Energy saving honeycomb having enhanced strength

Abstract

An injection molding method of producing a honeycomb body involves introducing an injection moldable polymer into a mold having a two-dimensional array of parallel pins separated from each other in a manner forming inter-cell reinforcement volumes between honeycomb cells being molded for strengthening the honeycomb. The pins can be cylindrical or have hexagonal shapes, trapezoidal shapes, and diamond shapes. Reinforcement fibers can be introduced into the polymer for even further strengthening the honeycomb body. Foaming agents can be added to the molten polymer with or without the fibers to decrease the density of the honeycomb and reduce heat transfer through the honeycomb for saving energy. Roughening, or producing textured surfaces of the honeycomb product can reduce glare due to sunshine that is detrimental should the honeycomb be used in the construction of buildings and the like. Foaming agents introduced into the polymer during molding can also produce such textured surfaces.

Dependencies are inferred from the claim text.