US3166456A - Structural honeycomb materials - Google Patents

Structural honeycomb materials Download PDF

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Publication number
US3166456A
US3166456A US179703A US17970362A US3166456A US 3166456 A US3166456 A US 3166456A US 179703 A US179703 A US 179703A US 17970362 A US17970362 A US 17970362A US 3166456 A US3166456 A US 3166456A
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US
United States
Prior art keywords
web
layers
sections
adhesive
sheet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US179703A
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English (en)
Inventor
White Desmond Deverell
Thwaites Peter John
Judd Geoffrey Ronald
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dufaylite Developments Ltd
Original Assignee
Dufaylite Developments Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dufaylite Developments Ltd filed Critical Dufaylite Developments Ltd
Application granted granted Critical
Publication of US3166456A publication Critical patent/US3166456A/en
Anticipated expiration legal-status Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H45/00—Folding thin material
    • B65H45/12—Folding articles or webs with application of pressure to define or form crease lines
    • B65H45/30—Folding in combination with creasing, smoothing or application of adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D3/00—Making articles of cellular structure, e.g. insulating board
    • B31D3/02—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section
    • B31D3/0223—Making honeycomb cores, e.g. by piling a plurality of web sections or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D3/00—Making articles of cellular structure, e.g. insulating board
    • B31D3/02—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section
    • B31D3/0223—Making honeycomb cores, e.g. by piling a plurality of web sections or sheets
    • B31D3/0246—Plane webs having essentially longitudinal adhesive strips being folded transversely into stacks or being cut transversely into sections which are piled, e.g. zigzag-folding the webs preceding the cutting
    • B31D3/0261—Plane webs having essentially longitudinal adhesive strips being folded transversely into stacks or being cut transversely into sections which are piled, e.g. zigzag-folding the webs preceding the cutting by applying longitudinal adhesive strips to the web and zig-zag folding the strips transversely
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H45/00—Folding thin material
    • B65H45/02—Folding limp material without application of pressure to define or form crease lines
    • B65H45/06—Folding webs
    • B65H45/10—Folding webs transversely
    • B65H45/101—Folding webs transversely in combination with laying, i.e. forming a zig-zag pile
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1003—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina by separating laminae between spaced secured areas [e.g., honeycomb expanding]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1007—Running or continuous length work
    • Y10T156/1015—Folding

