Importance

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Abstract

A method of manufacturing a multi-strength honeycomb core and a multi-strength honeycomb stricture produced form the multi-strength honeycomb core. The method includes the steps of (a) stacking first layers of a first thickness with adhesive at a first adhesive spacing to produce a first honeycomb core having a first density and (b) stacking second layers of a second thickness with adhesive at a second adhesive spacing onto the first honeycomb core to produce a second honeycomb core having a second density stacked on top of the first honeycomb core. The method may also include the step of (c) stacking third layers of a third thickness with adhesive at a third adhesive spacing onto one of the first and second honeycomb cores to produce a third honeycomb core having a third density stacked on top of one of the first and second honeycomb cores. Alternatively, the method of manufacturing a multi-strength honeycomb core includes the steps of (a) removing a top protective layer from a first honeycomb core having layers of a first thickness and adhesive at a first adhesive spacing and (b) bonding a second honeycomb core having layers of a second thickness and adhesive at a second adhesive spacing onto the first honeycomb core to produce the second honeycomb core of a second density stacked on top of the first honeycomb core of a first density. The method may also include the steps of (c) removing a protective layer from one of the first and second honeycomb cores and (d) bonding a third honeycomb core having layers of a third thickness and adhesive at a third adhesive spacing onto one of the first and second honeycomb cores to produce the third honeycomb core of a third density stacked on top of one of the first and second honeycomb cores of respective first and second densities. The multi-strength honeycomb core may be cured, as required, in one press cycle, machined, and/or expanded to produce a multi-strength honeycomb structure.

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First Claim