AN ADVANCED METHOD AND APPARATUS FOR COST-EFFECTIVELY AND CONTINUOUSLY PRODUCING EXPANDED THERMOFORMABLE HONEYCOMB MATERIALS

摘要

A method for continuously and cost-effectively producing expanded thermoformable honeycomb materials comprising the steps of: providing raw thermoformable thermoplastic material (such as flakes or pellets) into an extruder; heating the material in the extruder; extruding the continuous sheet material to a suitable gauge and width; trimming the extruded material while it is still hot to desired widths; conveying this hot thermoformable, continuous sheet into a preheat/heating section comprised of either hot forming rolls or belts; heating the thermoformable continuous sheet on forming rolls or between continuous forming belts that have specific geometries machined on the surfaces; adhering the continuous sheet on the forming surfaces by hot tack adhesion; expanding the continuous sheet into expanded honeycomb by separating the forming surfaces so as to effect an expansion of the cross-section of the thermoformable continuous sheet material; transferring the expanded honeycomb through an array of cooling rolls or belts thereby cooling the expanded honeycomb thereby maintaining its integrity and facilitating its release from the exit of the cooling region.