Folded Product Made From Extruded Profile and Method of Making Same

Abstract

A product made from an extruded sheet or web of material having a non-linear cross-section, and the process of making the product is provided. The extruded web or extrudate is plastically deformed in selected areas and then folded. When folded into the appropriate shape, the extrudate is formed into a product having a plurality of cells. Optionally, the cells can include one or more openings, allowing access to an interior of the cell and reducing the weight of the product.

1 . A process of making a product comprising:
 extruding a web of material having a generally non-planar profile;   flattening selected areas of the extruded web; and   folding the web.   
     
     
         2 . The process of  claim 1  further comprising forming a plurality of openings in the extruded web. 
     
     
         3 . The process of  claim 2  wherein forming a plurality of openings in the extruded web comprises stamping the material. 
     
     
         4 . The process of  claim 1  wherein flattening selected areas of the extruded web comprises contacting the extruded web with a heated element. 
     
     
         5 . The process of  claim 1  further wherein the extruded web has a generally corrugated shape with flattened peaks and flattened valleys. 
     
     
         6 . The process of  claim 1  wherein the extruded web is folded along transversely extending fold lines. 
     
     
         7 . A process of making a product comprising:
 extruding a web of material such that the extruded web has a generally non-linear cross-section;   flattening selected areas of the extruded web; and   folding the extruded web along transversely extending fold lines.   
     
     
         8 . The process of  claim 7  further comprising forming at least one opening in the extruded web. 
     
     
         9 . The process of  claim 8  wherein forming a plurality of openings in the extruded web comprises stamping the material. 
     
     
         10 . The process of  claim 7  wherein the extruded web is flattened in selected areas by at least one tool applying pressure. 
     
     
         11 . The process of  claim 7  wherein the extruded web is flattened in selected areas by at least one tool applying heat. 
     
     
         12 . The process of  claim 8  wherein creating a plurality of openings in the extruded web comprises removing material from the extruded web using at least one tool. 
     
     
         13 . A process of making a product comprising:
 extruding a web of material such that the extruded web has a generally non-linear cross-section;   plastically deforming selected areas of the extruded web; and   folding the extruded web along transversely extending fold lines.   
     
     
         14 . The process of  claim 13  wherein said extruded web is corrugated plastic. 
     
     
         15 . The process of  claim 13  wherein said step of plastically deforming selected areas of the extruded web comprising using at least one heated tool. 
     
     
         16 . A honeycomb product comprising:
 an extruded web having a non-planar profile formed and folded into a plurality of similar cells arranged in rows, at least some of the rows of cells being made of two row walls, each of said row walls having alternating planar and non-planar regions, the planar regions of adjacent said row walls being joined together and the non-planar regions of adjacent said row walls defining side walls of the cells, each of the cells having a top and bottom.   
     
     
         17 . The honeycomb product of  claim 16  wherein at least some of the cells have at least one opening created by at least one tool. 
     
     
         18 . The honeycomb product of  claim 16  wherein at least some of the openings are in lateral sidewalls of at least some of the cells. 
     
     
         19 . The honeycomb product of  claim 16  wherein at least some of the cells have at least one opening of a predefined size. 
     
     
         20 . The honeycomb product of  claim 16  wherein at least some of the cells have at least one opening of a predefined shape. 
     
     
         21 . A product comprising:
 an extruded web material having a longitudinal dimension formed into a plurality of similar cells arranged in rows, at least some of the cells being made of a continuous cell wall, the continuous cell wall being in the shape of a ring, the cells oriented substantially 90° to the longitudinal dimension.   
     
     
         22 . A product made by the process of:
 extruding a web of material, the extruded web having a generally non-linear cross-section;   creating a plurality of generally planar areas in said extruded web;   folding said extruded web along edges of said generally planar areas to create a plurality of cells arranged in rows, at least some of the rows of cells being made of two row walls, each of said row walls having planar and non-planar regions, the regions of adjacent said row walls being joined together, and the non-planar regions of adjacent said row walls defining side walls of the cells, each of the cells having a top and bottom.   
     
     
         23 . The product of  claim 22  wherein at least some of said tops and bottoms of said cells are in the shape of a polygon. 
     
     
         24 . The product of  claim 22  wherein at least some of the cells has an opening allowing access to an interior of the cell. 
     
     
         25 . The product of  claim 22  wherein the polygon is a hexagon. 
     
     
         26 . The product of  claim 22  wherein the web of material has a plurality of openings formed therethrough. 
     
     
         27 . The product of  claim 22  wherein the folding of said extruded web creates a plurality of identical cells oriented 90° relative to said extruded web. 
     
     
         28 . The product of  claim 25  wherein at least some of the openings are located in the tops and bottoms of the cells. 
     
     
         29 . The product of  claim 22  wherein the material is plastic. 
     
     
         30 . A product made by the process of:
 extruding a web of material, the extruded web having a generally non-linear cross-section;   creating a plurality of generally planar areas in said extruded web;   folding said extruded web along edges of said generally planar areas to create a plurality of cells arranged in rows.   
     
     
         31 . The product of  claim 30  wherein the extruded web is corrugated plastic. 
     
     
         32 . A product made by the process of:
 extruding a web of material, the extruded web having a generally non-linear cross-section;   creating a plurality of plastically deformed areas in said extruded web;   folding said extruded web along said plastically deformed areas to create a plurality of cells arranged in rows.   
     
     
         33 . The product of  claim 32  wherein the extruded web is corrugated plastic. 
     
     
         34 . The product of  claim 32  wherein the cells are vertically oriented.