Hyperbolic aluminum panel

Aluminum honeycomb panels are suitable for civil construction, vehicle and ship decoration, etc. They represent the application of aerospace materials in the civil construction sector. The entire processing is completed in modern factories using hot-press forming technology. Due to the high thermal conductivity between the aluminum skin and the honeycomb, the thermal expansion and contraction of the inner and outer aluminum skins are synchronized. The aluminum honeycomb skin has small holes that allow free gas flow within the panel. The sliding installation buckle system prevents structural deformation during thermal expansion and contraction. The panel primarily uses high-quality 3003H24 alloy aluminum plate or 5052AH14 high-manganese alloy aluminum plate as the base material, with a panel thickness of 0.8–1.5mm fluorocarbon roll-coated plate or color-resistant baked paint. Color-resistant baked paint outperforms PVDF in scratch resistance, acid rain corrosion resistance, color change resistance, and self-cleaning properties. The bottom plate thickness is 0.6–1.0mm, and the total thickness is 25mm.

The core material adopts a hexagonal 3003-type aluminum honeycomb core, with aluminum foil thickness ranging from 0.04 to 0.06mm and side lengths of 5–6mm. Roll-forming technology is used to shape the front and back surfaces, and fully automated machinery folds the edges, ensuring the front and back surfaces tightly interlock at the installation edges. The entire processing is completed in modern factories using hot-press forming technology. Due to the high thermal conductivity between the aluminum skin and the honeycomb, the thermal expansion and contraction of the inner and outer aluminum skins are synchronized. The aluminum honeycomb skin has small holes that allow free gas flow within the panel. The sliding installation buckle system prevents structural deformation during thermal expansion and contraction, ensuring extremely high flatness. The adhesive used is a two-component polyurethane high-temperature curing adhesive. The panels are formed under high temperature and pressure using fully automated honeycomb panel composite production equipment, overcoming the brittleness issues of previous honeycomb panel adhesive layers. The inner layer consists of specially designed hexagonal aluminum honeycomb, made from H19-hardness aluminum alloy, which acts as a core board adhered within the sandwich structure,承受压力 tangentially. These densely packed, interconnected honeycombs function like numerous small I-beams, dispersing pressure from the panel direction and ensuring even force distribution. This guarantees high flatness even over large panel areas.

Installation is done on both sides without mechanical damage. The sliding installation buckle system accommodates thermal expansion and contraction, and the anti-slip buckle at the bottom of the panel controls the direction of expansion. The 25mm hidden seam system is aesthetically pleasing and self-cleaning. The completed box-type honeycomb panel integrates the inner and outer plates with the honeycomb structure. Additionally, the hollow honeycomb significantly reduces the panel's thermal expansion.

Due to its excellent properties such as resistance to high wind pressure, shock absorption, sound insulation, thermal insulation, flame retardancy, and high specific strength, honeycomb materials have been used in various civil fields abroad since the 1960s and have developed rapidly. In China, honeycomb technology has only recently been applied in various sectors of civil industry. Aluminum honeycomb panel curtain walls, with advantages such as light weight, high strength, and high stiffness, are widely used in exterior wall decoration of high-rise buildings. A honeycomb panel with a total thickness of 15mm and panel and base thicknesses of 1.0mm each weighs only 6kg/m². A honeycomb panel with the same stiffness weighs only one-fifth of an aluminum single plate and one-tenth of a steel plate. The interconnected aluminum honeycomb core functions like countless I-beams, with the core layer distributed and fixed across the entire panel surface, enhancing stability. Its wind pressure resistance far exceeds that of aluminum composite panels and aluminum single plates, and it features resistance to deformation and excellent flatness. Even with large panel sizes, extremely high flatness can be achieved, making it a lightweight material in the construction industry.