Novel porous aluminum honeycomb structure forming process method

Abstract

The invention discloses a novel porous aluminum honeycomb structure forming process method, which utilizes numerical control punching equipment to form uniformly distributed through holes in the vertical direction of an aluminum honeycomb plate so as to replace the traditional roller needle punching process. By designing a special punching die, optimizing aperture and pitch parameters and adopting a step-by-step blanking process, the consistency of hole patterns and the quality of hole walls can be effectively improved, the honeycomb structure is prevented from collapsing, and the bonding strength and the overall flat pressing performance of the panel are kept. Meanwhile, according to the method, accurate control over the air permeability is achieved, and the problems that in a traditional roller hole process, the hole diameter is uncontrollable, and the mechanical property is reduced are solved. The method has the advantages of being high in process stability, high in product consistency and wide in application range, and is suitable for the fields of aerospace, rail transit, automobile lightweight, building energy saving and the like.

Description

Technical Field

[0001] This invention relates to a novel forming process for porous aluminum honeycomb structures, belonging to the field of aerospace structural materials technology. Background Technology

[0002] Honeycomb sandwich structures are widely used in aerospace, shipbuilding, transportation, and high-end equipment manufacturing due to their high specific strength, high specific stiffness, and excellent cushioning and thermal insulation properties. In aerospace vehicles, aluminum honeycomb panels are often used as the main load-bearing and thermal insulation structure for skin or compartments, requiring them to have good mechanical properties and heat resistance.

[0003] However, when the honeycomb panel is in orbit or during flight, a gas pressure difference will occur between the inside and outside of the structure. If the honeycomb panel is completely sealed, internal gas or external pressure changes will cause delamination at the interface between the skin and the honeycomb core material, which can lead to debonding, bubbling, or even skin damage in severe cases. Therefore, in engineering, tiny vents are set in the thickness direction of the honeycomb core material to ensure that the gas can gradually escape and reduce the internal and external pressure difference. Existing technology mainly uses a roller needle punching method: a roller with a large number of steel needles is rolled on the surface of the honeycomb core material filter, causing the steel needles to pierce the honeycomb wall and form holes. Although this method is simple and efficient, it has the following drawbacks:

[0004] (1) During the processing of roller needles, due to pillow wear, angle deviation and differences in the thickness of honeycomb unit walls, the aperture is uncontrollable, the size is different and the distribution is random.

[0005] (2) The needle punching method has generated plastic deformation and wrinkles around the honeycomb wall material, weakening local stability and reducing flat compressive strength and bonding strength.

[0006] (3) The large difference between the pore size and the pore spacing results in a high dispersion of the overall air permeability, making it difficult to meet the stringent stability requirements of aerospace structures.

[0007] (4) After the roller needle pierces into the aluminum foil, burrs and aluminum chips are easily generated. Some chips remain in the honeycomb cavity, affecting subsequent bonding and air permeability.

[0008] Therefore, the existing roller needle punching method has obvious defects in terms of the consistency of the formation of vent holes, the quality of the hole walls, and the impact on mechanical properties. There is an urgent need for an improved perforated aluminum honeycomb forming method to improve the overall stability and controllability of the honeycomb panel. Summary of the Invention

[0009] The technical problem solved by this invention is to overcome the shortcomings of the prior art and provide a novel perforated aluminum honeycomb structure forming process that avoids the defects of the traditional needle punching method.

[0010] The technical solution of this invention is:

[0011] This invention discloses a novel process for forming porous aluminum honeycomb structures, comprising:

[0012] Pre-treat the aluminum foil;

[0013] Using a CNC punching machine, ventilation holes are opened on the surface of the pre-treated aluminum foil according to the design distribution to obtain the punched aluminum foil surface.

[0014] Adhesive is evenly applied to the surface of the punched aluminum foil by roller coating and then dried to obtain the coated punched aluminum foil.

[0015] The coated perforated aluminum foil is stacked according to a predetermined number of layers and direction to form an initial aluminum foil stack.

