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A three-dimensional support structure is provided and includes a single sheet of material that is folded into a repeating pattern of cells. Each of the cells is formed by first and second spaced-apart endwalls and first and second sloped sidewalls spanning between the endwalls. Each endwall comprise

A three-dimensional support structure is provided and includes a single sheet of material that is folded into a repeating pattern of cells. Each of the cells is formed by first and second spaced-apart endwalls and first and second sloped sidewalls spanning between the endwalls. Each endwall comprises two plies of material while each sidewall comprises a single ply of material. The first and second sidewalls are adjoined at a folded edge. The cells are aligned such that the first endwall of one cell from the repeating pattern abuts the second endwall of an adjacent cell of the repeating pattern to form a four-ply wall of the material. A first liner may be attached to a first side of the folded material and a second liner may be attached to a second side of the folded material.

대표청구항 ▼

I claim: 1. A structure comprising a single sheet of material folded into a repeating pattern of cells, each of the cells being formed by first and second spaced-apart endwalls and first and second sloped sidewalls spanning between the endwalls, each of the endwalls having two plies of the material

I claim: 1. A structure comprising a single sheet of material folded into a repeating pattern of cells, each of the cells being formed by first and second spaced-apart endwalls and first and second sloped sidewalls spanning between the endwalls, each of the endwalls having two plies of the material and each of the sidewalls having a single ply of the material, the first and second sidewalls being adjoined at a folded edge, the cells being aligned such that the first endwall of one cell from the repeating pattern abuts the second endwall of an adjacent cell from the repeating pattern to form a continuous four-ply wall of the material for providing strength to the structure. 2. The structure according to claim 1, wherein the repeating cells form opposite first and second surfaces having a recess therein for each of the repeating cells, a liner being attached to the first surface. 3. The structure according to claim 2, wherein an additional liner is attached to the second surface. 4. The structure according to claim 2, wherein the two plies of material for each of the first and second endwalls join at a top fold, two adjacent top folds in the four-ply wall forming part of the first surface and serving as a platform for supporting an adhesive that secures the liner to the first surface. 5. The structure according to claim 4, wherein the two adjacent top folds form part of a support rail extending along the first surface. 6. The structure according to claim 2, wherein the liner is planar. 7. A structure comprising a plurality of the structures of claim 1. 8. A three-dimensional support structure comprising a single sheet of material folded into a pattern of repeating cells and being provided with a plurality of columns of recesses formed from the plurality of cells, the single sheet of material forming a substantially-continuous four-ply wall of material between each adjacent pair of columns of recesses. 9. The structure according to claim 8, wherein the substantially-continuous four-ply walls extend parallel to each other. 10. The structure according to claim 9, wherein each substantially-continuous four-ply wall is formed from a plurality of longitudinally-disposed, four-ply wall segments. 11. The structure according to claim 9, wherein each recess is formed in part by spaced-apart four-ply wall segments. 12. The structure according to claim 10, wherein each four-ply wall segment is formed from a pair of two-ply wall segments, each of the two-ply wall segments formed from two plies of the material joined at a fold extending longitudinally along the two-ply wall segment. 13. The structure according to claim 8, wherein the material is paper. 14. The structure according to claim 8, wherein the pattern of repeating cells forms opposite first and second planar surfaces extending parallel to each other. 15. The structure according to claim 14, further comprising a liner attached to the first planar surface. 16. The structure according to claim 15, further comprising an additional liner attached to the second planar surface. 17. The structure according to claim 14, wherein the substantially-continuous four-ply walls extend between the first and second planar surfaces. 18. The structure according to claim 17, wherein the substantially-continuous four-ply walls extend perpendicular to the first and second planar surfaces. 19. A structure comprising a sheet of material having a top surface, the sheet of material having a plurality of first crease paths extending parallel to each other and a plurality of second crease paths extending parallel to each other and intersecting the first crease paths, each first crease path being formed from a plurality of first path segments and each second crease path begin formed from a repeating pattern consisting of first and second chevron legs and a straight line extending from a free end of one of the first and second chevron legs, each second crease path being foldable in an opposite direction from the adjacent second crease path so that the second crease paths form an alternating pattern of ridges and valleys as the sheet of material is being folded; each of the first crease paths being straight lines extending between the ridges and valleys of adjacent second crease paths to form a pattern of facets on the top surface of the sheet of material; the sheet of material being foldable along the first and second crease paths for form a three dimensional support structure extending in a plane characterized by a repeating pattern of normal walls formed by the facets between the chevron legs and inclined walls formed by the facets between the straight lines, the normal walls extending perpendicular to the plane and the inclined walls being inclined walls being inclined relative to the plane, each of the normal walls formed by the facets comprises a wall having four plies of the sheet of material when the sheet of material is folded into the support structure. 20. The structure according to claim 19, further comprising a liner attached to the three dimensional support structure.