Abstract: A panel for attenuating noise is disclosed comprising a face skin having a first inner surface, a base skin having a second inner surface, a cellular core connected to and forming a plurality of cells between the face skin and the base skin, wherein the cellular core is defined by a cell structure having a plurality of cell walls extending between the face skin and the base skin defining each of the plurality of cells and a septum disposed within each of the plurality of cells, the septum defining an upper chamber proximate the face skin and a lower chamber proximate the base skin, wherein the face skin comprises a plurality of perforations fully through the face skin and in fluid communication with the upper chamber.

Abstract: A panel for attenuating noise is disclosed comprising a face skin having a first inner surface, a base skin having a second inner surface, a cellular core connected to and forming a plurality of cells between the face skin and the base skin, wherein the cellular core is defined by a cell structure having a plurality of cell walls extending between the face skin and the base skin defining each of the plurality of cells and a septum disposed within each of the plurality of cells, the septum defining an upper chamber proximate the face skin and a lower chamber proximate the base skin, wherein the face skin comprises a plurality of perforations fully through the face skin and in fluid communication with the upper chamber.

Abstract: A panel for attenuating noise is disclosed comprising a face skin having a first inner surface, a base skin having a second inner surface, a cellular core connected to and forming a plurality of cells between the face skin and the base skin, wherein the cellular core is defined by a cell structure having a plurality of cell walls extending between the face skin and the base skin defining each of the plurality of cells and a septum disposed within each of the plurality of cells, the septum defining an upper chamber proximate the face skin and a lower chamber proximate the base skin, wherein the face skin comprises a plurality of perforations fully through the face skin and in fluid communication with the upper chamber.

Abstract: A method is provided for forming a structural panel. During this method, a core structure is formed by shaping a first portion of a sheet of ribbon material to form a first baffle and a first septum. Thermoplastic material is then overmolded onto the ribbon material, between the first baffle and the first septum, to form a first set of walls.

Abstract: A panel for attenuating noise is disclosed comprising a face skin having a first inner surface, a base skin having a second inner surface, a cellular core connected to and forming a plurality of cells between the face skin and the base skin, wherein the cellular core is defined by a cell structure having a plurality of cell walls extending between the face skin and the base skin defining each of the plurality of cells and a septum disposed within each of the plurality of cells, the septum defining an upper chamber proximate the face skin and a lower chamber proximate the base skin, wherein the face skin comprises a plurality of perforations fully through the face skin and in fluid communication with the upper chamber.

Abstract: During a method for forming a structural panel, a core structure is formed that includes a plurality of corrugated ribbons and a plurality of walls. Each of the corrugated ribbons is laterally between a respective adjacent pair of the walls. Each of the corrugated ribbons includes a plurality of baffles and a plurality of porous septums. Each of the porous septums is longitudinally between a respective adjacent pair of the baffles. The forming of the core structure includes bonding a first of the walls to a first of the corrugated ribbons and subsequently bonding a second of the walls to the first of the corrugated ribbons. The core structure is bonded to a first skin. The core structure is bonded to a second skin. The core structure is vertically between the first skin and the second skin, and the first skin is configured with a plurality of perforations.

Abstract: A method is provided for forming a structural panel. During this method, a core structure is formed by shaping a first portion of a sheet of ribbon material to form a first baffle and a first septum. Thermoplastic material is then overmolded onto the ribbon material, between the first baffle and the first septum, to form a first set of walls.

Abstract: During a method for forming a structural panel, a core structure is formed that includes a plurality of corrugated ribbons and a plurality of walls. Each of the corrugated ribbons is laterally between a respective adjacent pair of the walls. Each of the corrugated ribbons includes a plurality of baffles and a plurality of porous septums. Each of the porous septums is longitudinally between a respective adjacent pair of the baffles. The forming of the core structure includes bonding a first of the walls to a first of the corrugated ribbons and subsequently bonding a second of the walls to the first of the corrugated ribbons. The core structure is bonded to a first skin. The core structure is bonded to a second skin. The core structure is vertically between the first skin and the second skin, and the first skin is configured with a plurality of perforations.

Abstract: A machine and method for corrugating a metal foil strip utilizes an enclosure defining a chamber and a controllable heat source for heating the chamber. The chamber may optionally include at least one gas that is also heated by the heat source. At least one tool set received in the chamber forms corrugations in the metal foil strip. Foil entry feeder elements supply and guide the metal foil strip from outside the chamber into the chamber and to the tool set. A drive for the tool set is mounted outside the chamber and coupled to the tool set to actuate the tool set. Foil exit delivery elements guide the strip from the tool set and out of the chamber. Where required to prevent oxidation of the foil strip, a source supplying an inert gas to the chamber at a controlled rate is used.

Abstract: A machine and method for corrugating a metal foil strip utilizes an enclosure defining a chamber and a controllable heat source for heating the chamber. The chamber may optionally include at least one gas that is also heated by the heat source. At least one tool set received in the chamber forms corrugations in the metal foil strip. Foil entry feeder elements supply and guide the metal foil strip from outside the chamber into the chamber and to the tool set. A drive for the tool set is mounted outside the chamber and coupled to the tool set to actuate the tool set. Foil exit delivery elements guide the strip from the tool set and out of the chamber. Where required to prevent oxidation of the foil strip, a source supplying an inert gas to the chamber at a controlled rate is used.

Abstract: An automatic machine for rapidly fabricating a continuous length of metallic honeycomb core having a finite width and a precise height for use, substantially as fabricated, in bonding in a honeycomb core panel structure from a continuous strip of preformed metal foil having spaced crest and trough sections. The machine includes a fixed central foil guide that directs a continuous strip of metallic foil to a horizontally translatable guide that positions the foil strip between two banks of vertically biased banks of individual weld blocks having sets of vertically disposed weld pin electrodes. A spreader carriage that is horizontally translatable in synchronism with the translatable guide momentarily spreads individual opposed biased weld blocks to permit the foil strip to be laid against a previously received portion of such foil strip in horizontal and vertical registry of the crests and troughs of the preformed strip.