Provided is a method for producing a packing sheet with improved insulation and storage properties, which can greatly reduce logistics costs by minimizing a volume during storage and transportation and also greatly increase insulation.

A system for producing a multiple layer material (49), comprising first and second corrugation rolls (14, 15) for providing a corrugated profile (16) having a plurality of crests (47), wherein the system further comprises first and second press rolls (21, 22) for applying a material sheet (19, 20) to crests (47) of the corrugated profile (16), and a plurality of heating members (28) arranged between the press rolls (21, 22) for welding the material sheet (19, 20) to the crests (47) of the corrugated profile (16) to form the multiple layer material (49). A guiding plate (48) is arranged between the corrugation 10 rolls (14, 15) and the heating members (28). The guiding plate (16) is arranged with a profile engaging side (50) having a plurality of crests (52) corresponding to the crests (47) of the corrugated profile (16). A cooling arrangement is provided for cooling the guiding plate (48). A method for producing the multiple layer material (49) is also disclosed.

Fluted core sandwich panels are joined together to form a composite structure. Variations in panel ends are accommodated by a core stiffener insert installed in a joint between ends of the panels.

A non-continuously laminated structure of thermoplastic films comprises thermoplastic films with differing material compositions and differing functional benefits. In particular, one or more embodiments comprise thermoplastic films that are co-extruded separately and then combined together by a post-extrusion bonding process. The differing composition of the various films of the non-continuously laminated structure of thermoplastic films and the post-extrusion bonding process, provide the structures with the functional benefits of the individual films.

A fiber reinforced composite material structure comprises a thin sheet that includes a first surface and a plurality of convex portions which protrude and are regularly arranged on the first surface and each of which includes a top face; and a surface material that includes a second surface and is bonded to the top faces on the second surface.

An automated system and method are disclosed for producing an inflatable product having a first sheet, a second sheet, and a plurality of tensioning structures between the first and second sheets. The system includes an upstream tensioning structure production subsystem that produces the tensioning structures and a downstream preassembly production subsystem that couples the tensioning structures to the first and second sheets. The subsystems may operate simultaneously to produce the inflatable product in an automated, efficient, and repeatable manner.

Multi-layer bags may be formed to include first and second sidewalls joined along a first side edge, an opposite second side edge, and a closed bottom edge. The first and second layers may be non-continuously laminated together in discrete sections to include bonded regions in which the layers are bonded and unbonded regions in which the layers are not bonded. Such a bag may be described as a bag-in-a-bag type configuration in which the inner bag is non-continuously bonded to the outer bag. The inventors have surprisingly found that such configurations of non-continuous bonding provides increased and unexpected strength properties to the multi-layer films and bags.

The present disclosure encompasses three-dimensional articles comprising flexible composite materials and methods of manufacturing said three-dimensional articles. More particularly, the present system relates to methods for manufacturing seamless three dimensional-shaped articles usable for such finished products as airbags/inflatable structures, bags, shoes, and similar three-dimensional products. A preferred manufacturing process combines composite molding methods with specific precursor materials to form flexible fiber-reinforced continuous shaped articles.

An article of manufacture that has at least three layers of heat sealable material. There is at least one first heat seal between at least two of the layers in a first area effected at a first temperature. There is also at least one second heat seal between at least two more layers, where at least one of these two layers is distinct from the at least two layers joined by the first heat seal, in a second area effected at a second temperature, where the second temperature is different than the first temperature, thereby allowing for heat sealing of discrete areas of the article in discrete steps.

Tip bonded formed laminates, and methods for making tip bonded formed laminates, are made from multiple layers of formed substrates made from films which are bonded together at the tips of their formed protrusions. Tip bonded laminates can be designed with greater resistance to bending, improved resilience to compression, and can be patterned for directionally oriented responses to tensile loads. Also, tip bonded formed laminates made from multiple layers of formed substrates can use their layered structure to provide better aesthetics as well as better physical properties such as improved puncture resistance. Tip bonded formed laminates can be configured with thicker portions and designed patterns, which are appealing to consumers. A tip bonded formed laminate can be made from two or more formed substrates and can be used instead of a single, thick, unformed, substrate, so the laminate can use about the same amount of material, while still providing surprising functional benefits. Tip bonded formed laminates can provide these benefits without relying on more expensive polymers and/or high concentrations of additives and offer significant improvements at a reasonable cost, when compared with unformed, single layer substrates.