[0016] The initial aluminum foil stack is solidified and shaped to form a stack;

[0017] The stacked blocks are unfolded and shaped to obtain a honeycomb structure with polygonal units. The pores are regularly distributed on the honeycomb wall, resulting in a preliminary sample of a porous aluminum honeycomb structure.

[0018] The perforated aluminum honeycomb structure prototype is cut to the required size to obtain the perforated aluminum honeycomb structure.

[0019] Furthermore, in the above method, the pretreatment of the aluminum foil specifically involves: anodizing the surface of the aluminum foil with phosphoric acid; the thickness of the aluminum foil is 0.03 to 0.07 mm.

[0020] According to claim 1, the method is characterized in that the pore diameter ranges from 0.1 to 1.0 mm, and the pore spacing is from 2 to 10 mm.

[0021] Furthermore, in the above method, the punching process adopts a single-needle multiple-impact method or a multi-needle matrix synchronous impact method.

[0022] Furthermore, in the above method, the adhesive has a thickness of 5–15 μm and a perforation spacing of 0.5–3.0 mm; and is dried at 60–80 °C for 10–30 s.

[0023] Furthermore, in the above method, the initial aluminum foil stack has 3 to 50 mm of layers.

[0024] Furthermore, in the above method, the stretching height of the initial sample of the perforated aluminum honeycomb structure is 1.2 to 1.5 times the stack height.

[0025] Furthermore, in the above method, the side length of each cell in the honeycomb structure is symmetrical with respect to the pore size.

[0026] Furthermore, in the above method, the step of curing and shaping the initial aluminum foil stack specifically involves:

[0027] Curing should be carried out according to the adhesive curing curve at a temperature of 150–180℃ for 1–3 hours. After curing, the adhesive should be cut and the edges sanded.

[0028] This invention discloses an aluminum honeycomb panel prepared by a novel porous aluminum honeycomb structure forming process. The honeycomb panel has air vents evenly distributed in the vertical direction, with a vent diameter of 0.1 to 1.0 mm and an air permeability of 100%. The honeycomb panel is used in aerospace skin structures, pressure compartments, satellite instrument compartments, and sandwich structures that require pressure relief.

[0029] The advantages of this invention over the prior art are as follows:

[0030] (1) This invention employs a high-precision mechanical punching technique before aluminum foil forming, enabling precise positioning of the holes while the aluminum foil is unfolded. The hole walls are smooth, without tears or burrs, and the process avoids tearing and wrinkling caused by roller needle insertion during subsequent forming. This solution achieves improved hole diameter consistency, uniform hole distribution, and stable air channels, solving the technical problems of unstable hole shape, severe hole wall damage, and difficulty in controlling hole distribution due to forming interference in traditional roller needle punching. It also further improves the overall air permeability and structural reliability of the honeycomb core.

[0031] (2) By placing the punching process in advance and eliminating the traditional roller needle punching step, the production line is simplified from "rolling-punching-applying glue-drying-stacking-stretching" to "punching-rolling-applying glue-drying-stacking-stretching". This improves the production efficiency of a single batch of honeycomb cores and reduces equipment maintenance and energy consumption. It solves the common technical problems in the industry that existing roller needle punching equipment is slow, easily damaged and requires frequent maintenance.

[0032] (3) By adopting a technical solution that is synergistically optimized with the punching and stacking processes, the pores are arranged in a regular array after the honeycomb is stretched and unfolded. This ensures continuous air channels with low resistance, stable air permeability within a predetermined range, and the honeycomb wall is no longer affected by the structural weakening of the needle-punched areas, thus maintaining stable key mechanical properties such as compressive strength and tensile strength. This solution achieves a stable and enhanced air permeability effect, solving the technical problems of traditional roller needle punching leading to a decline in mechanical properties and large fluctuations in air permeability between different batches.

