Honeycomb fabrication

Abstract

Methods and apparatus for forming honeycomb structure from a plurality of substrate layers. The layers are bonded together by spaced, parallel, solid node strips of thermoplastic material pressed and heated above the softening temperature to bond to the substrate surfaces and form a block. After cooling, the block is expanded into a honeycomb structure.Alternatively, the solid node strips can be placed on the spaced raised crests of corrugated layers of substrate, and successive layers bonded together by pressure and sufficient heat between the crests of one layer and the corresponding depression of the successive layer, to elevate the node strips above the softening temperature.Several alternative methods and apparatuses for achieving the result are disclosed.

Description

BACKGROUND OF THE INVENTION

This invention relates to a method and apparatus for making honeycomb structure.

Honeycomb structure has been found useful for a wide variety of functions and purposes. As such, it is made from various materials including metal, e.g., aluminum, as well as paper, cloth and other materials. The primary techniques of forming honeycomb from layers, webs or sheets include expansion and corrugation. With the expansion technique, the sheets are adhered together at intervals and expanded. With the corrugation technique, layers or sheets are first formed into the corrugated configuration and then interconnected as by adhesive bonding, welding or otherwise.

In the known expansion process, the flat foil, fabric or film layers are typically joined together with thermosetting adhesive which is printed on the substrate sheet at discrete intervals to form bonding nodes. Adjacent sheets are printed at laterally offset intervals, see e.g. U.S. Pat. No. 4,957,577. The adhesive is suspended in a solvent typically amounting to around 80% of the composition. Multiple sheets and the applied thermosetting adhesive are cured under heat and pressure. If the substrate or layers are of a porous material, such as some fibrous materials, the liquid adhesive tends to penetrate completely through the layer so as to appear between the underlying and overlying layers, unless the sheets are specially pretreated. If this penetration happens, some or all of these layers may become bonded together in the heating and pressurizing stage into an unexpandable block. Consequently, preimpregnation pretreatment of the porous material sheets has normally been practiced as set forth, for example, in U.S. Pat. No. 3,519,510, to forestall penetration by the solvent adhesive clear through the layers. The solvent is evaporated from the adhesive and the layers and adhesive are carefully treated with heat and pressure applied to the plurality of sheets on which the adhesive has been printed. After cooling, the bonded structure is expanded, e.g., by connecting elements to the outer layers and pulling the structure into an expanded honeycomb.

The above-noted preimpregnation adds production steps and cost to the honeycomb forming process and product.. Moreover, preimpregnation must be performed just right to prevent the product from becoming scrap. As an example, glass cloth is normally preimpregnated with a thermosetting resin and partially cured. This is done so that the cloth may be printed on later without the adhesive bleeding through the fabric. In this procedure the resin content and degree of curing are critical areas. If the resin content is too high, the core will be very difficult to expand. If the resin content is not high enough, there will be holes through which the later applied adhesive will bleed. This may result in a bond in the area that must remain unbonded for the honeycomb to be expanded, resulting in an unexpandable block. Cure of the resin is also critical. If the impregnating resin is not cured enough, it will soften and bond to the adjacent layer of material during the subsequent press cycle. This also results in an unexpandable block. If the resin is overcured, the material becomes very hard and rigid, so that during the expansion process the node adhesion is insufficiently strong and will break, resulting in a partial or total failure of the block. After the fabric has been preimpregnated, lines of adhesive are printed on the surface. The adhesive must be partially cured by passing through an oven. However, this also advances the cure of the preimpregnated resin. Therefore, getting the preimpregnated polymer cured to the degree needed is difficult.

Typically, after the block is expanded it is dipped in thermosetting resin and cured. Dipping may occur as many times as necessary to achieve the desired density and strength for the honeycomb.

In the corrugation process, foil or film is first passed through configurated rolls to form individual corrugated sheets. Fabrics are impregnated and/or coated somewhat first, and then corrugated. These sheets are cut to length. After corrugation, adhesive is applied to the protruding flat surface areas of the corrugated sheets, the sheets are stacked and pressed together to bring the formed flat areas together, and the thermosetting adhesive is cured, usually by heat, to form the final honeycomb core. Alternatively, the corrugated sheet flat areas can be fused together by welding. Thus, a series of foils, films or fabric layers become bonded together at the contacting surfaces to form the honeycomb core. In the welding process described in prior patents such as U.S. Pat. Nos. 4,957,577, 5,139,596 and 5,039,567, unreinforced substrates are welded together by using "anvils" which can tend to cut rather than weld the substrate, when physical alignment is off and/or temperatures are too high. The node areas need to be compressed a great deal to achieve flow of the resin to cause welding, and sometimes cause cutting when the correct parameters do not exist.

SUMMARY OF THE INVENTION

The present development enables formation of honeycomb, even utilizing fibrous porous sheets or layers, yet without requiring preimpregnation of the layers and without the previous difficulty of the bonding material penetrating through the porous fibrous layers to undesirably bond to underlying and/or overlying layers and cause an unexpandable block. The curing problems of the prior preimpregnated resin are not involved. Also, the solvent evaporation problem of the prior technology is not present. The bonding material does not require a solvent. Also, cutting of substrates by anvils is avoided. Rather, the development involves laying down of sheets or webs of substrate material, preferably a fibrous base material, with intermediate, evenly spaced strips of solid, reinforced or unreinforced thermoplastic, node strips having a desired softening temperature distinctly different from and less than its melting temperature. The structure is bonded together by applying pressure and sufficient heat to elevate the temperature of the strips to a temperature above the softening temperature of the thermoplastic material, but preferably below the melting temperature thereof, for a sufficient time to cause some of the softened, pressed, node bonding material to penetrate around the surface fibers of the adjacent fibrous layers, or by fusion to the adjacent layer, and thereby bond to the layers. Subsequently, the pressure is removed and the structure cooled. When the expansion process is employed, the bonded layers are expanded into a honeycomb structure.

In creating the layered assembly, various novel forms of apparatus can be employed to apply and fuse the thermoplastic node strips to the substrate material. The resulting material can be coiled for further processing at a later date, and/or may be cut to length and stacked, immediately or later, for honeycomb formation. Alternatively, the solid thermoplastic node strips may be applied at the time of sheeting. That is, the fiber based substrate may be cut to length and laid down with alternating layers of node material. Each layer may be pressed and heat fused individually to the underlying layer, or a plurality of sheets may be stacked into multiple layers and all pressed and heated at the same time. As noted, the solid node material is pressed and heated sufficiently to cause the thermoplastic strips to soften, but not so much as to cause the strips to melt and flow in an uncontrolled fashion under pressure. This feature of the solid thermoplastic strips, the ability to soften without melting, because of a distinct difference between the softening and the melting temperatures, is highly preferred because it allows the node material to bond the layers of the substrate together without bleeding through layers and fibrous substrates and creating an unexpandable block. The pressed block of honeycomb is subsequently expandable by a conventional expansion technique. The expanded honeycomb may be subsequently heat set or dipped in resin, typically a thermosetting resin, and cured to retain its final shape. It may also be dipped in resin repeatedly in order to increase its density and strength to the point desired.

