materials can be tessellation folded with an infinite variety of patterns in a one-step folding process by placing the sheet material against a pallet having flat rigid segments and flexible hinges, exerting forces against the pallet in accordance with information as to the pattern desired to initiate folding, and continuing folding to the degree of folding collapse wanted. A heat setable material can be heated prior to folding so the material will be set as folded. An uncured cementitious material can be folded, and held in a mold until the material is cured. Due to natural pantographic degradation, a continous belt can be folded in one area, with sheet material to be folded being placed against the belt before folding, and removed as the belt unfolds.

Abstract: A nondisassembling partition assembly comprising a partition matrix made up of intersecting first and second slotted plastic partitions, each of the partitions having at least one slot. The slots of the partitions are engaged with each other at a plurality of intersections. The matrix is held together in a nondisassembling relationship by at least one parent weld formed by heating an edge of the partitions at one or more intersections with one or more heat sources until the intersecting partitions become molten, removing the heat source or sources from edge of the intersecting partitions and allowing the partitions to cool. The parent welds formed by this process permanently secure the partitions together in the nondisassembling relationship without the use of any material other than the partitions themselves.

Abstract: Perforated core honeycomb panel and pump system including a panel comprised of a core of perforated, thermoplastic elastomeric honeycomb bonded to and disposed between upper and lower sheets of thermoplastic elastomeric facing material. The core is made from a plurality of advanced grade, thermoplastic elastomeric strips that have been perforated, such that there is a matrix of small holes formed in the core walls. The strips are intermittently fusion welded or bonded to form a stack which can be expanded to form a honeycomb-like network of cells. The upper and lower facing sheets are bonded to the core and extend outwardly beyond the core, and are sealed around their perimeters so as to form a closed chamber which is hermetically sealed and adapted to contain a suitable gas. In one embodiment, the chamber is communicatively coupled, via a conduit, to an exhaust valve and a bulb pump in order to permit the gas contained within the chamber to be selectively increased or decreased in pressure or volume.

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 honeycomb core or honeycomb structure 1 is made up of an arrangement of hollow cylindrical cells individually separated by cell walls made of base sheets 4. Each base sheet is a complex mixture of para-aramid fibers 2 and meta-aramid pulp material. The para-aramid fibers 2 occupy a weight percentage of from not less than 20% to less than 50% The honeycomb core is made by either the expanding method of the steps of stacking a plurality of base sheets 4, applying stripes of adhesive and then extending the stack or by the corrugating method of the steps of corrugating respective base sheets, stacking and bonding the corrugated sheets. If desired, after-treatment for reinforcement may be executed to apply or impregnating phenolic resin or other impregnating agent.

Abstract: An expanded paper cylinder formed from a spiral is disclosed as a void fill. A delivery system is provided for manual and automatic delivery of the expanded paper from a continuous, unextended wound roll of an extendible sheet material. The cushioning material formed by the expander can be used as a expanded sheet around an article or as void fill, or can be formed into spiral cylinders for use as void fill. The manual dispensing system includes a support member supporting a rotatable feed roll. A restraining restraining device slows the free delivery of the wound feed roll of unextended sheet material, so that the sheet material expands while it is being drawn, under tension from the feed roll. An automatic system uses expander rollers to expand the slit paper and can be coordinated with apparatus which cuts and forms the spiral cylinders.

Abstract: A syntactic structural foam product in flat sheet form or curved three-dimensional form adaptable to such uses as a light weight structural core for composite laminates, is made of a mixture of hollow ceramic microspheres and dry resin powder, of either thermosetting or a high-temperature thermoplastic resin, distributed in the interstices of the mass of microspheres for integration of the mixture into desired form upon heating and cooling. The dry resin powder in another embodiment of the invention includes unexpanded expandable powder which will expand into microballoons in the confined spaces in which they reside and effect a bonding relation with surrounding particles upon supply of heat to the mixture. The foam product is produced by thoroughly intermixing and depositing the mixture as a layer over a surface having a release agent thereover within a dimension defined region.

Abstract: An acoustic tile for masking the acoustic signature of a surface or submarine vessel and including an inner skin for securing the tile to the hull of the vessel, an outer water-impervious skin, and a core sandwiched between the inner and outer skins, the core being made of an expanded honeycomb structure being affixed to said inner and outer skins by thermocompression bonding.

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 package for cigarettes and the like comprises a honey-comb structure which defines a plurality of elongated parallel cells each for receiving a respective cigarette. The structure includes two opposite walls which close said cells at their ends, one of these end walls being adapted to be opened to low access to the cells containing the cigarettes.

