Method of making a cellular core with internal septum

A method of making a cellular core panel with internal septum for installation in the high velocity air flow region of an engine nacelle, and other applications requiring sound absorption and increased air frame strength, the steps consisting of:

• placing a destructible mold on a base;
• perforating a film of septum material in a desired perforation pattern;
• positioning the perforated film of septum material on top of the mold, the film of the septum material having a desired thickness;
• positioning a cellular core above the film of septum material and pressing the core through the septum material and into the material of the destructible mold until the septum material is at a precise position internally in the core;
• and
• stabilizing the septum material until the septum material is self-supporting within each cell of the core and subsequently removing the mold thereby providing a permanent internal septum with a planar geometric configuration.

A method of making a cellular core panel with internal septum for installation in the high velocity air flow region of an engine nacelle, and other applications requiring sound absorption and increased air frame strength, the steps consisting of:

• placing a destructible mold on a base;
• positioning a film of septum material on top of the mold, the film of the septum having a desired thickness;
• positioning a cellular core above the film of the septum material and pressing the core through the septum material and into the material of the destructible mold until the septum material is at a precise position internally in the core;
• stabilizing the septum material until the septum material is self-supporting within each cell of the core and subsequently removing the mold thereby providing a permanent internal septum with a planar geometric configuration;
• and
• perforating the septum material within each cell of the core forming a desired perforation pattern.

A method of making cellular core panel with internal septum for installation in the high velocity air flow region of an engine nacelle, and other applications requiring sound absorption and increased air frame strength, the steps consisting of:

• placing a destructible mold on a base;
• positioning a film of septum material on top of the mold, the film of the septum having a desired thickness;
• positioning a cellular core above the film of the septum material and pressing the core through the septum material and into the material of the destructible mold until the septum material is at a precise position internally in the core;
• forming a permanent septum in each cell of the core by heat curing the septum material;
• and
• removing the mold from the cellular core by heating and melting the mold therefrom.