Producing a three dimensional contoured sandwich structure including first thermoplastic covering layer, second thermoplastic covering layer and core material, comprises e.g. machining or carrying out separate processing of core material

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This invention relates to a process for manufacturing three-dimensional contoured sandwich structures. The structure consists of a core material with a honeycomb architecture, placed between two thermoplastic covering layers. The process includes shaping the core material to the desired 3D form, matching the covering layers, and joining everything together via hot pressing to create a strong, cohesive piece.

Use CasesContent extracted from patent full text and abstract with AI.

• Automotive panel production, such as for car doors or hoods requiring lightweight strength
• Aerospace applications like aircraft panels or interior components
• Furniture manufacturing, including lightweight, strong structural components
• Construction materials for architectural panels or facade elements
• Sporting goods, such as strengthening lightweight components in equipment

BenefitsContent extracted from patent full text and abstract with AI.

• Enables the production of lightweight yet strong three-dimensional structures
• Improved design flexibility for complex, contoured shapes
• Efficient bonding method yields strong, cohesive layered products
• Potential to reduce material costs and product weight
• Increased versatility for a range of industries using sandwich constructions

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Patent Abstract

Producing a three dimensional contoured sandwich structure consisting of a first thermoplastic covering layer, a second thermoplastic covering layer and a core material with a honeycomb structure, arranged between the covering layers, comprises (a) machining and/or carrying out separate processing of the core material until the desired three-dimensional contour is obtained, (b) sequentially or parallely cutting the covering layers of the three-dimensional contour, and (c) applying thermoplastic covering layers onto the processed core material and cohesively connecting by hot pressing. Producing a three dimensional contoured sandwich structure consisting of a first thermoplastic covering layer, a second thermoplastic covering layer and a core material with a honeycomb structure, arranged between the covering layers, comprises (a) machining and/or carrying out separate processing of the core material (contouring process) until the desired three-dimensional contour is obtained, (b) sequentially or parallely cutting the covering layers of the three-dimensional contour obtained in the step (a), and (c) applying thermoplastic covering layers onto the processed core material and cohesively connecting by hot pressing.