Laser-perforated metal honeycomb material

Abstract

A perforated metal honeycomb structure is described. The perforated metal honeycomb structure may include a metal honeycomb structure having a plurality of laser-drilled holes wherein at least some of the plurality of holes are non-uniform in second, shape, and/or spacing between holes. In another embodiment, the perforated metal honeycomb structure may include an array of intercellular holes between hexagonal cells in the honeycomb structure. The array of intercellular holes may include at least a first hole and a second wherein the first and second holes are different from each other.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
         1 . A perforated metal honeycomb structure, comprising:
 a metal honeycomb structure having a plurality of laser-drilled holes, wherein at least some of the plurality of holes are non-uniform in at least one of size, shape, and spacing between the holes.   
     
     
         2 . The structure of  claim 1 , further including at least a first laser-drilled hole and a second laser-drilled hole, wherein the first and second laser-drilled holes are different from each other. 
     
     
         3 . The structure of  claim 1 , wherein at least some of the plurality of laser-drilled holes are larger than 0.10 mm in diameter. 
     
     
         4 . The structure of  claim 2 , wherein the first laser-drilled hole has a first size and the second laser-drilled hole has a second size different from the first size. 
     
     
         5 . The structure of  claim 2 , wherein the first laser-drilled hole has a first shape and the second laser-drilled hole has a second shape different from the first shape. 
     
     
         6 . The structure of  claim 2 , further comprising a third laser-drilled hole, wherein the first laser-drilled hole has a first spacing from the third laser-drilled hole and the second laser-drilled hole has a second spacing from the third laser-drilled hole different from the first spacing. 
     
     
         7 . The structure of  claim 1 , wherein the honeycomb structure is expanded. 
     
     
         8 . The structure of  claim 1 , wherein the honeycomb structure is a honeycomb before expansion (HOBE) construction. 
     
     
         9 . The structure of  claim 1 , wherein the honeycomb structure is corrugated. 
     
     
         10 . A perforated metal honeycomb structure, comprising:
 a honeycomb structure including an array of intercellular holes between hexagonal cells in the honeycomb structure, wherein the array of intercellular holes includes at least a first hole and a second hole, wherein the first and second holes are different from each other.   
     
     
         11 . The perforated metal honeycomb structure of  claim 10 , wherein the array of holes are laser-cut through free walls of the honeycomb structure. 
     
     
         12 . The perforated metal honeycomb structure of  claim 10 , wherein the array of holes are formed between glue lines and in a web direction of the honeycomb structure. 
     
     
         13 . The perforated metal honeycomb structure of  claim 10 , wherein at least a portion of holes in the array of holes are between 0.050 mm and 0.10 mm in diameter. 
     
     
         14 . The perforated metal honeycomb structure of  claim 10 , wherein at least a portion of holes in the array of holes are larger than 0.10 mm in diameter. 
     
     
         15 . The perforated metal honeycomb structure of  claim 14 , wherein a volcano height of the array of holes is less than 30 microns and a volcano width is less than 20 microns. 
     
     
         16 . The perforated metal honeycomb structure of  claim 15 , wherein a heat-affected zone of the at least a portion of the array of holes is less than 17 microns. 
     
     
         17 . The perforated metal honeycomb structure of  claim 16 , wherein the heat-affected zone is less than 6 microns. 
     
     
         18 . The perforated metal honeycomb structure of  claim 16 , wherein the volcano height of the array of holes is less than 2 microns and the volcano width is less than 8.5 microns. 
     
     
         19 . The perforated metal honeycomb structure of  claim 16 , wherein the volcano height of the array of holes is less than 7 microns and the volcano width is less than 20 microns.