Method of manufacturing sandwich panel

Abstract

The invention relates to a method of manufacturing a sandwich panel comprises the steps of:a) providing a plate-shaped assembly of a first cover part and a second cover part and between these cover parts a core part of a thermoplastic material containing a physical blowing agent,b) heating the assembly resulting from step a) under pressure between press tools in a press to a foaming temperature below the glass transition temperature of the thermoplastic material in the core part, thereby effecting adhesion of the foamed core part to the first and second cover partsc) foaming the thermoplastic material in the core part under pressure and at the foaming temperature wherein the spacing between the press tools is increased;d) a cooling step of cooling the foamed sandwich panel resulting from step c), while the sandwich panel is maintained under pressure between the press tools;e) removing the thus cooled sandwich panel from the press; andf) drying the sandwich panel thus obtained;wherein the cooling step d) comprises a first substep d1) of cooling the foamed assembly from the foaming temperature to an intermediate temperature in the range of 70-100° C. at a first cooling rate and a second substep d2) of cooling the foamed assembly from the intermediate temperature to ambient temperature at a second cooling rate, the second cooling rate is less than the first cooling rate.

1 - 11 . (canceled) 
     
     
         12 . Method of manufacturing a sandwich panel comprising the steps of:
 a) an assembling step of providing a plate-shaped assembly of a first cover part and a second cover part and between these cover parts a core part of a thermoplastic material containing a swelling agent, wherein the thermoplastic material of the core part is an amorphous polymer selected from the group consisting of polyetherimide (PEI), polyethersulfone (PES), polysulfone (PSU), polyphenylsulfone (PPSU), and polycarbonate (PC) and the swelling agent is a swelling agent for the thermoplastic material;   b) a heating step of heating the assembly resulting from step a) under pressure between heated press tools in a press to a foaming temperature below the glass transition temperature of the thermoplastic material in the core part;   c) a foaming step of foaming the thermoplastic material in the core part under pressure and at the foaming temperature wherein the spacing between the press tools is increased;   d) a cooling step of cooling the foamed sandwich panel resulting from step c), while the sandwich panel is maintained under pressure between the press tools;   e) a discharging step of removing the thus cooled sandwich panel from the press; and   f) a drying step of drying the sandwich panel thus obtained;   wherein the cooling step d) is carried out in two substeps, comprising a first substep d1) of cooling the foamed assembly from the foaming temperature to an intermediate temperature in the range of 70-100° C. at a first cooling rate and a second substep d2) of cooling the foamed assembly from the intermediate temperature to ambient temperature at a second cooling rate, wherein the first cooling rate is at least 140° C./min and wherein the second cooling rate is less than the first cooling rate, thereby effecting bonding of the foam core part to the first and second cover parts.   
     
     
         13 . Method according to  claim 12 , wherein the swelling agent is acetone. 
     
     
         14 . Method according to  claim 13 , wherein the first cooling rate is more than 200° C./min. 
     
     
         15 . Method according to  claim 12 , wherein the second cooling rate is less than half of the first cooling rate. 
     
     
         16 . Method according to  claim 13 , wherein the second cooling rate is 25° C./min or less. 
     
     
         17 . Method according to  claim 12 , wherein during substeps d1) and d2) the temperature difference between the press tools is less than 2° C. 
     
     
         18 . Method according to  claim 12 , wherein the surface of the press tools is provided with a layer of a material having a heat conductivity coefficient, which is higher than that of the construction material from which the press tools are made. 
     
     
         19 . Method according to  claim 17 , wherein the layer of material having the higher heat conductivity coefficient is a layer made of copper or aluminium. 
     
     
         20 . Method according to  claim 12 , wherein at least one of the first and second cover parts comprises a layer of a thermoplastic. 
     
     
         21 . Method according to  claim 20 , wherein the thermoplastic of a cover part is selected from the group consisting of polyetherimide (PEI), polyethersulfone (PES), polyphenylsulfone (PPSU) and polysulfone (PSU). 
     
     
         22 . Method according to  claim 12 , wherein the thermoplastic of the core part is polyetherimide (PEI). 
     
     
         23 . Method according to  claim 21 , wherein at least one of the first and second cover parts comprises a layer of a fibre-reinforced thermoplastic. 
     
     
         24 . Method according to  claim 14 , wherein the second cooling rate is less than half of the first cooling rate. 
     
     
         25 . Method according to  claim 14 , wherein the second cooling rate is 25° C./min or less. 
     
     
         26 . Method according to  claim 13 , wherein during substeps d1) and d2) the temperature difference between the press tools is less than 2° C. 
     
     
         27 . Method according to  claim 13 , wherein the surface of the press tools is provided with a layer of a material having a heat conductivity coefficient, which is higher than that of the construction material from which the press tools are made. 
     
     
         28 . Method according to  claim 13 , wherein the thermoplastic of the core part is polyetherimide (PEI). 
     
     
         29 . Method according to  claim 14 , wherein the thermoplastic of the core part is polyetherimide (PEI). 
     
     
         30 . The method of  claim 28 , wherein the second cooling rate is 25° C./min or less. 
     
     
         31 . The method of  claim 29 , wherein the second cooling rate is 25° C./min or less.