Method for Manufacturing a Sandwich Panel

Abstract

The invention relates to a method for manufacturing a sandwich panel as a semi-finished product where at least one layer of a non-metallic material is positioned between at least two metallic layers. At least one of the metal layers is shaped into a three dimensional layer, and the metal layers are in direct mechanical contact to enable resistance weldability of the semi-finished product in order to connect the semi-finished product to a desired combination of solutions in a subsequent manufacturing process.

Claims

1. A method for manufacturing a sandwich panel as a semi-finished product comprising, positioning at least one layer of a non-metallic material between at least two metallic layers wherein at least one of the metal layers is shaped into a three dimensional layer, and the metal layers directly contact each other to enable resistance weldability of the semi-finished product for connecting the semi-finished product to a desired combination of solutions in a subsequent manufacturing process.

2. The method according to claim 1, wherein the non-metallic layer is positioned in recess spaces formed between the metal layers with variable filling degrees of a maximum of 60%.

3. The method according to claim 1, wherein the three dimensional layer is a corrugated metal strip.

4. The method according to claim 1, wherein the three dimensional layer is a metal piece in a shape of knobs or nubs on a surface of the three dimensional layer.

5. The method according to claim 1, wherein the metal layers are made of a same metal material.

6. The method according to claim 1, wherein the metal layers are made of different metal materials.

7. The method according to claim 6, wherein the metal layers are made of metals with two different thermal expansion coefficients influencing the thermal expansion of the sandwich panel.

8. The method according to claim 1, wherein the metal layers are made of stainless steel or carbon steel.

9. (canceled)

10. The method according to claim 1, wherein the metal layers are made of copper.

11. The method according to claim 1, wherein the metal layers are made of aluminium.

12. The method according to claim 1, wherein the metal layers are made of magnesium.

13. The method according to claim 1, wherein the non-metallic layer is made of a polymer material.

14. The method according to claim 1, wherein the non-metallic layer is made of a resin material.

15. The method according to claim 1, wherein the non-metallic layer is made of cold or thermosetting one or two component adhesive glue.

16. The method according to claim 1, wherein the non-metallic layer is made of a two component sandwich-adhesion material containing resin and hardener.

17. The method according to claim 1, wherein the semi-finished sandwich panel is joined, for connecting the semi-finished product to a desired combination of solutions, by welding in a subsequent manufacturing process.

18. The method according to claim 1, wherein the semi-finished sandwich panel is joined, for connecting the semi-finished product to a desired combination of solutions, by resistance spot welding in a subsequent manufacturing process.

19. The method according to claim 1, wherein the semi-finished sandwich panel is joined, for connecting the semi-finished product to a desired combination of solutions, by resistance roller welding in a subsequent manufacturing process.

20. The method according to claim 1, wherein the semi-finished sandwich panel is joined, for connecting the semi-finished product to a desired combination of solutions, by laser or electron beam welding in a subsequent manufacturing process.

21. The method according to claim 1, wherein the semi-finished sandwich panel is joined, for connecting the semi-finished product to a desired combination of solutions, by micro-plasma welding in a subsequent manufacturing process.

Description

[0024] The invention is described in more details referring the following drawings where

[0025] FIG. 1 illustrates one preferred embodiment of the invention in a schematic manner from the side view, and

[0026] FIG. 2 illustrates one another preferred embodiment of the invention in a schematic manner from the side view.

[0027] According to the FIG. 1 a flat metal layer 1, a polymer layer 2 and the three dimensional metal layer 3. The polymer layer 2 is positioned in recess spaces formed between the metal layers 1 and 3.

[0028] In FIG. 2 the flat metal layer 11, a polymer layer 12 and the three dimensional metal layer 13 are similar to the layers described in connection with the description of FIG. 1. The sandwich consisting of metal layers 11 and 13 and the polymer layer are welded to a metal sheet 14 by resistance spot welding 15.