Various substrate materials can be employed, including woven or nonwoven, natural or man made materials. These include, but are not limited to, glass cloth, glass mat, aramid paper, wood pulp paper, cotton cloth, polyester cloth, and/or polyester, polypropylene or polyethylene spun bonded papers. These materials may be preimpregnated, if desired, but this is not necessary for this process. Each individual layer can also be a laminate of thermoplastic film between or on both sides of sheets of the above noted porous materials. It is advantageous and preferable that the surfaces of the materials for these layers be fibrous in nature, and necessary that the layer materials be strong enough to withstand the forces imposed during the subsequent expansion process, and that the material surfaces have the capacity of not being softened, degraded or deteriorated at the softening temperature of the node bonding material.

The node bonding material is typically a solid thermoplastic substance, capable of being softened without melting, i.e., have a distinctly different softening temperature and melting temperature, and can be of a thermoplastic material including but not limited to one or more of polypropylene, polyethylene, polycarbonate, polyetherimide, polyethersulfone, polyetheretherketone and polyurethane polymers. High temperature thermoplastic can be used in applications where higher service temperatures are involved. The term thermoplastic used herein can, in its broadest sense, include materials that are otherwise considered thermosetting, but are not yet fully cured.

The node strips can be unreinforced or reinforced. The solid node strips can be reinforced with fiberglass or other engineered materials, resulting in increased strength of the honeycomb core. Reinforcing the thermoplastic node strips helps to prevent tearing and also helps to control the flow of the thermoplastic resin. The orientation of the reinforcing fibers can be varied in arrangement to obtain a variety of structural properties. Reinforcing materials may be fiberglass, Kevlar.RTM., carbon fiber, quartz fiber, polyester fiber, or any other material that may be laminated, commingled, coated or impregnated with thermoplastic or partially cured thermosetting resin. The form of the solid node polymer strips can vary, including but not limited to nonperforated, perforated, expanded webbing, nonexpanded webbing, unidirectional, woven or random filaments or fibers, and polymer coated glass filaments or fibers.

This development substantially simplifies the creation of honeycomb structures, eliminates costly production steps, can be practiced on a variety of substrate materials, enables a variety of post-expansion steps to be practiced to produce a final product of desired characteristics, and is adaptable to high speed production techniques. Flow of the softened thermoplastic adhesive can be controlled by selection of rheometric properties, eliminating the need to preimpregnate the substrate and yet preventing bleed-through. Solvents, which bleed-through and present environmental problems, are not required.

A variation of the corrugation process can also be employed. Specifically, the individual substrate layers are corrugated to form layers or sheets with parallel, spaced, elevated surfaces or crests for bonding with like parallel, spaced, depressed surfaces of the adjacent layer. Strips of solid node bonding material are placed on those elevated surfaces and they are bonded by heat and pressure, using methods and equipment described in U.S. Pat. No. 4,957,577 or 5,139,596, both incorporated herein by reference, the solid bonding material being heated to a temperature above its softening temperature to cause the softened node material under pressure to extend around the surface fibers of the corrugated layers. The layers are then cooled and the pressure is removed, resulting in a honeycomb structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one step of a general showing of a process according to this invention, namely layering of solid strips of nodal bonding material with intermediate substrate layers, when using the expansion technique;

FIG. 2 is a perspective, partially diagrammatic view of another step of the process of FIG. 1, namely the application of heat and pressure;

FIG. 3, is a perspective view of a further step of the process in FIGS. 1 and 2, namely the expansion of the honeycomb;

FIGS. 4A-4F are perspective views of alternative polymeric node strip characteristics exemplary of those useable with this invention, specifically:

FIG. 4A is a perspective view of cloth with polymeric strands woven at 45.degree.;

FIG. 4B is a perspective view of a solid polymeric strip formed, e.g., by extrusion or the like;

FIG. 4C is a perspective view of an open polymeric web or net;

FIG. 4D is a perspective view of polymer coated glass strands;

FIG. 4E is a perspective view of side-by-side, parallel, polymer filaments formed, e.g., by spinning or extrusion;

FIG. 4F is a perspective view of cloth polymeric strands woven at 90.degree.;

FIG. 5 is a perspective view of an in-line web and continuous in-line strips being applied to the web;

FIG. 6 is a perspective representation of sheets of substrate and strips, cut from the continuous web and strip ribbons of nodal material in FIG. 5, the cut sheets and strips shown being stacked;

FIG. 7 is a perspective view of an in-line web and extruded in-line strip ribbons, each strip ribbon optionally formed of multiple strands as depicted in FIG. 8;

FIG. 8 is an enlarged perspective view of one of the extrusion heads in FIG. 7, shown forming several (four) strands of a strip;

FIG. 9 is a perspective view of press apparatus and a plurality of strips being applied cross line to substrate sheets cut from a web;

FIG. 9A is a side elevational diagrammatic view of process steps 1 and 2 related to FIG. 9;

FIG. 9B is a side elevational diagrammatic view of process step 3 related to FIG. 9;

FIG. 9C is a side elevational diagrammatic view of process step 4 related to FIG. 9;

FIG. 9D is a side elevational diagrammatic view of process step 5 related to FIG. 9;

FIG. 9E is a side elevational diagrammatic view of process step 6 related to FIG. 9;

FIG. 9F is a side elevational diagrammatic view of process step 7 related to FIG. 9;

FIG. 9G is a side elevational diagrammatic view of process step 8 related to FIG. 9;

FIG. 9H is a side elevational diagrammatic view of process step 9 related to FIG. 9;

FIG. 9I is a side elevational diagrammatic view of process step 10 related to FIG. 9;

FIG. 9J is a side elevational diagrammatic view of process step 11 related to FIG. 9;

FIG. 10 is an isometric view of a cylindrical, cross-strand applicator onto web substrate stock;

FIG. 11 is an enlarged, partial, isometric view of a portion of FIG. 10;

FIG. 12 is an end elevational view of laminating apparatus for adhering the strands of FIGS. 10 and 11 to the web;

FIG. 13 is an enlarged, plan, projection view of a portion of the applicator in FIG. 10, shown as a planar, cross line strand and sheet applicator;

FIG. 14 is a plan view of a double cross line sheeter and strand applicator, moving in one direction;

FIG. 15 is a plan view of the opposite side of sheeter and applicator in FIG. 14, with the strands moving in the opposite direction;

FIG. 16 is an end elevational view of the apparatus in FIGS. 14 and 15;

FIG. 17 is a side elevational view of an in-line windup, double side web and node strip apparatus for simultaneously forming two honeycomb blocks;

FIG. 18 is a perspective view of the apparatus in FIG. 17;

FIG. 19 is an isometric view of a cross wind web and transverse strip laminator for forming two honeycomb blocks;

FIG. 20 is a top plan view of the apparatus in FIG. 19;