Definitions

  • the present invention relates to the production of structural honeycomb material of the expandable type from bibulous sheet material, for example paper, using a wet adhesive. In its expanded form the material is widely used as the core of sandwich structures on account of its high strength to Weight ratio and favorable cost.
  • the production of the material for expansion involves securing together layers of sheet material in face to face contact by parallel bands of the adhesive positioned such that the bands at one face of any layer are staggered with reference to the bands at the other face thereof.
  • One type of method which has been proposed involves folding a continuous web of the sheet material bearing the wet adhesive in such a manner as to produce a stack in which the layers are formed by folding the material backwards and forwards and it is with this type of method that the present invention is concerned.
  • To provide apparatus for merely folding material backwards and forwards is a simple matter but major difiiculties arise from the need to accomplish accurate folding in the presence of the wet adhesive.
  • the folding mechanisms which have been proposed to ensure satisfactory results have been elaborate in nature and low in output or inflexible or wasteful in operation.
  • a high folding speed has been obtainable only by giving the layers such small dimensions between folds as to enable the material to be produced only in or near its finally required thickness, taken in the axial direction of the cells, and so has not enabled the rate of production to be effectively multiplied by subsequently forming the stack into a large number of slices.
  • the apparatus is suitable for serious commercial use, only with adhesives which can be dried before the layers are contacted together and subsequently activated in a final step of the process.
  • the wet adhesives with which the invention is concerned are preferred in the art and adopted where possible in spite of their difi'lculties.
  • One form of the folding method which has been proposed involves feeding a web of paper printed with glue lines on both sides vertically downwardly towards a support and folding the material upon the support by the action of arms or other mechanical members operating from the opposite ends of the support in turn, the feeding and folding steps being carried out at such relative speeds that there is always a sufiicient length of suspended material to permit its being folded without appreciable drag thereon.
  • the speed of this method depends upon the speed of the mechanical members which has to be limited in order to avoid tearing the suspended material.
  • the folds obtained tend to be bulky rather than sharp with the result that pronounced bulges build up at the ends of the block and considerable trimming waste is incurred.
  • a method for the production of structural honeycomb material which comprises applying wet bands of adhesive to both faces of a web of bibulous sheet material in positions such that the bands applied to one face are staggered with reference to the bands applied to the other face, feeding the web downwardly towards a support and folding it backwards and forwards upon the support so that it is accumulated upon the support in the form of a stack of layers which are adhered together by the wet hands and are interconnected at their ends, characterized in that the web is formed at equidistant intervals along its length and thereby divided into discrete sheet sections, with hinge formations, conveniently sets of colinear transverse slits which leave the sheets joined together by intervening sections of intact material, and is fed dodwnwardly to the support at a rate of feed such that it swings freely backwards and forwards under the reaction of the support and is accumulated in the form of a stack of layers in which each layer is constituted by one of said sheets and the sheets are joined together by folds
  • each sheet Under the free swinging conditions each sheet is guided accurately into position as it descends by its hinged attachment to the preceding and succeding sheets. There are no impulsive disturbances producing shock waves or other sources of distortion.
  • the movement of the sheet material during the descent closely resembles a wave motion with no significant folding at the hinge formations until the particular sheets which they define are being laid on the support.
  • the form of this motion is rendered complex by air-damping and by the discontinuities introduced by the hinge formations where the sheets are attached one to the other.
  • the maximum rate of free swing approximates to the rate of a simple pendulurn whose length equals the distance of free descent.
  • the system would be too complex, even in the absence or air-damping, for any precise relationships to be formulated but the required motion is readily achieved by adjusting the rate of feed of the web and/ or the distance of its descent to the support.
