Honeycomb structure and method of manufacturing honeycomb structures

• US 6,383,601 B2
• Filed: 05/21/1999
• Issued: 05/07/2002
• Est. Priority Date: 05/22/1998
• Status: Expired due to Fees

• Current Assignee: US Philips Corporation (Koninklijke Philips N.V.)
• Original Assignee: US Philips Corporation (Koninklijke Philips N.V.)
• Inventors: Jans, Johannes C., Prins, Menno W. J., Linders, Petrus W. J.
• Primary Examiner(s): Zimmerman, John J.
• Application Number:
  US09/316,779
• Publication Number:
  US 20010051250A1
• Time in Patent Office: 1,082 Days
• Field of Search: 428/586, 428/593, 428/116, 428/118, 228/118, 228/181, 156/197
• US Class Current: 428/118
• CPC Class Codes: B29C 37/0075 using release sheets
• CPC Class Codes: B29D 99/0089 Producing honeycomb structures consisting of porous ceramic ware C04B38/0006
• CPC Class Codes: G21K 1/10 Scattering devices; Absorbing devices; Ionising radiation filters
• CPC Class Codes: Y10T 156/1003 by separating laminae between spaced secured areas [e.g., honeycomb expanding]
• CPC Class Codes: Y10T 428/1234 Honeycomb, or with grain orientation or elongated elements in defined angular relationship in respective components [e.g., parallel, inter- secting, etc.]
• CPC Class Codes: Y10T 428/12347 Plural layers discontinuously bonded [e.g., spot-weld, mechanical fastener, etc.]
• CPC Class Codes: Y10T 428/24149 Honeycomb-like
• CPC Class Codes: Y10T 428/24165 Hexagonally shaped cavities

Abstract

The invention relates to a method of manufacturing honeycomb stuctures in which multiple foils are welded together by means of thermal compression and the multiple foils form the honeycomb structure in the expanded condition. The bonding locations, where the foils are fused together, are defined by inserting a structured separating layer between the foils. The invention also relates to, for example, luminaries and x-ray apparatus using a honeycomb structure so manufactured.

Claims

1. A method of manufacturing honeycomb structures comprising:

providing structured separating layers on at least one side of each of a plurality of foils,

fusing the plurality of foils and structured separating layers against one another to realize a compressed stack of interconnected foils and structured separating layers to physically connect the foils to corresponding foils at bonding locations of the structured separating layers, which compressed stack of foils and separating layers form a honeycomb structure in the expanded condition, and

expanding the compressed stack of interconnected foils and structured separating layers in a direction transversely of the surface of the foils in order to form the honeycomb structure.

2. A method as claimed in claim 1, wherein the step for providing the structured separating layers further comprises:

providing structures in the structured separating layers by the removal of material from the structured separating layer thereby forming openings to realize the bonding locations.

3. A method as claimed in claim 1, wherein the step for fusing the plurality of foils and structured separating layers further comprises:

stacking the plurality of foils and structured separating layers, and

heating the stack to a temperature beyond the melting point of the foils.

4. An expanded honeycomb structure comprising a plurality of foils and structured separating layers, which foils are fused to one another at various bonding locations provided by the structured separating layers, wherein the bonding locations are separated from one another by the structured separating layers which are provided on at least one side of each of the plurality of foils.

5. An expanded honeycomb structure as claimed in claim 4, wherein neighboring foils are locally connected to one another along bonding seams, the ratio of the width of the individual bonding seams to the distance between neighboring bonding seams being in the range of from 0.1 to 0.4.

6. An expanded honeycomb structure as claimed in claim 4, wherein the structured separating layers containing a metal having a thickness in a range of more than 5 nm and less than 500 nm.

7. An expanded honeycomb structure as claimed in claim 6, wherein the metal contains aluminum.

8. An expanded structure of claim 5 wherein the ratio of the width of the individual bonding seams to the distance between neighboring bonding seams is from approximately ¼

to approximately ⅓

.

9. A diagnostic X-ray apparatus comprising an X-ray filter, including a honeycomb structure, comprising a plurality of foils and structured separating layers, which foils are fused to one another at various bonding locations, the bonding locations being separated from one another by the structured separating layers which are provided on at least one side of each foil.

10. A luminary comprising a diffuser, wherein the diffuser includes a honeycomb structure, comprising a plurality of foils and structured separating layers, which foils are fused to one another at various bonding locations, the bonding locations being separated from one another by the structured separating layers provided on at least one side of each foil.