FIG. 21 is a sectional elevational view of the apparatus in FIGS. 19 and 20;

FIG. 22 is an end elevational view of a web corrugator;

FIG. 23 is an isometric view of the corrugator in FIG. 22, with the web cut into sheets and solid node strips applied for forming a honeycomb;

FIGS. 24A-D are end views of the sequential honeycomb forming steps using the apparatus in FIGS. 22 and 23;

FIG. 25 is a plan view of steps of forming a honeycomb block using stencil node material;

FIG. 26 is a perspective view of an in-line windup, multi-sided web and node strip apparatus for simultaneously forming a multiple of honeycomb blocks;

FIG. 27 is an end elevational view of the apparatus in FIG. 26; and

FIG. 28 is a schematic end elevational view of the apparatus in FIGS. 26 and 27 and separated honeycomb blocks.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now specifically to the drawings, FIGS. 1-3 depict basic process steps in forming a honeycomb by the expansion technique and according to the concept herein. FIG. 1 illustrates a composite 10 which is formed of a plurality of individual layers 12, 14, 16 et seq. These layers are shown to be sheets cut to length as from a coil or web of stock. The layers are of foils, film and porous, fibrous woven or nonwoven materials, including but not limited to glass cloth, glass mat, aramid paper, wood pulp paper, cotton cloth, polyester cloth, polyester, polypropylene and/or polyethylene spun bonded materials, having fibers on the surfaces thereof, or films of polyetherimide, polycarbonate, polyetheretherketone, or polyether-sulfone. Using the novel technology, it is not necessary to preimpregnate fibrous layers in order to avoid bonding of the layers into an unexpandable block or mass. These materials should be strong enough to withstand the forces imposed during the subsequent expansion process, and have the capacity of not being softened, degraded or deteriorated at the softening temperature of the node bonding material to be described. Optionally, each layer, or some layers, may be formed of a laminate of more than one sheet such as a thermoplastic film between a pair of fibrous sheets, with the exposed surfaces being fibrous or on both sides of a fibrous sheet. Woven fabrics which may be used include fiberglass cloth of various weaves, weights and grades, one example being 108 E Glass from supplier Clark & Schwebel; woven plastics such as polypropylene, nylon, polyetherketone, polyetheretherketone, polyetherimide, polyesters, aromatic polyamides and aramids; woven cotton or other cellulose fibers; carbon fiber cloth; and others. Nonwoven fabrics which may be used include glass mat, polyester fiber, polypropylene fiber, polyethylene spun bonded material and others. Combinations of the above materials may be in laminated form or preimpregnated with polycarbonate, for example, or paper laminated with polypropylene, for example.

This node bonding material is either a solid thermoplastic or reinforced thermoplastic substance which can be softened without melting, i.e., have a distinctly different and lower softening temperature relative to a melting temperature thereof, separated by at least several degrees. Examples of such materials with particularly widely differential temperatures are polyetherimide with a Vicat softening point of about 426.degree. F. and a melting temperature of about 620.degree. F., and polyethersulfone with a Vicat softening temperature of about 438.degree. F. and a melting temperature of about 620.degree. F. Preferred operating temperatures of the node strips in this temperature range are about 500.degree.-550.degree. F. The solid node bonding material is denominated as thermoplastic herein, it being understood that a partially cured thermoset material can behave like a thermoplastic. Therefore, the term solid thermoplastic strips used herein is intended to encompass solid, partially cured thermosetting strip materials which will soften under heat and pressure. The term strip is used to include that which is a unitary solid as well as solid woven, nonwoven, strands, web and spun bonded material et at. This node bonding material is formed into strips 20 which are placed on the layers in a manner spaced from and parallel to each other on each layer, and spaced from, parallel to and alternatingly offset laterally from any strips which are thereabove and therebelow. Thus, strips 20 on sheet 14 are not only parallel to each other, but are laterally offset to lie midway between the underlying strips on layer 16, for example, and aligned with the strips on the layer below layer 16 etc. The spacing of strips on each layer determines the diameter width of the honeycomb cell to be formed. The width of each strip determines the width of the wall connection to the adjacent cell. This solid thermoplastic node bonding material may include, but is not limited to, one or more of polyethylene, polypropylene, polycarbonate, polyetherimide, polyethersulfone, polyethylene, polyetheretherketone and polyurethane materials. Each of these strips can be in a variety of forms, e.g., a solid homogeneous unitary thermoplastic strip, a group of solid thermoplastic filaments, strips of solid thermoplastic impregnated cloth, solid thermoplastic-coated glass filaments, expanded thermoplastic film or unexpanded thermoplastic film. Some of these forms are most readily created by extrusion, either earlier or in situ.

The node strips can be unreinforced or reinforced. The orientation of the reinforcing fibers can be varied in arrangement to obtain a variety of structural properties. Reinforcing materials may be fiberglass, Kevlar.RTM., carbon fiber, quartz fiber, polyester fiber, or any other material that may be laminated, commingled, coated or impregnated with a thermoplastic resin. The form of the solid node polymer strips can vary, including but not limited to nonperforated, perforated, expanded webbing, nonexpanded webbing, linear, woven or random filaments or fibers, and polymer coated glass filaments or fibers. In FIGS. 4A-4F are illustrated some examples of these potential strip forms. FIGS. 4A and 4F show woven cloth forms of strips, with 20A being diagonally woven polymeric strands and 20F being crosswise woven polymeric strands. Form 20B in FIG. 4B is shown as solid polymer, e.g, extruded, in unitary form. Form 20C in FIG. 4C depicts a net or web formed of individual strands in a pattern. Form 20D in FIG. 4D is formed of a series of polymer coated glass strands in a pattern. Form 20E in FIG. 4E depicts a group of polymeric filaments or strands lying side-by-side in parallel fashion. Similarly, the strips can also be formed of polymeric threads commingled with other filament materials.

The individual strips can be applied in continuous form to a web by heating and fusing a plurality of continuous, spaced strips to a web layer of base material on a web handling line, so that the resulting strips and web can be coiled up for further processing at a later date, e.g., later cut into sheets and short strips, and stacked on each other. Alternatively, the solid thermoplastic node material may be applied at the time of sheeting from a web. In either case, the fibrous base substrate is cut to length, and is laid down with alternating layers of node material, the node strips on successive sheets being laterally offset to be midway between the node strips on the sheet immediate thereabove and the sheet immediately therebeneath.

Each layer may be pressed and heat fused individually to the node strips on one other layer, or alternatively a stack of a plurality of layers and intermediate node strips can all be pressed and heated at the same time, as shown in FIG. 2, the arrows graphically depicting the applied pressure. Thus, the layup can be with one press cycle, or a series of sequential press cycles.

