# US 10,308,003 B2 · Method and apparatus for manufacturing a sandwich part

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 10,308,003 B2
- Document ID: US10308003B2
- Status: Granted
- Kind: B2
- Application number: 14/978,926
- Filed: 2015-12-22
- Published: 2016-06-23
- Granted: 2019-06-04
- Earliest claimed: 2014-12-22
- Assignees: MAGNA STEYR Fahrzeugtechnik AG & Co KG
- Applicants: MAGNA STEYR Fahrzeugtechnik AG & Co KG
- Inventors: Guenter Wolfsberger
- Web page: https://patentgrep.com/patent/US10308003B2

## CPC

- B29C 70/86: Incorporated in coherent impregnated reinforcing layers, {e.g. by winding}
- B32B 37/1284: {Application of adhesive}
- B29C 70/68: by incorporating or moulding on preformed parts, e.g. inserts or layers {, e.g. foam blocks (mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70)}
- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B32B 5/00: Layered products characterised by the non- homogeneity or physical structure {, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 37/0053: {Constructional details of laminating machines comprising rollers; Constructional features of the rollers}
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B32B 37/146: {whereby one or more of the layers is a honeycomb structure}
- B32B 37/18: involving the assembly of discrete sheets or panels only
- B32B 37/22: involving the assembly of both discrete and continuous layers
- B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)}
- B32B 38/08: Impregnating
- B32B 38/18: Handling of layers or the laminate
- B29C 70/681: {Component parts, details or accessories; Auxiliary operations}
- B32B 2038/0076: {Curing, vulcanising, cross-linking}
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2305/024: Honeycomb
- B32B 2605/00: Vehicles
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

a method for producing a sandwich component, and an apparatus for producing a sandwich component. The method includes providing a plurality of webs of material, applying at least one matrix material to an upper side and/or an underside of at least one of the webs of material, wherein applying the at least one matrix material includes applying the at least one matrix material such in different ways to create at least one zone of the sandwich component having mechanical properties that differ from mechanical properties of other parts of the sandwich component, arranging at least one core layer on one of the webs of material, and pressing the webs of material and the at least one core layer to form the sandwich component such that the core layer is arranged between at least two of the webs of material.

## Claims

### Claim 1

A method for producing a sandwich component, comprising:
providing a plurality of webs of material including first and second webs of material that are each composed of fibrous material;
unrolling the first of the webs of material from a single holding roller so that the first web of material has a single layered configuration;
unrolling a first portion of the second web of material from a first holding roller and a second portion of the second web of material from a second holding roller different from the first holding roller;
arranging the first and second portions of the second web of material onto each other to be in direct contact with each other so that the second web of the material has a double layered configuration;
applying matrix materials, of different types, to an upper side and/or an underside of the first web of material, wherein applying the matrix materials includes applying the matrix materials in different ways so that two of the matrix materials are each in direct physical contact with a same one of an uppermost surface or a lowermost surface of the first web of material, wherein the two matrix materials are applied to the same one of the uppermost surface or the lowermost surface separately from each other, and each of the two matrix materials includes an adhesive;
arranging the second web of material, that has the double layered configuration, on the two matrix materials;
arranging at least one core layer on the second web of material that has the double layered configuration; and
pressing the plurality webs of material and the at least one core layer to form the sandwich component such that the at least one core layer is arranged between the plurality of webs of material and so that the two matrix materials are in direct contact with the second web of the material that has the double layered configuration.

### Claim 2 (depends on 1)

The method of claim 1, wherein the applying the matrix materials in different ways includes applying different amounts of the matrix materials.

### Claim 3 (depends on 1)

The method of claim 1, wherein the first and second webs of material are arranged on one side of the at least one core layer.

### Claim 4 (depends on 1)

The method of claim 1, wherein the at least one core layer comprises a honeycomb core layer.

### Claim 5 (depends on 1)

The method of claim 1, wherein the matrix materials are admixed with fibres so as to include the fibres.

### Claim 6 (depends on 1)

The method of claim 1, wherein the applying the matrix materials comprises at least one of spraying, dipping, or rolling the matrix materials.

### Claim 7 (depends on 1)

The method of claim 1, wherein the webs of material are guided with respect to a beginning of the webs of material horizontally at a distance and/or vertically at a distance in a direction of a press.

### Claim 8 (depends on 1)

The method of claim 1, wherein providing the plurality of webs of material comprises guiding the plurality of webs of material substantially horizontally, parallel to one another and over one another and/or substantially vertically next to one another in a direction of a press to press the plurality of webs of material and the at least one core layer.

### Claim 9 (depends on 8)

The method of claim 8, wherein pressing the plurality of webs of material and the at least one core layer comprises a wet-pressing process.

### Claim 10 (depends on 1)

The method of claim 1, wherein:
a first of the two matrix materials includes fibres, and a second of the two matrix materials includes fibres; and
all of the fibres of the first matrix material are longer than all of the fibres of the second matrix material.

### Claim 11 (depends on 10)

The method of claim 10, wherein the first matrix material includes a first type of fibre, and the second matrix material includes a second type of fibre and is free of the first type of fibre.

### Claim 12 (depends on 1)

The method of claim 1, further comprising, simultaneously with the pressing, cutting the plurality of webs of material and the at least one core layer to form the sandwich component.

### Claim 13 (depends on 1)

The method of claim 1, wherein the at least one core layer is in direct contact with the second web of the material.

### Claim 14 (depends on 1)

The method of claim 1, wherein the first web of material, the two matrix materials, the second web of material, and the at least one core layer are disposed in that stated order on a straight line.

### Claim 15 (depends on 14)

The method of claim 14, further comprising:
unrolling a first portion of a third of the plurality of webs of material from a fourth holding roller;
unrolling a second portion of the third of the plurality of webs of material from a fifth holding roller different from the fourth holding roller;
arranging the first and second portions of the third of the plurality of webs onto each other so that the third of the plurality of webs has a double layered configuration; and
unrolling a fourth of the plurality of webs of material from a single holding roller so that the fourth of the plurality of webs of material has a single layered configuration;
disposing the third of the plurality of webs of material on the at least one core layer; and
applying second matrix materials, that each include an adhesive, to the third of the plurality of webs of material.

### Claim 16 (depends on 15)

The method of claim 15, further comprising arranging the at least one core layer, the third web of material, the second matrix materials, and the fourth web of material to be disposed in that stated order on the straight line.

### Claim 17 (depends on 1)

The method of claim 1, wherein the unrolling of the first and second portions includes concurrently unwinding the first and second portions from the first and second holding rollers with a same unwinding unit.

### Claim 18 (depends on 1)

The method of claim 1, wherein a main direction of fibres of the first web of material is nonparallel to a main direction of fibres of the second web of material.