阅读说明：本技术 复合材料和用于生产该复合材料的方法 (Composite material and method for producing the same ) 是由 本特·A·G·尼尔森 于 2018-03-16 设计创作，主要内容包括：描述了一种复合材料(100)。该复合材料(100)包括第一覆盖片(1)、第二覆盖片(1、2)和设置在第一覆盖片(1)与第二覆盖片(1)之间的芯层(3),所述芯层(3)包括与第一覆盖片(1)接触的第一粘合剂层(4)、与第二覆盖片(2)接触的第二粘合剂层(5),以及从第一粘合剂层(4)延伸至第二粘合剂层(5)的纤维(6)。第一覆盖片(1)具有比芯层(3)大的延伸部,并且第一覆盖片(1)至少包括无芯层(3)的第一边缘区域(7),其中,第一边缘区域(7)从第一覆盖片(1)的外边缘(9)延伸至芯层(3)。(A composite material (100) is described. The composite material (100) comprises a first coversheet (1), a second coversheet (1, 2) and a core layer (3) disposed between the first coversheet (1) and the second coversheet (1), said core layer (3) comprising a first adhesive layer (4) in contact with the first coversheet (1), a second adhesive layer (5) in contact with the second coversheet (2), and fibers (6) extending from the first adhesive layer (4) to the second adhesive layer (5). The first coversheet (1) has a larger extension than the core layer (3), and the first coversheet (1) comprises at least a first edge region (7) free of the core layer (3), wherein the first edge region (7) extends from an outer edge (9) of the first coversheet (1) to the core layer (3).)

1. A composite material (100) comprising:

a first covering sheet (1),

a second covering sheet (1, 2), and

a core layer (3), said core layer (3) being disposed between said first and second cover sheets (1, 1), said core layer (3) comprising:

a first adhesive layer (4), the first adhesive layer (4) being in contact with the first coversheet (1),

a second adhesive layer (5), the second adhesive layer (5) being in contact with the second coversheet (2), and

flocked material in the form of individual fibres (6), the fibres (6) extending from the first adhesive layer (4) to the second adhesive layer (5), characterized in that the first coversheet (1) has a larger extension than the core layer (3) and that the first coversheet (1) comprises at least a first edge region (7) without the core layer (3), wherein the first edge region (7) extends from the outer edge (9) of the first coversheet (1) to the core layer (3), wherein the extension of the first edge region (7) exceeds the outer edge (18) of the core layer (3) by at least 20mm, and that the fibres (6) extend from the first adhesive layer (4) to the second adhesive layer (5)

Wherein the second coversheet (2) extends no more than 5mm beyond the outer edge (18) of the core layer (3).

2. The composite (100) according to claim 1, wherein the extension of the first edge region (7) beyond the outer edge (18) of the core layer (3) is at least 50 mm.

3. The composite (100) according to claim 1 or 2, wherein the first edge region (7) extends around the entire outer edge (9) of the first coversheet (1) such that the first edge region (7) surrounds the core layer (3).

4. The composite (100) according to claim 1, 2 or 3, wherein the second coversheet (2) extends no more than 1mm beyond the outer edge (18) of the core layer (3).

5. A container (21) formed from a composite material (100) according to any one of claims 1 to 4, wherein the second covering sheet (2) forms an inner bottom (23) of the container (21) and at least a part of the first edge region forms a side wall (24) of the container (21).