A one press cycle sequence .is set forth in more detail as follows:

1. Lay down alternative layers of substrate and solid thermoplastic node material. Repeat as necessary to generate a block of desired size. 2. Place block in a press under sufficient heat to soften the node strips but not sufficient to melt the node strips, and apply pressure to fuse the node material to the substrate layers. 3. Remove the block from the press, cool it to room temperature, and expand it to the desired honeycomb configuration. (This may be sinusoidal, hexagonal, or rectangular.) 4. Where possible, heat set the block to maintain the expanded shape. 5. When desired, the expanded block may be dipped in uncured thermosetting resin, then cured to achieve desired weight and strength characteristics.

Sequential press cycles are as follows:

1. Place the node strips in parallel spaced fashion on the topmost layer of substrate, offsetting the nodes from any previous layer. 2. Place another layer of substrate on top of the above noted layer of node strips. 3. Fuse the nodes to the substrate layers by pressing them under heat and pressure sufficient to soften the node strips. Repeat steps 1, 2 and 3 as necessary to achieve the desired block size. (This eliminates the need for a lengthy press cycle later.) 4. Expand the block to the desired cell configuration. 5. Where possible, heat set the block to maintain the expanded shape. 6. When desired, the expanded block may be dipped in thermosetting resin, then cured to achieve desired weight and strength characteristics.

When the material is pressed and heated, the temperature of the solid node bond material strips should be elevated sufficiently to equal or exceed the softening temperature of the strips. The particular strip polymer used should normally be characterized by a distinct difference between the softening and the melting temperatures thereof. The heat and pressure applied cause the softened portions of the polymer node strips to be forced around surface fibers of the fibrous sheet stock for bonding thereto. In the case of unreinforced node strips and unreinforced substrates, the heat of the node strips has to be able to soften the substrate sufficiently to cause fusion with the node strip when under pressure. The particular pressure and temperatures will be selected to suit the particular materials used for the node strips and substrates. Consequently, when the product is subsequently cooled and the pressure is removed, the node adhesive and the substrate, especially the fibers of a fibrous substrate, interlock, resulting in a strongly bonded, laminated structure, with sequential layers being bonded at alternating, linear node intervals.

This bonded structure is then expanded by any conventional expansion technique to result in a honeycomb structure. This expansion is graphically depicted in FIG. 3, with the arrows representing an opposite outward pulling action to produce honeycomb core 30.

Subsequently, the honeycomb structure can be dipped or otherwise coated in thermosetting polymer, e.g., a phenolic resin, which is uncured, followed by curing thereof to rigidify the structure and prevent subsequent collapse. The particular type and amount of thermosetting polymer applied to the honeycomb will depend upon the ultimate properties and uses desired. The thermosetting polymer is cured by heat in a known conventional fashion.

The production manner in which the node material is applied to the substrate layers can vary widely, with several representative apparatuses and processes being set forth herein as the preferred ones.

Referring first to the showing in FIGS. 5 and 6, the plurality, here eight, of continuous thermoplastic strips 21G are here shown to be unwinding from a like number of spools 22G. These strips can be, e.g., of tape, being spaced from and parallel to each other as they pass around work roll 24G to engage a generally continuous fibrous web 18G from web coil 26G as the web passes around work roll 28G. The continuous strands 21G are heated and pressed against web 18G as the strips and web pass between the cooperative, squeezing work rolls 24G and 28G to produce the combination 32G of fibrous web and thermoplastic strips adhered to one side of the web. Successive portions of this combination web and strips can be severed into sheets 14G by a suitable cutter 34G such as a guillotine blade, a water jet, or other known cutting devices. The cut portions or segments have spaced nodal strips 20G, with the successive sheets being placed one on top of another, but each being laterally offset relative to the one therebelow by an amount equal to one-half of the spacing between the individual parallel strips 20G of node material. As the thermoplastic strips are paid out from spools 22G and meet the web paid out from coil 26G, and both pass between rollers 24G and 28G, the roller 28G engaging the back side of the web is preferably maintained at a temperature sufficiently above the softening temperature of the thermoplastic node material to heat the node strips above that temperature and cause adherence thereof to the web, while roller 24G is purposely maintained at a lower temperature in order to prevent sticking of the node material to this roller. The node material is normally not heated above the melting temperature of the material to limit flow of resin into the web. When the multiple of sheets with the strips applied are placed in a stack as noted above, resting upon a support such as a lower press platen 36G, heat and pressure are applied to the stack, as with an upper platen 38G, sufficient to soften the node strips, causing the softened node material to penetrate the surface fibers of the adjacent sheet. After cooling, this forms a block 10G to be subsequently expanded into a honeycomb structure. Alternatively, the web with the thermoplastic node material bonded to it could be coiled up for storage, shipment and processing at a later date, rather than immediately being cut into sheets and stacked into an unexpanded block.

In FIGS. 7 and 8 is disclosed an in-line web arrangement wherein the individual strips of node bonding material are formed in situ from extruder heads, simultaneously with advancement of the web. Specifically, web 18H is paid off web coil 26H and advanced between a lower, heated, press roll or work roll 28H and a cooperative, upper, cool, press roll or work roll 24H. Simultaneously, a plurality of conventional extruder heads 25H positioned in side-by-side fashion, spaced from each other along the width of the web stock 18H and along the length of roll 24H, extrude spaced strips 21H of node bond material, which solidify after extrusion onto the cool or cold roll 24H, to travel therearound in spaced parallel fashion for bonding to web 18H as the two pass between the press rolls 24H and 28H and are heated. In FIG. 8, the extruder heads 25H are shown to be extruding a plurality of, here four, strands which together form a strip 21H. The resulting web with bonded strips can be rolled into a coil for later sheeting, or can be sheeted into individual sheets 14H having parallel solid node strips 20H adhered thereon. When stacked, each individual sheet is laterally offset relative to the sheet therebelow and the sheet thereabove, an amount which is one-half the spacing between strips 20H, so that the node bond material is in alternating arrangement as depicted in FIG. 3.

In FIG. 9 is shown another alternative technique and apparatus for forming the substrate and node strip combination, thus forming the honeycomb block to be expanded. In this instance, a cross-line sheeter is employed. More specifically, a web 18I is advanced from web coil 26I as by a pair of draw rolls 27I and severed into individual sheets 14I, as by a blade or the like, which sheets are to be advanced into a stack of sheets. On each sheet a plurality of transversely oriented strips 20I are applied in spaced parallel fashion. These nodal strips on each sheet are offset relative to the node strips immediately therebeneath an amount which is one-half the spacing between the strips. The stack of sheets and strips is placed on a lower press platen 40I cooperative with an upper, vertically reciprocable press platen 42. These platens can be heated by any suitable means such as electrical resistance elements, internal heated fluid, or a variety of other conventional techniques, for increasing the temperature of the solid node strips 20I. These individual strips are formed from a plurality of spools 22I of continuous strip material 21I.

