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

Claim 0:
1. A method of manufacturing a composite sandwich component, the composite sandwich component comprising a first core structure, a second core structure, a third core structure, a top reinforcement layer, and a bottom reinforcement layer, each of the first, second and third core structures being made of a material selected from the group consisting of polymer foam and wood, each of the first, second and third 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, second, and third 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 the left edge surface of the third core structure, extending from the top surface of the third core structure to the bottom surface of the third core structure;
(vi) forming a sixth plurality of grooves in the right edge surface of the third core structure, extending from the top surface of the third core structure to the bottom surface of the third core structure;

(b) chamfering an intersection of the top surface of at least one of the first, second, and third core structures and an edge surface of the at least one of the first, second, and third core structure, and an intersection of the bottom surface of the at least one of the first, second, and third core structures and an edge surface of the at least one of the first, second, and third core structures;
(c) arranging the first, second and third core structures in relation to each other such that the left edge surface of the third core structure abuts the right edge surface of the first core structure, and such that the right edge surface of the third core structure abuts the left edge surface of the second core structure;
(d) arranging the first, second and third core structures on the bottom reinforcement layer;
(e) arranging the top reinforcement layer on the top surfaces of the first, second and third core structures;
(f) enclosing the arranged first, second, and third 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 left edge surface of the third core structure abuts the right edge surface of the first core structure and the right edge surface of the third 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 and third pluralities of grooves in the top surfaces of the first and second core structures, respectively, and whereby the liquid resin is transported vertically along the fifth plurality of grooves in the left edge surface of the third core structure and the sixth plurality of grooves in the right edge surface of the third core structure, 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 bottom surface of the second core structure.