Method of manufacturing a lightweight laminate
A method of producing a laminated article comprising placing a first metal skin, a core, and a second metal skin freely onto each other as discrete layers to provide a layered component; and forming the layered component into a shaped article via a die prior to producing a laminated article by applying pressure and heat to the shaped article, wherein at least the first skin moves relative to the core and/or second skin during the forming.
1. A method of producing a laminated article comprising:
arranging first and second discrete layers to be freely in contact with each other within a die, wherein the first discrete layer comprises a laminated first skin and a first core and the second discrete layer comprises a laminated second skin and a second core, the first skin and the second skin each having a respective stiffness that is greater than a stiffness of the first core or a stiffness of the second core;
forming via the die a shaped article from the layers such that the layers move relative to each other during the forming; and
laminating the shaped article.
2. The method of claim 1 , wherein the first skin, the second skin, or both are metallic.
3. The method of claim 1 , wherein a chemical composition of the first discrete layer is different than a chemical composition of the second discrete layer.
4. The method of claim 1 , wherein the first core and the second core have different chemical compositions.
5. The method of claim 1 , wherein a thickness of the first discrete layer differs from a thickness of the second discrete layer.
6. The method of claim 1 , wherein the forming includes applying pressure and heat to the article.
7. The method of claim 1 , wherein the first skin and the second skin have a same chemical composition.
8. The method of claim 1 , further comprising establishing a connection between the two discrete layers, and prior to the forming, removing the connection.
9. The method of claim 1 , wherein the first core comprises at least one blowing agent.