FIGS. 9A-9J illustrate the steps of the individual strips of nodal material being applied to the surface of the fibrous sheets. Referring first to FIG. 9A, a first pair of strip grippers 46I secure the ends of the strips 21I on one side of the stack of sheets 14I and, as illustrated in FIG. 9B, are moved across the stack of sheets to the opposite side thereof to extend the strips thereacross. Then the second pair of strip grippers 48I clamp the strips at the first side of the stack as in FIG. 9C, and the adjacent cutoff knife 50I is vertically actuated relative to its cooperative anvil to sever a length of the continuous strips to form the nodal strips 20I which are then lowered onto the sheet stock 14I (FIG. 9E), after which another sheet 14I is applied atop the strips (FIG. 9F). Following this action to form the desired layer thickness, upper platen 42I is lowered so that heat and pressure are applied to the strips and sheets between platens 40I and 42I to soften the nodal strips and cause them to flow around fibers on the surface of the sheets. The upper platen is then retracted (FIG. 9H), after which the clamping knife 50I is separated from its anvil (FIG. 9I), as well as grippers 46I being separated, after which grippers 46I are returned to the initial position for the next cycle (FIG. 9J). The tag ends of the strips can be removed by any desired technique.

In FIGS. 10-15 are shown other structures and methods of forming the composite for the honeycomb block. One technique is cross stringing, shown in two versions in FIGS. 10-13 and FIGS. 14-15. Specifically, referring first to FIGS. 10-13, web 18J is paid off coil 26J to pass between a pair of cooperative lower and upper rolls 28J and 24J to press the strands and web together, with lower roll 28J being heated above the softening temperature of the nodal strips, and upper roll 24J being cool. The strands of parallel, solid, polymeric, continuous nodal material are advanced along the length of upper roll 24J by draw pins 24'J which move along longitudinal slots in roller 24J as driven by internal advancing mechanism. This pulls the strand crosswise of the web. The filament material 27J forming the strands is fed off a spool 29J and advanced to a plurality of stationary guide pins 31J (FIG. 11) which extend around the periphery of cylinder 24J, spaced from each other, and projecting radially outwardly from the end of cylinder 24J adjacent spool 29J. The strand 27J thus is peripherally advanced during rotation of cylinder 24J, as well as axially extended by the stringing pins, such that when the peripheral portions of the cylinder reach web 18J, the doubled strand is basically extended substantially the full length of cylinder 24J to extend substantially across the width of web 18J. Engagement of the web and the doubled strand between the two cylinders or rolls 24J and 28J presses the doubled strand against web 18J, with the temperature of the hot lower roll 28J increasing the temperature of the solid strand sufficient to soften it, causing the strand to bond to web 18J and form a strip.

As an alternative to rolls 24J and 28J are the rolls 30J, 34J and 32J. The web is advanced past heated rolls 30J which press it against a central heated work roll 32J (in place of roll 28J) and then past a pair of cold rolls 34J pressing it against work roll 32J as shown in FIG. 12.

The following series of pins 24'J likewise sequentially advance the succeeding double strand portions to the far end of cylinder 24J, each pin then returning axially of the cylindrical roller back to its starting position to repeatedly engage successive portions of strand 27J coming from spool 29J. The web with the nodal material bonded thereto at spaced intervals can be cut into sheet stock. The sequential operation is illustrated more schematically in projection drawing FIG. 13, showing how the axially advancing pins 24'J draw the strand 27J around stationary pins 31J and over the length of cylinder 24J.

As an alternative to the cylindrical arrangement depicted in FIGS. 10-12, a planar type arrangement can be employed wherein the cross line stringers advance filaments in both directions, i.e., from both sides across the width of the sheet stock, as illustrated in FIGS. 14-16. In this instance, a sheet of fibrous stock material 14K is placed on top of a platen and continuous filaments 27K of thermoplastic node material are laced back and forth around pins 31K adjacent opposite edges of the sheet. Optionally several filaments may be run across the web to add strength and width to the node. The filaments basically define the edges of each of the spaced node lines. After the node lines have all been laced across the web, another sheet of substrate is placed on top of the first sheet and its node strips. Again, filaments are laced back and forth across this sheet, with the second set of pins being offset by one-half of the distance or spacing between the nodes of the previous layer (shown in hidden lines) so that the filament node lines on this second sheet will be midway of the node lines on the underlying sheet. This process of laying down individual sheets of substrate and running filaments around the pins, laying another sheet thereon and repeating the filament run on offset pattern, is continued until the desired number of sheets have been applied to form the block. The block is then pressed under heat and pressure sufficient to soften the nodal thermoplastic and bond the layers together at the desired node locations. The solid block is then cooled and expanded as needed to form honeycomb.

Referring now to FIGS. 17 and 18, this illustrates apparatus and a method for in-line, two-sided windup formation of honeycomb blocks. (In FIGS. 26-28 is depicted a multiple sided forming apparatus to be described hereinafter.) Specifically as to FIGS. 17 and 18, web substrate material 14L is paid out from alternating coils 26L, here shown to be two in number, with a pair of node spools 29L of thermoplastic strips 21L or filaments being simultaneously unwound to pay out strips of thermoplastic node material, one set of strips between two layers of substrate and the other beneath the lower substrate. These two layers of substrate and two series of node strips then pass between a pair of press rolls 24L and 28L, the upper one 24L being heated, so that the node material is softened to bond to the substrate layers. The bonded layers and strips are then advanced to a windup form shown in the form of a plate 31L which rotates about a transverse axis 33L intermediate its ends, causing the layers of substrate and node strips to be wound upon each other to a desired thickness and number of layers. This creates two unexpanded blocks of honeycomb, one on each face of the plate. The individual blocks can then be severed from each other and from the plate, removed, and placed individually in a press in which they are heated above the nodal material softening temperature and pressed, to fuse the material together only along the node sites. Alternatively, the layers can all be pressed and heated while still on the windup plate, then severed and removed as blocks. The blocks are ultimately expanded into honeycomb structures.

In FIGS. 26-28 is disclosed an alternative apparatus 10Q and method to those just described relative to FIGS. 17 and 18. In this apparatus the node strips are bonded to substrate layers and two substrate layers are bonded together as well as to the node strips, as the layers and node strips are wound onto the rotating, multiple faced windup form or mandrel 31Q. Hence, no further or subsequent press and bonding steps or cycles are necessary. Rather, the individual, bonded, unexpanded honeycomb blocks are severed from the mandrel and subsequently expanded and/or cut as desired.