6. A method (300) for producing a composite material (100) according to any one of claims 1 to 4, comprising the steps of:

(301) providing a first covering sheet (1) and a second covering sheet (2),

(302) applying a first adhesive layer (4) on the first coversheet (1) and a second adhesive layer (5) on the second coversheet (2),

(303) applying a flock material in the form of individual fibers (6) on one of the adhesive layers (4, 5),

(304) arranging the first coversheet (1) adjacent to the second coversheet (2), wherein the first adhesive layer (4) faces the second adhesive layer (5), and wherein the fibers (6) are in contact with the first adhesive layer (4) and the second adhesive layer (5),

(305) curing the adhesive layers (4, 5) to form a core layer (3) of the first adhesive layer (4), the second adhesive layer (5) and the fibers (6), characterized in that the first coversheet (1) has a larger extension than the core layer (3) and the first coversheet (1) comprises at least a first edge region (7) without the core layer (3),

wherein the first edge region (7) extends from an outer edge (9) of the first coversheet (1) to the core layer (3),

wherein the extension of the first edge region (7) beyond the outer edge (18) of the core layer (3) is at least 20mm, and

wherein the second coversheet (2) has substantially the same extension as the core layer (3) and the second coversheet (2) extends no more than 5mm beyond the outer edge (18) of the core layer (3).

7. A method according to claim 6, wherein the extension of the first edge region (7) beyond the outer edge (18) of the core layer (3) is at least 50 mm.

8. Method according to claim 6 or 7, wherein the first adhesive layer (4) is applied on the first covering sheet (1) and the second covering sheet (2) is applied on the second covering sheet (2) using an application head (25), the application head (25) operating at a distance from the first covering sheet (1) and the second covering sheet (2).

9. A method according to claim 6, 7 or 8, wherein the applicator head (25) comprises a slot (26), adhesive leaves the applicator head (25) through the slot (26), and the adhesive is forced through the slot (26) by applying pressure on the adhesive inside the applicator head (25).

10. Method according to claim 9, wherein the application of the adhesive on the respective covering sheet (1, 2) is ended by:

moving the application head (25) away from the respective cover sheet (1, 2), and

reducing the pressure on the adhesive inside the applicator head (25).

11. Method according to claim 10, wherein the coating head (25) is moved away from the respective cover sheet (1, 2) at a speed of at least 200mm per minute by at least 5 mm.

12. The method according to claim 10 or 11, wherein the pressure on the adhesive inside the applicator head (25) is reduced to below ambient pressure.

Technical Field

The present invention relates to a composite material and a method for producing the composite material. More particularly, the present invention relates to a composite material comprising a first coversheet, a second coversheet and a core layer disposed between the first and second coversheets. The core layer includes a first adhesive layer in contact with the first cover sheet, a second adhesive layer in contact with the second cover sheet, and a flocked material in the form of individual fibers extending from the first adhesive layer to the second adhesive layer.

Background

The composite material includes a first coversheet, a second coversheet, and a core layer disposed between the first coversheet and the second coversheet.

WO2013156166 describes a method for producing large lightweight metal sheets comprising layers formed of at least two metal cover layers and at least one non-metallic core layer.

The core layer may include a first adhesive layer in contact with the first cover sheet, a second adhesive layer in contact with the second cover sheet, and a flocked material in the form of individual fibers extending from the first adhesive layer to the second adhesive layer. Many advantages are obtained with such a composite material compared to a solid material having the same dimensions. For example, high bending stiffness, good formability, good flexibility and/or high mechanical or acoustic energy absorption capability may be obtained while keeping the weight of the composite material low. The desired properties to be optimized may be selected by the type, shape, density, thickness, length and arrangement of the fibers in the core layer. The core layer in such a composite includes a first adhesive layer in contact with the first cover sheet, a second adhesive layer in contact with the second cover sheet, and fibers extending from the first adhesive layer to the second adhesive layer.

EP0333685 describes a sandwich construction and a method for its production. The sandwich construction comprises two plates or sheets with a material applied between them by electrostatic deposition, so-called flocking. The material applied by flocking is a non-conductive material such as nylon fibers.

WO9801295 describes a sandwich construction which is more temperature resistant than the material in EP0333685 due to the use of metal fibres instead of the nylon fibres of EP 0333685.

WO 2004/098886 describes a workpiece made of a composite layer structure and a method for its manufacture.

