MXPA94004044A - Pretensed panal, method and apartment - Google Patents

Abstract

The present invention relates to an elastic prestressed honeycomb structure comprising a honeycomb core including a plurality of splice partition walls and opposite hollow cell faces defining flat surfaces and a front sheet secured to one of the flat surfaces, at least one of the flat surfaces is deformed by compression to a predetermined depth to provide a substantially continuous cushioned front portion so that the padded front portion is sufficiently resilient to substantially cushion all surfaces of a body in contact therewith substantially uniform characterized in that the partition walls or the front sheet is permeable to air to allow the flow of air through it when one of the flat surfaces is deformed by compression

Description

PRESSED PANTHEON, METHOD AND APPARATUS Messrs. ROBERT E. JAEGERS, REUBEN C. CARDER, WILLIA B. WOODWARD, JR., ROBERT R. REED, of United States nationality residing respectively at 1302 Marble Hill Drive, Lake Zurich city, State of Illinois, - 302 Main Street, Michigan City, State of Indiana; 4852 East San Jacinto, City of Fallbrook, State of California; and 29 North Orchard Street, city of Wallingford, State of Connecticut, all in the United States of North America, inventors, cede, sell and transfer to HEXACOM CORPORATION, American company, with address at 75 Tri State International, Suite 200, city of Lincolnshire , State of Illinois, United States of America, United States of America, all rights to the invention described below: SUMMARY OF THE INVENTION A resilient pretensioned honeycomb structure describes, where at least one of its planar surfaces is defined. it is supported on its lateral length, substantially deforming continuously under compression at a preselected depth. A one-step method for simultaneously cutting and forming a cord structure for pretension paper and its apparatus is also described. Also disclosed is a method for forming an improved resilient prestressed paper honeycomb structure and its apparatus. A preferred embodiment of the honeycomb structure for resilient pre-stressed paper is sufficiently strong and lightweight to be used for use as an interior package, to provide cushioning protection for articles having an interior fragility factor rating of approximately 85 G against multiple impacts. In another embodiment, the core or front sheet of the resilient prestressed corduroy structure is perforated to allow flow of through air when the planar surface is deformed. RELATED APPLICATION This related request corresponds to a continuation-part of the patent application of the US. No. d Series 070,097 filed May 28, 1993. TECHNICAL FIELD This invention relates to a prestressed cord structure, to a method and apparatus for forming this prestressed honeycomb structure and article manufacture from this prestressed honeycomb structure, and in particular to a prestressed paper honeycomb structure, having at least one substantially continuous resilient padded car. BACKGROUND OF THE INVENTION One of the areas of increased public concern and serious is the disposal of solid waste in the environment. Contributing to this waste concern is the increasing amount of disposable packaging materials, particularly plastic packaging materials. A large part of solid waste consists of plastic packing, about one third of the cushioning materials used to support and protect relatively fragile contents. One of the most common of these is expanded polystyrene. There are numerous items that are not self-supporting or require adequate cushioning support of contours, bord and projecting surfaces, to prevent damage and breakage p lateral movement of external compression and therefore loss This need is particularly great to avoid breakage loss of displacement of instruments electronic, vidri porcelain and other similar items relatively delicate transit or moving. Consequently, many manufacturers look for environmentally friendly replacements, however cheap, that are alternatives to plastic in interior packing areas, in particular. There is also a continuing need for a lightweight, yet strong materi, suitable for filling space hue around a contained article and for padding the article against damage during storage during shipment. This need has been covered to a certain extent by plastic cushioning materials, such as moldable polyethylene copolymer, expanded polystyrene polystyrene foams, styrene acrylonitrile and polyurethane, packaging polyethylene air bubbles, "popcorn" and "peanuts" polystyrene and cushioning materials based on celluloses such as curled or coiled chips, popcorn, shredded or corrugated folded paper and kraft honeycomb structures. However, many of the cushioning materials are not recyclable or even if they are recyclable, they tend to be expensive and lack the combined lightness, strength and rigidity, which are provided by a paper honeycomb structure. Due to its enormous resistance of support and durability and combination with its lightness, low cost and recyclability, and structure of paper honeycomb, for a long time it has been used convenient way for handling and protective packaging materials. Paper honeycomb structures, typically made from Kraft, can distribute the weight homogeneously to support static loads of up to approximately 5,448 (12,000 pounds) and dynamic loads to approximately 1,36 kg (3,000 pounds). Specifically, a paper honeycomb structure provides a lower cost, thicker protective reinforcement material, with superior strength than that provided by corrugated structures, made from comparable Kraft. The term "corrugated" is intended to refer to the well-known reinforcing material consisting of a series of parallel elongated ridges, commonly referred to as grooves, to which interior and exterior paper coatings are typically held. More importantly, a honeycomb structure is also a recyclable item and in this way is a convenient, environmentally friendly, economical, light and strong alternative to plastic. In particular, the hollow fills and the interi packaging to protect relatively delicate products, typically having a brittleness that requires moderate protection with approximately a peak deceleration of 40 to about 8 (g) should conveniently cushion against damage or rupture for multiple impacts. However, while bideodegradable material, including conventional pap honeycomb structures, generally offer adequate support protection against a single impact, they show limited protection against multiple impacts. For example, as a cushioning material, a conventional paper honeycomb structure ordinarily offers adequate protection in general with simple impacts at moderate levels of protection, but shock absorbing characteristics for multiple impacts require more weight and more bulk than polymeric cushioning materials. . In this way, there is still a need for protective, economical, resilient inner packaging material which can cushion against multiple impacts, however, preference is as strong, light, economical and recyclable as the paper honeycomb structure. The resilient pretension honeycomb structure prepared by the method and apparatus of the present invention meets these needs.