Referring more specifically to FIGS. 26-28, the apparatus comprises a multiple faced form or mandrel 31Q which is shown to have eight faces around its periphery, but can have as few as two faces or as many faces as desired, conceivably up to an infinite number, i.e., cylindrical surface. The mandrel is mounted to rotate about its central, transverse axis. Powered rotation of this mandrel causes a pair of webs 14Q of substrate from coils 26Q to be wound thereon, as well as a pair of a series of laterally spaced, endless, intermediate node strips 21Q from spools 29Q between the substrate layers. Although two substrate layers and two sets of node strips are shown here to be wound simultaneously onto the mandrel, only one or several such layers and sets could be employed. Adjacent the periphery of mandrel 31Q is an elongated, rotational, heated press roll 40Q which presses the two layers of newly wound substrate and the intermediate node strips onto the underlying layers on the mandrel, to bond the node strips and substrate layers together as they are wound onto the mandrel. One set of the node strips is laterally offset relative to the other set an amount equal to one-half the spacing between those in the other set, as in the other embodiments disclosed. Hot air jet manifolds 42Q with nozzles assist in elevating the node strip temperature to a point above the softening temperature and the melting temperature thereof. Roll 40Q is mounted on spring biased flex supports (not shown) to allow it to follow the mandrel periphery while being biased toward the mandrel. After the desired number of substrate layers and node strips are wound onto the mandrel and bonded together, rotation of the mandrel is stopped and individual honeycomb blocks 10Q are severed from each other (FIG. 28). This can result in a small amount of scrap, shown in the form of pie-shaped pieces 44Q, at the corner junctions of the mandrel faces. The honeycomb blocks are later expanded as desired.

FIGS. 19, 20 and 21 illustrate a more complex cross wind arrangement employing a double action winder on axes which are normal to each other, such that winding in one dimension winds a pair of webs on the plate-type, windup form, and winding in the transverse dimension winds a pair of sets of strips on the form. The pair of webs 14M and 114M of substrate material are applied from opposite ends of the winder to the windup plate 31M from a pair of web coils 26M and 126M. Web coils 26M and 126M are suspended from respective pairs of laterally spaced, elongated supports 27M and 127M secured to respective cross beams 29M and 129M. These supports and cross beams are movable toward and away from winder plate 31M so as to respectively engage or disengage their end sockets 133M to or from a first set of four extending connector pins 131M. Two laterally spaced pins extend from each end of plate 31M in the opposite direction to the two spaced pins on the opposite end of plate 31M. When these pins and sockets are disengaged, the winder plate is free to rotate 180.degree. in the dimension of webs 14M and 114M to apply a layer of web on each of the opposite faces of plate 31M. This action is caused by rotation of plate 31M about a central transverse axis on pins 41M. This rotary motion is intermittent with rotation of plate 31M in the transverse dimension to apply two series of nodal strips across the layers of web on the opposite faces of plate 31M, as set forth below.

Two sets of nodal strips extend from spools 29M and 129M mounted on opposite sides of plate 31M, each on a pair of elongated, spaced supports 37M and 137M secured to respective cross beams 39M and 139M, respectively. Supports 37M and 137M each have end sockets 133'M that engage to or disengage from four pins 131'M. These latter pins 131'M are normal to pins 131M. Two of these latter pins 131'M extend from one side of plate 31M and two extend in the opposite direction from the opposite side of plate 31M. The supports 37 and 137 are movable toward and away from each other to engage or disengage the pins 131'M and sockets 133'M. When these are disengaged, and the pins 131M are engaged with their sockets 133M, plate 31M can be rotated 180.degree. to wrap one set of nodal strips across one web face, e.g., on the top of plate 31M, and wrap the second set of nodal strips across the second web face, e.g., on the bottom of plate 31M. These two opposite sets of strips are laterally offset relative to each other midway of the node strip spacings. Hence, when spools 29M apply one set of node strips on one face of plate 31M, the next set of node strips will be applied on this one face by spools 129M laterally offset from the first set. These node strips are applied when plate 31M is pivoted around the longitudinal axis of a pair of opposite coaxial pivot pins 43M mounted on cross beams 29M and 129M. By having the node strips which are wound upon the plate and upon the web substrate from one direction, offset relative to the node strips wound from the opposite direction, by an amount which is one-half the spacing between the node strips, the alternate node strips between successive layers of substrate are laterally offset to allow the honeycomb to be formed later. As noted, these alternating winding mechanisms rotate 180.degree. and then stop, the drive mechanism for that mechanism then disengaging while the alternate drive mechanism for the transverse winder engages, and that winder then rotates 180.degree.. The winding action automatically forms two honeycomb blocks, one on top and one beneath the windup plate. When the layers are the required thickness, the winding is stopped, the two layer stacks are heated and pressed, and the two resulting blocks are severed and removed from the plate and each other for expansion into honeycomb.

In FIGS. 22, 23 and 24A-24D is shown apparatus for a corrugation method of forming honeycomb, utilizing solid node thermoplastic bonding strip material. More specifically, web stock 14N is uncoiled from the coil 26N and passed between a pair of heating elements 27N to soften the web, and then between a pair of cooperative interengaging corrugating rollers 18N. The resulting corrugated substrate 14'N resulting is cut to length by a suitable cutter 15G and placed on a plurality of parallel, elongated, transverse, metal formers or fingers 16N which have a height equal to the corrugation cell height. Thus, the metal formers are equal in height to the height of the honeycomb cell to be formed. After one corrugated sheet is placed on these metal formers, a second set of formers 17N is placed on top of this corrugated sheet so that the formers are at alternating elevations one-half cell height and width apart. A plurality of solid node strips of thermoplastic nodal material is then placed along the spaced, parallel, coplanar, elevated upper surfaces or crests of the corrugated sheet. Then another corrugated sheet is lowered onto the second set of formers so that its depressions engage these strips on the elevated crests of the layer therebelow. A heated platen 42N is then brought down into engagement with the uppermost corrugated sheet, pressing it and the next adjacent sheet down into engagement with the first set of formers 16N, thereby heating and softening the node strips of solid material 20N between the engaging overlapping corrugated sheets. This bonds the corrugated sheets together, after which the lower set of formers is then removed, another plurality of nodal strips placed on the alternate upper corrugated sheet, and a further corrugated sheet is placed on top of it, heated and pressed for repeat of the sequence until a honeycomb structure of the desired height is made.

If desired, nodal template units as illustrated at 12P in FIG. 25 may be utilized for the node strips, e.g., in the corrugation method. Alternatively, the template type arrangement shown in FIG. 25 can be employed with the expansion type system. This template type arrangement includes a plurality of parallel strips 20P of node material connected at their ends by transverse carrier strips which can later be removed if desired. The length of the node strips enables them to extend across the entire width of the sheet substrate stock 14P. The successive templates have offset nodal strips relative to each other. Thus, referring to FIG. 25, step 1, the first block forming sheet will have the first nodal template with its node strips applied thereto, a second sheet will then be advanced over the top of this template, a second template of nodal strips (step 2) offset to be midway between the node strips previously applied to the sheet therebeneath, another sheet advanced (step 3), and another template of nodal material advanced (step 4), comparable to that in step 1, on top of the last sheet, and so forth. Ultimately the desired number of layers of substrate and nodal strips is obtained, and these are heated above the softening point and pressed to cause bonding of the thermoplastic nodal strips to the surface fibers of the substrate sheets. The block is cooled, and later expanded to form honeycomb.

