An extensible slit sheet paper product is produced having an expandable slit pattern that forms open cells upon expansion of the paper product. The paper product is an extensible paper having an extensibility in the range from 1-9% in the machine direction and 1-5% in the cross direction. The expansion produces an array of hexagonal cells. The expanded extensible paper can be used to wrap an object for shipping by wrapping and cushioning the object in the expanded slit sheet material. The extensible, expandable slit sheet paper can be wrapped around itself to produce a void fill product.

A method of manufacturing a composite core can include: wrapping a mandrel in a mandrel wrapping process by securing a mandrel with a winding jig; orienting the composite material at a wrap angle to the mandrel; and depositing the composite material around a circumference of the mandrel. The method can further include assembling the wrapped mandrels in a tool and applying a pressure to the composite material during a curing cycle.

A cellular structure includes a plurality of walls extending in a longitudinal direction and forming a plurality of cells adjacently arranged along a laterally extending plane. Each cell has a cross-section along the plane that includes fourteen sides formed by the plurality of walls. The fourteen sides of each cell are joined to each other to form a closed loop and six outward extending protrusions.

A cellular structure includes a plurality of walls extending in a longitudinal direction and forming a plurality of cells adjacently arranged along a laterally extending plane. Each cell has a cross-section along the plane that includes eighteen sides formed by the plurality of walls. The eighteen sides of each cell are joined to each other to form a closed loop and six outward extending lobes.

A cellular structure includes a plurality of walls extending in a longitudinal direction and forming a plurality of cells adjacently arranged along a laterally extending plane. Each cell has a cross-section along the plane that includes eighteen sides formed by the plurality of walls. The eighteen sides of each cell are joined to each other to form a closed loop and eight outward extending protrusions.

An intercellular structure and a battery module including the intercellular structure, and a method of assembling the battery module are provided. The intercellular structure includes a honeycomb structure including a plurality of hexagonal cells. Each of the plurality of hexagonal cells has an open-ended top and an open-ended bottom and is configured to be arranged around a middle section of one of a plurality of battery cells. The battery module includes a plurality of battery cells arranged in a predetermined pattern and the honeycomb structure including the plurality of hexagonal cells.

In the preferred embodiments, the present invention provides substantially improved slit sheet cushioning products by advantageously combining novel paper properties with novel slit patterns for improved features and characteristics. In some illustrative and non-limiting example embodiments, cushioning products of the present invention can include, e.g., a novel slit sheet material in combination with extensible paper employed as, e.g., a cushioning pad or as cushioning within an envelope product, wherein the cushioning product can be substantially more resilient, but, yet, e.g., thinner for better utilization of space.

A honeycomb for curved surface lightweight components includes a plurality of elongate ribbons and connecting regions. The connecting regions are provided, respectively, between opposing ribbons to connect the ribbons together in a portion-wise manner in a firmly bonded relationship in a transverse direction. The connecting regions are arranged at regular spacings along the longitudinal direction of a ribbon. Honeycomb-like cells form cavities between the ribbons. With respect to three successive ribbons, a displacement of the connecting regions between first and second ribbons relative to the connecting regions between second and third ribbons toward a first side of the longitudinal direction is lesser than toward a second side of the longitudinal direction. Consequently, at least a part of the cells in cross-section in the longitudinal direction/transverse direction plane have at least one longer limb corresponding to the greater displacement and at least one shorter limb corresponding to the lesser displacement.

A coating device for coating composite cellulose honeycomb support parts (1) each having a multiplicity of channels (5, 6) extending in an axial direction with an impregnation coating to increase fire, water-resistance and/or mechanical stability of the support parts (1). A conveyor (8) transports the support parts (1) in a conveying direction along a filling station (9) configured to pour impregnation agent (12) from above into the channels (5, 6), and damming agents (16) are configured such that the impregnation agent (12) is prevented or at least delayed from draining downwards out of the channels (5, 6) such that the impregnation agent (12) builds up in the channels (5, 6). An emptying station (19) is arranged downstream of the filling station (9) in the conveying direction, at which emptying station excess impregnation agent (12) drains out of the channels (5, 6) in the composite cellulose honeycomb support parts (1). A corresponding process is also disclosed.

A coating device for coating composite cellulose honeycomb support parts (1) each having a multiplicity of channels (5, 6) extending in an axial direction with an impregnation coating to increase fire, water-resistance and/or mechanical stability of the support parts (1). A conveyor (8) transports the support parts (1) in a conveying direction along a filling station (9) configured to pour impregnation agent (12) from above into the channels (5, 6), and damming agents (16) are configured such that the impregnation agent (12) is prevented or at least delayed from draining downwards out of the channels (5, 6) such that the impregnation agent (12) builds up in the channels (5, 6). An emptying station (19) is arranged downstream of the filling station (9) in the conveying direction, at which emptying station excess impregnation agent (12) drains out of the channels (5, 6) in the composite cellulose honeycomb support parts (1). A corresponding process is also disclosed.