Sandwich Component Additive Core Manufacturing
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Solution Overview
Problem
Current methods for producing sandwich components are inefficient, requiring separate production steps for cover layers and core layers, which increases processing time and complexity, and lack design flexibility for improved mechanical properties.
Innovation Solution
A method involving the direct formation of a closed cover layer on a mold using prepreg tapes or semi-finished fiber products, followed by additive manufacturing to create a core structure integrated with the cover layer, allowing for automated production of sandwich components in a single tool device with enhanced mechanical properties and reduced processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate production steps are used for cover layers and core layers with adhesive bonding, then manufacturing flexibility is maintained, but processing time increases and production efficiency decreases
Solution Approach 1:
The patent combines the production of cover layers and core layers into a single integrated manufacturing process. The core layer is built up directly on the first cover layer using additive manufacturing, eliminating the need for separate production steps and adhesive bonding operations. This merging of processes directly addresses the contradiction by improving productivity while reducing processing time.
Solution Approach 2:
The first cover layer is formed in advance on the mold surface before the core layer is added. This preliminary action allows the core to be directly constructed on top of it in the subsequent additive manufacturing step, creating an integrated structure without requiring post-production assembly. This sequential integration resolves the time loss associated with separate production and bonding steps.
2Ease of manufacture
If separate production steps with adhesive bonding are used, then manufacturing simplicity is maintained, but process complexity increases
Solution Approach 1:
By merging the production of cover layers and core layers into a single additive manufacturing process, the patent eliminates multiple discrete manufacturing steps and adhesive bonding operations. This integration simplifies the overall manufacturing workflow while reducing process complexity despite the advanced technology used.
3Reliability
If conventional separate production and bonding methods are used, then manufacturing precision is maintained, but delamination risk increases
Solution Approach 1:
The patent merges the production of cover layers and core layer into a single integrated structure through additive manufacturing. The core layer is constructed directly on the first cover layer with continuous material deposition, creating inherent bonding without interfaces that could delaminate. This eliminates the harmful effect of delamination risk associated with separate production and adhesive bonding methods.
4Adaptability or versatility
If standard additive manufacturing is used for core, then design flexibility is achieved, but integration with cover layers requires additional steps
Solution Approach 1:
The patent merges the additive manufacturing of the core with the cover layer formation into a single continuous process. The core is built up directly on the first cover layer within the same manufacturing setup, allowing design flexibility through variable core structures while avoiding additional integration steps. This resolves the contradiction by maintaining adaptability without increasing integration complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method streamlines the production process, reduces the risk of delamination, and offers improved mechanical strength and design flexibility by integrating the core and cover layers during production, resulting in faster and more precise manufacturing of sandwich components.
Implementation Method 1
the matrix material is converted into a viscous state immediately after deposition by applying heat, for example, using a heating device provided on the deposition head. This melts the individual fiber slivers and, if applicable, the individual layers of fiber slivers.
Implementation Method 2
The walls forming the cells are created by heating a wire- or ribbon-shaped plastic material to liquefy it and extruding it onto the inner surface of the first cover layer using a nozzle.
Implementation Method 3
The plastic material then hardens at the desired position by cooling.
Data Source
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AI summary
The present invention describes a method for manufacturing a sandwich component. According to the invention, a first cover layer (2) is formed on a mold surface of a mold tool (100), a core is created by building up a cell structure (30) with a plurality of cells (35) in a thickness direction (D) on the first cover layer (2) by means of an additive manufacturing process, and a second cover layer is formed on a deposit surface of the core located opposite the first cover layer (2). Furthermore, a core for a sandwich component and a sandwich component itself are described.