There are several advantages to the novel process: 1) Limited, controlled flow of the softened node strip is controlled by the application of heat and pressure to the node strips and use of reinforcing material, making it possible to bond layers of the substrate without preimpregnating, since the node material does not bleed or penetrate through the porous materials; 2) No solvent need be used in this process. Such solvents not only cause bleeding of the material through each layer but also result in environmental problems during evaporation thereof; 3) The node material can be of a variety of forms; 4) High temperature thermoplastic materials can be used in applications where higher service temperatures are encountered; 5) Better sequence of manufacture. All dipping is performed after the block has been made. If desired, the block can be left as raw fabric core; 6) Easier expansion process. The block will expand much more easily due to absence of resin on the fabric to make it stiffer. The block will not tend to become a "brick" because of improper cure of resin. The product will not tend to fail due to material brittleness resulting from improper cure or quantity of resin; 7) Nodes can be reinforced as with glass, quartz, carbon fiber, or other engineering materials, including thermosetting and thermoplastic materials. Orientation of reinforcement fibers can be arranged so that core properties can be improved; 8) Holes can be eliminated. Porosity in the fabric can be eliminated by laminating with thermoplastic film; 9) Many combinations of materials can be used. The substrate may be reinforced with thermoset material, thermoplastic material, or a combination of both. Reinforcement of the nodes can be different from the reinforcement of the substrate in both material and orientation; 10) No precufing of adhesive prior to bonding is required; 11) The node material is dry as applied; 12) Where desired, node material can be precured prior to application.

Further, node strength can be optimized through resin flow which is controlled by 1) selection of node material with desired melt and softening temperatures, and b) change of melt and softening temperatures by use of selected reinforcing materials such as glass, carbon, etc. (e.g., addition of glass filaments raises such temperatures). Also, bonding pressure is applied more directly to the node area due to the thickness of node strips.

These and several other advantages, features and various modifications will be apparent to those in the art upon studying this disclosure. Hence, the invention is not intended to be limited to the preferred embodiments set forth herein as illustrative of the invention, but only by the scope of the appended claims and the reasonably equivalent structures and processes to those defined therein.

Claims

1. A method of making honeycomb product comprising the steps of:

advancing a plurality of substrate layers to be overlaid relative to each other;

applying to individual ones of said substrate layers a plurality of segment node strips of solid polymeric material having a softening temperature and a higher melting temperature, said solid node strips being placed spaced from and parallel to each other on each said substrate layer, and placed in alternating offset but parallel relationship to solid node strips on substrate layers thereabove and therebelow;

placing said substrate layers in stacked relationship to each other and applying pressure to said substrate layers and said solid node strips while elevating the temperature of said solid node strips to a value above said softening temperature but below said melting temperature, and maintaining said pressure and said temperature for a time sufficient to force softened portions of said solid node strips into full engagement with said substrate layers;

removing the pressure and cooling said layers and solid node strips and thereby bonding said solid node strips to said substrate layers to form a laminated structure; and

expanding said cooled laminated structure into a honeycomb core structure.

2. The method of making honeycomb product in claim 1 wherein said step of placing said substrate layers in stacked relationship to each other comprises applying pressure and elevating the temperature of said node strips only after a plurality of said substrate layers are so stacked.

3. The method of making honeycomb product in claim 1 wherein said step of placing said substrate layers in stacked relationship to each other comprises applying pressure and elevating the temperature of said node strips after each substrate layer is so stacked.

4. The method in claim 1 including the step of applying an uncured thermosetting resin to said expanded honeycomb core structure, and curing said thermosetting resin.

5. The method in claim 1 wherein said solid thermoplastic node strips comprise one or more materials selected from the group consisting of homogeneous thermoplastic strips, thermoplastic filaments, thermoplastic preimpregnated cloth, thermoplastic coated glass filaments, expanded thermoplastic film, and unexpanded thermoplastic film.

6. The method in claim 1 wherein said thermoplastic node strips comprise one or more of the group of thermoplastic materials selected from the group consisting of polypropylene, polyethylene, polycarbonate, polyetherimide, polyethersulfone, polyetheretherketone, and polyurethane.

7. The method in claim 1 including the steps of providing a continuous web of substrate material, and severing said web into said plurality of substrate layers.

8. The method in claim 1 including the steps of providing continuous strips of said polymeric node material, and severing said continuous strips into said segment node strips.

9. The method in claim 7 including the steps of providing continuous strips of said polymeric node material, and severing said continuous strips into said segment node strips.

10. The method in claim 1 wherein said strips are in the form of templates, each successive template of strips in said stacked relationship being laterally offset from any template therebelow and offset from any template thereabove.

11. The method in claim 1, wherein said solid node strips are advanced from at least one spool.

12. The method defined in claim 1 wherein the substrate layers that are advanced are made of a porous material.

13. A method of making honeycomb product comprising the steps of:

advancing a continuous web of substrate material;

advancing a plurality of continuous node strips of solid thermoplastic node material in the same direction as said advancing substrate material;

applying said node strips to a surface of said substrate material while said node strips are retained spaced from and parallel to each other;

heating said node strips above the softening temperature thereof and applying pressure to said softened strips against said substrate material to adhere said parallel node strips to said substrate material;

transversely cutting said continuous substrate material into substrate sheets and said adhered node strips into node segments;

stacking said substrate sheets and adhered node segments in layers, with said segment node strips on successive layers being laterally offset and parallel to node strips on layers thereabove and therebelow;

heating said segment node strips above the softening temperature thereof and pressing said layers together to bond said layers together with each other and with said node strips, along said node strips, to form a block;

cooling said block; and

expanding said block into a honeycomb structure.

14. The method in claim 13 wherein said plurality of node strips are extruded in situ while advanced.

15. The method in claim 13 wherein at least some of said node strips are each formed of a plurality of filaments.

16. The method in claim 13 wherein said filaments are multiple strands.

17. The method in claim 13 wherein said strips are formed from at least one continuous filament which is advanced across said web at spaced intervals.

18. The method in claim 17 wherein said filaments are advanced as doubled strands.

19. A method of making a honeycomb structure comprising the steps of:

advancing substrate material in a first direction;

advancing node strips of solid thermoplastic polymeric node material in a second direction transverse to said first direction across said substrate material at spaced intervals to provide spaced parallel node strips, for a combination of substrate and node strips;

effecting a stack of layers of said combination substrate and node strips while offsetting said node strips on each layer to be laterally offset midway relative to any node strips on a layer therebelow and any node strips on a layer thereabove;

pressing said stack of layers including said node strips while heating said node strips sufficiently to soften said node strips to bond to the layer therebelow and the layer thereabove, forming a block;

cooling said block; and

expanding said block into a honeycomb structure.

20. The method in claim 19 including the steps of providing said node strips in continuous form, and severing said advancing continuous node strips to a length substantially equal to the width of said substrate material.

21. The method in claim 17 including the steps of providing said substrate material in continuous web form, and severing said web form into sheets.

