Sandwich panel, method for manufacturing the same, and sandwich panel structure

Patent metadata

Field	Value
Publication number	US-10569498-B2
Application number	US-201615562773-A
Country	US
Kind code	B2
Filing date	Mar 29, 2016
Priority date	Apr 3, 2015
Publication date	Feb 25, 2020
Grant date	Feb 25, 2020

Abstract

The present invention provides a sandwich panel and a sandwich panel structure formed by welding a plurality of the sandwich panels, each sandwich panel comprising: a flocking core layer; and skin layers laminated on both surfaces of the flocking core layer, respectively, wherein the sandwich panel comprises at least one contact portion, at which the two skin layers abut each other. In addition, the present disclosure provides a method for manufacturing a sandwich panel, the method comprising the steps of: preparing a sandwich panel comprising a flocking core layer and skin layers laminated on both surfaces of the flocking core layer, respectively; and applying heat and pressure to at least one surface of the skin layers, thereby forming at least one contact portion.

First claim

The invention claimed is:

1. A sandwich panel comprising:
a flocking core layer, wherein the flocking core layer comprises fibers flocked to an adhesive layer, wherein the fibers comprises a polyamide fiber, and wherein a thickness of the flocking core layer ranges from 0.5 mm to 2.0 mm; and
skin layers stacked on both sides of the flocking core layer, respectively,
wherein the sandwich panel further comprises at least one contact portion abutted by both skin layers,
wherein the at least one contact portion has a groove shape, and is formed by applying a pressure to at least one surface of the skin layer, and
wherein a groove depth of the at least one contact portion ranges from 0.5 mm to 2.0 mm.

2. The sandwich panel of claim 1 , wherein the contact portion has the number of 4 to 16 per unit area.

3. The sandwich panel of claim 1 , wherein the fibers have an average cross-sectional diameter of 20 μm to 70 μm.

4. The sandwich panel of claim 1 , wherein the fibers have an average length of 0.5 mm to 3 mm.

5. The sandwich panel of claim 1 , wherein the adhesive layer comprises at least one selected from the group consisting of an epoxy-based adhesive, an acrylic adhesive, a silicone-based adhesive, a rubber-based adhesive, and a combination thereof.

6. The sandwich panel of claim 1 , wherein the skin layer comprises at least one selected from the group consisting of aluminum, galvanized steel sheet (GI), stainless steel, magnesium, and a combination thereof.

7. A sandwich panel structure formed by welding the sandwich panel according to claim 1 ; and at least one selected from the group consisting of a metal layer, the sandwich panel, and a combination thereof.

8. The sandwich panel structure of claim 1 , wherein at least two of the sandwich panels are welded each other.

9. The sandwich panel structure of claim 1 , wherein the sandwich panel structure has an electrical conductivity of 100 S/cm to 1000 S/cm.

10. The sandwich panel structure of claim 1 , wherein the metal layer comprises at least one selected from the group consisting of iron, stainless steel (SUS), aluminum, magnesium, copper, and a combination thereof.

11. A method for manufacturing a sandwich panel according to claim 1 , comprising:
preparing the flocking core layer and the skin layers stacked on both sides of the flocking core layer, respectively; and
applying heat and pressure to at least one surface of the skin layers to form the at least one contact portion.

12. The method of claim 11 , wherein in preparing the sandwich panel, the flocking core layer is formed by an electrostatic deposition of fibers.

13. The method of claim 11 , wherein in forming the contact portion, the contact portion is formed by pressing the flocking core layer so that the skin layers on both sides are abutted each other.

14. The method of claim 11 , wherein the forming the contact portion is performed at a pressure of 0.2 MPa to 1 MPa.

15. The method of claim 11 , wherein the forming the contact portion is performed at a temperature of 50° C. to 150° C.

Assignees

• Lg Hausys Ltd

Inventors

• Rho Sang-Hyun
• Kim Dong-Eung
• Lim Ji-Won

Classifications

• B32B2250/40

  Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA · CPC title

• E04C2/292

  composed of insulating material and sheet metal · CPC title

• B32B2260/046

  Synthetic resin · CPC title

• B32B5/022

  Non-woven fabric · CPC title

• B32B3/28

  characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence) · CPC title