  • the rate of output depends upon the frequency of free swinging, and for convenient dimensioning of the layers a speed of 30 layers per minute is typical.
  • the apparatus is simple and the method is attractively economical for thisreason alone.
  • the method permits a procedure which has never been applicable heretofore.
  • the support may be mounted for horizontal movement in the direction of the length of the accumulated sheets sothat, on such movement, the material accumulates in a fresh stack by the side of the first which may be removed Without interrupting the feeding of the web. This is especially advantageous when the stacks are required to have only a small number of layers, as in the manufacture of honeycomb of large cell size for packaging purposes.
  • the operator is enabled to withdraw the accumulated material for consolidation under pressure at frequent intervals and without interrupting the process, thereby increasing the quality of the product by minimizing the time between laying the wet adhesive and consolidation.
  • FIG. 1 is a diagrammatic side elevation of an apparatus used in the method of the invention
  • FIG. 2 shows the arrangement of the slits in the web
  • FIG. 3 shows a portion of the slit web after the application of adhesive thereto.
  • a Web 1 of paper e.g. kraft paper or the thin cardboard known as chipboard, is drawn from a supply roll 2 to pass between a pair of slitting rollers 3 which operate to provide hinge formations in the sets of colinear transverse slits 4 dimensioned to leave narrow intact hinge portions 5 of the web material therebetween. After such slitting the web may be regarded as a series of sheets 6 interconnected by the hinge portions 5.
  • the web passes downwardly through printing heads 7 and 8 to be printed with parallel longitudinally extending bands a and b of wet adhesive, the bands a printed on one side lying between the bands b printed on the other side. It is preferably arranged, as shown in FIG. 3, that the hinge portions 5 lie on some of the adhesive bands while other adhesive bands pass through the slits.
  • the web leaving the lower printing head 8 descends to a horizontal support 9 and accumulates thereon in a stack of layers which are joined at their ends 10 and 11 by the hinge portions 5.
  • the suspended material 12 swings backwards and forwards in the direction shown by the arrows, the rate of feed of the web being adjusted so that the swinging takes place at the natural frequency which is governed by the vertical distance from the lower printing head 8 to the support 9.
  • the suppont 9 is mounted on rails 13 and after a chosen number of layers has accumulated, the support is moved rapidly by air cylinder 14, without interrupting the feeding of the web, to bring a second support 9 into position below the printing heads for the reception of further layers.
  • the material on support 9 is removed and consolidated under pressure for conventional slicing in the guillotine.
  • Intermittently acting air nozzles 15 are provided to 4 initiate the swinging of the web on starting the apparatus, but are not essential.
  • the method described herein is especially advantageous over methods involving the use of a rotary former when applied to manufacture from chipboard or other material whose thickness causes the waste, characteristic of such methods, to become substantial.
  • the trimming loss involved in squaring the end of the stack is trivial.
  • a method for producing structural honeycomb material consisting in forming rows of colinear spaced apart slits transversely of a flat web of bibulous sheet material, spacing said rows of slits at equal intervals along the length of said web dividing said web into sheet sections, spacing the slits in each of said rows thereof providing hinge sections of intact material between each pair of said slits joining adjacent sheet sections, applying wet bands of adhesive to both faces of said web at positions thereon such that the bands applied to one face are staggered with reference to the bands applied to the other face of said web, feeding said web of bibulous sheet material in a downward direction onto a receiving support, accumulating said web on said receiving support in stacks of superimposed layers in which each layer is constituted by one of said sheets and which layers are joined together by their hinge sections folded under the reaction of each sheet section reaching the material therebeneath on said receiving support, bonding said layers together in their stacked condition by said adhesive and slicing said bonded stacked layers into expandable sections.
  • a method for producing structural honeycomb material as claimed in claim 1 including controlling the rate of speed at which said web travels during its downward feeding imparting a free lateral swing to said web folding said hinge sections as they reach the end of each swing of said web.

