Process for producing a honeycomb of synthetic-resin material for use in an electrostatic precipitator

A process for producing a honeycomb collector structure for an electrostatic precipitator, comprising:

• (a) forming plate strips by introducing glass fiber mats covered on both sides by nonwoven mats of synthetic fibers into a mold and filling the mold with a liquid unsaturated polyester resin, said strips each comprising a planar base, a pair of planar shanks diverging from and adjoining said base and a pair of flanges of different widths each attached to and extending outwardly from a respective shank parallel to said base whereby said shanks and said base together define half of an equilateral hexagonal honeycomb channel, the sum of the widths of said flanges being substantially equal to the width of said base;
• (b) assembling said strips into a honeycomb configuration with hexagonal ducts by bonding the broader flange of a first of said strips and the narrower flange of a second of said strips against the base of a third of said strips and bonding still other broad and narrow flanges in overlapping relationship with the narrow and broad flanges of further strips, respectively;
• and
• (c) winding a shell of glass fibers and polyester resin about said honeycomb configuration to enclose the same.