Natural honeycomb structures occur in many different environments, from beehives to honeycomb weathering in rocks. Based on these, man-made honeycomb structures have been built with similar geometry to allow the reduction of the quantity of material used, and thereby realizing minimal weight and material cost.

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Man-made honeycomb structures have an array of hollow cells formed between thin vertical walls, so that the material has minimal density, strength in tension and high out-of-plane compression properties.

How are Honeycomb Composites Manufactured?

Honeycomb structures are manufactured using three conventional methods, namely, expansion, corrugation and molding, which can be traced back to the s.

Today, the manufacture of honeycomb cores involves the use of the expansion and corrugation processes where composite materials such as fibreglass, aluminium, and carbon fiber reinforced plastic are used. To manufacture thermoplastic honeycomb cores, the raw material used is polypropylene and the method used is extrusion.

A more recent cost efficient method for the manufacture of thermoplastic honeycomb structures enables continuous in-line production and direct lamination of skin. Similarly, continuous in-line production of metal honeycomb can also be performed from metal rolls by cutting and bending.

Apart from metal honeycomb composite structures, there are also paperboard honeycomb materials that are being manufactured for use in paper pallets and package blocking, cushioning, and bracing.

Honeycomb Composite Panel Lamination Processing

Companies Involved in Honeycomb Composites Manufacturing

The following is a list of companies manufacturing a variety of honeycomb composite materials with a brief introduction to each:

• Corex-Honeycomb is a UK-based company producing high-quality aluminium honeycomb core for use in a wide variety of applications including marine, defence, aerospace, rail, and automotive industries. Aluminium honeycomb is in high demand due to its excellent high strength-to-weight ratio, and also in areas where minimal weight and strength are required.
• Dupont is involved in the manufacture of two types of honeycomb composites, namely, DuPont&#; Nomex® and Kevlar®. Both products possess stiffness, toughness, strength, corrosion resistance and lightweight characteristics, which make these products a high-demand material for industries such as construction, mass transportation, and marine shipping. For example, in aircraft construction, thin Nomex® honeycomb sandwich composite sheets are used in aircraft parts such as interior walls, storage bins, flooring panels, engine nacelles, exterior control surfaces, and helicopter blades and tail booms. Likewise in the transportation industry, these lightweight honeycomb composite structures have helped provide cost-effective benefits such as energy savings.
• 3A Composites GmbH produces ALUCORE®, which is an aluminium composite panel comprising two cover sheets and a honeycomb core of aluminium. ALUCORE® is available in a variety of colors, and has exceptional flatness and high formability. This composite material finds application in many fields such as in transport, industry, and architecture. The aluminium honeycomb core provides the material with high rigidity and minimal weight. This material is thus popular for use as façade cladding or roofing especially in places with high levels of wind.
• Amber Composites is a UK-based company involved in the manufacture of high-performance composite materials. This company was recently acquired by TenCate Group, a global supplier of advanced composite materials for the anti-ballistics aerospace industry, and a wide range of industrial applications.

Benefits of Honeycomb Composites

The key benefits of using honeycomb composites are given below:

• Exceptional strength to weight ratio
• Corrosion resistance
• High toughness
• Fire and fungus resistant
• High temperature performance
• Does not absorb moisture
• Easily machinable and formable
• Provides cost-effective benefits like energy savings
• Aluminum honeycomb provides maximum stiffness with one of the highest strength to weight ratios of any structural core material in the market.
• Kevlar&#; honeycomb conforms to strict smoke, toxicity and flammability standards.

Applications

Honeycomb materials can be used in a huge number of applications. Some of the common applications are as follows:

• Skis and snowboards
• Rocket substructure and jet aircraft
• LED technology and loudspeaker technology
• Automobile structure
• Air, water, fluid, and light directionalisation
• Electric shielding enclosures
• Wind turbine blades
• Clean room panels and exterior architectural curtain wall panels
• Heating, ventilation, air-conditioning equipment and devices
• Energy absorption protective structures
• In the construction of boats for providing buoyancy that will help enhance speed
• In the rail industry for forming doors, floors, energy absorbers/bumpers, and furniture
• In the marine industry for constructing commercial vessels and naval vessel bulkheads, wall ceiling, partition panels, furniture, and several other applications

Sources and Further Reading

Disclaimer: The views expressed here are those of the author expressed in their private capacity and do not necessarily represent the views of AZoM.com Limited T/A AZoNetwork the owner and operator of this website. This disclaimer forms part of the Terms and conditions of use of this website.

