A manufacturing system to form a honeycomb core and a method of forming the same includes a sheet of fibrous material is fed into a perforation assembly. The sheet of fibrous material is perforated via the perforation assembly to form holes through the sheet of fibrous material. The sheet of fibrous material is cut to form layers. The layers are stacked on top of each other such that the holes of the layers align with each other and strips of adhesive bond the respective layers together to form a perforated stack. A coating is applied to the sheet of fibrous material at the holes. The perforated stack is expanded to form a honeycomb panel. The honeycomb panel is dipped in a solution, and the coating repels the solution. The solution adheres to the honeycomb panel except at the holes where the coating is applied to form the honeycomb core.

A product made from an extruded sheet or web of material having a non-linear cross-section, and the process of making the product are provided. The extruded web or extrudate is plastically deformed in selected areas and then folded. When folded into the appropriate shape, the extrudate is formed into a product having a plurality of cells. The cells may have one or more openings, allowing access to an interior of the cell and reducing the weight of the product.

A process of making a multi-layered product from an extruded sheet or web of material (42) having parallel upper and lower walls (130) and a plurality of spacers (134) extending between the upper and lower walls (130) is provided. Portions of the extruded web or extrudate (42) are removed in selected areas. The lightened web is then folded. Outer skins are then applied to the folded web. The extrudate (42) is formed into a product (10) having a plurality of cells (14). The cells (14) may have one or more openings (34), allowing access to an interior of the cell (14) and reducing the weight of the product (10).

A method for manufacturing a sound attenuating panel uses an alveolar-core structure including a first edge and a second edge separated by alveolar cells, the alveolar cells including walls extending from the first and second edges and defining a primary conduit for the circulation of a sound wave that is to be attenuated. The method includes covering the first edge or the second edge of the alveolar-core structure with a compartmentation wall; deforming the compartmentation wall to define at least one secondary conduit for the circulation of a sound wave that is to be attenuated, the secondary conduit extending at least partially within said primary conduit; and creating an opening in the compartmentation wall to permit communication between the primary and secondary conduits.

The present invention is directed to a 3D printed mold for creating three dimensional pulp products from a fibrous pulp slurry. Transverse filaments are integrated into an infill structure with an open-cell pattern. The transverse filaments form channels through the interior matrix of the mold. The open cell infill pattern and channels allow for the movement of vacuumed materials through the interior matrix of the 3D printed mold when vacuum pressure is applied. The product surface of the mold comprises an array of beads formed from the over-extrusion of melted material at the ends of the transverse filaments. The beaded array narrows the opening of the channels created by the transverse filaments, preventing the fibers from entering the matrix of the mold and clogging the flow of materials. This causes the fibers to aggregate on the product surface of the mold, forming the three dimensional pulp product.

A gripper for gripping a honeycomb-shaped part and depositing the part on a target surface includes gripping elements mounted on a support, each of the gripping elements being configured to be inserted into an internal cell of the honeycomb-shaped part. The gripping elements include a gripping surface that is laterally moveable relative to the support so as to come into contact with a side wall element of the internal cell.

A double-layer cushioning structure and a preparation process thereof, relating to technical field of packaging products. It includes a buffer cover. Hollow double-wall structure in buffer cover play a good buffer role, when an outer wall is deformed inwards by impact of external force, reactive force will offset impact of external force to achieve buffer effect; first reinforcing ribs and second reinforcing ribs strengthens strength of inner and outer walls, thereby reducing wall thickness, softening product, and saving processing materials; first connecting holes, second connecting holes, and support holes between inner and outer walls can better support inner and outer walls, and longitudinally strengthen buffer cover, and further ensure overall structural strength of buffer cover; soft material is provided on a wall surface of a product protection groove, to further soften wall surface in contact with the product to protect surface of product from being scratched.

The present invention is directed to a 3D printed mold for creating three dimensional pulp products from a fibrous pulp slurry. Transverse filaments are integrated into an infill structure with an open-cell pattern. The transverse filaments form channels through the interior matrix of the mold. The open cell infill pattern and channels allow for the movement of vacuumed materials through the interior matrix of the 3D printed mold when vacuum pressure is applied. The product surface of the mold comprises an array of beads formed from the over-extrusion of melted material at the ends of the transverse filaments. The beaded array narrows the opening of the channels created by the transverse filaments, preventing the fibers from entering the matrix of the mold and clogging the flow of materials. This causes the fibers to aggregate on the product surface of the mold, forming the three dimensional pulp product.

A honeycomb structure having a core made up of a plurality of corrugated sheets which are superposed and adhesively bonded together is described. The corrugated sheets are made from a thermally insulating material. Bear filaments are made up of thermally conductive filaments. The honeycomb structure can be used when the ambient temperature exceeds, for example, 120 C.

A thermoplastic folded honeycomb structure is described which is produced from a material by plastic deformation perpendicular to the plane of the material to thereby form half-hexagonal cell walls and small connection areas. The cell walls in L-direction of the honeycomb core have a wavy shape with an amplitude of about 10% of the cell wall length. A zero slope of the wavy shape at the cell wall connections allows an optimal shear load transfer between the cell walls. By folding in the direction of conveyance the wavy cell walls meet to thereby form the honeycomb structure.