[0033] (4) This invention employs a modular pre-punching method, allowing for precise design of hole diameter, spacing, and density before molding, ensuring high consistency between batches. This significantly enhances the designability of the honeycomb core, facilitating continuous and repeatable production of large-size panels and complex irregular honeycomb structures. This solution overcomes the technical limitations of traditional needle punching, such as difficulty in adjusting hole shape, uncontrollable hole type, and inability to adapt to different structural requirements, significantly improving the scalability and industrialization capability of honeycomb material production processes.

[0034] (5) The present invention achieves controllable punching (hole diameter, hole spacing, distribution, and hole wall quality are controllable) on the aluminum foil layer, thereby naturally forming through-thickness vent holes in the formed honeycomb core material, avoiding the defects of the traditional process of using roller needle punching. Attached Figure Description

[0035] Figure 1 This is the molding process of the present invention. Detailed Implementation

[0036] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0037] This invention discloses a novel process for forming porous aluminum honeycomb structures, comprising:

[0038] Pre-treat the aluminum foil;

[0039] Using a CNC punching machine, ventilation holes are opened on the surface of the pre-treated aluminum foil according to the design distribution to obtain the punched aluminum foil surface.

[0040] Adhesive is evenly applied to the surface of the punched aluminum foil by roller coating and then dried to obtain the coated punched aluminum foil.

[0041] The coated perforated aluminum foil is stacked according to a predetermined number of layers and direction to form an initial aluminum foil stack.

[0042] The initial aluminum foil stack is solidified and shaped to form a stack;

[0043] The stacked blocks are unfolded and shaped to obtain a honeycomb structure with polygonal units. The pores are regularly distributed on the honeycomb wall, resulting in a preliminary sample of a porous aluminum honeycomb structure.

[0044] The perforated aluminum honeycomb structure prototype is cut to the required size to obtain the perforated aluminum honeycomb structure.

[0045] Preferably, the aluminum foil is pretreated, specifically by phosphate anodizing the surface of the aluminum foil; the thickness of the aluminum foil is 0.03 to 0.07 mm.

[0046] According to the method of claim 1, the pore diameter ranges from 0.1 to 1.0 mm, and the pore spacing is from 2 to 10 mm.

[0047] Preferably, the punching process employs a single-needle multiple-impact method or a multi-needle matrix synchronous impact method.

[0048] Preferably, the adhesive has a thickness of 5–15 μm and a perforation spacing of 0.5–3.0 mm; and is dried at 60–80°C for 10–30 s.

[0049] Preferably, the initial aluminum foil stack has 3 to 50 mm of layers.

[0050] Preferably, the stretching height of the initial sample of the perforated aluminum honeycomb structure is 1.2 to 1.5 times the stack height.

[0051] Preferably, the side length of each cell in the honeycomb structure is symmetrical with respect to the pores.

[0052] Preferably, the initial aluminum foil stack is cured and molded, specifically as follows:

[0053] Curing should be carried out according to the adhesive curing curve at a temperature of 150–180℃ for 1–3 hours. After curing, the adhesive should be cut and the edges sanded.

[0054] This invention discloses an aluminum honeycomb panel prepared by a novel porous aluminum honeycomb structure forming process. The honeycomb panel has air vents evenly distributed in the vertical direction, with a pore size of 0.1 to 1.0 mm and an air permeability of 100%. The honeycomb panel is used in aerospace skin structures, pressure compartments, satellite instrument compartments, and sandwich structures that require pressure relief.

[0055] Example

[0056] This embodiment provides a novel perforated aluminum honeycomb structure forming process, comprising: pre-treating aluminum foil raw materials, and pre-punching the flattened aluminum foil using a CNC punching device before forming, so that the aluminum foil can form a through-hole structure with consistent pore size, smooth pore walls, no tearing or burrs, and uniform arrangement before entering subsequent processes; winding the punched aluminum foil into a roll and conveying it to the adhesive coating unit, uniformly applying adhesive to the surface of the aluminum foil by roller coating, and pre-curing the adhesive layer to a suitable adhesion state for stacking in a controlled constant temperature drying environment; then placing the adhesive-coated aluminum foil roll on a stacking device for multi-layer stacking, ensuring regular interlayer arrangement through stacking positioning, and then completely curing the interlayer adhesive through hot pressing to form a structurally stable honeycomb stack; after a cutting process, stretching to unfold the stacked structure into a three-dimensional honeycomb core material with regular hexagonal honeycomb units, thereby forming a perforated honeycomb core material with uniform pore size, stable air permeability, and high structural integrity.

