Two-phase manufacturing method for composite structural partitions with integrated aluminum honeycomb core

Abstract

The present invention relates to a method for manufacturing composite structural partitions (Composite Sandwich Partitions), which feature an integrated aluminum honeycomb core, can be applied on photovoltaic frames, and have high mechanical strength and improved thermal behavior. This is an invention whose innovative element is the two-phase bonding of the composite structural partitions using thermoplastic polyurethane (TPU / Scrim, Figure 3, A) and heating. The first phase of manufacturing the structural partitions involves the standard encapsulation of the photovoltaic elements (Figure 1) by adding an inert bonding layer (TPU / Scrim, Figure 3, A) protected by an anti-tack sheet on the rear side. The second phase involves the removal of the anti-tack sheet (Figure 2, A), the placement of aluminum honeycomb plates (Figure 2, B & C, Figure 3, B), the filling of the joints with thermoplastic polyurethane granules (TPU, Figure 2, D), and the application of a local, targeted thermal process (Figure 2, E) to create a unified sandwich-type structure (Figure 1, Figure 2, F).