Abstract: A void filler device for use in staggering or spacing apart items, such as paper rolls, during shipment includes a plurality of L-shaped members made of laminated paperboard, corrugated cardboard, plastic or other like suitable material. Each of the members has a first leg and a second leg which is angled approximately 90.degree. relative to the first leg. The first leg includes a plurality of spaced slots, which extend approximately half of the width of the first leg, by which the members interlock with each other to form an open-cell construction that is expandable and collapsible. The void filler expands and collapses by the members moving relative to each other.

Abstract: A foamed phenolic molding composed of a core made of a kraft paper honey comb structure consisting of plate and corrugate members impregnated with a phenolic resin; and expandable phenolic composites laminated to said core, wherein the expandable phenolic composites are made of a matted fiber material formed in the shape of a plate to which phenolic resin is bonded to at least one thereof. The expandable phenolic composites and core are molded such that the expandable phenolic material fills the cells of the kraft paper honey comb structure. The molding has excellent thermal insulation and sound insulating properties as well as high strength as compared to conventional cores without sacrificing to the lightweight characteristics and workability of the quadratic surfaces.

Abstract: A noise attenuation panel having a backing sheet, a facing sheet and a cellular core having a multiplicity of open-ended juxtaposed cells. The backing sheet extends across the ends of the cells at the rear of the core and the facing sheet extends across the ends of the cells at the front of the core. The facing sheet is made of a porous permeable thermoplastics material. The porous permeable thermoplastics material for the facing sheet is produced by powder sintering a thermoplastics material.

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: The present invention provides plastic-based fiber-reinforced honeycomb, and a process for its preparation. The fiber-reinforced honeycomb has high temperature durability yet can be fabricated and handled by simple techniques. Honeycomb structures in accordance with this invention have the strength, impact resistance and processing characteristics of thermoplastic materials and yet offer high temperature resistance and solvent resistance characteristics which permit such processing steps as the application of multiple coatings for purposes of density adjustment and enhancement of mechanical properties.

Abstract: A honeycomb body includes an axis, a jacket tube being conical relative to the axis, and a configuration being fitted in the jacket tube. The configuration includes at least one stack being wound about the axis in an involute. The stack has a plurality of sheet metal layers being layered on one another. The layers include a plurality of corrugated layers. Each of the layers has a circular ring segment shape being defined by an outer arc being approximately circular relative to a center point and an approximately circular inner arc being concentric with the outer arc and being disposed between the outer arc and the center point. Each of the corrugated layers has corrugations being oriented approximately radially relative to the center point. The corrugations have associated corrugation heights. The respective corrugation heights on each of the arcs is in a given ratio, and the arcs having lengths in a ratio being approximately equal to the given ratio.

Abstract: A package for preserving perishable food products such as produced shipped in large quantities on a pallet wherein the invention includes panels formed of honeycomb material covered by aluminum foil panels to provide a stronger and better insulated package.

Abstract: A honeycomb structural material formed from flat sheet material 60 by establishing a plurality of channels along parallel channel fold lines 68 and reverse channel fold lines 74 and reverse channel cuts 70. A spaced array of holes 66 are cut in the top surfaces 86 of the channels with triple point fold lines 72 formed in top surface 62 and side wall fold lines 74 formed in bottom surface 64. With all fold lines formed flat sheet 60 is folded into plurality of channels and compressed along the axis of the channels to form the honeycomb structure.

Abstract: An enhanced reinforced honeycomb structure is provided when at least one thread is stitched in a given pattern along each linear group of cells in the honeycomb structure. This reinforcement reduces the weight of the attached panels since additional structural strength is provided by the threads in the honeycomb structure.

Abstract: The invention relates to an insulative structure with both outwardly and inwardly facing aluminum foil layers supported by kraft paper layers which are, in turn, supported by a kraft paper honeycomb structure with walls perpendicular to the aluminum and kraft paper layers. The honeycomb structure includes a series of interlocking hexagonal compartments which support airspaces therewithin.

Abstract: An elongated lightweight fiber reinforced composite resin pultrusion-formed piece with a rectangular structural shape has an elongated light honeycomb structure body with a rectangular sectional shape and at least one fiber reinforced resin layer formed to cover at least a portion of the outer peripheral surface of the lightweight honeycomb structure body. The fiber reinforced resin layer comprises an axial fiber layer formed by aligning reinforcing fibers parallel to the longitudinal axis of the lightweight honeycomb structure body.

Abstract: A light weight honeycomb structure is disclosed made from aramid fibers and exhibiting extremely high shear modulus.