[0057] like Figure 1 As shown, this embodiment provides a novel perforated aluminum honeycomb structure forming process, comprising the following steps:

[0058] (1) Material preparation: Select aluminum alloy foil with a thickness of 0.05mm, pre-treat the aluminum foil, clean the surface of the original aluminum foil and adjust the tension to ensure that its surface is flat and free of oil stains.

[0059] (2) Punching process: Before the aluminum foil enters the stacking or coating process, ventilation holes are opened on the surface of the aluminum foil according to the design distribution using CNC punching equipment. The hole diameter, spacing and arrangement can be adjusted according to the application requirements.

[0060] (3) Adhesive coating process: The adhesive is evenly coated on the surface of the punched aluminum foil by roller coating and pre-drying in a drying environment to a suitable bonding state.

[0061] (4) Stacking process: The perforated aluminum foil after coating is stacked according to the predetermined number of layers and direction to form the initial aluminum foil stack.

[0062] (5) Molding and shaping: The aluminum foil stacks are cured and shaped according to the curing rules of the adhesive.

[0063] (6) Cutting: Cut to the required size according to the actual needs of the project.

[0064] (7) Stretching and shaping: The stack is unfolded and shaped in a special stretching equipment to obtain a honeycomb structure with hexagonal or other polygonal units, and the pores are regularly distributed on the honeycomb wall.

[0065] The detailed steps are as follows:

[0066] (1) Aluminum foil punching

[0067] High-precision CNC punching machines or roller punching machines are used for punching, allowing for precise hole positioning even when the aluminum foil is unfolded. The hole walls are smooth, without tears or burrs, and this process avoids the tearing and wrinkling caused by roller insertion during subsequent forming. The hole diameter ranges from 0.1 to 1.5 mm, and the hole spacing ranges from 0.5 to 3.0 mm. Arrangement methods include straight lines, triangles, and honeycomb patterns. The key control point is maintaining the integrity of the aluminum foil after punching and preventing edge curling.

[0068] (2) Applying adhesive and drying

[0069] The adhesive is either epoxy or phenolic, and the coating method is roller coating, with a thickness controlled at 5–15 μm and a pore spacing of approximately 0.5–3.0 mm. Dry at 60–80°C for approximately 20 seconds to ensure the surface is completely dry.

[0070] (3) Shaping and curing

[0071] Curing should be carried out according to the adhesive curing curve, at a temperature of approximately 150–180℃, for a curing time of 1–3 hours. After curing, the adhesive should be cut and the edges sanded.

[0072] (4) Stacking and stretching

[0073] Depending on the number of aluminum foil stack layers (3-50mm), the stretching is 1.2-1.5 times the original height. The main control points are: ensuring symmetrical side lengths of the honeycomb units to avoid deformation of the honeycomb structure.

[0074] Ventilation holes are formed in the vertical direction (thickness direction) of the aluminum honeycomb core material to ensure gas decompression of the honeycomb sandwich structure under external pressure difference; the method includes the following steps:

[0075] (1) Provide aluminum foil required for aluminum honeycomb core material forming, and the surface of the aluminum foil is subjected to phosphate anodizing treatment before forming;

[0076] (2) A through hole is formed in the thickness direction of the honeycomb core material (aluminum foil) by mechanical punching process. The mechanical punching process includes: positioning and clamping fixture, controllable punch assembly, stamping guide die sleeve and hole diameter control device to ensure hole diameter consistency.

