Process for making a honeycomb core from a honeycomb half-cell structure and honeycomb core made thereby

A process for making a hexagonal-cell honeycomb core from a honeycomb half-cell structure, the structure having a plurality of peaks and valleys and a diagonal surface between each consecutive peak and valley, comprising the steps of:

• (a) applying a sticky adhesive having a viscosity of at least about 500 centipoise to the peaks of the half-cell structure, comprising the sub-steps of:
• (i) applying a cyanate ester and an epoxy to a first group of peaks on one side of the structure, and
• (ii) applying the epoxy and a catalyst to a second group of peaks on the other side of the structure;
• (b) cutting the half-cell structure across the diagonal surface into a plurality of sheets while the adhesive on the peaks remains sticky;
• and
• (c) stacking the half-cell structure to bring the first and second group of peaks into contact with each other while the viscosity of the adhesive remains at least about 500 centipoise at the temperature at which the half-cell structure is stacked.