Sandwich panel and method for manufacturing same

Patent metadata

Field	Value
Publication number	US-10647082-B2
Application number	US-201615559763-A
Country	US
Kind code	B2
Filing date	Mar 21, 2016
Priority date	Mar 19, 2015
Publication date	May 12, 2020
Grant date	May 12, 2020

Abstract

Provided are a sandwich panel and a method for manufacturing same, the sandwich panel comprising: a flocking core layer; and skin layers stacked on either side of the flocking core layer, wherein the flocking core layer comprises a mixed fiber containing at least two types of fibers having different average cross sectional diameters.

First claim

The invention claimed is:

1. A sandwich panel comprising:
a flocking core layer; and
skin layers stacked on both sides of the flocking core layer,
wherein the flocking core layer comprises:
a layer formed of only a mixed fiber; and
a layer of an adhesive comprising a planted end portion of the mixed fiber, wherein the planted end portion of the mixed fiber is stacked in the layer of the adhesive,
wherein the mixed fiber comprises:
a first fiber, wherein an average cross-sectional diameter of the first fiber ranges from 40 μm to 70 μm; and
a second fiber, wherein an average cross-sectional diameter of the second fiber ranges from 10 μm to 20 μm,

wherein the mixed fiber comprises one selected from the group consisting of a polyamide fiber, a polyester fiber, and a combination thereof, and
wherein a volume ratio of the first fiber to the second fiber in the flocking core layer ranges from 4:1 to 9:1.

2. The sandwich panel of claim 1 , wherein the adhesive includes one selected from the group consisting of acrylic adhesive, silicone-based adhesive, rubber-based adhesive, and a combination thereof.

3. The sandwich panel of claim 1 , wherein the mixed fiber has an average length of 0.5 mm to 2.0 mm.

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

5. The sandwich panel of claim 1 , wherein the skin layer has a thickness of 0.1 mm to 1.0 mm.

6. The sandwich panel of claim 1 , wherein the flocking core layer has a thickness of 0.5 mm to 2.0 mm.

7. The sandwich panel of claim 1 , wherein the sandwich panel is used as a display device lower cover.

8. A method for manufacturing a sandwich panel comprising:
preparing a mixed fiber containing at least two types of fibers having different average cross-sectional diameters, wherein
the mixed fiber comprise:
a first fiber, wherein an average cross-sectional diameter of the first fiber ranges from 40 μm to 70 μm; and
a second fiber, wherein an average cross-sectional diameter of the second fiber ranges from 10 μm to 20 μm,

the mixed fiber comprises one selected from the group consisting of a polyamide fiber, a polyester fiber, and a combination thereof;

preparing two skin layers and applying an adhesive to one side of each of the skin layers;
planting the mixed fiber on the adhesive of at least one skin layer of the two skin layers in which the adhesive is applied to one side; and
stacking the two skin layers so that the respective sides applied with the adhesive face each other to thereby manufacture a sandwich panel having a flocking core layer between the two skin layers, wherein
the flocking core layer comprises:
a layer formed of only the mixed fiber; and
a layer of the adhesive comprising a planted end portion of the mixed fiber, wherein the planted end portion of the mixed fiber is stacked in the layer of the adhesive, and

a volume ratio of the first fiber to the second fiber in the flocking core layer ranges from 4:1 to 9:1.

9. The method of claim 8 , wherein the planting of the mixed fiber is performed by an electrostatic deposition method.

10. The method of claim 8 , wherein at the time of applying an adhesive to one side of each of the skin layers, the adhesive is applied so that an average thickness of the adhesive is 100 to 300 μm.

11. The method of claim 8 , further comprising:
curing the adhesive applied.

Assignees

• Lg Hausys Ltd

Inventors

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

Classifications

• B32B3/12 Primary

  characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure · CPC title

• B32B5/08

  the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres} · CPC title

• B32B2262/106

  Carbon fibres, e.g. graphite fibres · CPC title

• B32B2262/0261

  Polyamide fibres · CPC title

• B32B37/1284

  Application of adhesive · CPC title