[0077] (3) The diameter of the punched hole is in the range of 0.1 to 1.0 mm, and the hole spacing is controlled between 2 and 10 mm;

[0078] (4) The punching positions are randomly or quasi-uniformly distributed to avoid local stress concentration and peeling of the bonding interface;

[0079] (5) The honeycomb core material after punching is combined with the upper and lower composite skins by a hot pressing process.

[0080] Compared with the existing roller-pinning method for forming air holes, this invention replaces roller-pinning with mechanical punching, achieving controllable hole diameter, smooth hole walls, and consistent hole diameter distribution, thereby improving the flat pressing strength and bonding strength of the honeycomb panel, while ensuring the stability of air permeability.

[0081] The mechanical punching process uses a servo-controlled punch, which enables programmable control of punching depth, speed, and pressure to reduce plastic deformation and wrinkles in the honeycomb wall material.

[0082] The punching process is combined with a vacuum adsorption device to remove chips in a timely manner, preventing aluminum chips from remaining in the honeycomb cavity and affecting the air permeability and honeycomb bonding strength.

[0083] The perforation distribution patterns include: random distribution, annular distribution, and uniform grid distribution. Users can choose different distribution patterns according to application requirements to balance air permeability and mechanical performance.

[0084] The punching process can employ either a single-needle multiple-impact method or a multi-needle matrix synchronous impact method to improve production efficiency.

[0085] The air permeability can be controlled by adjusting the relationship between pore size and pore spacing, and the air permeability control range is 100%.

[0086] Punching is performed before the honeycomb core material is stacked, which can reduce the number of steps in the synchronous production process and enhance the interfacial bonding strength of the surrounding areas.

[0087] Compared with the roller needle insertion method, the method reduces the wrinkle rate of honeycomb wall material and reduces the standard deviation of hole diameter by 10-15%.

[0088] An aluminum honeycomb panel prepared using a novel porous aluminum honeycomb structure forming process is disclosed. The honeycomb panel has uniformly distributed air pores in the vertical direction, with a pore diameter of 0.1 to 1.0 mm and an air permeability of 100%. The honeycomb panel is used in aerospace skin structures, pressure compartments, satellite instrument compartments, and sandwich structures that require pressure relief.

[0089] The following embodiments are for further illustration of the present invention, and not for limiting the present invention.

[0090] Example 1

[0091] Aluminum foil with a thickness of 0.05 mm was selected. First, its surface was cleaned and tension adjusted to ensure flatness and cleanliness. Then, circular holes with a diameter of 0.3 mm and a spacing of 1.0 mm were punched into the aluminum foil surface using a CNC punching process. After punching, phenolic resin adhesive was evenly coated onto the aluminum foil surface and dried at 70℃ for approximately 30 seconds to keep the adhesive layer semi-dry. Subsequently, multiple layers of punched aluminum foil were stacked in a predetermined direction and then molded and cured under a certain pressure. After a 1.25x stretching process, a honeycomb core with a height of 5 mm was obtained. Testing revealed that the pressure relief performance of this honeycomb core was 18% higher than that of the unpunched sample, and the hole walls were smooth without obvious burrs or tears, verifying the advantages of pre-punching.

[0092] Example 2

[0093] Aluminum foil with a thickness of 0.06 mm was used to create regular pores with a diameter of 0.5 mm and a spacing of 1.5 mm on the foil through the same pre-punching process. Epoxy resin adhesive was used for the coating process, with the coating thickness controlled at approximately 10 μm, and drying at 65℃ for 20 seconds. The perforated aluminum foil stacks after adhesive coating were then stretched to obtain a honeycomb structure with a core height of 8 mm. Performance tests showed that this sample improved air permeability by approximately 10% compared to traditional roll-bonded perforated honeycomb cores, while increasing production efficiency by 12%, further demonstrating the dual improvement in efficiency and performance brought about by pre-processing.

