Patent ID: 7785520

Claim:
A process of making a honeycomb comprising cells having edges forming a face of the honeycomb, the face defined by a plurality of points, at least two of the points located in different tangential planes, comprising the steps of: a) forming a honeycomb having expanded cells from a plurality of sheets comprising thermoplastic material having a melting point of from 120 to 350° C. and high modulus fiber having a modulus of 600 grams per denier (550 grams per dtex) or greater; b) impregnating the honeycomb with a thermoset resin which requires curing; c) curing or partially curing the thermoset resin of b) to form a cured or partially cured honeycomb; d) pressing the cured or partially cured honeycomb in a direction perpendicular to a plane of parallel lines of adhesive to fracture at least a portion of the thermoset resin; e) pulling the pressed honeycomb apart in a direction perpendicular to a plane of parallel lines of adhesive to fracture at least a portion of the cured or partially cured thermoset resin to collapse at least a portion of cells of the honeycomb; f) bending, molding, or forming the honeycomb in a mold or over a form; g) heating the honeycomb to allow the thermoplastic material to flow; and h) cooling the honeycomb to substantially retain the shape of the mold or form.