BRIEF DESCRIPTION OF THE INVENTION The present invention relates to a resilient prestressed honeycomb structure comprising hollow cellular fronts defining planar surfaces, wherein at least one substantially planar surface is substantially laterally cushioned to a predetermined depth. Also described is the one-stage method and a first apparatus for simultaneously cutting and forming a resilient pre-stressed paper honeycomb structure in accordance with this invention. In addition, a second apparatus for deforming the planar surface in an incrementally lateral manner to form a resilient prestressed pap honeycomb structure is described. The terms "resilient prestressed honeycomb structure and" pre-stressed honeycomb "are used interchangeably herein to define a paper honeycomb structure, wherein one of the faces of hollow cells has been substantially continuously deformed over its lateral length to a lateral depth at a predetermined depth under the compression conditions described herein, to provide it with a resilient prestressed cushioned frent portion The cushioned front portion of the resilient prestressed paper honeycomb structure mode, surprisingly increases the shock absorbency to multiple impact and also reduces the amount of weight and volume of the honeycomb structure ordinarily required for a given level of protection rating even against simple impacts.Another, the prestressed honeycomb retains the convenient benefits of strength, durability and economics and recyclability associated with the honeycomb structures The resilient prestressed paper honeycomb structures can advantageously be prepared from conventional paper structures which have been conditioned prior to prestressing by the method and apparatus described herein. In a preferred method of the embodiment, the resilient prestressed paper honeycomb structure is formed by prime exposing a conventional paper honeycomb structure of preselected thickness and length to a humidification or drying conditioning environment, for a sufficient period to condition the honeycomb structure of paper. Briefly described, the paper honeycomb structure is conditioned to a predetermined moisture level at which the paper honeycomb deems compressible, yet substantially rigid and structurally sound. The conditioned paper honeycomb is then removed from the conditioning environment and subsequently, in one step can use one of the described apparatuses, be cut simultaneously to a predetermined size and shape and deformed in substantially continuous lateral form, onto one of the planar surfaces of their cellular faces hollow to a predetermined depth to form the prestressed cushioning front portion. In alternate form, the paper honeycomb can be deformed incrementally laterally, first using the other described apparatus then cut to a predetermined size or cut first and then be reformed laterally in an increased manner. By releasing the compression, the prestressed frent portion retains sufficient memory to substantially uniformly pad all the surfaces of a body in contact with it. The surfaces of a body can be an exterior surface of an article or the walls of boxes, such as a shipping and storage box. The term "memory" as used herein, refers to the capacity of the padded frent portion of the prestressed honeycomb structure to partially recover from the depth at which it was deformed. In various preferred embodiments, the resilient prestressed paper honeycomb structure may include a paper face sheet, subject to one or both of its padded frent portions either before or after pretensioning by the method described. In another embodiment, the front sheet or the dividing walls of the honeycomb core comprising the corduroy structure can be air permeable, such as in forming perforation to allow air flow through the front sheet dividing walls, when the honeycomb structure is comprehensively deformed. Additionally, pre-tensioned honeycomb cushions with variable thicknesses, which have been prestressed at an equal or drent depth, can be combined with internally adjustable packages, which are environmentally friendly. The resilient prestressed honeycomb structure described offers the benefit of a lightweight material, yet strong enough to effectively accommodate multiple impacts. Another benefit is that the honeycomb structure of resilient pretension paper is recyclable and economical. In this way it offers the advantages of improved packaging protection and reduced size, resulting in savings in storage area and lower packaging cost combined with an environmentally friendly recyclable package. BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings, which form a portion this description: Figure 1 is a perspective view of a conditioned paper honeycomb structure, in the form of a cushion having a front face illustrated before compressively pretensionars to a resilient honeycomb structure mode according to the method of this invention. Figure IB is a perspective view of the cushioned front portion of the resilient pretension honeycomb mode, which is formed from the cushion illustrated in FIG. Figure 2A is a perspective view of a partial section of another perforated and conditioned honeycomb structure, the shape of a block having two facing sheets opposite to that illustrated before being comprehensively pretensioned to the resilient honeycomb structure embodiment; according to the method of this invention. Figure 2B is a perspective view of a partial cutaway of the cushioned front portion of the resilient pretensioned pan mode, which is formed from the perforated block illustrated in Figure 2A. Figure 3 is a perspective view of a die cut press used to practice an apparatus mode of the present invention. Figure 4 is a perspective view of a die cutting tool used to practice the embodiment of the apparatus illustrated in Figure 3. Figure 5 is a side view of the die cutting tool embodiment illustrated in Figure 4, cuts through a honeycomb structure conditioned. Figure 6 is a side view of the conditioned honeycomb structure seen in Figure 5 prestressed to form a cushioned front portion; Figure 7 is a perspective view of an apparatus modality of the present invention; Figure 8 is a side elevation view of the back of the apparatus mode illustrated in Figure 7; Figure 9 is a side elevational view of the front of the apparatus illustrated in Figure 7, showing a honeycomb structure, vertical cross section, laterally deformed incrementally. Figure 10A is a side view of another honeycomb structure of paper conditioned in the form of a panel having sheets of opposite faces illustrated before being prestressed in a manner compliant to a resilient cord structure embodiment, in accordance with the method of this invention; Figure 10B is a side view of the pre-stressed honeycomb mode that is formed from the panel illustrated in Figure 10A. Figure HA is an exploded elevation view of an inner packing mode illustrated as a multi-piece assembly of prestressed, resilient, pre-tensioned honeycomb cushions that are formed and pretensioned to different depths according to the method and the apparatus. of this invention. Figure 11B is a perspective view of a pre-stressed honeycomb preform embodiment that has been slotted with notches at two sites for use in another embodiment of the inner package mounting cushion illustrated in Figure HA; Figure 11C is a perspective view of a pre-stressed honeycomb preform embodiment which has been slotted with notches at three sites for use in another embodiment of the inner package mounting cushion illustrated in Figure HA. DESCRIPTION OF THE PREFERRED MODALITIES For convenience, the terms "resilient prestressed bread structure" and "pre-stressed honeycomb" will be used interchangeably to refer to paper honeycomb structures where the planar surface of one of the hollow cell faces has deformed into substantially continuous shape on its lateral length at a predetermined depth, under the compressive condition described herein to provide a preselected resilient cushion face portion. The terms "paper honeycomb structure" and "honeycomb core" as used herein in their commonly understood meaning refer to a network of oval or generally hexagonal cells typically supported by adhesive or laminated to a high-strength, thin-skinned brake foil. two front leaves of the thin resistance. The honeycomb core is a three-dimensional network formed by a plurality of confining partition walls disposed in the configuration of a general or oval honeycomb pattern, to define a planar surface that comprises hollow cell faces. Paper honeycomb structures are commercially available in different cell sizes from cores. For packaging cushion materials, the useful cell widths may vary from about 0.6 (about 0.25 inch) to about 2.5 (about 1 inch) and the useful thickness may vary from about 0.6 cm (about 0.25 inch) to about 6.25 cm (about 4 inches) but they are not limited to them. It is recognized that paper honeycomb structures having cell width and thickness that are larger smaller may be employed and still fall within the scope of this invention, provided that the honeycomb structure can form pre-stressed honeycomb, which is described. Typically, dividing walls of the bread core are constructed from paper, such as kraft does not bleach other types of paper and cardboard, including recycled fibers may be employed without departing from the intended scope of the invention. Additionally, the hollow cells can be impregnated with resin to impart water resistance and other materials such as plastic films can also be used as desired. As will be appreciated the width of the cells, height of the dividing walls or the weight of the kraft can all be varied to impart various desired honeycomb material characteristics. Typically, at least one front sheet covers one of the hollow cell faces of a paper honeycomb structure, but is not essential for the practice of this invention. These front sheets are also preferably made from kraf although other materials such as plastic films , aluminum and similar, may be employees.

In one embodiment of the preferred method, the resilient prestressed honeycomb structure is prepared from its conditioned paper bread net. A conventional paper honeycomb structure of preselected length and thickness is first conditioned by exposing it to an environment having a predetermined relative ambient and humidity temperature. This exposure is maintained for a sufficient period to dry or humidify the paper bread structure at a predetermined moisture level. Depending on the weight of kraft, a moisture level is chosen at which conditioned paper structure is judged flexible enough to be laterally compressible on the planar surface of at least its hollow cell faces, however substantially strong in structural sense. For simplicity the term "conditioned honeycomb" will be used below to refer to this honeycomb structure whether or not it includes front leaflets. In practice, a useful preferred conditioning environment is found to have a room temperature from about 25 ° C (about 85 ° F) about 35 ° C (about 95 ° F) and relative humidity from about 35 to about 65 %. Useful humidity level for the conditioned honeycomb is preferably 4% to less than about 8%, m preferably about 5% to about 7%.

The conditioned honeycomb is then removed from the conditioning environment and then cut and tensioned preferably in a step to a predetermined size and shape to provide it with a resilient pre-stressed conditioned front portion, the cutting and tensioning being performed in separate operation, preferably the The conditioned honeycomb was pretensioned within several hours, more preferably in about one hour, of being removed from the conditioning environment. As the conditioned honeycomb is cut, it deforms simultaneously substantially continuously in lateral sense over the length of the planar surface of one of the hollow cell faces. The deformation is achieved by compressing selected planar surface of the honeycomb conditioned at a predetermined depth with an apparatus having a means for simultaneously cutting and compressing the conditioned honeycomb. The compression is then released and the resulting resilient pretensioned honeycomb is removed. In practice, it was found that by releasing compression, the pretensioned face or front portion of the pan retrieves approximately half of its memory to achieve desired thickness, such that the depth of the compression can easily be determined by the desired thickness of the pre-tensioned pan. . For example, to obtain a pre-stressed honeycomb having a thickness of about 7.5 cm (about one inch), a conditioned honeycomb structure having an approximate thickness of about 10 cm (about 4 inches) compressively deforms to about half the original thickness. Any reference to the thickness of the pretensioned honeycomb present, therefore refers to its thickness after it releases the compression. In practice, it was found that compressive deformation of a honeycomb conditioned to approximately half its original thickness produces a fully deformed bread core with a substantially deformed portion. This type of honeycomb core will be referred to here as a "fully cushioned honeycomb". It was also found that compressive deformation of a honeycomb conditioned to less than about half its original thickness provides a partially deformed honeycomb core and surprisingly the honeycomb core portion that remains un-cushioned substantially retains stiffness and strength. The term "partially cushioned bread" is used herein to describe a pre-tensioned honeycomb core having a front facing portion cushioning one of its planar surfaces and a portion that does not cushion opposite. With reference to Figures IA and IB, a conditioned bread cushion 10, having a front sheet 12, is illustrated before and after being formed in the pretensioned honeycomb 20. The bread 10 includes a honeycomb core 15 comprising confining separation walls. 17 that form hexagonal cells 14.