Disclosure of Invention

It is an object of the present invention to provide a composite material of the following type and a method for producing such a material: the composite has a core layer comprising a flocked material in the form of individual fibres, which is an alternative to the composites of the prior art.

Another object of the invention is to provide a composite material of the following type and a method for producing such a material: the composite has a core layer comprising a flocked material in the form of individual fibres, which is more easily formed by pressing than prior art composites.

These objects are achieved by a composite material and a method according to the independent claims.

Additional advantages of the invention are provided by the features in the dependent claims.

According to a first aspect of the present invention, a composite material is provided. The composite includes a first cover sheet, a second cover sheet, and a core layer disposed between the first cover sheet and the second cover sheet, the core layer including a first adhesive layer in contact with the first cover sheet, a second adhesive layer in contact with the second cover sheet, and a flocked material in the form of individual fibers extending from the first adhesive layer to the second adhesive layer. The composite is characterized in that the first coversheet has a larger extension than the core layer and the first coversheet comprises at least a first edge region free of the core layer, wherein the first edge region extends from the outer edge of the first coversheet to the core layer. The first edge region extends at least 20mm beyond the outer edge of the core layer and the second coversheet extends no more than 5mm beyond the outer edge of the core layer.

An extension from an outer edge of the core layer refers to an extension perpendicular to the edge of the core layer. In addition, the extension is the largest extension of the first edge region. The edge region may have a smaller extension in some regions.

The first edge region may be formed in the same way as a coversheet without any core layer. Since the second covering sheet has a small extension, the covering sheets do not have to be attached to each other. The extension of the first edge region as described above advantageously enables the edge region to be formed into a desired shape of a finished product, such as for example a side wall of a container.

Preferably, the composite has only two covering sheets, i.e. the composite does not comprise covering sheets in addition to the first and second covering sheets.

The composite materials described in WO9801295 and EP0333685 are lightweight materials, which have a high flexural rigidity compared to conventional materials of the same weight. The composite materials described in WO9801295 and EP0333685 also have plastic formability. However, the techniques used to form such composite materials are slightly different from those used to form metal sheets.

The composite material according to the first aspect has a high flexural rigidity in the region of the core layer. The areas of the first cover sheet not covered by the core layer may be formed using conventional techniques for forming such cover sheets.

Preferably, the cover sheet is a metal sheet, but other materials may be used as the cover sheet. When a metal sheet is used as the covering sheet, the usual techniques for forming a metal sheet can be employed for forming the edge region. This makes it easier for the user of the composite material to form the material according to the user's requirements. The composite material according to the first aspect is therefore particularly useful when the area of the composite material covered by the core layer is flat in the final product. An example of such a product is a drawer. The side walls of the drawer are primarily under tensile stress, while the bottom of the drawer is under flexural stress. Thus, the sidewalls need not have the same flexural strength as the base.

Another example of a product that can be manufactured with the composite material according to the invention is a wall panel for the facade of a building. In this case, the area of the composite material covered by the core layer preferably forms the main area of the panel, while the first edge area may be used for attaching the panel to a building.

In the composite, according to the first aspect, the thickness of the cover sheet may be in the range of 0.05mm to 2 mm. This range is preferred because it provides a low weight composite and achieves a large flexural strength from the core layer.

The thickness of the core layer is preferably in the range of 0.2mm to 6 mm. This thickness provides high flexural strength to the composite.

The extension of the first edge region from the core layer may be at least 50 mm. Such an extension of the first edge region is advantageous in being able to form the first edge region as a side wall, for example.

The first edge region may extend around the entire outer edge of the first coversheet such that the first edge region surrounds the core layer. This is advantageous in case the compound is to be formed into a container, wherein the side walls of the container are to be formed by the edge regions. It is of course also possible to let the edge region extend around only a part of the outer wall. Such composite materials may be used to produce, for example, shelving or other products in which edge regions are to be formed using crimping or bending to connect to a shelf chassis or other structure.

