EconCore: Economic Core and Panel Technologies: ThermHex - TorHex

Core material and process
The patented TorHex honeycomb material and technology allows production from a continuous corrugated cardboard sheet by successive in-line operations.

The TorHex core production uses the cost efficient machinery from the corrugated cardboard industry to a maximum extent adding lengthwise slitting and in-line rotation of the strips.

The production of TorHex cores from different corrugated boards (A-, C-, K-Flute) leads to different cell sizes (5 mm, 3.5 mm, 6.5 mm). The large scale production at high production speeds is especially economic in the thickness range from about 4 mm to 15 mm.

Production line
The TorHex production technology is developed to be integrated into continuous panel and part production lines.

TorHex Applications

EconCore technologies allow the production of TorHex paper honeycomb cores as sheets or as a continuous endless web and enable direct in-line further processing.

In combination with different skin materials EconCore honeycombs offer a wide range of application possibilities. The low production costs of EconCore honeycombs enable substitution of other honeycomb cores and homogeneous panel materials. In development projects with our customers and licensees we develop panels and parts for automotive, furniture, building and packaging markets.

TorHex technologies for automotive interior parts

The in-line lamination of skins (e.g. from natural fibre reinforced polypropylen) onto the TorHex paper honeycomb core allows to produce a lightweight sandwich panel directly in-line with the core production. These sandwich panels with thermoplastic skins enable the forming of very cost efficient sandwich parts for automotive interior applications.

EconCore technologies enable furthermore to produce TorHex honeycomb cores with attached glass fibre or natural fibre reinforcements according to customer requirements. These preforms can be used for thermoset processing.

Sandwich panels with TorHex honeycomb cores are especially applicable to the following automotive interior components:
·         headliner, sun roof panels and roof stiffening elements
·         luggage compartment floors and spare wheel covers
·         trim luggage compartment
·         door panels
·         parcel shelfs
·         trim cabin front

TorHex technologies for interior und furniture

TorHex honeycombs with CPL (Continuous Pressure Laminate) or MDF (Medium Fibre Density Board) skins may be used for interior and furniture applications. These material combinations offer very good weight-specific mechanical properties at low costs.

The direct in-line lamination of skins onto the continiously produced TorHex paper honeycomb core allows for a very cost efficient production of panels for interior and furniture.

EconCore materials may substitute other wood-based panels such as chipboard, OSB and MDF in cabinet doors, shelves and drawer elements. The TorHex technologie is especially interesting for take-away-furniture, because of the large weight and cost savings and the potential for high volume production.

TorHex technologies for packaging applications

TorHex paper honeycombs with Kraftliner or Testliner skins are especially applicable to high quality transportation packaging.

TorHex honeycomb cardboard provides high stability and surface quality and may therefore be applied to packaging of high value goods and for advertisement displays. However, also double flute corrugated cardboard, which is used for standard transportation packaging boxes may be substituted by TorHex honeycomb cardboard.

Production of TorHex honeycomb cardboard directly in-line with the single flute corrugation only slightly exceeds production costs of double flute corrugated cardboard and offers material savings of 20-30 %.