In this embodiment, the cushioned frontal portion 22 can be obtained by partially compressing the conditioned honeycomb 10 to an approximate thickness of three quarters of its original thickness. For example, a conditioned honeycomb cushion that has an initial thickness of about 10 centimeters (approximately 4 inches) is formed into a pre-stretched honeycomb cushion about 7 centimeters (3 inches) thick, for convenience and not in any way limitation. , honeycomb conditioned in Figure IA, is illustrated to have hexagonal confining cells 14, each having a substantially uniform wall height and width, to uniformly distribute any load applied laterally to the faces of continuous hollow cells. honeycomb, the resistance q is provided by the dividing walls, resists compression up to a predetermined limit of pressure, which is determined p the dimensions of hollow cells and the weight of the applied load The application of the force of a predetermined magnitude greater the front of conditioned honeycomb structure, however will result in the compression and formation of the inner hollow cells to form A front portion conditions pre-tensioned. For use as an indoor packing modality, a cell width of about 2.5 cm (about 1 inch), preferably about 1.9 cm (about 0.75 inch) or less, is typically desirable, but not limited thereto. Turning to Figures 2A and 2B, another conditioned bread structure 110, is illustrated in the form of a block having two opposite facing sheets 112, 116, before and after it constitutes in the pretensioned honeycomb 120. The bread structure 110, like structure 10, includes a honeycomb core 115 q comprises confining partition walls 117 that form hexagonal cells 114. In this embodiment, the resilient cushion portion 122 can be obtained by partially compressing conditioned honeycomb structure 110 to an approximate thickness of two. thirds of its original thickness. For example, a conditioned honeycomb block having an initial thickness of approximately 7 centimeters (approximately 3 inches) is formed in a pre-tensioned honeycomb block of approximately 6 centimeter (approximately 2 inches). In this embodiment, the partition walls 117 and the front sheets 112 and 116 may include perforations 118 to allow air trapped in the cells 114 to permeate through the perforations 118 when the honeycomb structure 110 compresses. The perforations 118 allow the relief of accumulation of air pressure, which occurs during compression that has sometimes been known to cause the rupture of any of the walls 117, the front sheets 112 and 116 both during compression.

Preferably, each of the perforations 118 approximately 0.31 cm (approximately 0.125 inch) diameter. Preferably the partition walls 117 of the numeral 115 include a plurality of rows and perforation columns 118. Preferably, the perforations 118 in each of the columns are generally aligned vertically with each other and are spaced approximately 2.5 centimeters (1 inch) apart. In the embodiment of Figure 2A, each of the columns includes three arranged vertical perforations 118, since the honeycomb core 115 has a thickness of 7.5 centimeters (3 inches) preferably, the perforations 118 in each of the rows generally align horizontal to each other. Although the Figure shows a honeycomb structure 110, wherein each of the division walls 117 includes perforations 118, it is understood that the invention encompasses a honeycomb structure 110, wherein some of the division walls 117 include perforations 11 For example, each sautéed sheet of paper used to form the core can be perforated with the other sheets without perforation. Preferably, the perforations 118 are formed at least in the confined flange partition wall 117. The front sheet 1 includes a plurality of offset or stepped rows and perforation columns 118. The perforations 118 are separated from each other at predetermined distances varying according to the cell size and the honeycomb core 115. PreferablyOne of the perforations 118 is placed in the front sheet 112 such that each is generally centrally aligned with a respective core cell 114 below the front sheet 112. For example, if the honeycomb core is used. with a cell size of 1.25 centimeters (0.5 inch), each of the rows and columns of displacement will include perforations 11 spaced approximately 2.5 centimeters (1 inch) apart For another example, if the core of honeycomb 115 with cell size of 0.9 cm (0.375 inch) is used, each of l rows of displacement and each of the columns will include perforations 118 spaced approximately 1.9 centimeters (0.7 inch) apart. Not only the core and perforated front sheets can be used, but also front and core sheets that are constructed of porous or air permeable paper, can be used. The cutting and compression of the conditioned honeycomb, preference is elaborated in one step by an apparatus mode illustrated as the cutting press with die 130, in Fig. 3, and the mode of the cutting tool with die 14 illustrated in Figs. to 6. The cutting tool c matrix 140 consists of a blade 142 projecting slightly on the compression plate 144, which is mounted on support 150 in the cutting press with die 130. Blade edges such as saws, perforations and the like can be used and the depth of the compression can be varied by placing the distance of the blade edge from the ca of the compression plate 144. A useful press can be a 150 ton punch press. As illustrated in Figures 5 and 6, when die cutting tool 140 is lowered onto a conditioned honeycomb structure 210, the blades 142 cut through its core and any front sheet present and compress in substantially simultaneous laterally over the planar surface of the face in contact with the movement compression plate 144 at the predetermined depth. In this way the pretensioned honeycomb 220 is formed with the resilient cushion front portion 222 and the desired shape is obtained in an etap. Figure 3 illustrates a mode of a complete pretensioned bread panel 220, having multiple cuts 15 made by the apparatus. 130 in a stage. In practice, this stage of prestressing and cutting with a single stage matrix can be carried out in approximately 0.5 second, when a 150 ton punching press is used. The padded front portion 222 obtained can provide substantially uniform shock absorbency for a contact article with additional applied compressive load or impact. Figures 7 to 9 illustrate another apparatus, generally designated 151, for incrementally compressive and lateral deformation of the honeycomb structure, to form a resilient pretensioned honeycomb structure.