In focus: the Honeycomb Base Design

Today&#;s packaging for meat and proteins has come a long way. In years past, meat and proteins were packaged in cardboard paper-pulp cartons, often becoming a soggy mess from grocery store to consumer. High-quality thermoformed plastic packaging took security and freshness to a new level, keeping meats and proteins moist while maintaining the packaging&#;s rigid structure.

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With the introduction of another new feature, EasyPak has again raised the bar for its line of rigid trays for meat and protein. The proprietary honeycomb design is an exciting feature of our lightweight and strong line of protein and meat trays designed to enhance the display and shelf appeal of freshly-packed meats and proteins.

How does the Honeycomb work?

Today&#;s consumers expect freshness and long shelf lives for the products they buy- all with an appealing shelf look. In addition, a growing number of consumers expect sustainable design and less waste.

With these growing consumer demands in mind, EasyPak&#;s honeycomb structure tackles the interconnected

This structure, which covers the bottom of trays in the meat and produce replacement line, captures and holds liquids in the honeycomb cells. Even if the package is inverted, the honeycomb holds liquids.

This quality technology reduces the need for an additional moisture-absorbing pad within the container. That equals cost savings, with a reduction in necessary packaging.

The Honeycomb: versatile design for food processing

EasyPak&#;s honeycomb base design is available in a variety of popular sizes for food processing. Additionally, these honeycomb trays offer features to ensure they perform at a high level for any food processing operation. The trays feature an enhanced corner design, which allows for the trays to be stretch wrapped on a high-speed production line or by hand without warping or puncturing the film.

The design is also suitable for complex, multi-layer-material Modified Atmosphere Packaging (MAP). The MAP packaging process is designed to maintain food&#;s appearance, texture, and nutrition without relying on chemical additives or food stabilizers. MAP is ideal for delicate and fresh products. This packaging process ensures optimal taste and texture for products. Because consumers expect an extended shelf life, as well as clean labels, MAP technology has grown in popularity. EasyPak&#;s honeycomb design meets these consumer demands while also continuing to provide the sturdy, high-quality design of all our other lines.

These trays are available in both clear and black plastic, in a variety of popular sizes and shallow to deep configurations. For food processors, these trays highlight the freshness and quality of meat and proteins. And that appearance isn&#;t just window dressing: the innovative honeycomb technology and enhanced designs backs up the outstanding look.

The added bonus of sustainability

This innovative protein and meat trays are formed using 100% post-consumer recycled content (PCR). PCR plastics are recycled from existing PET plastics, including bottles. Through recycling programs, these materials are made into new products.

Using PCR to create packaging like our meat and protein trays offers several environmental benefits, including reducing our carbon footprint and lessening our impact on landfills.

As consumers demand more environmentally-friendly products, those options must also provide the security and freshness protection they&#;re accustomed to with other options.  This PCR packaging matches the quality of regular packaging: the same level of protection, barrier performance, and strength. These plastics still block light, oxygen, and other gases, while providing unmatched leak protection.

This added bonus of sustainability is a complement to EasyPak&#;s consistency in the design and manufacturing of high-quality trays and all our product lines.

Get the honeycomb

The honeycomb base trays are just one of several industry-leading special features offered by EasyPak, as part of our high-quality line of smart, secure, and sustainable thermoformed plastic packaging.

You can get a sample of these honeycomb base trays sent directly to you by sending us a sample request.

If you&#;re looking for a meat or protein tray in a specific size, we can help. Contact us so we can work with you to determine the best custom solution to fit your needs.

For more information, please visit Honeycomb Paper Manufacturers.