The second cover sheet has substantially the same extension as the core layer. The purpose of the second coversheet is to provide flexural rigidity to the composite. Thus, any extension of the second coversheet outside the core layer has no effect on the flexural rigidity of the composite.

However, there may be other reasons for the extension of the second coversheet to be outside the core layer and for the edge region of the second coversheet to be free of the core layer. Thus, alternatively, the second covering sheet may have a larger extension than the core layer. The second edge region extends from the outer edge of the second coversheet to the core layer. One reason for having a second edge region is that it is difficult to manufacture a composite material as described above if the core layer extends all the way to the outer edge of the second coversheet. If the core layer is to extend all the way to the edge of the second coversheet, the adhesive material must be applied all the way to the outer edge of the second coversheet. At the same time, it is desirable to avoid adhesive outside the second coversheet, as adhesive on the machine used to apply the adhesive can be problematic.

In order to provide a safety margin when applying the adhesive, the composite material may be arranged such that the second coversheet has a second edge region which extends no more than 5mm beyond the outer edge of the core layer and preferably no more than 1mm beyond the outer edge of the core layer. If the adhesive can be applied with very high precision, there need not be an edge region on the second cover sheet. However, due to manufacturing reasons, it may be difficult to avoid narrow edge regions as described above.

The second edge region may extend around the entire edge of the first coversheet such that the second edge region surrounds the core layer.

Features relating to the first aspect may be combined in the same embodiment to the extent that they are not alternatives to each other.

According to a second aspect, there is provided a container formed from a composite material according to the first aspect in combination with any of the features described above. The second cover sheet may form an inner bottom of the receptacle and at least a portion of the edge region may form a wall of the receptacle.

According to a third aspect, there is provided a method for producing a composite material according to the first aspect of the invention. The method comprises the following steps: providing a first covering sheet and a second covering sheet; coating a first adhesive layer on the first cover sheet and a second adhesive layer on the second cover sheet; applying a flock material in the form of individual fibers on one or both of the adhesive layers; disposing the first cover sheet adjacent to the second cover sheet, wherein the first adhesive layer faces the second adhesive layer, and wherein the fibers are in contact with the first adhesive layer and the second adhesive layer; and curing the adhesive layer to form a core layer comprised of the first and second adhesive layers and the fibers. The method is characterized in that the first coversheet has a larger extension than the first adhesive layer and the first coversheet comprises at least a first edge region without an adhesive layer, wherein the first edge region extends from the outer edge of the first coversheet to the first adhesive layer. The extension of the first edge region is at least 20 mm. The second cover sheet has substantially the same extension as the core layer and extends no more than 5mm beyond the outer edge of the core layer.

By the method according to the third aspect, a composite material according to the first aspect is provided, which has the advantages as described above.

The adhesive may be applied to the first and second cover sheets using an applicator head, wherein the applicator head operates at a distance from the first and second cover sheets. The position of the applied adhesive is easier to control by avoiding contact of the application means with the first and second coversheet as is normal according to the prior art. The applicator head is stationary and the cover sheet moves past the applicator head. The width of the cover sheet ranges from 0.2 meters to several meters. It can be difficult to move a cover sheet of this size to be able to apply adhesive to the outer edge of the cover sheet without applying adhesive outside the outer edge. Thus, it is advantageous that the second coversheet has a larger extension compared to the core layer.

The distance between the applicator head and the cover sheet may preferably be no more than 0.2mm more than the thickness of the adhesive.

The distance between the application head and the cover sheet is preferably controlled with very high precision and preferably has a variation of no more than 0.1mm and most preferably has a variation of no more than 0.05 mm.

The applicator head may include a slot through which adhesive exits the applicator head and through which adhesive is forced by applying pressure to the adhesive within the applicator head. By applying pressure in this manner, the application of the adhesive can be precisely controlled.

