Disclosed are a honeycomb cell shock-protection paper pad structure, and a fabrication method and a fabrication apparatus, for overcoming springing back of a stretched honeycomb cell paper shock-protection pad. The honeycomb shock-protection paper pad structure includes paper strips that have an unconnected site of which upper and lower ends are formed with folded-edge bend portions and a connected site that is formed with a central bend portion. A shape-fixing method includes stretching a cellular-form shock-protection paper pad for extension, bending upper and lower ends of the paper strips of the stretched honeycomb cell shock-protection paper pad toward one side, and conducting shape-fixing rolling with paired rollers. A shape-fixing apparatus includes a chassis portion, an edge scraper portion including flexible upper and lower scraper blades mounted obliquely on the chassis portion, and a shape-fixing roller portion including rigid shaping paired roller mounted on the chassis portion.

The present invention discloses a method of producing at least a pair of interlocking adjacent layers of a paper packaging product, the pair of interlocking adjacent layers being formed of a sheet of slit paper having a slit pattern, the slit pattern upon expansion, forming cells that include land regions that are inclined with respect to a plane of an unexpanded sheet. The method comprises slitting the sheet of slit paper with beveled blades that have a first wedge angle on one side of the blades and a second wedge angle on the other side of the blades, wherein the first wedge angle is wider than the second wedge angle to produce slits that upon expansion, produce the lands regions that have angles of inclination in a range for 50 to 85 degrees.

The present invention discloses a method of producing at least a pair of interlocking adjacent layers of a paper packaging product, the pair of interlocking adjacent layers being formed of a sheet of slit paper having a slit pattern, the slit pattern upon expansion, forming cells that include land regions that are inclined with respect to a plane of an unexpanded sheet. The method comprises slitting the sheet of slit paper with beveled blades that have a first wedge angle on one side of the blades and a second wedge angle on the other side of the blades, wherein the first wedge angle is wider than the second wedge angle to produce slits that upon expansion, produce the lands regions that have angles of inclination in a range for 50 to 85 degrees.

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.

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.

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.

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.

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.

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.

Disclosed are a honeycomb cell shock-protection paper pad structure, and a fabrication method and a fabrication apparatus, for overcoming springing back of a stretched honeycomb cell paper shock-protection pad. The honeycomb shock-protection paper pad structure includes paper strips that have an unconnected site of which upper and lower ends are formed with folded-edge bend portions and a connected site that is formed with a central bend portion. A shape-fixing method includes stretching a cellular-form shock-protection paper pad for extension, bending upper and lower ends of the paper strips of the stretched honeycomb cell shock-protection paper pad toward one side, and conducting shape-fixing rolling with paired rollers. A shape-fixing apparatus includes a chassis portion, an edge scraper portion including flexible upper and lower scraper blades mounted obliquely on the chassis portion, and a shape-fixing roller portion including rigid shaping paired roller mounted on the chassis portion.