Ubusi honeycomb structures are unique because they are made from corrugated board. Most paper based honeycomb structures are made from laminating paper together. Ubusi structure uses b flute corrugated board to makes its structures.

By using corrugated board to make the honeycomb the walls of the cells have their own structural strength. B flute corrugated board is used extensively to make cardboard boxes. Many board combinations are available as a raw material. The corrugated shape delivers a much higher compression value than normal paper would. Corrugated board is also resistant to bending or crushing and thus helps to strengthen the final honeycomb. By making the cell wall from corrugated board ubusi has big advantages compared to honeycomb made from paper.

Why use corrugated board?
In the search for the best honeycomb we came across studies carried out on aluminium honeycomb panels which indicate that it is better to make the cell walls thicker than to increase the thickness of the surface panels. There was also research conducted on Kraft paper honeycomb by the Wood Composites Group in the University of British Columbia, which stated that “buckling of the honeycomb core was identified as the major cause of failure of the paper honeycomb sandwich panels. It will therefore be useful to investigate ways to reduce the buckling stresses in the core, by examining the effect of variations in the thicknesses of the paper used in the manufacture of honeycombs. To increase the mechanical strength properties of the sandwich panels, it is recommended to identify a balance between honeycomb cell sizes and cell wall thicknesses. The knowledge acquired here can help understand and improve the design of Kraft paper honeycomb panels for furniture applications.” (Sam-Brew et al. 2011, Forest Products Journal 61(5): 381-389; http://circle.ubc.ca/handle/2429/28008). Thicker paper cells are still prone to buckling. By giving the honeycomb cell wall structure a b-flute corrugation and making the cell walls thicker, a better result is obtained with the same amount of material.

  • Better Gluing: The bigger surface of the b-flute edge also leads to improved gluing.
  • The cell size is 34 mm wide. To accomplish this cell size, VG ideas Pty ltd had to build its own machinery. Folding the strips of B flute board in the exact locations allows for an easily expandable structure. Many hollow core doors have much bigger cell sizes. A smaller cell size leads to higher strength so lots of development and innovation has been done to make the size as small as possible.
  • Any Height. We can make any height of structure required. The height of the structure is determined by the height of the strip which is cut in house. Current standard heights are 20, 30, 50 and 90 mm. Strips are glued together in an even-uneven pattern to create a honeycomb when expanding the glued strips.
  • Sandwich Gluing of the Ubusi structure between paper, wood or other is improved by including a special design into the strips. The design makes sure that all the top and bottom surfaces of the structure will be in contact with the object to which it is glued. Using the right glue and pressure will lead to an optimal result.
  • The structures are ideal to be used in the wood industry. They can either be supplied as a closed structure and expanded in your production or we can glue them on a paper backing
    so the structure is already expanded. The Ubusi structure is a good alternative as it is very cost effective and still strong.
  • Excellent protection even if used as a core itself. Wrap it around your product or push in between pallets for securing your load.

// Code Margo Added