22. A method of making honeycomb blocks comprising the steps of:

providing a windup form having faces and being rotational about its center;

winding up onto said form at least one web of substrate material to form substrate layers thereof on said faces, while winding up a plurality of spaced parallel node strips of solid thermoplastic node material between the said layers of substrate material, said solid node material having a softening temperature and a higher melting temperature, and causing said spaced parallel solid node strips applied to successive substrate layers to be midway between the solid node strips applied to the previous substrate layer; and

heating and pressing said solid node strips and substrate layers to a temperature above said softening temperature, but below said melting temperature of said solid node strips to sufficiently soften said solid node strips and cause them to bond between adjacent layers of said substrate material.

23. The method in claim 22 wherein said step of heating and pressing is performed on said windup form, and then said bonded substrate layers and node strips are severed into honeycomb blocks.

24. The method in claim 22 including the step of separating said substrate layers and node strips wherein they are first separated from said windup form and then are heated and pressed sufficiently to elevate the temperature of said node strips above the softening temperature thereof to bond said substrate layers and node strips into honeycomb blocks.

25. The method in claim 22 wherein said strips are wound in the same direction as said substrate is wound.

26. The method in claim 25 wherein said strips are wound in a direction transverse to the direction that said substrate is wound.

27. The method in claim 22, wherein said solid node strips are advanced from at least one spool.

28. The method defined in claim 22 wherein the substrate layers that are wound up onto said rotational form are made of a porous material.

29. A method of making honeycomb precursor product, capable of expansion into a honeycomb product, from sheet stock, comprising the steps of:

providing a plurality of substrate layers;

corrugating said layers to result in parallel, spaced, offset crests and depressions in each layer;

placing on said crests node strips of solid thermoplastic node material having a softening temperature and a higher melting temperature, with said node strips being spaced from and parallel to each other;

stacking said substrate layers to cause said depressions in each layer to engage said node strips on the said crests of the layer therebelow, and thereby cause said node strips on said crests of each layer to engage the depressions of the layer thereabove;

applying pressure to said crests and depressions of successive said substrate layers while heating said node strips to a temperature above said softening temperature to bond said node strips to said substrate layers of said crests and depressions, and thereby bond said corrugated substrate layers together; and

cooling and removing said pressure from said substrate layers to result in a honeycomb structure.

30. A method for forming a precursor block expandable into a honeycomb structure, comprising the steps of:

providing and advancing substrate layers, and stacking said substrate layers;

providing and advancing successive sets of pluralities of solid polymeric node strips in parallel relationship, at equal spacings, onto said substrate layers before or while said substrate layers are stacked, one set for each layer, and each set laterally offset halfway relative to the strip spacing of the set therebelow; and

softening said solid node strips and pressing them into bonding relationship with said substrate layers to form a block, to thereby form an expandable block.

31. The method in claim 30, wherein said solid node strips are advanced from at least one spool.

32. The method defined in 30 wherein the substrate layers that are advanced are made of a porous material.

33. A method for forming a precursor block expandable into a honeycomb structure, comprising the steps of:

providing and advancing at least one web of substrate material to a stacking apparatus that stacks successive layers of said substrate material;

providing and advancing a plurality of spaced parallel node strips of solid thermoplastic node material toward said web of substrate material, said node material having a softening temperature and a higher melting temperature; and

heating said solid node strips to a temperature above said softening temperature, but below said melting temperature as said solid node strips are applied between adjacent layers of said substrate material to bond the adjacent layers of substrate material together as said solid node strips are allowed to cool.

34. The method in claim 33, wherein said solid node strips are advanced from at least one spool.

35. The method in claim 33, wherein said thermoplastic node strips are thermoplastic coated glass filaments.

36. The method defined in claim 33 wherein the substrate layers that are advanced are made of a porous material.

37. A method for forming a precursor block expandable into a honeycomb structure, comprising the steps of:

providing a windup form having faces and being rotational about its center;

winding up onto said windup form at least one web of substrate material to form substrate layers thereof on said faces;

advancing a plurality of spaced parallel node strips of solid thermoplastic node material toward said windup form, said node material having a softening temperature and a higher melting temperature; and

heating said solid node strips to a temperature above said softening temperature, but below said melting temperature as said solid node strips are wound upon said windup form between adjacent layers of said substrate material to bond the adjacent layers of substrate material together as said solid node strips are allowed to cool.

38. The method in claim 37 and further including the step of pressing said alternate layers of substrate material and node strips as said layers are wound onto said windup form.

39. The method in claim 38 and further including the step of severing the bonded substrate layers to form honeycomb blocks.

40. The method in claim 37, wherein said node strips are wound onto said windup form in the same direction as the substrate is wound.

41. The method in claim 37, wherein said solid node strips are advanced from at least one spool.

42. The method in claim 37, wherein said thermoplastic node strips comprise one or more materials selected from the group consisting of homogeneous thermoplastic strips, thermoplastic filaments, thermoplastic preimpregnated cloth, thermoplastic coated glass filaments, expanded thermoplastic film, and unexpanded thermoplastic film.

43. The method in claim 37, wherein said thermoplastic node strips comprise one or more of the group of materials selected from the, group consisting of polypropylene, polyethylene, polycarbonate, polyetherimide, polyethersulfone, polyetheretherketone, and polyurethane.

44. The method in claim 37, wherein said thermoplastic node strips are thermoplastic coated glass filaments.

45. The method in claim 37 including providing continuous strips of solid node material and a continuous web of substrate material, and severing the layers of substrate material and strip nodes after the layers of substrate material are bonded together by said strip nodes.

46. The method defined in claim 37 wherein the substrate layers that are wound up onto said rotational form are made of a porous material.

47. A method for forming a honeycomb structure, comprising the steps of:

providing a windup form having faces and being rotational about its center;

winding up onto said windup form a first web of porous substrate material on said faces to form a plurality of layers of said first substrate web;

advancing a first set of spaced parallel node strips of solid thermoplastic node material toward said windup form for application onto said first substrate web, said node material having a softening temperature and a higher melting temperature;

winding up onto said windup form a second web of porous substrate material on said first set of spaced parallel node strips to form a plurality of layers of said second substrate web;

advancing a second set of spaced parallel node strips of said solid thermoplastic node material toward said windup form for application onto said second substrate web, said second set of node strips being applied to said second substrate web at spacings off-set halfway between the node strips of said first set;

heating said solid node strips of said first and second set to a temperature above said softening temperature, but below said melting temperature as said solid node strips are wound upon said windup form between adjacent layers of said first and second substrate layers to bond the adjacent substrate layers together as said solid node strips are allowed to cool, said node strips being applied as a softened solid material to prevent wicking of the node strips through the layers of said first and second webs of porous substrate material;

rotating said windup form until a multi-layered structure is formed that includes a plurality of alternating layers of said first and second substrate webs bonded together along nodes formed therebetween by said node strips;

cutting the multi-layered structure into flat precursor blocks; and

expanding a precursor block into a honeycomb structure.

48. The method defined in claim 47 and further including the steps of:

coating said honeycomb structure in a resin; and

curing said resin-coated honeycomb structure to form a rigid honeycomb structure.