# US 12,180,608 B2 · Forming acoustic panel with multi-layered septum(s) > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,180,608 B2 - Document ID: US12180608B2 - Status: Granted - Kind: B2 - Application number: 17/688,301 - Filed: 2022-03-07 - Published: 2023-09-07 - Granted: 2024-12-31 - Earliest claimed: 2022-03-07 - Assignees: Rohr, Inc. - Applicants: Rohr, Inc. - Inventors: Steven Kestler - Web page: https://patentgrep.com/patent/US12180608B2 ## CPC - C25D 7/04: Tubes; Rings; Hollow bodies - G10K 11/172: using resonance effects - B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure - B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12} - B64C 1/40: Sound or heat insulation {, e.g. using insulation blankets} - C25D 5/02: Electroplating of selected surface areas - C25D 5/48: After-treatment of electroplated surfaces - G10K 11/168: Plural layers of different materials, e.g. sandwiches - B32B 2307/102: Insulating - B32B 2607/00: Walls, panels - Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft - C25D: PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR - G10K: SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B64C: AEROPLANES; HELICOPTERS - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract A formation method is provided during which a cellular core is provided. The cellular core includes a plurality of cavities that include a first cavity. Each of the cavities extends through the cellular core. A metal substrate is disposed within the first cavity. The metal substrate is electroplated to form a septum within the first cavity. The septum is bonded to the cellular core. ## Claims ### Claim 1 A formation method, comprising: providing a cellular core, the cellular core comprising a plurality of cavities that include a first cavity, each of the plurality of cavities extending through the cellular core; disposing a metal substrate within the first cavity; electroplating the metal substrate while the metal substrate is disposed within the first cavity to form a septum within the first cavity; bonding the septum to the cellular core; and forming an acoustic panel, the acoustic panel comprising a core structure between a perforated first skin and a second skin, and the core structure comprising the cellular core and the septum. ### Claim 2 (depends on 1) The formation method of claim 1, wherein the cellular core comprises a honeycomb core. ### Claim 3 (depends on 1) The formation method of claim 1, wherein the first cavity extends along a centerline through the cellular core; and the first cavity has a polygonal cross-sectional geometry in a plane perpendicular to the centerline. ### Claim 4 (depends on 1) The formation method of claim 1, further comprising: attaching the metal substrate to a tool; inserting the tool into the first cavity to dispose the metal substrate within the first cavity; and holding the metal substrate within the first cavity using the tool during the electroplating. ### Claim 5 (depends on 4) The formation method of claim 4, further comprising detaching the tool from the metal substrate subsequent to the bonding of the septum to the cellular core. ### Claim 6 (depends on 4) The formation method of claim 4, wherein the metal substrate is attached to the tool using a vacuum. ### Claim 7 (depends on 4) The formation method of claim 4, wherein the tool comprises a base and a protrusion; the metal substrate is abutted against the base; and the protrusion projects out from the base through a perforation in the metal substrate. ### Claim 8 (depends on 1) The formation method of claim 1, further comprising: disposing the cellular core and the metal substrate into an electroplating bath; and applying an electric charge to the metal substrate to electroplate the metal substrate within the electroplating bath. ### Claim 9 (depends on 8) The formation method of claim 8, wherein the metal substrate is electrically decoupled from the cellular core within the electroplating bath. ### Claim 10 (depends on 1) The formation method of claim 1, further comprising heating an assembly subsequent to the electroplating to activate bonding material and bond the septum to the cellular core, the assembly comprising the cellular core and the septum. ### Claim 11 (depends on 10) The formation method of claim 10, wherein the bonding material comprises an adhesive. ### Claim 12 (depends on 10) The formation method of claim 10, further comprising disposing the bonding material with the cellular core prior to disposing the metal substrate within the first cavity. ### Claim 13 (depends on 10) The formation method of claim 10, further comprising applying the bonding material to an edge of a wall of the cellular core that at least partially forms the first cavity. ### Claim 14 (depends on 1) The formation method of claim 1, where the septum comprises one or more perforations. ### Claim 15 (depends on 1) The formation method of claim 1, wherein the first cavity extends along a centerline through the cellular core; and the septum is angularly offset from the centerline by an acute angle. ### Claim 16 (depends on 1) The formation method of claim 1, further comprising: disposing a second metal substrate within a second cavity, the plurality of cavities further including the second cavity; electroplating the second metal substrate to form a second septum within the second cavity; and bonding the second septum to the cellular core. ### Claim 17 A formation method, comprising: providing a cellular core and a metal substrate, the cellular core comprising a first cavity that extends through the cellular core, and the metal substrate comprising one or more perforations; electroplating the metal substrate while the metal substrate is disposed within the first cavity to form a septum with one or more perforations; bonding the septum to the cellular core, the septum disposed within the first cavity; and forming an acoustic panel, the acoustic panel comprising a core structure between a perforated first skin and a second skin, and the core structure comprising the cellular core and the septum. ### Claim 18 A formation method, comprising: forming a core structure comprising a cellular core and a septum, the cellular core comprising a first cavity that extends through the cellular core, the septum comprising a first metal layer, a second metal layer and one or more perforations extending through the first metal layer and the second metal layer, and the septum disposed within the first cavity and bonded to the cellular core; wherein the forming comprises disposing the first metal layer within the first cavity; and electroplating the first metal layer while the first metal layer is disposed within the first cavity to form the septum within the first cavity; arranging the core structure between a perforated first skin and a second skin; and bonding the core structure to the perforated first skin and the second skin to form an acoustic panel, wherein the cellular core comprises a honeycomb core.