The thickness of the adhesive layer may preferably be in the range of 0.1mm to 0.5mm, and most preferably in the range of 0.15mm to 0.3 mm. This has been shown to provide good results in terms of controlled stopping of the applied adhesive.

The application of the adhesive can be ended by: the applicator head is moved away from the cover sheet and the pressure on the adhesive within the applicator head is reduced. By reducing the pressure, the adhesive flow from the applicator head is reduced and completely stopped if the pressure is sufficiently reduced.

The coating head may be moved at least 5mm at a speed of at least 200mm per minute. By moving the applicator head away from the cover sheet, the adhesive flow is effectively shut off.

The pressure on the adhesive in the applicator head may preferably be reduced simultaneously as the applicator head moves away from the cover sheet. The pressure is reduced at least below the ambient pressure of the applicator head.

Features relating to the third aspect may be combined in the same embodiment to the extent that they are not alternatives to each other. Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

Drawings

Fig. 1 shows a composite material according to a first embodiment in a side view.

Fig. 2 shows the composite material from fig. 1 in a top view.

Figure 3 shows a barrier formed from a composite material.

Fig. 4 shows a composite material according to an embodiment of the invention in a top view.

Fig. 5 shows a composite material according to various embodiments of the invention in a top view.

Fig. 6 shows the composite material of fig. 4 and 5 in a side view.

Fig. 7 shows a pod according to an embodiment of the invention.

Fig. 8 schematically illustrates a method for applying an adhesive layer to a cover sheet.

FIG. 9 is a flow chart of a method for producing a composite material.

Detailed Description

In the following description of the preferred embodiments, like features in different drawings will be denoted by like reference numerals. It should be noted that the drawings are not to scale.

Fig. 1 shows a composite material 100 in a side view. Fig. 2 shows the composite material of fig. 1 in a top view. The composite material comprises a first coversheet 1, a second coversheet 2 and a core layer 3, the core layer 3 being disposed between the first coversheet 1 and the second coversheet 2. The core layer 3 comprises a first adhesive layer 4 in contact with the first coversheet 1, a second adhesive layer 5 in contact with the second coversheet 2, and fibers 6 extending from the first adhesive layer 1 to the second adhesive layer 2. The first cover sheet 1 has a larger extension compared to the core layer 3 and the first cover sheet 1 comprises a first edge region 7 without the core layer 3, wherein the first edge region 7 extends from an outer edge 9 of the first cover sheet 1 to the core layer 3. The extension of the first edge region 7 beyond the edge 18 of the core layer 3, i.e. the maximum extension, is denoted X in fig. 2. The maximum extension X of the first edge region 7 beyond the edge 18 of the core layer 3 is at least 20 mm. The second covering sheet 2 comprises a second edge region 10, which second edge region 10 is opposite the first edge region 7 of the first covering sheet 1. The second edge region 10 is free of a core layer. The second edge region 10 extends from the outer edge 9 of the second coversheet 2 to the core layer 3. The extension of the second edge region 10 beyond the edge 18 of the core layer 3, i.e. the maximum extension, is denoted Y in fig. 2. As can be seen from fig. 2, the second edge region 10 extends mainly along one side of the core layer 3 and is much narrower than the first edge region 7. The second cover sheet extends no more than 5mm beyond the outer edge 18 of the core layer 3. As can be seen in fig. 2, the core layer 3 extends along the upper and lower sides in fig. 2 almost to the edges of the first and second coversheet 1, 2. The first coversheet further comprises a third edge region 15, the third edge region 15 extending from the outer edge 9 of the first coversheet 1 to the core layer 3 on the opposite side of the core layer 3. The extension of the first edge region 7 perpendicular to the core layer is at least 20mm, and preferably at least 50 mm. This allows the edge region to be formed as a side wall of the receptacle or container.