With reference to Figures 7 and 8, the apparatus 15 comprises a support frame 152, which includes two elongated and vertical front skids 154, two elongate rear and vertical legs 155 and two horizontal support members 156 and 157 extending transversely between the legs 154 and 155 respectively. A honeycomb conveyor structure 158 secured to the lower portion of the support frame 152 and m particularly to the lower portion of the legs 154 and 155. the conveyor structure 158 includes a pair of reinforcements 159 159a extending the length of the frame support 15 and transversely to the legs 154 and 155. The ends of the reinforcements 159 are attached to the front legs 154, while the ends of the reinforcements 159a are attached to the rear legs 155. A pair of parallel and spaced rollers 161 and 162 extend between and transversely to the reinforcements 159 and 159. A conveyor belt 163 surrounds the rollers 161 and 162. The horizontal support table 169 positioned below the conveyor belt 163 extends longitudinally between the rollers 161 and 162 and transversally through the roller. width of the support frame 152. Each of the rollers 161 and 162 is rotated for rotation in the bearings 167. Each of the rollers 161 and 1 has a sprocket gives impulse 164 at one end. Although illustrated in the figures, it is noted that the driving sprocket 164 on the roller 161 has two parallel tooth assemblies The rollers 161 include another driving sprocket 165 at the same end, including the driving sprocket 164. sprocket The pulse 165 has a larger diameter than the diameter of the driving sprocket 164. An impulse chain 166 surrounds the driving sprockets 164 for connecting the two rollers 161 and 162 to each other, for coupled and simultaneous rotation. A chain drive 168, associated with the drive motor assembly 170, encircles the tooth pulse gear 164 on the roller 161. The drive chain 166 encloses a set of teeth on the drive sprocket 164, while the driver chain 168 surrounds the other set of teeth the driving sprocket 164. According to the invention, pulse motor assembly 170 displaces the chain drive 1 which moves the roller 161, which by the drive chain 1 moves the roller 162 thus causing the rotational movement of the conveyor belt 163. The apparatus 151 further comprises a compression apparatus such as a compression roll frame 172, which includes pair of horizontal reinforcements 174 and 176, which extend by length of the frame support 152 and between legs 154 and 15 respectively. The ends of the reinforcements 174 hold the upper portion of the two front legs 154, while the ends of the reinforcements 176 are fastened to the upper portion of the two rear legs 155. Parallel and spaced compression rollers 177 to 180 are spaced apart. They extend transversely between the reinforcements 174 and 176. Each of the compression rollers 177 to 180 is stacked for rotation on the bearings 182. Furthermore, each of the compression rollers 177 to 180 can be mounted on the reinforcements 174 and 176, for vertically independent adjustable s, to allow the positioning of the compression rollers 177 to 180 at incrementally different heights with respect to the horizontal table 169 and the conveyor 163. The compression roller 177 may include a plurality of needles or pins 181, or other convenient piercing means, which extend radially outwardly from the outer surface, which allows piercing of the front needle 116 for Improve compression. Attached to one end of each of the compression rollers 177 to 180 is a drive sprocket 184. The compression roller 180 includes another drive gear 185 at the same end including the drive sprocket 184. The drive sprocket 185 has a diameter greater than the diameter of the driving sprocket 184. The pulse chain 186 surrounds the driving sprockets 18 thereby connecting the four compression rollers 177 180 together for a coupled and simultaneous rotation. A tension pulley 187 connected to the outer reinforcing surface 176 is operatively associated with the driving sprocket 185 in a compression roll 180. The tension pulley 187 includes the secondary gears 188 and 189, a secondary pivot arm 1 and a secondary spring 191. The gear 188 is connected to the end of the pivot arm 190 and is additionally connected to operatively associated with the spring 191. A chain driver 192 encircles the sprocket 165 of the roller 165 161, the gears 188 and 189 and a portion of the driving sprocket 185 on the compression roller 180. According to the invention, the pulse motor assembly 170 displaces the driving chain drive 168 and chain drive 192 , which by means of the tension pulley 187 displaces the compression roller 180 which, in turn, by means of the impulse chain 186, moves the compression rollers 177 179. A retainer 193 is held in each of the legs 15 and 155. Each end of the reinforcements 174 and 176 are placed within each of the retainers 193 respectively to allow vertical movement of the roller frame 172 with respect to support frame 1 € 2, while at the same time avoiding The horizontal movement of the roller frame 172 relative to the support frame 152. The apparatus 151 further comprises a pair of roller height adjusters 194 and 195. Each of the roller height adjusters 194 and 195 includes first and second collars. 196 and 198 respectively fixed to the horizontal support members 156 and 157 in the support frame 152. Each of the roller height adjusters 194 and 195 also includes first and second vertically extending posts 200 202. posts 200 and 202 extend through first and second collars 196 and 198, respectively. At the extreme end, the posts 200 and 202 are fastened to the reinforcements 174 and 1 respectively. Each of the roller height adjusters 194 195 further includes an elongated and rotatable connector arrow 20 which extends horizontally between and operatively associates c the collars 196 and 198. A manually rotatable wheel or handle 206, is connected to one end of the arrow 204. Manual rotation of the wheels 206, causes rotation of the arrows 204, which causes vertically coupled and simultaneous movement of the posts 200 and 202, which causes the vertical displacement of the roller frame ends 172 at their v. The roller height adjusters 194 and 195 s independently operable to allow independent vertical movement and variant of the roller frame ends 172, such that the roller frame 172 can be angularly displaced with respect to the support frame 15 and the horizontal table 169. The mechanism associated with the collar 196 and 198 and the posts 200 and 202, for converting the rotary movement of the arrows 204 into the vertical movement of the posts 200 and 202, may comprise any convenient mechanism including, but not limited to, the use of a helical gear in the collars 196 and 198, in cooperation with the teeth on the posts 200 and 202. With reference to Figure 9, the apparatus 151, and m particularly the adjustable roller frame 172, allows the increased lateral compression of the honeycomb structure as it is transported further. beyond the compression rollers 177 to 180 to form a pre-tensioned honeycomb structure. The pretensioned honeycomb structure is formed with the apparatus 151 as described below. Initially, the roller frame 172 is positioned at a predetermined height and angle with respect to the support frame 152 and the horizontal table 169. In alternate for, each of the compression rollers 177 to 180 can be adjusted vertically, in such a way that they are placed at altur incrementally different with respect to the horizontal table 17 Subsequently, the honeycomb structure such as the honeycomb structure 110 illustrated in Figure 2A, is placed on the conveyor belt 163 and subsequently transported by the band 1 beyond the compression rollers 177 to 180. Due to the angular displacement of the roller frame 172 or, alternatively, the individual adjustment of the compression means 177 to 180, each of the compression rollers 1 to 180 will be placed at an incrementally different height c with respect to the horizontal table 169 and the planar surface superi of the honeycomb structure 110. As a result, the compression roller 177 compresses the planar surface sup The honeycomb structure at a first depth, while the successive compression rollers 178 to 180 laterally compress the planar surface of the honeycomb structure 110 incrementally greater depths, until the honeycomb structure 110 passes through all the honeycomb rollers. compression 177 180 and honeycomb structure 110 is formed in a pretensioned honeycomb structure such as the pretensioned bread structure 120 illustrated in Figure 2B. The horizontal support table 169 supports and prevents buckling of the pan structure 110 as it is compressed and transported through the apparatus 151 The compression roller 177 not only compresses the honeycomb structure, but preferably also by means of pins or pin 181, performs perforations in the surface of the front sheet 11 of the honeycomb structure as the honeycomb structure transports beyond the compression roller 177. As an example, to form a prestressed bread structure 120 having a thickness of 7.6 cm (3 inches) from a honeycomb structure 110 having a thickness of 8.7 cm (3.5 inches) from the end of the roller frame 17 adjacent to the front legs 154 of the support frame 152 will be placed approximately 6.25 cm (2.5 inches) away from The horizontal table 169 at an angle A of about 20 degrees with respect to the front part 154, such that the planar surface of the honeycomb structure 110 is incrementally deformed. ater to a total depth of about 2.5 cm (1 inch). E alternately, the same increased lateral compression of 2.54 (1 inch) can be achieved by placing the roller frame 17 horizontally at approximately 8.75 cm (3.5 inches) away from the horizontal table 169 and then placing each of the compression rollers 177 to 180 respectively at a distance of approximately 8.12, 7.50. , 6.87, 6.25 cm (3.25, 3.0, 2.75, 2.50 inches away from the horizontal table 169. The apparatus 151 is positioned to deform the honeycomb structure to a depth of 2.54. (1 inch), instead of 1.3 cm (0.5 inch) since a front facing portion recovers approximately half of its memory (i.e. about 1.3 cm (0.5 inch) after compression.) Although the