Method for producing expandable honeycomb material

A process of producing expandable honeycomb material comprising:

• heating the surface of a continuous strip of material suitable for use as honeycomb material;
• applying adhesive resinous material in a plurality of lines longitudinally along the length of said heated surface;
• chilling said surface to cool and solidify said adhesive into a dry, hard and non-sticky state;
• adjusting said elongated strip into continuous, elongated tapes each being approximately twice the width of said resultant honeycomb material;
• folding each said tape longitudinally along opposite lateral side portions into a generally flat, tubular form having upper and lower layers each said layer having at least a pair of adhesive lines on the surface thereof disposed proximate the center portion of said layer;
• winding the continuous length of flat tubular tape about a generally annular rack in such a manner that said tubular tape is stacked in a plurality of layers one on top of the other with the paired adhesive lines between adjacent layers being aligned and abutting each other;
• radially cutting said wound stack and removing said cut tubular tapes from said rack by depositing them into elongated, flat trays to form vertically aligned stacks of tubular tapes;
• heating said vertically aligned stacks under compression to bond said abutting adhesive lines so as to adhere said layers together and form a unitary stack of tubular material;
• and
• cooling and then trimming the ends said stack of tubular material to form a stack of expandable honeycomb material.