Process for manufacturing a honeycomb composite material

Abstract

The process relates to the continuous production of a web of a composite material, comprising: providing a web of honeycomb material; providing at least one web of face sheet material having a corrugated medium with a first face covered with a linerboard and an exposed second face, including unrolling the face sheet material from a roll; carrying said web of honeycomb material and said at least one web of face sheet material along a production line; and adhesively applying the exposed second face of the at least one web of face sheet material to one face of said honeycomb material while said honeycomb material is being conveyed through the production line and maintained in an expanded state.

1 . A process for a continuous production of a web of a composite material, the process comprising the steps of: 
 providing a web of honeycomb material;    providing at least one web of face sheet material having a corrugated medium with a first face covered with a linerboard and an exposed second face, including unrolling the face sheet material from a roll;    carrying said web of honeycomb material and said at least one web of face sheet material along a production line; and    adhesively applying one of said first face and second face of the at least one web of face sheet material to one face of said honeycomb material while said honeycomb material is being conveyed through the production line and maintained in an expanded state.    
     
     
         2 . A process as claimed in  claim 1 , further comprising the step of expanding said honeycomb material from a collapsed state to said expanded state while said honeycomb material is being conveyed through the production line.  
     
     
         3 . A process as claimed in  claim 1 , wherein the step of adhesively applying said at least one web of face sheet material to one face of said honeycomb material further comprises 
 applying an adhesive on one of at least one face of said web of honeycomb material and a face of each of said at least one web of face sheet material;    laminating said at least one web of face sheet material on said web of honeycomb material, said adhesive being located therebetween; and    permitting said adhesive to set to keep said at least one web of face sheet material laminated with said web of honeycomb material.    
     
     
         4 . A process as claimed in  claim 3 , wherein said adhesive is applied on at least one face of said web of honeycomb material.  
     
     
         5 . A process as claimed in  claim 3 , further comprising heating said adhesive.  
     
     
         6 . A process as claimed in  claim 1 , further comprising trimming said web of composite material.  
     
     
         7 . A process as claimed in  claim 1 , further comprising cutting one of said at least one face sheet material of said web of composite material and bending said web of composite material to a predetermined angle.  
     
     
         8 . A process as claimed in  claim 1 , further comprising cutting longitudinally said web of composite material.  
     
     
         9 . A process as claimed in  claim 1 , further comprising cutting transversally said web of composite material.  
     
     
         10 . A process as claimed in  claim 1 , wherein the step of adhesively applying includes adhesively applying the exposed second face of the face sheet material to the honeycomb.  
     
     
         11 . A process for a continuous production of a web of a composite material, the process comprising the steps of: 
 unrolling a face sheet material from a roll, the face sheet having a corrugated medium with a first face covered with a linerboard and an exposed second face;    carrying said unrolled face sheet material along a production line;    expanding a web of honeycomb material into an expanded state; and    adhesively applying said face sheet material to the web of honeycomb material in the expanded state.    
     
     
         12 . A process as claimed in  claim 11 , further comprising expanding said honeycomb material from a collapsed state to said expanded state while said honeycomb material is being conveyed through the production line.  
     
     
         13 . A process as claimed in  claim 11 , wherein the step of adhesively applying said at least one web of face sheet material to one face of said honeycomb material further comprises 
 applying an adhesive on one of at least one face of said web of honeycomb material and a face of each of said at least one web of face sheet material;    laminating said at least one web of face sheet material on said web of honeycomb material, said adhesive being located therebetween; and    permitting said adhesive to set to keep said at least one web of face sheet material laminated with said web of honeycomb material.    
     
     
         14 . A process as claimed in  claim 13 , wherein said adhesive is applied on at least one face of said web of honeycomb material.  
     
     
         15 . A process as claimed in  claim 13 , farther comprising heating said adhesive.  
     
     
         16 . A process as claimed in  claim 11 , further comprising trimming said web of composite material.  
     
     
         17 . A process as claimed in  claim 11 , further comprising cutting one of said at least one face sheet material of said web of composite material and bending said web of composite material to a predetermined angle.  
     
     
         18 . A process as claimed in  claim 11 , further comprising cutting longitudinally said web of composite material.  
     
     
         19 . A process as claimed in  claim 11 , further comprising cutting transversally said web of composite material.  
     
     
         20 . A process as claimed in  claim 11 , wherein the step of adhesively applying includes adhesively applying the exposed second face of the face sheet material to the honeycomb.