compression rollers 177-180 illustrated in Figures 7 to 9 are mounted on a single integral compression roller frame 172, it is understood that each of the rollers 177 a 180, can be mounted on their own separate compression roller frame and operatively associated with four roller height adjusters respectively, such as the roller adjusters 194 and 195, to be independently adjustable in a vertical direction, to allow placement of the rollers 177 a 180 at different incremental heights with respect to the horizontal table 169 and conveyor 163. The apparatus 151 can be made longer than the one illustrated in Figures 7 to 9, to allow the placement of the rollers 177 to 180 further apart than as shown in FIGS. currently illustrates • further minimizing the possibility of buckling of the honeycomb structure as it is transported through and compresses the apparatus 151. The incremental lateral compression of the honeycomb structure is advantageous because it eliminates homogeneous deformation and damage to the split walls of the honeycomb core, which occasionally results when the planar surface is compressed to a predetermined depth in one step, such as for example in apparatus 130. Incremental compression allows gradual and increased application of pressure to the division walls, thereby minimizing the possibility of inhomogeneous deformation and damage. Furthermore, the incremental application and pressure graduated coupled with the formation of perforations in the front leaf of the honeycomb structure, minimizes the possibility of bursting the dividing walls or the front sheets, which occasionally occurs when the honeycomb structure is compressed. one stage The apparatus 151 can be employed independently of any other apparatus, or alternatively, as a modular addition component to existing lines to constitute the honeycomb structure. In Figures 10A and 10B, the side view of conditioned honeycomb structure 210 is illustrated in the panel form having two front sheets 212, 216 before and after completely cushioning to form pre-stressed honeycomb 220. As previously described, the position of Fully cushioned front 122 can be obtained by compressing the conditioned corduroy structure 210 approximately half of its original thick. For example, a conditioned honeycomb panel having a starting thickness of approximately 7.5 cm (approximately inches) forms a pre-stressed honeycomb panel with approximately 3.8 cm (approximately 1.5 inches). A honeycomb structure, for cushions, panel blocks, can be constituted by any useful bleached or unbleached, new or recycled kraft, and any resistance in weight. For example, a useful front sheet can be made from rated kraft from approximately 11.8 kg of weight (26 pounds) to approximately 40.8 kg (90 pounds) of weight, and its useful cell core can be made of kraft sized approximately 11.8 kg (26 pounds) of weight to approximately 1 kg (42 pounds) of weight. The facing sheets can be fastened on one or both sides by adhesive either before the prestressed stage or to the prestressed honeycomb. Additionally, the planar surface of the resilient cushioned front portion d of the prestressed honeycomb may define an irregular surface, by leaving its honeycomb core without a front, as illustrated in Figures IA and IB. In alternate form, a non-linear planar surface can be defined by compressing the honeycomb structure angularly or by compressing it into variable depths on its lateral axis or by cutting with an additional punch or die cutting, to provide the cushioned front cavities and the hinged sections. To the foregoing, it still falls within the scope of this invention, provided the planar surface includes a partially browned partial front portion. Figures HA, 11B and 11C illustrate an inner packing mode 310, composed of an assembly of four prestressed honeycomb cushions 324, 326, 328 and 330, each formed formed from honeycomb prestressed by the method and apparatus of this invention. By way of illustration and not in limitation form, the inner packing mode 310, adjusts to the measure an article A having a fragility factor q requires moderate protection below a deceleration pi (G) of about 85 G. For example, Precision instruments and electronic equipment typically have to be protected below a G-level rating of less than 40 G, generally referred to as their frailty factor. Most mechanical and electrical equipment have a brittleness factor typically at about 40 G and about 85 G, as discussed in more detail below. For convenience and not by way of limitation, article A as illustrated in Figure HA, in the form of a substantially rectangular product, such as would be found with a laptop. In Figur HA, HB and HC, each of the prestressed bread cushion embodiments, 324, 326, 328 and 330, were prepared from pre-stressed honeycomb preforms, such as 320 and 321, having the two facing sheets. Opposite 312, 316. For example, useful pre-stressed honeycomb preforms, can have elaborate kraft front sheets with approximately 19 kg (42 pounds) of weight with a honeycomb core of approximately 15 kg (33 pounds) kraft weight and a width of cells of approximately 1.2 cm (0. inch). As illustrated in Figures HA, HB and HC, each of the pre-stressed honeycomb cushions can be formed from a conditioned honeycomb preform, which is pre-cut to the desired thickness to the desired thickness, to fit the inner package inside the box C, as described below, is not limited to it. The pretensioned honeycomb cushions 326 and 328 are illustrated in Figure HA, in the form of abutment cushions in the form of each of which a prestressed honeycomb preform, such as the prestressed bread preform, has been individually formed from a preformed honeycomb preform. illustrated in Figure HB. The prestressed bread preform 320 is cut as a substantially oblong rectangular cushion which is partially cushioned to an approximate thickness of three thirds of the original thickness of the conditioned honeycomb, eg approximately 7.5 cm (approximately 3 inches) approximately 5 cm (approximately 2 cm). inches). The length of the preform 320 is chosen such that the partially cushioned ca portion 322 of the stop cushion 326 contacts the upper part T and the upper portion of the left and right rows RS, LS of article A and that of the cushion of the cushion 326. top 328 contacts and protects the bottom B and the lower portion of the left and right sides RS, LS of article A. As illustrated in Figure HB, the prestressed bread preform 320 has been partially cushioned and also notched with grooves in two places through its non-cushioned ca portion to a depth sufficient to create the bisagr 318 (indicated by the dotted horizontal lines) on its padded front portion 322. Hinges 318, preferably located at each end portion for forming the three hinged cushion sections 320A, 320B, and 320C to form a U-shaped buffer cushion suitable for inter-packing 310. The hinges 318 allow each of the cushion sections to be restrained. fold and place around and with your front portion padded 322, in contact with the surface of a structure, such as article A as illustrated in FIG. In this manner, as illustrated in Figure HA, the pre-stressed honeycomb buffer pad 326 comprises the three hinged cushion sections 326a, 326b and 326c of pre-stressed honeycomb, the cushioned fronts of which protect the upper and stage surfaces of the sides of the honeycomb. article A and the prestressed bread stop cushion 328, comprises the three sections of abyssager cushion 328a, 328b and 328c of pre-tensioned honeycomb, the cushioned fronts of which protect the bottom and bottom surfaces of the sides of article A. In a manner of illustration and not limitation, when the inner packing 310 is assembled and housed in the box C (as indicated by the arrow), the stop cushion section 326b contacts the upper part T, the stop cushion section 328b contacts the Bottom B of article A, stop cushion section 326A confined stop cushion section 328a and stop cushion section 326c confines stop cushion section 328c. The prestressed honeycomb buffer pads 324 and 330, s illustrate in FIG. HA in the form of helmet-shaped cushion pads, each of which has similarly formed a prestressed honeycomb preform, such as the preform. prestressed cord 321 illustrated in Figure 11c. For this modality the prestressed honeycomb preform 321 is cut as a substantially rectangular cushion which has been fully cushioned by an approximate thickness of half the original thickness of the conditioned cord, for example approximately 7.5 cm (3 inches to approximately 3.75 cm (1.5 inches The prestressed honeycomb preform 321, as illustrated in Figure HC, is notched with grooves (indicated by solid lines at three locations, at a depth sufficient to form four hinged pre-stressed honeycomb cushion sections 318 321a, 321b and 321c, which can be bent into a shaped hull and the prestressed honeycomb cushion section 32Id, which can be bent to confine against the cushion section 321c, thereby the width and length of the prestressed honeycomb preform 32c choose and notch with slots to provide the helmet-shaped bump cushions 324 and 330, each having cuat cushion sections as illustrated in Figure HA. When the inner package 310 is illustrated in Figure HA, it is fully assembled and the fully cushioned face of the cushion 324a is placed in the box, it protects the upper surface of the front face FF, and that of the cushion 324 protects the upper surface of the rear face RF (not shown from article A, cushion section 324b confines against stop section 326b, both to additionally protect cover T, co to fill hollow space and cap and cushion 324c is confined against cushion section 324d to fill the hollow space in the back and also protects the upper rear face RF. Similarly, the cushioned face of the cushion section 330a, protects the lower surface of the front face and that of the cushion section 330d, protects the bottom surface of the rear face RF (not shown) of article A, the cushion section 330b confines against the stop cushion section 328b tant to fill the hollow space in the bottom as well as protect bottom B while the cushion 330c fills the hollow space and also protects the lower rear face RF, when the inner packing s accommodates the box C.

