Method of making honeycomb core

Claim 1

In a method of making honeycomb core structure in a stack suitable for further processing by at least expanding the same and in which a pair of webs is laminated face-to-back, each web having a pattern of transversely printed adhesive node lines thereon, the pattern of one web being staggered along its length with respect to the other, and in which the laminated web is cut into a plurality of equal lengths that are stacked one upon the other to form a lay-up, the steps of: A. printing the patterns of node lines side-by-side along the length of a double width web, on one face thereof, with the patterns staggered along the length of the web, each pattern occupying somewhat less than half of the web, respectively, B. perforating the web along its length on two transversely spaced rows, one row being in a clear path between the side edge of one pattern and one edge of the double width web, the other being in a clear path between patterns, the perforation pitch of each row being equal along the row and each perforation of one row being transversely aligned with an identical perforation in the other row normally to the rows irrespective of the staggered arrangement of the patterns relative one another, C. dividing the web along its centeR to provide a pair of half webs each having a pattern and a row of perforations, D. bringing together the half webs with their perforations in register and without changing their lengthwise relative orientation substantially, to form a two-ply web prior to cutting, the cut length dimension being chosen as a multiple of a minimum dimension at which one pattern of adhesive lines has a whole number of node pitches and the row of perforations has a whole number of perforation pitches, both numbers being repetitive for each of said minimum dimension occurring.

Claim 11

The method of making honeycomb core structures of different cell sizes on the same machine in different runs with a minimum modification of the machine for each cell size, comprising the steps of: A. printing, with a print roller of circumference C, a pattern of node lines of pitch Pc on the halves of a double width web; B. staggering the node lines in one pattern relative to the other; C. applying perforations of pitch R along an edge of each pattern in identical transverse location along the length of the web; D. slitting the double web in half after printing and applying the perforations; E. registering the two half webs in face to back engagement with the perforations of one half registered with those of the other half; F. cutting simultaneously the engaged half webs in equal lengths L of any multiple M of a whole number X; G. said steps of printing, applying perforations, and cutting in combination determining the dimensional requirements of X nPc mR C/u where n, m, and u are whole numbers and; H. changing only the print roller pitch Pc to a different value for said printing step for each respective cell size.

Claim 12

The method of making honeycomb core structures of different cell sizes on the same machine in different runs with a minimum modification of the machine for each cell size, comprising the steps of: A. printing, with a print roller of circumference C, a pattern of node lines of pitch Pc on the halves of a double width web; B. staggering the node lines in one pattern relative to the other; C. applying perforations of pitch R along an edge of each pattern in identical transverse location along the length of the web; D. slitting the double web in half after printing and applying the perforations; E. registering the two half webs in face to back engagement with the perforations of one half registered with those of the other half; F. cutting simultaneously the engaged half webs in equal lengths L of any multiple M of a whole number X; G. said steps of printing, applying perforations, and cutting in combination determining the dimensional requirements of X nPc mR C/u where n, m, and u are whole numbers and; H. changing only the print roller pitch Pc to a different value for said printing step for each respective cell size.