[0094] Example 3

[0095] Aluminum foil with a thickness of 0.06 mm was selected, and a uniform perforation pattern with a aperture of 0.8 mm and a spacing of 2.0 mm was set during the punching process. After roll coating and stacking, a honeycomb core with a height of 12 mm was formed, and pre-dried at 75°C for 50 seconds to ensure the adhesive was in a semi-cured state. After curing, the honeycomb cells were fully expanded under a 1.3x stretching operation. Test results show that the honeycomb core exhibits particularly stable pressure relief performance in large-size samples, with uniform pore distribution on the honeycomb wall and no stress concentration or local collapse, proving that this parameter combination is suitable for the preparation of medium-thickness honeycomb cores.

[0096] Example 4

[0097] A honeycomb core with a height of 20 mm was prepared by using 0.1 mm thick aluminum foil with a punch diameter of 1.0 mm and a spacing of 2.5 mm to increase the layer thickness. After epoxy adhesive was roller coated, the core was dried at 75°C for 50 seconds and then stretched at a ratio of 1.3. The resulting honeycomb core exhibited excellent air permeability while maintaining its compressive strength.

[0098] Comparative Example 1

[0099] Traditional processes, which integrate needle punching into the molding process followed by stretching and cutting of the honeycomb core, suffer from several drawbacks. Fluctuations in stress during needle punching result in poor repeatability of hole diameter and position, and the formation of burrs and aluminum shavings that easily become trapped between layers within the roll. These foreign matter are then trapped between layers or within the adhesive layer during subsequent gluing and drying, affecting interfacial wetting and adhesion. Furthermore, the holes may shrink or deform during subsequent drying and molding curing due to interlayer compaction or thermal stress, leading to unstable air permeability and increased batch-to-batch variations. Therefore, while needle punching offers advantages in equipment investment and unit punching speed, it suffers from significant shortcomings in hole quality, cleanliness, and subsequent bonding reliability, hindering the large-scale, stable production of high-reliability honeycomb cores.

[0100] Comparative Example 2

[0101] Arranging the punching process after the honeycomb core stretching and forming, and mechanically punching directly into the honeycomb cell walls, although it can create pores, causes some cell walls to buckle or even collapse due to the impact force, resulting in significant damage to the honeycomb geometry and difficulty in cleaning internal debris. The results show that the mechanical properties of the honeycomb are greatly reduced, proving that punching after forming is not feasible.

[0102] Comparative Example 3

[0103] While pre-punching is feasible, excessively large apertures (e.g., 3mm or larger) can lead to other problems. Large apertures, after aluminum foil lamination and stretching, result in severe thinning of the effective cross-section of the unit wall. This leads to high stress concentration around the aperture edges under forming stress and service loads, causing microcracks to initiate and propagate during stretching or subsequent use, resulting in a decrease in local or overall load-bearing capacity. Engineering tests show that exceeding a certain aperture threshold causes a sharp decline in the compressive strength and fatigue life of the honeycomb core, compromising structural reliability while meeting ventilation requirements. Therefore, although pre-punching is feasible, the aperture size must be controlled within a reasonable range; otherwise, it can lead to mechanical failure modes that are different from but equally fatal to traditional punching.

[0104] Comparative Example 4

[0105] If the hole spacing is set too small (0.3mm) during aluminum foil pre-punching, the aluminum foil between the holes will perforate each other during subsequent lamination and stretching stages, causing localized through cracks in the material. This can lead to large-area tearing or failure to form complete honeycomb units during stretching and expansion. Overly dense hole arrays result in insufficient continuous material between unit walls to withstand molding and usage loads, significantly increasing the molding failure rate. Therefore, the hole spacing design for pre-punching needs to strike a balance between ensuring air permeability and maintaining unit wall integrity. However, overly dense hole arrays will also negate the advantages of pre-punching; therefore, proper parameter settings are crucial.

[0106] The mechanical properties of the honeycomb core were tested using the following methods: QJ1343-88 Test Method for Planar Compression Performance of Adhesive-bonded Honeycomb Sandwich Structures or Cores; and GJB130.3-86 Test Method for Node Strength of Adhesive-bonded Aluminum Honeycomb Cores.

