Patent ID: 11884046
Assignee: DIAB INTERNATIONAL AB
Field: Surface technology, coating (Chemistry)
Classification: CPC B | IPC B

Claim 2:
3. A method of manufacturing a composite sandwich component, the composite sandwich component comprising a first core structure, a second core structure, a top reinforcement layer, and a bottom reinforcement layer, each of the first and second core structures being made of a material selected from the group consisting of polymer foam and wood, each of the first and the second core structures having a respective top surface, a bottom surface, a left edge surface, and a right edge surface, the method comprising the steps of:
(a) forming grooves in the first and second core structures by:
(i) forming a first plurality of grooves in the top surface of the first core structure, extending from the right edge surface of the first core structure;
(ii) forming a second plurality of grooves in the bottom surface of the first core structure, extending from the right edge surface of the first core structure;
(iii) forming a third plurality of grooves in the top surface of the second core structure, extending from the left edge surface of the second core structure;
(iv) forming a fourth plurality of grooves in the bottom surface of the second core structure, extending from the left edge surface of the second core structure;
(v) forming a fifth plurality of grooves in at least one of the right edge surface of the first core structure and the left edge surface of the second core structure, the fifth plurality of grooves extending from the top surface to the bottom surface of the first and second core structures (201, 202), respectively;

(b) chamfering at least one intersection of a top surface of at least one of the first and second core structures and one of the left and right edge surfaces of the at least one of the first and second core structures, and at least one intersection of a bottom surface of at least one of the first and second core structures and one of the left and right edge surfaces of the at least one of the first and second core structures;
(c) arranging the first and second core structures in relation to each other such that the right edge surface of the first core structure abuts the left edge surface of the second core structure;
(d) arranging the first and second core structures on the bottom reinforcement layer;
(e) arranging the top reinforcement layer on the top surfaces of the first and second core structures;
(f) enclosing the arranged first and second core structures and top and bottom reinforcement layers in an enclosure;
(g) feeding liquid resin onto the top reinforcement layer in a resin feed area above which the right edge surface of the first core structure abuts the left edge surface of the second core structure; and
(h) while the feeding of liquid resin continues, evacuating the enclosure of air, whereby the liquid resin is transported horizontally along the first plurality of grooves in the top surface of the first core structure and the third plurality of grooves in the top surface of the second core structures, respectively, and whereby the liquid resin is transported vertically along the fifth plurality of grooves in the right and left edge surfaces of the first and second core structures, respectively, and horizontally along the second plurality of grooves in the bottom surface of the first core structure and the fourth plurality of grooves in the second core structure.