Fig. 3 shows a barrier 20 formed from a composite material similar to that shown in fig. 1 and 2. The lower end 19 of the barrier 20 comprises a first edge region 7 and a second edge region 10. As can be seen in fig. 3, the second edge region 10 has the same extension as the first edge region 7. As can be seen in fig. 3, the first edge region 7 and the second edge region 10 have been bent outwards from the core layer 3 such that the ends of the first edge region 7 and the second edge region 10 provide a stable support for the barrier 20 when the barrier 20 is resting on a surface. The barrier 20 as shown in fig. 3 may be used in many different ways. One suitable field of application is the use of barrier members 20 in sports where balls such as indoor soccer balls are used. In an indoor soccer ball, it is desirable to use the barrier 20 to keep the ball in the field. However, it is also desirable to play on a field that is not only specific for soccer. It is therefore desirable to be able to stock the barrier 20 between different occasions during a soccer game. The barrier 20 shown in fig. 3 is very light and at the same time provides sufficient strength to the barrier 20. The low weight ensures that the barrier 20 is easy to handle.

Fig. 4 shows different embodiments of the following composite material in a top view: the composite material comprises a first 1 and a second 2 coversheet and a core layer 3 arranged between the first 1 and the second coversheet 2. Fig. 5 shows different embodiments of the following composite material in a top view: the composite material comprises a first 1 and a second 2 coversheet and a core layer 3 arranged between the first 1 and the second coversheet 2. In fig. 4, the second cover sheet 2 and the core layer 3 are rectangular in shape. Fig. 6 shows the composite material of fig. 4 and 5 in a side view. The first covering sheet 1 has a larger extension than the core layer 3 and the first covering sheet 1 comprises a first edge region 7 without the core layer 3. The first edge region 7 extends from the outer edge 9 of the first coversheet 1 to the core layer 3 and extends around the entire outer edge 9 of the first coversheet 1 such that the first edge region 7 surrounds the core layer 3. As can be seen most clearly in fig. 5, the second covering sheet 2 has substantially the same extension as the core layer 3. The second coversheet 2 comprises a narrow second edge region 10 without the core layer 3. The second cover sheet extends not more than 5mm beyond the outer edge of the core layer and preferably not more than 1mm beyond the outer edge of the core layer, i.e. the third edge region has an extension of not more than 5mm, preferably of not more than 1 mm. Thus, the second edge region 10 extends around the entire edge of the first coversheet such that the second edge region 10 surrounds the core layer. In fig. 4, the extension of the core layer 3 is shown with a dashed line 18. In fig. 5, the second covering sheet 2 has an irregular shape. The shape of the first adhesive layer 4 and thus of the core layer 3 may be obtained by providing the first coversheet 1 with a cover piece (not shown) having the shape of the first edge region 7. The mask is removed after the first adhesive layer 4 has been applied, leaving a first edge region 7 uncovered by adhesive. The second covering sheet 2 is shown as having the same extension as the adhesive layer in figure 4. The maximum extension of the first edge region 7 beyond the edge of the core layer 3 is denoted X in fig. 5.

The extension of the core layer is shown as rectangular in fig. 4. However, a core layer shaped in a parallelogram may be provided.

In an alternative embodiment, the composite material comprises an edge region 28 extending in a small area outside the core layer 3, as indicated by the dashed region 28 in fig. 4. The dashed area 28 may be sufficient for attachment to the facade (not shown) of a building when the area defined by the core layer 3 defines the area of the facade elements to be attached to the facade. The extension of the dashed area 28 beyond the edge of the core layer 3 is indicated as X in fig. 4.

Fig. 7 shows a receiving member 21 according to an embodiment of the present invention. The container 21 is formed from the composite material 1 as shown in fig. 4 and 6. The first edge region 7 has been reformed into a side wall 22 according to any of claims 2 to 5, wherein the second covering sheet 2 forms an inner bottom 23 of the receptacle 21 and the first edge region 7 forms a side wall 22 of the receptacle 21. In the embodiment shown in fig. 7, the second covering sheet 2 is substantially flat. The term flat means that the amount of change perpendicular to the surface of the second covering sheet 2 does not vary more than 10% of the maximum extension of the second covering sheet 2. As shown in fig. 7, the formation of the wall 22 will ensure that sufficient strength is provided by the shape of the wall 22. The strength of the inner bottom 23 of the receptacle 21 is provided by the sandwich arrangement of the first cover sheet 1, the second cover sheet 2 and the core layer 3.