In this way this modality provides cushion protection against static or dynamic loads applied to each quadrant by a 360 ° arc both vertically and laterally. The shock absorbance of another internal packing modality was examined in a preliminary free fall test. This embodiment comprises a plurality of prestressed honeycomb blocks secured by adhesive, each directly to a surface of a corrugated support structure. The supporting structure was then folded around a laptop (laptop) to which a standard accelerometer was connected. The support structure was bent in order to place substantially all of the surfaces of the contained computer, in contact with the padded front portions of the prestressed honeycomb blocks thereby providing, in effect, an inner packing of the substantially rectangular box, coated with the prestressed bread. This inner packing was then placed in a sealed box. The box was then connected to the dropped test instrument, and subjected to a free fall from a height of approximately 1 meter and the impression of the acceleration waveform was taken. The free fall test was initiated by dropping the box on a their faces, the box then turned and the fall test s repeated on another of their faces. This procedure was carried out using various prestressed honeycomb cushions that incorporate the principles of this invention. The test was carried out at an ambient temperature of approximately 23 ° C and an ambient humidity of approximately 55%. The peak deceleration (G) in grams (g) and duration (D in milliseconds (ms) as measured, was found to be in the ga of approximate G levels of 37 ga less than approximately 80 to a duration of approximately 19 ms a Approximately 2 ms. These preliminary results showed that the properties of impact cushioning of the inner pack made of pre-stressed honeycomb cushions, was sufficient to protect moderately delicate items to delicate ones that have a fragility factor with a rating of less than approximately 8 G. It is well known that moderately delicate electronic items such as television stereo receivers, radios and flexible disk drives have a fragility factor of approximately 60 to 85 G. Delicate items such as aircraft accessories, electric writing machines, cash registers, computer display terminals and printers as well as office equipment, have a factor of fragility d approximately 40 to about 60 G. Figure 12 illustrates another embodiment of internal packaging 410, which is convenient for protecting a computer printer. This embodiment comprises a set of pretensioned honeycomb cushions 420, 422 and 424, but it is not intended to be so limited. The cushion assembly can be prepared from a single prestressed honeycomb preform, having two front leaflets 412 and 416, each with different resistances. For example, the front sheet 412 can be approximately 42 kg pounds kraft and the front sheet 416 can be kraft approximately 11.8 kg (26 pounds) in weight, with kraft cells approximately 11.8 kg (26 pounds) in weight, and an approximate width of 1.25 cm (0.5 inch). As illustrated, the conditioned honeycomb can be pretensioned to approximately 60% of its original thickness ie from an original thickness of approximately 77.5 (approximately 3 inches) to an approximate thickness of 4.4 (approximately 1.75 inches). The three pretensioned honeycomb cushions 420, 422 and 42 can also be cut with a matrix from a simple pre-stressed, cushioned honeycomb preform, by the apparatus method of this invention. The prestressed honeycomb cushion 424 illustrates as a U-shaped base cushion that has been cut matrix, from a pre-stressed honeycomb preform generally rectangular and further notched with slot in two sites to provide hinges 418 in the portion of cushioned front 42 In this manner, the base cushion 424 comprises the three cushion sections, 224a, 424b and 424c, which can be bent to form the U-shaped base cushion 424.