Landscapes

  • Laminated Bodies (AREA)
  • Making Paper Articles (AREA)
  • Folding Of Thin Sheet-Like Materials, Special Discharging Devices, And Others (AREA)
  • Nonwoven Fabrics (AREA)
US179703A 1961-03-22 1962-03-14 Structural honeycomb materials Expired - Lifetime US3166456A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB10441/61A GB981875A (en) 1961-03-22 1961-03-22 Structural honeycomb materials

Publications (1)

Publication Number Publication Date
US3166456A true US3166456A (en) 1965-01-19

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Application Number Title Priority Date Filing Date
US179703A Expired - Lifetime US3166456A (en) 1961-03-22 1962-03-14 Structural honeycomb materials

Country Status (5)

Country Link
US (1) US3166456A (de)
AT (1) AT240150B (de)
CH (1) CH381412A (de)
ES (1) ES275406A2 (de)
GB (1) GB981875A (de)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3392890A (en) * 1963-09-13 1968-07-16 Wm A Cruikshank Jr Pliable material supporting method and apparatus
US3455755A (en) * 1963-12-31 1969-07-15 L A Drevfus Co Method and apparatus for producing laminated slabs
US3475252A (en) * 1964-11-27 1969-10-28 Dufaylite Dev Ltd Structural honeycomb material
US3770549A (en) * 1971-10-20 1973-11-06 Emmanuele Fallacaro Method and apparatus for manufacturing honeycomb structures
FR2495057A1 (fr) * 1980-10-20 1982-06-04 Johns Manville Procede et appareil de production de plaques isolantes fibreuses relativement epaisses, par stratification et produits d'isolation ainsi obtenus
US4397898A (en) * 1980-10-20 1983-08-09 Manville Service Corporation Thick batt of fibrous insulation
US4500380A (en) * 1983-12-19 1985-02-19 Bova Joseph D Method and apparatus for continuous production of expandable honeycomb
WO1990006845A1 (en) * 1988-12-22 1990-06-28 Schnebly John T Multi-cellular collapsible shade
US5015317A (en) * 1988-12-22 1991-05-14 Comfortex Corporation Method and apparatus for making a multi-cellular collapsible shade
US5160563A (en) * 1989-10-05 1992-11-03 Graber Industries, Inc. Method and apparatus for making an expandable cellular shade
US5228944A (en) * 1990-02-15 1993-07-20 Hoechst Aktiengesellschaft Apparatus for producing composite bodies from layers of plastic flim laminated to one another
US5395465A (en) * 1992-06-09 1995-03-07 Oji Kenzai Kogyo Co., Ltd. Method for manufacturing laminate for honeycomb structure
US5482750A (en) * 1991-01-02 1996-01-09 Hunter Douglas Inc. Multiple cell honeycomb insulating panel and method of hanging
US5654073A (en) * 1991-11-13 1997-08-05 Hunter Douglas Inc. Treated fabric panel
US6527895B1 (en) 2000-08-17 2003-03-04 Newell Window Furnishings, Inc. Method and apparatus for making a cellular structure

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4732630A (en) * 1986-03-26 1988-03-22 Thermocell, Ltd. Method for producing expandable honeycomb material

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB659075A (en) * 1948-03-04 1951-10-17 Dufay Chromex Ltd Improvements in or relating to the production of structural elements from sheet material
US2581421A (en) * 1948-04-27 1952-01-08 Douglas Aircraft Co Inc Method and apparatus for making structural elements
US2610934A (en) * 1948-11-22 1952-09-16 California Refinforced Plastic Method of and apparatus for making honeycomb material
US2619444A (en) * 1947-02-06 1952-11-25 Dufay Ltd Method of producing structural elements from web material
US2663434A (en) * 1949-05-23 1953-12-22 American Mfg Company Inc Sheet charging apparatus
US2684107A (en) * 1952-05-20 1954-07-20 Owens Corning Fiberglass Corp Method and apparatus for processing fibrous materials
GB723621A (en) * 1950-07-15 1955-02-09 Lockheed Aircraft Corp Improvements in or relating to a light weight laminated building unit
US2865639A (en) * 1954-06-18 1958-12-23 Dictaphone Corp Folded belt record machine
US2897874A (en) * 1955-12-16 1959-08-04 Owens Corning Fiberglass Corp Method and apparatus of forming, processing and assembling fibers
GB865813A (en) * 1956-10-24 1961-04-19 Sud Aviation Apparatus for the manufacture of cellular material of the honeycomb type
US3074839A (en) * 1956-09-17 1963-01-22 Messrs Dufaylite Developments Method of making honeycomb material
US3123269A (en) * 1959-05-25 1964-03-03 Handler for folding tape

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2619444A (en) * 1947-02-06 1952-11-25 Dufay Ltd Method of producing structural elements from web material
GB659075A (en) * 1948-03-04 1951-10-17 Dufay Chromex Ltd Improvements in or relating to the production of structural elements from sheet material
US2581421A (en) * 1948-04-27 1952-01-08 Douglas Aircraft Co Inc Method and apparatus for making structural elements
US2610934A (en) * 1948-11-22 1952-09-16 California Refinforced Plastic Method of and apparatus for making honeycomb material
US2663434A (en) * 1949-05-23 1953-12-22 American Mfg Company Inc Sheet charging apparatus
GB723621A (en) * 1950-07-15 1955-02-09 Lockheed Aircraft Corp Improvements in or relating to a light weight laminated building unit
US2684107A (en) * 1952-05-20 1954-07-20 Owens Corning Fiberglass Corp Method and apparatus for processing fibrous materials
US2865639A (en) * 1954-06-18 1958-12-23 Dictaphone Corp Folded belt record machine
US2897874A (en) * 1955-12-16 1959-08-04 Owens Corning Fiberglass Corp Method and apparatus of forming, processing and assembling fibers
US3074839A (en) * 1956-09-17 1963-01-22 Messrs Dufaylite Developments Method of making honeycomb material
GB865813A (en) * 1956-10-24 1961-04-19 Sud Aviation Apparatus for the manufacture of cellular material of the honeycomb type
US3123269A (en) * 1959-05-25 1964-03-03 Handler for folding tape

Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3392890A (en) * 1963-09-13 1968-07-16 Wm A Cruikshank Jr Pliable material supporting method and apparatus
US3455755A (en) * 1963-12-31 1969-07-15 L A Drevfus Co Method and apparatus for producing laminated slabs
US3475252A (en) * 1964-11-27 1969-10-28 Dufaylite Dev Ltd Structural honeycomb material
US3770549A (en) * 1971-10-20 1973-11-06 Emmanuele Fallacaro Method and apparatus for manufacturing honeycomb structures
FR2495057A1 (fr) * 1980-10-20 1982-06-04 Johns Manville Procede et appareil de production de plaques isolantes fibreuses relativement epaisses, par stratification et produits d'isolation ainsi obtenus
US4342610A (en) * 1980-10-20 1982-08-03 Manville Service Corporation Method for intermittently slitting and folding fibrous insulation
US4397898A (en) * 1980-10-20 1983-08-09 Manville Service Corporation Thick batt of fibrous insulation
US4500380A (en) * 1983-12-19 1985-02-19 Bova Joseph D Method and apparatus for continuous production of expandable honeycomb
WO1990006845A1 (en) * 1988-12-22 1990-06-28 Schnebly John T Multi-cellular collapsible shade
US5015317A (en) * 1988-12-22 1991-05-14 Comfortex Corporation Method and apparatus for making a multi-cellular collapsible shade
US5160563A (en) * 1989-10-05 1992-11-03 Graber Industries, Inc. Method and apparatus for making an expandable cellular shade
US5228944A (en) * 1990-02-15 1993-07-20 Hoechst Aktiengesellschaft Apparatus for producing composite bodies from layers of plastic flim laminated to one another
US5482750A (en) * 1991-01-02 1996-01-09 Hunter Douglas Inc. Multiple cell honeycomb insulating panel and method of hanging
US5601885A (en) * 1991-01-02 1997-02-11 Hunter Douglas Inc. Support system for supporting a vertically disposed multi-cell panel
US5670000A (en) * 1991-01-02 1997-09-23 Hunter Douglas Inc. Method of making a honeycomb panel
US6319586B1 (en) 1991-01-02 2001-11-20 Hunter Douglas Inc. Honeycomb insulating panel
US5654073A (en) * 1991-11-13 1997-08-05 Hunter Douglas Inc. Treated fabric panel
US5690778A (en) * 1991-11-13 1997-11-25 Hunter Douglas Inc. Method of fabricating honeycomb panel for window covering
US5691031A (en) * 1991-11-13 1997-11-25 Hunter Douglas Inc. Cellular panel
US5395465A (en) * 1992-06-09 1995-03-07 Oji Kenzai Kogyo Co., Ltd. Method for manufacturing laminate for honeycomb structure
US5545284A (en) * 1992-06-09 1996-08-13 Oji Kenzai Kogyo Co., Ltd. Apparatus for manufacturing laminate for honeycomb structure
US6527895B1 (en) 2000-08-17 2003-03-04 Newell Window Furnishings, Inc. Method and apparatus for making a cellular structure

Also Published As

Publication number Publication date
CH381412A (fr) 1964-08-31
ES275406A2 (es) 1962-07-01
AT240150B (de) 1965-05-10
GB981875A (en) 1965-01-27

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