Honeycomb structure and method of making

A method of making a honeycomb structure comprising the steps of:

• a) intermittently slitting a sheet of material such that longitudinal slits are aligned in alternating staggered rows, each staggered row having a lateral centerline spaced substantially uniformly from adjacent row centerlines, said longitudinal slits in each staggered row having substantially uniform lateral spaces between each slit, said lateral spaces being twice a thickness dimension of said resulting honeycomb structure;
• b) applying continuous stripes of adhesive laterally across a top side and a bottom side of said sheet such that each stripe is spaced apart longitudinally and centered on a row of slits, said stripes alternating between said top side and said bottom side;
• c) pleating said sheet such that pleats run longitudinally, each of said pleats having a top fold and a bottom fold aligned with a longitudinal slit;
• d) gathering said pleats together in a closed stack and compressing said stack to cause said stripes of adhesive to bond said pleats together at adhesive contact points;
• and
• e) pulling said pleats laterally apart to generate hexagonal cells having interconnections at said adhesive contact points and openings between said adhesive contact points.