The U-shaped base cushion 424 in this manner accommodated the bottom B of the printer P when it sits in contact with padded front portion 428 of the cushion section 42 (indicated by the arrow). The cushioned front portion 428 the cushion section 424a, and the padded front portion 428 the cushion section 424c, respectively come into contact with the front face FF and the rear face RF of the printer P. The honeycomb cushion patterns prestressed 420 and 42 each provide side stop cushions for the printed P. Both the side stop cushions 424 to 422 can cut with matrix, from the central portion of the prestressed bread preform, which is used to form the cushion base 424. In this embodiment, the side stop cushions 424 to 422 are illustrated as providing cushioning protection at the corners of the front face FF, the sides, and outer portion of the printer cover P when fastened with its portions Padded fren that confine against the printer after it is placed on the base pad 424 as illustrated by the arrows. For example, once the printer P is straddled by the pre-tensioned U-shaped honeycomb pad 42 the outer corners and the side typically extend outwardly from the periphery of the cushion. In this manner, the pretensioned front portion of the pre-tensioned honeycomb stop cushion 4 is placed in contact with the printer P, such that the cushioned front portion 428 of the top cushion section 422A, protects the outer front face FF, the cushioned ac portion 428 of the stop cushion section 422b, protects the outer portion of the upper surface T and the accommodated face portions of the buffer cushion sections 422c, 422d 422e protect the left side portion LS. Similarly, the stop pad 420 is positioned such that the padded face portion 428 of the stop cushion section 420a, protects the opposite outer corner of the printer. In this manner, the padded front portion 428 of the cushion section. of stops 420b, protects the opposite upper outer portion, and the padded front portions of 420c, 42Od 420e, protect the right side RS of printer P. As illustrated, the stop pads 420 and 422 have been matrix cut and hinged to provide 4 vertical cushions and a horizontal cushion. As can be seen, the for the pre-tensioned honeycomb assembly, is not limited and can be modified as desired and falls within the scope of this invention, provided that all the cushions have front portions cushioned and are with the structure to be protected. Shock absorbance of another convenient inner packing mode for similar protection or printer is determined for two units using the free fall test described above. The preliminary results were compared against those obtained for two indoor packing units of similar size expanded polystyrene foam (EPS) subjected to the same test. The resulting multiple impact ratings were as follows for the pre-stressed honeycomb (PH). Face EPS PH Tested Unit 1 Unit 2 Unit 1 Unit 2 Right side 40 36 36 57 Left side 42 39 35 88 Front 60 56 37 49 Back 72 75 57 76 Background 83 98 87 67 Top 98 92 42 94 * Average rating G 66 60.5 Note * The upper corner cushion was twisted. These preliminary results showed that on average the inner package of pre-stressed honeycomb protection of cushioning against multiple impacts, compared with or better inner foam packaging. In further tests, the pre-stressed honeycomb has been found to be superior to the foam cushioning material. Methods to determine solvency and material collision characteristics, such as honeycomb structures, are generally found in ASTM D1596 (Standard Test Method for Shock Absorption Characteristics of Packaging Packaging Materials) and all are well known to those skilled in the art. the technique of material tests. The reception curves obtained by these methods are related to the peak deceleration (G) experienced by the acoustic weight in a free fall to the static load C defined as S = W / A; e where W is the weight of the product and A is the support area po below the weight (contact area between the weight and cushion). L curves are normally presented in the form of a graph with peak deceleration (G) on the vertical axis and static load (p.0703 Kg / cm2) (psi) on the horizontal axis. Materials that show good absorbance of shocks have lower G values, and less dense materials are mainly preferred. Once the tensioned honeycomb is made, it can be further cut, or grooved by notches to form a hinge, or it can be cut with a punch in a preselected section, to provide a pre-tensioned projection point cushion. The resilient pretension paper honeycomb structure can be cut into the shape of a cushion, block or panel It has been found that the greater sheltering protection when the honeycomb structure is tensioned to a depth less than about half its original thickness, to be supplied with a partially cushioned load portion. Additionally, one of the resilient pretension honeycomb structures may be further confined against a resilient pretensioned honeycomb structure which is pretensioned to an equal depth of different if desired to obtain various levels of protection of reception.

Additionally, the resilient pretension honeycomb structure can be cut and assembled to any shape and size by a step by the method and apparatus of this invention to provide a strong, light inner packing having all of the planar surfaces accommodated. It provides beneficially substantially uniform cushioning protection for items that have a frailty rating, less than approximately 85 G cont. Multiple impacts. Furthermore, the above inner packing can also be formed with cavities in almost any way to tailor products of various configurations and weights with the added advantage of substantially uniformly cushioning all product surfaces. So far, the interior packing benefits made of paper honeycomb structures have these pre-stressed resilient surfaces were not available. Additionally, the resilient pretension honeycomb structure can be attached directly to the surface of the interior walls of boxes, cartons and the like, with a front facing portion facing inward and bordering the interior walls. Alternatively, the resilient pretensioned bread structure can be inserted, such as in cushion form, between an article and the wall of the box or box as a gift.

