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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t  Low-density polyethylene as a core
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