Fig. 8 schematically shows a method for applying the adhesive layers 4, 5 on the cover sheets 1, 2. The method comprises the use of an applicator head 24, the applicator head 24 operating at a distance Da from the first and second cover sheets 1, 2. The applicator head 24 includes a slot 25 through which the adhesive exits the applicator head 25 and is forced through the slot 25 by applying pressure to the adhesive within the applicator head 24. The adhesive is said to be squeezed out of the application head 24 through the slot 25 when moving the cover sheets 1, 2 in the direction 30. During application of the adhesive layer, the adhesive forms a continuous flow from the trough to the cover sheets 1, 2. In order to provide the truncated end of the adhesive layer, the following steps are carried out: wherein the application of the adhesive is ended by: the applicator head is moved away from the coversheet distance D during time period T and the pressure P on the adhesive within the applicator head 24 is reduced. The distance D is at least the thickness of the adhesive layers 4, 5 plus at least 5mm, preferably at least 7mm, and the time period T is less than 5 seconds, preferably less than 0.5 seconds. The pressure P drops below ambient pressure. This provides an abrupt stop of the adhesive flow. During application of the adhesive on the cover sheet, the distance Da between the application head and the cover sheets 1, 2 is typically less than 0.2mm plus the thickness of the adhesive layers 4, 5. The thickness of the adhesive layers 4, 5 is typically 0.15 to 0.3. The adhesive is stored in a reservoir 26. Pressure on the adhesive is provided by pressure means 27. The dashed lines show the position of the applicator head 24 ', the reservoir 26 ' and the pressure device 27 ' when the application of adhesive has been terminated.

Fig. 9 is a flow diagram of a method 300 for producing the composite material 100 according to the embodiment of fig. 1, 2, 4, 5 and 6. The method comprises the following steps: in step 301, a first cover sheet 1 and a second cover sheet 2 are provided; in step 302, a first adhesive layer 4 is applied on the first coversheet 1 and a second adhesive layer 5 is applied in contact with the second coversheet 2; in step 303, applying a flock material in the form of individual fibers on one or both of the adhesive layers; disposing the first cover sheet adjacent to the second cover sheet, wherein the first adhesive layer faces the second adhesive layer, and wherein the fibers are in contact with the first adhesive layer and the second adhesive layer; and in step 305, curing the adhesive layer. The first adhesive layer 4 and the second adhesive layer may be applied in many ways. However, it is important to provide a well-defined core layer. The fibres 6 may be of many different materials, for example metal or plastic. It is well known in the art how to apply flocked material in the form of fibres 6 to a surface. The fibers 6 will adhere to the adhesive layer oriented substantially perpendicular to the surface. When the second coversheet 2 is disposed adjacent to the first coversheet 1, with the fibers 6 in contact with the first adhesive layer and the second adhesive layer 2, only curing of the adhesive layer is required to form the composite 100. The fibres 6 will only adhere to the adhesive layers 4, 5. Thus, the extension of the core layer will be defined by the adhesive layer. More preferably, there are two adhesive layers of the same extension. It is important to avoid that the first adhesive layer is larger than the second adhesive layer, as this will result in that the fibers are only adhered to the first coversheet in some areas. In case fibers are applied to both adhesive layers, it is important that both adhesive layers have an approximately equal extension.

The described embodiments of the invention may be modified in many ways without departing from the scope of the invention, which is limited only by the appended claims.

The composite material may of course have other shapes than those already shown in the above embodiments.