Sandwich-panel
History and Major Development
• Development of advanced sandwich-panel first began in the 1930’s.
• Unlimited range of configurations.
• Variety of colors, finishes, thicknesses
• Good structural strength
• High level of insulation
• Low weight
Introduction
• Sandwich panels consist of two layers of a rigid material bonded to
either side of a light weight core.
• Better performance than the individual alone.
• Lightweight core provides Insulation, Correct position and Resists
shear forces.
• Two faces provide durability, weather and impact resistance.
• Thin face-sheets (Carbon, Glass or Kevlar (synthetic fibre)
• Thick core materials (Foam, honeycomb or balsa etc.)
• Joined with adhesive (liquid resin, adhesive film, foaming adhesives
etc.).
• Sandwich panels provide high bending stiffness at low weight.
• The principle is the same as a traditional ‘I’ beam
• Bending stiffness can be enhanced by increasing the thickness of panel.
Types of Sandwich Panels
3D-printed biopolymer panels
Structural Insulated Panels (SIP)
Aluminum Composite Panels (ACP)
3D-printed biopolymer panels
Energy absorption Natural fibre
Continuous synthetic fibers New geometric complexities can be
achieved
Structural Insulated Panel (SIP)
Used in the construction Industry.
SIP consists of an insulating layer of rigid core sandwiched between two layers.
SIPs share the same structural properties as an I-beam.
The rigid insulation core of the SIP acts as a web.
Structural board:
Sheet metal Plywood Cement
Magnesium oxide board (MgO) Oriented strand board (OSB)
Core:
Expanded polystyrene foam (EPS) Polyisocyanurate foam
Extruded polystyrene foam (XPS) Polyurethane foam
Composite honeycomb (HSC)
Manufacturing Structural Insulated Panel (SIP)
Regulate pressures and heat are used.
Two main processing methods which correspond to the materials used for the SIP Panel core.
Using polystyrene core both pressure and heat are required to ensure the bonding glue has
penetrated and set completely.
The three pieces are set into a large clamping device until the glue has cured.
Manufacturing Structural Insulated Panel (SIP) with Polystyrene
While using polystyrene as core in sandwich panel production, both pressure and heat are
maintained as long as the bonding glue has penetrated and set completely.
The adhesive material is first coated over the foam core to covered it and then skin is set in place.
Now, three pieces are set into a large clamping device.
Apply pressure and heat on these materials.
The three pieces must stay in the clamping device until the glue has cured.
Manufacturing Structural Insulated Panel (SIP) using polyurethane
During foaming process, pressure and heat are produced
The skins are set in clamping device to serve as mold.
Liquid polyurethane to flow into the device.
The mold/press is generally configured to withstand the heat and the pressures generated from
the chemical foaming.
The SIP Panel is left in the mold/press to cure slightly.
Benefits of Structural Insulated Panel
Tighter building envelope and the walls
Higher insulating properties
Decrease in operating costs.
Less construction time
These panels can be used as floor, wall, and roof
Saves 40% (upto) total life cost of SIP compared to conventional frame.
Aluminum composite panels (ACP)
Aluminum composite panels (ACP) are made up of aluminum composite material (ACM).
Flat panels Signage.
Cladding of buildings false ceilings
Insulation Machine coverings
Container construction
Light-weight and very durable material in construction
Lower cost, higher durability, and efficiency.
Its flexibility, low weight, and easy forming and processing allow for innovative design with
increased rigidity and durability.
ACP material has been used in famous structures as Spaceship Earth, VanDusen Botanical Garden,
the Leipzig branch of the German National Library.
Coating of aluminum sheets
Painting of Aluminum sheets
Wide range of metallic and non-metallic colors
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Why we select Aluminum composite panel
Multiple color
Available in almost 40 different colors
Light weight
ACP is 2.5 pounds per square foot
Sustainable
85% recycled aluminum material is used
Fire Resistant
How Aluminum composite panel can be produced?
Production process of Aluminum composite panel include
cold composite method
Cleaning of Aluminum composite sheets:
Lubricant
Prolonged lifespan of structure
Partitions:
False Ceilings:
Heat insulator
Signage (commercial or public display signs)
Weather resistant
Important features of Sandwich panels
Antioxidant
Flexible
Hidden self tapping screws for aesthetic appeal.
Fast installation and ease of handling.
Crane assembly therefore no support required
No thermal bridges and good thermal insulation
Leak proof and great energy saver.
Various designs/vivid colors
Light weight. Space Saving
Panels can be installed horizontally or vertically
Satisfy Aesthetic taste
Fluorocarbon coated Aluminum composite panel
thermal composite method
After cleaning, Chemical protective film is developed on Aluminum sheets
General process of cleaning
Removal of self adhesive protective film
Compounding with the plastic core material
Applying adhesive material.
Combine with Aluminum sheets.
Cutting
Applications of Aluminum composite panel
Cladding:
Durable
Easy to handle
Durable
Dirt
Coating of required paint
Light weight
Rigidity
Reliable robust mechanical performance
Thermal, fire and sound insulation.
Air tightness
Strong and durability
Low maintenance / cleaning requirements.
Low capital cost and low lifetime costs
Chemical and biological resistance
Weather resistance.
Dimensional stability.
Sandwich Panel construction
Material Property Honeycomb Advantages
Foam includes Relatively low crush strength and Excellent crush strength and
polyvinyl chloride stiffness Increasing stress with stiffness
polymethacrylimide increasing strain Friable Limited Constant crush strength
polyurethane strength Fatigue Cannot be Structural integrity Exceptionally
polystyrene formed around curvatures high strengths available
phenolic High fatigue resistance
polyethersulfone
Wood-based includes
plywood Very heavy density Excellent strength-to-weight ratio
balsa Subject to moisture degradation Excellent moisture resistance
particleboard Flammable Self-extinguishing, low smoke
versions available
Manufacturing of Sandwich Structure
Sandwich Panel construction processing methods
Autoclave Vacuum bag Press
Heat pressing
Single shot process.
Suitable for metallic
Prepreg facing skin materials may be pre-cured by using a
press
Vacuum Bag
Vacuum Bag Processing, used for curved and complex form
panels.
The component should be assembled for cure as a single shot
process, the necessary consolidation is obtained using a
vacuum. This can be cured in an oven, and additional
pressure can be applied if an autoclave is used.
This method is suitable for items with prepreg or metallic
facing skins. When flexible honeycomb core and film
adhesives are used complex items may be produced.
Autoclave Processing
Mature and standardized method for composites manufacturing
Controlled thermal Program, high pressure environment
High fiber volume fraction, low void content hence,
maximum strength
Largest autoclave size (30’ x 76’)
expected to be 20% more fuel efficient than Al jets with
multiple other attributes
Building types that commonly feature sandwich panels include
Temporary buildings Shopping centers
Storage buildings Sports facilities
Clean rooms Transport buildings
Agricultural buildings
Industrial buildings and processing plants
Applications of Sandwich Panels
Industrial Buildings
Roof Partitions
Walls False Ceiling
Commercial Buildings
Elevation Side wall paneling Partitions
Warehouses / Godown
Roof Walls Partitions
Cold Stores / Blast Freezers
Insulated Ceiling Insulated Walls
Farm House
Decorative Siding Panels
Pharmaceutical Manufacturing Units
Clean Rooms Walk-on False Ceiling Return-Air Boxing
Air Handling Units
Insulated Panels
Poultry Farm
Ceiling Walls
Dairy Industry
Ceiling Walls
Malls / Departmental Stores
Facades Partition Walls
