Application US20180093443

LASER-PERFORATED METAL HONEYCOMB MATERIAL AND METHOD OF MANUFACTURING SAME
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US20180093443

1. A method of manufacturing perforated metal honeycomb material, the method comprising: (8) (4)

printing a roll of metal foil with adhesive;

laser perforating the roll of metal foil to provide a plurality of holes in the metal foil;

sheeting the printed and perforated roll of metal foil into a plurality of stacked sheets; and

laminating the sheets of metal foil into a honeycomb before expansion block (HOBE).

2. The method of claim 1, further comprising cutting the HOBE block into a plurality of HOBE slices. (1) (0)

4. The method of claim 1, wherein the roll of metal foil is printed with adhesive prior to laser perforation. (0)

5. The method of claim 1, wherein the roll of metal foil is printed with adhesive after laser perforation. (0)

6. The method of claim 1, wherein at least some of the plurality of holes are larger than 0.10 mm in diameter. (0)

7. The method of claim 1, wherein at least some of the plurality of holes are non-uniform in size and/or shape. (0)

8. The method of claim 1, wherein the spacing between at least some of the plurality of holes is non-uniform. (0)

9. The method of claim 1, further comprising corrugating the roll of metal foil to produce a corrugated honeycomb structure. (0)

10. The method of claim 1, wherein the method of manufacturing perforated metal honeycomb material does not include the process step of compression of the metal foil after the perforation process step. (0)

11. A method of manufacturing perforated metal honeycomb material, the method comprising: (0) (6)

printing a roll of metal foil with adhesive;

laser perforating the roll of metal foil to provide a plurality of holes in the metal foil;

sheeting the printed and perforated roll of metal foil into a plurality of stacked sheets;

laminating the sheets of metal foil into a honeycomb before expansion block (HOBE);

cutting the HOBE block into a plurality of HOBE slices; and

expanding the HOBE slices into expanded honeycomb structures having a plurality of perforations.

12. A perforated metal honeycomb structure, comprising: (5) (1)

a metal honeycomb structure having a plurality of laser-drilled holes wherein at least some of the plurality of holes are non-uniform in size, shape, and/or spacing between holes.

13. The structure of claim 12, including at least first and second laser-drilled holes, wherein the first and second holes are different from each other. (3) (0)

14. The structure of claim 12, wherein at least some of the plurality of holes are larger than 0.10 mm in diameter. (0)

18. The structure of claim 12, wherein the honeycomb structure is expanded. (0)

19. The structure of claim 12, wherein the honeycomb structure is HOBE. (0)

20. The structure of claim 12, wherein the honeycomb structure is corrugated. (0)

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Application US20180093443

LASER-PERFORATED METAL HONEYCOMB MATERIAL AND METHOD OF MANUFACTURING SAME

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