A method of anchoring a connector in a first object includes providing the connector, the connector having a liquefiable material that is liquefiable by mechanical vibration, such as a thermoplastic material, bringing the connector into contact with low density layer that has an arrangement of discrete elements and gas-filled (empty) spaces between the discrete elements, pressing the connector against the low density layer and coupling mechanical vibration energy into the connector to cause the connector to penetrate into the low density layer to deform the discrete elements, until a flow portion of the liquefiable material becomes flowable and is caused to interpenetrate spaces between the deformed discrete elements so that an intertwined structure of the liquefiable material and the deformed discrete elements results, and stopping the mechanical vibration energy and causing the flow portion to re-solidify to anchor the connector in the low density layer.

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.

Methods and related structures to splice two sizes of cores in a manner to directly interface the facets of the cells and avoid the common practice of using fillers, casting materials, and expanding adhesives is useful to optimize the specific strength of the design and minimize the weight while maximizing the load carrying capability of the structure and to allow the core to vent moisture and other gasses.

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 method of anchoring a connector in a first object includes providing the connector, the connector having a liquefiable material that is liquefiable by mechanical vibration, such as a thermoplastic material, bringing the connector into contact with low density layer that has an arrangement of discrete elements and gas-filled (empty) spaces between the discrete elements, pressing the connector against the low density layer and coupling mechanical vibration energy into the connector to cause the connector to penetrate into the low density layer to deform the discrete elements, until a flow portion of the liquefiable material becomes flowable and is caused to interpenetrate spaces between the deformed discrete elements so that an intertwined structure of the liquefiable material and the deformed discrete elements results, and stopping the mechanical vibration energy and causing the flow portion to re-solidify to anchor the connector in the low density layer.

A method of forming a thermoplastic cellular structure includes positioning a lower surface of a trough of a first corrugated thermoplastic sheet against an upper surface of a crest of a second corrugated thermoplastic sheet; positioning a support against a lower surface of the crest of the second corrugated thermoplastic sheet; and pressing a thermoplastic welding element against an upper surface of the trough of the first corrugated thermoplastic sheet so that at least a portion of the lower surface of the trough of the first corrugated thermoplastic sheet melts and bonds to at least a portion of the upper surface of the crest of the second corrugated thermoplastic sheet.

The invention describes a device and method for making corrugated products. The device can be used with any substrate and includes, at least, first and second drive rollers for driving a middle substrate and a single wall corrugated product. In other embodiments the invention includes upper drive rollers, lower drive rollers and middle drive rollers for driving an upper substrate, a lower substrate and a middle substrate. The middle substrate is driven between the upper and lower substrates at a higher velocity to form flutes that are anchored between the upper an lower substrates thereby forming a corrugated product. The invention also provides for customized corrugated products having multiple fluted substrates in various desirable arrangements. Examples of such products include mattress, partition panels, other furniture and construction products.