[0107] The test results are shown in Table 1.

[0108] Table 1 Comparison of Mechanical Properties of Punching

[0109]

[0110] As shown in Table 1, while maintaining 100% porosity, the compressive and tensile strengths of the honeycomb core material in the embodiments of the present invention are superior to those in the comparative example. The compressive strength of the embodiments is consistently maintained in the range of 676–685 MPa, higher than the 660–670 MPa of the comparative example, indicating that the pre-punching process avoids damage to the honeycomb wall structure caused by roller needle punctures. In terms of tensile strength, the embodiments are stable at 20.8–21.6 MPa, superior to the 20.0–20.5 MPa of the comparative example, demonstrating the positive impact of uniform pore size distribution and the integrity of the molding process on performance.

[0111] By eliminating the traditional roller needle punching process, this invention reduces process time and improves manufacturing efficiency. At the same time, it yields a honeycomb core material with uniform hole distribution and excellent mechanical properties, demonstrating its application advantages in aerospace structural components.

[0112] Although the present invention has been described in detail through the preferred embodiments above, it should be understood that the above description should not be considered as a limitation of the present invention. Various modifications and substitutions to the present invention will be apparent to those skilled in the art after reading the above description. Therefore, the scope of protection of the present invention should be defined by the appended claims.

[0113] The contents not described in detail in this specification are common knowledge to those skilled in the art.

Claims

1. A novel process for forming a perforated aluminum honeycomb structure, characterized by, The application relates to a honeycomb structure of aluminum foil. The aluminum foil is pretreated; A plurality of air holes are formed on the surface of the pretreated aluminum foil by a numerical control punching device according to a design distribution, so that a punched aluminum foil surface is obtained; An adhesive is uniformly coated on the punched aluminum foil surface by a roller coating method, and the punched aluminum foil is dried to obtain a glued punched aluminum foil; The glued punched aluminum foil is stacked according to a predetermined number of layers and direction to form an initial aluminum foil stack; The initial aluminum foil stack is solidified and formed to form a stack; The stack is unfolded and formed to obtain a honeycomb structure with a polygonal unit, and the pores are regularly distributed on the honeycomb wall surface, so that an initial honeycomb structure of aluminum foil with holes is obtained; The initial honeycomb structure of aluminum foil with holes is cut into a required size to obtain a honeycomb structure of aluminum foil with holes.

2. The method of claim 1, wherein, The aluminum foil is pretreated by anodic oxidation with phosphoric acid.

3. The method of claim 1, wherein: The thickness of the aluminum foil is 0.03-0.07 mm.

4. The method of claim 1, wherein: The air hole diameter ranges from 0.1 to 1.0 mm, and the hole distance is 2-10 mm.

5. The method of claim 1, wherein, The punching process adopts a single-needle multiple-impact mode or a multi-needle matrix synchronous impact mode.

6. The method of claim 1, wherein, The thickness of the adhesive is 5-15 microns, the punching hole distance is 0.5-3.0 mm, and the drying is carried out at 60-80 DEG C for 10-30 s.

7. The method of claim 1, wherein: The number of layers of the initial aluminum foil stack is 3-50 mm.

8. The method of claim 1, wherein: The stretching height of the initial aluminum foil stack is 1.2-1.5 times the height of the stack.

9. The method of claim 1, wherein, The length of each unit of the honeycomb structure is symmetrical to the pore. The initial aluminum foil stack is solidified and formed according to the adhesive curing curve, and the temperature is 150-180 DEG C, the curing time is 1-3 h, and the stack is cut and the edges are polished after curing.

10. An aluminum honeycomb panel prepared using the novel perforated aluminum honeycomb structure forming process described in claim 1, characterized in that: The honeycomb plate uniformly distributes the air holes in the vertical direction, the hole diameter is 0.1-1.0 mm, the air permeability reaches 100%, and the honeycomb plate is applied to aerospace skin structures, pressure cabin sections, satellite instrument cabins and sandwich structures requiring pressure relief.

Images