Abstract: A machine (300) and the process for manufacture of a unique completely pleated product (110) which is made from a continuous, flexible web (311) for the covering of windows and the like. The machinery consists of a production line (300) with at least a screen printing assembly (306), printing phase control apparatus (330), a unique pleating assembly (400 or 800) and an optional folding assembly (500) for stacking and receiving the final product. Screen printing and web travel phasing is performed in accordance with standard practices in the industry, while the pleating and folding of the finished product is performed by apparatus designed and constructed by the instant inventors. After predetermined patterns of adhesive or bonding material (212) have been applied to the continuous web (311), it is pleated by a paired roller assembly (400 or 800) and, through the optional use of an air knife assembly (500), folded into a collecting apparatus.

Abstract: Apparatus for cutting a continuous web into precise length sheets and precisely stacking the sheets, relative to each other, includes first and second moving endless belt tables for advancing the web, a sheet orientation table and a stacking table. A vacuum holds the web firmly, without tension, against the respective belts. A shearing device is disposed between the first and second endless belts. Web, detectors positioned along the line of travel of the web, detect printed or colored lines on the web to obtain accurately cut sheets. Individually driven and positioned sheet grippers grasp the cut sheet positioning each sheet under dual hole punching devices which punch precisely positioned holes in each sheet. A pair of aligning pins on a sheet stacking bed are used as guides for orienting the sheets in interleave configuration. Each sheet is secured to its adjacent sheet to maintain sheet orientation.

Abstract: A shaped panel and method of manufacture thereof comprises an open-cell core having multiple cells with cell walls extending perpendicularly to the opposite sides of the core. Linerboard covers one or both sides of the core with thermoplastic resin being provided as adhesive between the core and the one or more linerboards. The resulting sandwich structure is heated and shaped in a mold.

Abstract: A package for preserving perishable food products such as produce shipped in large quantities on a pallet wherein the invention includes panels formed of honeycomb material covered by aluminum foil panels to provide a stronger and better insulated package.

Abstract: A honeycomb panel manufacturing system and method comprises expansion tables, a curing chamber, adhesive application table, and a pressing station for bonding face sheets to honeycomb panels. The method of manufacture comprises expanding honeycomb material, curing expanded panels, and pressing face sheets onto opposite sides of cured panels.

Abstract: The invention relates to a multiple pot comprising individual pots interconnected by connector portions so as to be capable of being pulled out. The multiple pot is used to raise and transplant seedlings of plants. The invention also relates to a method of fabricating the pot. The pot is designed especially to promote growth of roots across the side walls of the individual pots after transplantation. Also, the resistance encountered when the multiple pot is unfolded is reduced. Further, the individual pots are uniform in size. These feature arise from the facts that the connector portions are formed by applying a waterproof paste discontinuously and that a water-soluble paste is not applied around the edges of the individual pots created when the multiple pot is unfolded. Hence, a coating of the paste is formed in none of these portions. The multiple pot is fabricated by continuously carrying out three steps.

Abstract: A disc used primarily in extruding machines positioned between a fluid strainer and a forming die. The disc includes multiple adjacent walls which define honeycomb passages for the fluid to flow through. The disc may serve as a support for the strainer, or with modifications, may be used to achieve other functions, such as fluid mixing and flow rate enhancing.

Abstract: A filter cartridge of the type made from a sheet of filter paper pleated as an accordion on a cylindrical surface. It is produced by pinching pairs of contiguous pleats at various levels in order to make on the outer surface of the cartridge a plurality of honeycombs. The invention results in substantially prolonged life of the filter cartridges, which have applications in a variety of uses, including regeneration of solvents of washing baths for dry cleaning machines, filtration of air for internal combustion engines and water filtration.

Abstract: An apparatus having rotary shearing and forming dies which expand a web of formable material by imparting to the web a surface configuration having rows of generally sinusoidal convolutions extending longitudinally along the web, each row lying 180.degree. out of phase from abutting rows. The meshing rotary dies include flat portions defining a neutral zone wherein no web deformation occurs, with the result that each convolution in a row is joined to the next longitudinally succeeding convolution by a flat web section lying in the original plane of the formable sheet material. The expanded web is laminated to a flat web of paper-like material and the resulting composite web is converted to expanded cigarette wrappers.

Abstract: Apparatus is provided for packing articles, for example apples and other readily damaged fruits, in expanded slices of honeycomb using a conveyor on which the honeycomb is fitted, and carried through a filling station to an unloading station.Means are provided for expanding the slices of honeycomb and applying them to the conveyor in turn. A preferred arrangement is to supply the unexpanded slices one by one from a magazine and accelerate each slice so that it is projected into position for engagement by vacuum cups of an expansion device. Having been expanded, the slices are fitted to the conveyor where they are held in the expanded state by attachment devices provided thereon.At the unloading station, the packages of articles are removed from the conveyor for stacking in a confining carton while confining them in the horizontal direction to retain the position of articles packaged in incomplete cells.