Newport Corporation

Dennis C Terry

Waldemiro M Filho

John J Turechek

Thomas R Musser

A method of manufacturing a honeycomb table having a table leaf with apertures suitable for mounting components in sensitive applications, attaches a supporting section to that table leaf, attaches a sealing sheet to that supporting section, attaches a section of honeycomb core to that sealing sheet, and attaches a facing sheet at a position on the table such that the section of honeycomb core is positioned between the table leaf and that facing sheet. Apertures are drilled and tapped in the table leaf. A honeycomb table having at least a width dimension comprises a top facing sheet perforated with openings having a top surface for supporting components and a bottom surface, a bottom facing sheet parallel to the top facing sheet, a section of corrugated sheet material extending for at least a distance corresponding substantially to the width of the table beneath the top facing sheet, and a honeycomb core having cells of equal length extending between continuous flat top and bottom surfaces and between the section of corrugated sheet material and the bottom facing sheet. The section of corrugated sheet material is secured to the bottom surface and between the top facing sheet and the honeycomb core.

Honeycomb table manufacture and clean-room compatible honeycomb tables

Apparatus upon which components may be mounted have a table leaf with an outside surface and a pattern of mounting holes in that table leaf, and a facing sheet spaced from that table leaf by a first distance. A section of honeycomb core is situated between the table leaf and the facing sheet, being less than but at least one-half the first distance in depth. A sealing sheet is situated between the table leaf and the section of honeycomb core at a second distance from that table leaf which is several times smaller than the first distance. A load-bearing support section is between that sealing sheet and the table leaf. Methods of manufacturing a structure suitable for mounting components form an apertured table leaf, and a facing sheet spaced from the table leaf. These methods place a section of honeycomb core between the table leaf and the facing sheet, and seal off apertures in the table leaf from the section of honeycomb core with a sealing sheet which prevents contaminants from migrating between the apertures and the honeycomb core. The table leaf, the sealing sheet, the facing sheet, and honeycomb core are connected together.

In order to render honeycomb tables with apertured table leaves clean-room compatible, sealing sheets are provided with projections corresponding in number and location to apertures in the table leaves and projecting into cells of honeycomb cores for a distance being several times smaller than the depth of such cores. These sealing sheets and their projections seal the honeycomb cells against the table leaf apertures inside the table leaves. Debris and lubricant residues accumulate inside these projections during provision of the table leaf apertures and are removed through these apertures preparatory to use of each honeycomb table in a clean room. The apertures are structured for receiving fasteners for attaching objects to the honeycomb tables. A load-bearing sealing structure may be molded from a sealing sheet or may otherwise be provided with cavities situated like the above mentioned projections. Sitting on top of the honeycomb core, that sealing structure bears the table leaf and objects or other loads placed or imposed on the table, in addition to ensuring clean-room compatibility.

Method of manufacturing clean-room compatible honeycomb tables

Honeycomb tables with apertured table leaves are rendered clean-room compatible by sealing the honeycomb cells against the table leaf apertures inside the table leaf. A sealant covering inside surface areas of the table leaf at the honeycomb core may be employed for releasably covering the table leaf apertures. Alternatively, the honeycomb cells may be sealed at a level thereof spaced from the table leaf by a distance several times smaller than a distance between the table leaf and a facing sheet spaced from such table leaf by the honeycomb core.

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Costa Mesa, CA, United States of America

Dennis C Terry