Claims (64)

1. Is contained, to provide cushion protection for substantially all surfaces. The foregoing is illustrative of the principles of the invention. In addition, since many modifications and changes will easily occur to those with desires in the specialty, it is not desired to limit the invention to the exact construction and operation illustrated and described. According to this, all modifications and equivalents may be resorted to while still falling within the scope of the invention. NOVELTY OF THE INVENTION Having described the invention as above, s claims as property what is contained in the following: CLAIMS 1. A resilient pretensioned honeycomb structure comprising a conditioned honeycomb having fronts or expensive hollow cells, defining planar surfaces, wherein However, one of the faces has been compressively deformed in a lateral manner on its planar surface, at a predetermined depth to provide a substantially continuous padded front portion, such that the padded front portion is sufficiently resilient to substantially cushion all of the surfaces of the surface. a body in substantially uniform contact.
2. 2. - The prestressed honeycomb structure resilient as described in claim 1, compressively deformed so as to reduce the structure of its original thickness by up to about half, without substantial loss of structural strength stiffness in the remaining non-cushioned portion.
3. 3. - The pretensioned honeycomb structure resilient as described in claim 1, pretensioned to a predetermined depth in confinement with a resilient pre-tensioned paper honeycomb structure wherein the cushioned front portion is a predetermined depth equal or different.
4. 4. - The prestressed honeycomb structure resilient as described in claim 1, wherein the resilient cushioned front portion defines an irregular planar surface.
5. 5. The resilient pre-tensioned honeycomb structure as described in claim 1, including at least one front sheet fastened opposite the resilient pad face portion before or after pretensioning.
6. 6. The prestressed honeycomb structure resilient as described in claim 1, which includes opposite front sheets held before or after pre-tensioning.
7. 7. The prestressed honeycomb structure resilient as described in claim 1, in the form of a block or panel cushion.
8. 8. - The pre-tensioned honeycomb structure resilient as described in claim 7, which further includes a notch groove to create a hinge.
9. 9. The prestressed honeycomb structure resilient as described in claim 1, capable of cushioning substantially uniform form an article having a brittle factor rating of less than about 8 peak deceleration (G), when the article is in contact with the resilient pretensioned cushioned portion, such that the article is protected during at least one impact as determined by a free fall test.
10. 10. The prestressed honeycomb structure resilient as described in claim 1, wherein the structure makes paper.
11. 11. The pre-tensioned honeycomb structure resilient as described in claim 1, wherein the honeycomb structure comprises a honeycomb core that includes a plurality of confining partition walls, and a front sheet held au of the planar surfaces, the walls of the honeycomb. Division or leaf fronts are air permeable to allow the flow of ai through when one of the faces is compressively deformed
12. 12. - The prestressed honeycomb structure resilien as described in claim 11, wherein the front sheet or the dividing walls include a plurality of perforations, the air circulates through the perforations when one of the faces is compressively deformed.
13. 13. - The prestressed honeycomb structure resilient as described in claim 11, where the front sheet or dividing walls are constituted by a porous material, the air flows through the porous material when one of the faces is compressively deformed.
14. 14.- Method for simultaneously forming and shaping a resilient prestressed paper honeycomb structure, having a substantially continuous resiliently cushioned front portion, the method comprising the steps of: a) exposing a pre-selected thickness and length of paper panel structure , to a conditioning environment having a predetermined ambient air temperature and relative humidity p for a period sufficient to provide a conditioned paper honeycomb structure, comprising a moisture level of about 4% by weight to less than about 8% by weight which is compressible, however, is structurally strong rigid substantially; b) remove the paper honeycomb structure from the conditioning environment; c subsequently cutting the honeycomb structure conditioned to its predetermined size and shape while substantially deforming the conditioned honeycomb structure, laterally substantially continuously on a planar surface, by compressing it to a predetermined depth to provide a honeycomb structure having a front portion resilient pre-tensioned substantially continuous, without substantial loss of rigidity and structural resistance; and e) releasing the compression and removing the resulting resilient pretensioned honeycomb structure.
15. 15. Method as described in claim 14 further comprising the step of securing at least one front sheet to the resilient pretensioned honeycomb structure and repeating l steps c) and d) in all or a portion of the resilient pretension honeycomb structure. with front finish.
16. 16. Method as described in claim 14 further comprising the step of securing at least one front face to the honeycomb structure prior to step (a).
17. 17. Method as described in claim 14 further comprising a step of fastening a front sheet to the pre-tensioned cushion portion after step (d).
18. 18. Method as described in claim 14 further comprising the step of making a notch groove in the resilient pretensioned honeycomb structure in a preselected section to create a hinge.
19. 19. Method as described in claim 14 that the conditioning environment has an ambient temperature from about 25 ° C (about 85 ° F) to about 35 ° C (about 95 ° F) and a relative ambient humidity of between about 35 and approximately 65%.
20. 20. - A method as described in claim 14 further comprising the step of confining one of the resilient pretensioned honeycomb structures against a second resilient pretensioned honeycomb structure, of which the padded frent portion is the same or different.
21. 21. The resilient prestressed honeycomb structure q is obtained by the method according to claim 14, capable of substantially uniformly cushioning an article having a relatively delicate fragility factor rating of less than about 85 peak deceleration (G), when article is in contact with the resilient pretensioned cushion portion such that the article is at least protected from impact as determined in a free fall test.
22. 22. Packaging material of internal packaging shaped to protect an article having a preselected configuration against one or more impacts, the inner package contains or more cushions of a resilient pretensioned honeycomb structure obtained by the method of claim 14, ca cush has stiffness and structured strength sufficient to cushion an article having a brittle factor rating of about 40 and about 85 peak deceleration (G) when the article is in contact with the resilient pre-tensioned padded front portion, so that the article is protects against it as a free fall test is determined.
23. 23. - Method for cutting a honeycomb structure comprising opposed hollow front cells defining a planar surface to a predetermined shape and size, while the honeycomb structure conditioned substantially laterally on one of the planar surfaces is formed in a substantially compressive manner. at a predetermined depth, to provide a resilient pretensioned bread structure having a resilient pre-tensioned cushion front portion without substantial loss of structural strength stiffness.
24. 24. Method as written in claim 23, wherein the honeycomb structure is made of paper having a moisture level of about 4% by weight to less about 8% by weight.
25. 25. - Resilient pre-tensioned honeycomb obtained by the method as described in claim 23, capable of cushioning an article having a fragility factor rating, less than about 85 deceleration pi (G) when the article is in contact with the resilient pre-tensioned cushioned brake portion, such that the article is protected from at least one impact, as determined in a free fall test.
26. 26.- Apparatus for cutting and forming a resilient pre-tensioned paper honeycomb structure of predetermined size and shape in a stage, the apparatus comprises: means for cutting through a paper honeycomb structure, comprising opposite hollow cell fronts, which defines planar surfaces on a predetermined line to form a predetermined structure; b) at least one plate associates cooperatively with the cutting means, the plate is able to compress the paper honeycomb structure, substantially continuously on at least one of its planar surfaces, c) means for simultaneously guiding the cutting means to Through the honeycomb structure, while the laterally compressive surface is deformed at a predetermined depth, to form a resilient pre-tensioned padded frent portion, such that a pre-tensioned honeycomb structure having a planar, cushioned surface is obtained. resilient continuous.
27. 27. Box for article, which includes one or more of the resilient prestressed honeycomb structures as described in claim 1.
28. 28.- Box as described in claim 27, wherein the front-facing portion of the structure Resilient pretensioned part is about to contact the article.
29. 29.- Cushion formed by the resilient prestressed corduroy structure as described in claim 1 capable of substantially cushioning all body surfaces.
30. 30. - Cushion as described in claim 29, wherein the resilient pretensioned honeycomb structure includes less a notch groove to provide at least a hinged cushion portion, such that the hinged portion is capable of placing the front facing portion contact with the surface of the body.
31. 31. A box comprising a bottom and walls extending upwards from the bottom, the box having an inner surface and a resilient pretensioned honeycomb structure attached to all or a portion of the interior surface, resilient pretensioned honeycomb structure comprises faces opposing hollow cells, which define planar surfaces in which at least one of the faces has been laterally comprehensively deformed on its planar surface at a predetermined depth to supply a substantially continuous front-facing portion, such that the braking portion cushioned is resilient enough to cushion the inside surface of the box in substantially uniform form
32. 32. - Box as described in claim 31, wherein the cushioned front portion of the resilient pretensioned pan structure faces inwardly.
33. 33. Box as described in claim 31, wherein the cushioned front portion of the resilient prestressed bread structure is confined to the inner box surface.
34. 34. - Box as described in claim 31, wherein it includes an article in contact with the resilient pretensioned bread surface.
35. 35.- Box as described in claim 31, sealed form.
36. 36.- Box comprising a bottom, walls extending upwards from the bottom, the box having an interior surface, an article inside the box and its resilient pretensioned honeycomb structure, between the contained article and the interior surface of the box, the resilient prestressed honeycomb structure comprises opposite hollow cell fronts defining planar surfaces, wherein at least u of the fronts or faces has been compressively deformed on a planar surface at a predetermined depth to provide a substantially continuous padded front portion, such as that the cushioned front portion resilient enough to substantially cushion every surface of the article contained substantially uniformly.
37. 37. Resilient pretensioned honeycomb structure, comprising a honeycomb core that includes a partition wall priority confinantes and opposed hollow cell fronts q define planar surfaces, and a front sheet subject to a planar surfaces, at least one of The planar surfaces are compressively deformed to a predetermined depth to provide a cushioned front, the dividing walls or front sheet are permeable to air to allow through flow, when one of the planar surfaces is compressively deformed.
38. 38. The prestressed honeycomb structure resilien as described in claim 37, wherein the front sheet includes a plurality of perforations, the air q circulates through the perforations when one of the planar surfaces is compressively deformed.
39. 39.- The prestressed honeycomb structure resilien as described in claim 37, wherein the front sheet is composed of a porous material, the air circulates through the porous material, when one of the planar surfaces is compressively deformed.
40. 40. The prestressed honeycomb structure resilient as described in claim 37, wherein it further comprises an air permeable front sheet secured to the other planar surfaces.
41. 41. The prestressed honeycomb structure resilient as described in claim 37, wherein the dividing walls include a plurality of perforations, the air q circulates through the perforations when one of the planar surfaces is compressively deformed.
42. 42. - The pre-tensioned honeycomb structure resilien as described in claim 37, where the division walls are composed of a porous material, the air circulates through the porous material, when one of the planar surfaces is comprehensively deformed.
43. 43. - Honeycomb core including a plurality of confining partition walls and opposite hollow cell faces defining planar surfaces, at least some of the partition walls are permeable to air, to allow through flow when the core is compressively deformed .
44. 44. - Honeycomb core as described in claim 43, wherein the dividing walls include a plurality of perforations, air circulates through the perforations when the core is compressively deformed.
45. 45. - Honeycomb core as described in claim 43, wherein the dividing walls are composed of a porous material, the air circulating through the porous material when the core is compressively formed.
46. 46. Apparatus for forming a resilient pretensioned bread structure, comprising: a) a conveyor for a honeycomb structure, the honeycomb structure includes hollow cell fronts that define opposite planar surfaces; and b) compression apparatus for laterally compressive deformation of one of the planar surfaces of the honeycomb structure as the honeycomb structure is transported beyond the compression apparatus.
47. 47. Apparatus as described in claim 4 wherein the compression means comprises a compression roller.
48. 48. Apparatus as described in claim 3 wherein further comprises means for varying the height of compression rod with respect to the conveyor, to vary depth at which one of the planar surfaces deformed compressively.
49. 49. Apparatus as described in claim 4 wherein the compression roller includes a plurality of pins that extend radially outwardly from an exterior surface, to form perforations in the honeycomb structure, as the honeycomb structure is transported beyond the roller. Of compression.
50. 50. Apparatus as described in claim 4 wherein the compression apparatus comprises a plurality of parallel compression rollers, placed on the transport and the honeycomb structure, each of the compression rollers being placed at an incrementally different height with respect to conveyor, to laterally compressively deformate incremental mode, one of the planar surfaces of the honeycomb structure, as the honeycomb structure is transported beyond the compression apparatus.
51. 51. Apparatus as described in claim 5 wherein further comprises a roller frame that supports the compression rollers and means for adjusting the height angular displacement of the roller frame with respect to conveyor, such that the compression rollers place at incrementally different heights with respect to conveyor, to laterally compressively compressively deform one of the planar surfaces of honeycomb structure.
52. 52. Apparatus as described in claim 5 wherein the means for adjusting the height and angular displacement of the roller frame comprises an adjuster for roller height, operatively associated with the roller frame to adjust the height and angular displacement of the frame. roller.
53. 53. Apparatus as described in claim 5 wherein the roller height adjuster is operatively associated with one end of the roller frame, to adjust the height of one roller frame end, the apparatus further comprises another adjuster for height of the roller operatively associated with the other end of the roller frame, to adjust the height of the other end of the roller frame.
54. 54. Apparatus as described in claim 5 wherein further comprises means in the roller frame, to independently adjust the vertical position of each of the compression roller.
55. 55. Apparatus as described in claim 5 wherein further comprises a support frame and a plurality of retainers attached to the support frame, the roller frame is held within the retainers, to allow vertical movement of the roller frame with respect to the frame of the frame. support.
56. 56. Apparatus for forming a resilient pretensioned bread structure, comprising: a) a support frame; b) a band for transporting a honeycomb structure, honeycomb structure includes opposing hollow cell fronts that define opposing planar surfaces; c) a roller frame positioned on the band, the roller frame is mounted for pivotal movement with respect to the support frame; d) a plurality of parallel and elongated compression rollers mounted on the roller frame, to deform in a laterally compressive manner one of the planar surfaces of honeycomb structure as the honeycomb structure is carried beyond the compression rollers; e) a roller height adjuster, attached to the support frame and operatively associated with the roller frame, to vary the vertical and angular displacement of the roller frame, with respect to the support frame and place the compression rolls at different heights with respect to to the support frame, such that when structure or honeycomb is transported beyond the compression rollers, the compression rollers compress in laterally incrementally one of the planar surfaces at a predetermined depth to form a pre-tensioned padded fren portion of a structure honeycomb pretensioned
57. 57. - The apparatus as described in claim 56, further comprising retainers attached to the support frame, the roller frame is held within the retainers to allow vertical and angumovement of the roller frame with respect to the support frame.
58. 58. Apparatus as described in claim 5 wherein the roller height adjuster is operatively associated with one end of the roller frame, to vary the height of one end of the roller frame, the apparatus further comprises another height adjuster Roller associated with the end ot of the roller frame to vary the height of the end of the roller frame.
59. 59. Apparatus as described in claim 5 wherein further comprises means in the roller frame, to independently adjust the vertical position of each of the compression rollers.
60. 60. Apparatus as described in claim 5 wherein also comprises a connector arrow and an adjustment wheel operatively associated with the roller height adjuster, the connector arrow is connected to one end with roller height adjuster and at the other end With the adjustment wheel, the adjustment wheel is manually operable to adjust the height of the roller height adjuster.
61. 61. - Method for forming a resilient pretensioned bread structure, comprising the steps of: a) moving a honeycomb structure on a conveyor, the honeycomb structure comprises faces or fronts of opposite hollow cells, q defining opposite planar surfaces, and b) deforming in laterally compressive form one of the planar surfaces of honeycomb structure as the honeycomb structure passes a pre-selected prong along the conveyor, one of the planar surfaces is deformed laterally compressed to a predetermined depth to form a portion of the brake pretensioned cushioned resilient of a prestressed bread structure.
62. 62. - A method as described in claim 6 further comprising the step of laterally compressing further forming the resilient pretensioned front facing portion after step (b) at a further preselected point on the conveyor.
63. 63.- Method as described in claim 6 further comprising the step of fastening at least one front sheet to one of the fronts of hollow cells before or during the eta (a).
64. 64. - Method as described in claim 61 further comprises the step of piercing the front sheet before during step (b). IN WITNESS WHEREOVER, I have signed the foregoing description and Novelty of the Invention as proxy of HEXACO CORPORATION, in Mexico City, D. F., today, May 30, 1994, p. p. HEXACOMB CORPORATION SAMUEL DORANTES F. RS / sms [43] / Carder