Folded-sheet honeycomb structure

A process for the production of a folded honeycomb formed from a plurality of similar cells arranged in rows by folding a continuous flat blank of web material provided with cuts to form strip-shaped regions, comprising the following steps;

• a) providing a web material
• b) cutting the web material to size wherein there is produced a flat blank and in that operation, cuts (9) are provided to form first strip-shaped regions (22) and second strip-shaped regions (20, 21) which alternate with each other, cuts (9) being provided in the second strip-shaped regions (20, 21) between which bridging portions (13, 16) remain the bridging portions (13, 16) connecting together the first strip shaped regions (22);
• c) deforming the first strip-shaped regions (22) transversely with respect to the strip direction in order to provide half-honeycomb corrugations with corrugation ridges (22c, 22d), and corrugation dips (22a, 22b) on which flat portions are formed;
• d) folding the flat blank which is deformed in the first strip-shaped regions (22) into rectangular corrugations along fold lines (1, 2, 3, 4) which separate the first and second strip-shaped regions (20, 21, 22) from each other, wherein the bridging portions come to lie in crests or troughs of the corrugations;
• and
• e) contacting the flat portions of the corrugation ridges (22c, 22d) or corrugation dips (22a, 22b) into relationship with oppositely disposed flat portions of the conjugation dips (22a, 22b) or corrugation ridges (22c, 22d).

A process for the production of a folded honeycomb layer formed from a plurality of similar cells arranged in rows by folding a flat blank of web material comprising the steps:

• a) providing a web material;
• b) cutting the web material into cuts (9) first strip-shaped regions (22) and second strip-shaped regions (20, 21) which alternate with each other, cuts (9) providing in the second strip-shaped regions (20, 21) between which bridging portions (13, 16) remain connecting together the bridging portions (13, 16) and the first strip shaped regions (22);
• the cuts 9 being U-shaped cuts (9) in rows in order to prepare flat blanks with side leg walls (14, 17) of a second series which are separated from each other by the bridging portions (13, 15) which form connecting surfaces of a first group, wherein cut edges (11, 12) along the limbs of the U-shape extend in accordance with the limbs of the U-shape at an acute angle or coincidentally with continuous fold lines (I, 2, 3, 4) to separate the first strip-shaped regions (22) from the second strip-shaped regions (20, 21) and a further cut edge (10) extends in accordance with the base of the U-shape transversely with respect to the continuous fold lines (I, 2, 3, 4);
• (c) the flat blanks are folded into rectangular corrugations along the continuous fold lines (I, 2, 3, 4) in order to form corrugation crest surfaces and corrugation trough surfaces with the second strip-shaped regions (20, 21) and leg walls of a first series with the first strip-shaped regions (22);
• e) folding the side leg walls (14, 17) of the second series out of the respective plane of the corrugation crest or the corrugation trough respectively into the folded honeycomb layer along lug fold lines (5, 5) wherein the bridging portions (13, 16) remain in said corrugation crest or corrugation trough planes respectively.

A process for the production of a folded honeycomb formed from a plurality of similar cells arranged in rows and formed from a flat blank of web material comprising the steps:

• a) providing a web material;
• b) providing the web material with meander cuts (37, 39) to form flat blanks, wherein the meander cuts (37, 39) are displaced relative to each other and the flat blanks are subdivided along first fold lines (35, 36) into narrower and wider strips (55, 56, 57, 58);
• c) folding the flat blanks are folded in mutually overlapping relationship along the first fold lines (35, 36) to form an overlapping structure;
• d) deforming the overlapping structure along second fold lines (31, 32, 33, 34) which extend perpendicularly to the first fold lines (35, 36) to constitute rectangular corrugations so that the narrower and wider strips (55, 55, 57, 58) form individual rectangular corrugations which are inserted one into the other;
• and
• e) pulling apart the rectangular corrugations which are inserted one into the other, in which case the narrower strips (55, 57) are arranged with their rectangular corrugations in planes perpendicularly to the plane of the folded honeycomb and the wider strips (56, 58) are arranged with their rectangular corrugations in the plane of the folded honeycomb.