Method and Apparatus for Manufactoring a Sandwich Component

Abstract

A method for manufacturing a sandwich component includes applying at least one matrix material to the upper side and/or the underside of at least one material blank, and arranging the material blanks above one another and/or next to one another. At least two of the material blanks differ in design or matrix material may be applied in different ways along the upper side and/or underside thereof, or matrix material is applied in different ways to at least one of the material blanks along the upper side and/or underside thereof. In that way, at least one horizontal and/or vertical zone of the sandwich component is created having different mechanical properties than other regions of the sandwich component. The material blanks are then pressed to form the sandwich component.

Claims

1-20. (canceled)

21. A method for manufacturing a sandwich component, comprising: providing a plurality of material blanks; applying at least one matrix material to an upper side and/or an underside of at least one material blank of the material blanks; arranging the material blanks above one another and/or next to one another, with at least two material blanks being arranged one above another; and pressing the material blanks to form the sandwich component such that at least one horizontal and/or vertical zone of the sandwich component is created having different mechanical properties than other regions of the sandwich component, wherein at least two of the material blanks differ in design, or matrix material is applied in different ways along the upper side and/or the underside thereof, or matrix material is applied in different ways to at least one of the material blanks along the upper side and/or the underside thereof.

22. The method of claim 21, wherein the at least two material blanks differ in design with regard to surface area.

23. The method of claim 21, wherein at least two of the material blanks comprises fibrous material.

24. The method of claim 23, wherein the at least two material blanks differ in design with regard to a fiber direction of fibers contained therein.

25. The method of claim 21, wherein applying at least one matrix material comprises applying a different amount and/or a different type of matrix material.

26. The method of claim 21, wherein one of the material blanks is formed by a core layer arranged so as to lie between at least two other material blanks of the sandwich component.

27. The method of claim 21, wherein the at least one horizontal zone of the sandwich component comprises a deformable zone for pedestrian protection.

28. The method of claim 21, wherein at least two of the material blanks have a different shape before completion of the sandwich component, and at least one material blank is cut to a same shape as a further material blank.

29. The method of claim 21, wherein at least two of the material blanks have a different shape after completion of the sandwich component, in order to form the at least one horizontal zone.

30. The method of claim 26, wherein: at least two of the material blanks are arranged at least on one side of a core layer; matrix material is applied in different ways to the at least two material blanks; and/or matrix material is applied in different ways to at least one of these two material blanks along a surface area thereof.

31. The method of claim 26, wherein the core layer is formed in the manner of a honeycomb.

32. The method of claim 21, wherein fibers are admixed with the matrix material.

33. The method of claim 21, wherein applying the at least one matrix material comprises spraying the at least one matrix material, and/or dipping the at least one matrix material, and/or rolling the at least one matrix material.

34. The method of claim 21, wherein spraying the at least one matrix material is performed using a spraying unit having at least one second spray head.

35. The method of claim 21, wherein pressing the material blanks is performed via a wet-pressing method.

36. The method of claim 21, wherein providing the material blanks is performed via a multi-layer holding unit such that the material blanks are held vertically one above another and moved apart horizontally.

37. An apparatus for manufacturing a sandwich component, the apparatus comprising: at least one multi-layer holding unit configured to hold a plurality of material blanks vertically one above another; at least one application unit configured to apply at least one matrix material to an upper side and/or an underside of at least one of the material blanks; and at least one press configured to press the material blanks to form the sandwich component.

38. The apparatus of claim 37, wherein the multi-layer holding unit comprises a fan-type gripper configured to arrange the material fans so as to be positioned radially outward with respect to one another.

39. The apparatus of claim 37, wherein the application unit comprises a spraying unit, and/or a dipping unit, and/or a rolling unit.

40. The apparatus of claim 39, wherein the spraying unit has at least one second spray head configured to apply matrix material in different ways by applying a different amount and/or different type of matrix material.

Description

DRAWINGS

[0062] The invention is described below by way of example with reference to the drawings.

[0063] FIG. 1 shows a schematic illustration from above of a fan-type gripper and an application unit of an apparatus according to the invention for carrying out the method according to the invention for manufacturing a sandwich component.

[0064] FIG. 2 shows a schematic illustration from the side of a fan-type gripper of an apparatus according to the invention for manufacturing a sandwich component.

DESCRIPTION

[0065] FIG. 1 shows a fan-type gripper 7 which is embodied as a robot and serves as a manipulator for four material blanks 1, 2, 3 and 4 (also called layers). The fan-type gripper 7 brings the layers, i.e. material blanks 1, 2, 3, 4, also comprising the core 5 formed by the material blank 2, into the respective position opposite the spray head of the spraying unit 6 for the spraying application.

[0066] After the spraying application, the layers 1, 2, 3, 4 are moved (vertically) one above another by means of the fan-type gripper 7 and inserted into the press. The fastening points or holding points of the respective layers, i.e., material blanks 1, 2, 3, 4, are then opened individually one after another or simultaneously on the fan-type gripper 7 such that layer by layer can be deposited in the heating pressing tool. The press is closed and the sandwich pressed. Pressing can optionally also take place as soon as the layers are moved one above another (positioned vertically one above another) and while the layers are still fastened to the respective fans of the fan-type gripper 7.

[0067] FIG. 2 illustrates a side view of a fan-type gripper 7, wherein the individual layers, i.e. material blanks 1, 2, 3, 4 and even further material blanks are held in an arrangement offset vertically and are provided for further processing.

LIST OF REFERENCE SIGNS

[0068] First material blank [0069] Second material blank [0070] Third material blank [0071] Fourth material blank [0072] Core layer [0073] Spray head [0074] Fan-type gripper