Applications

Architecture

Lightness, durability and flatness qualify alufoil honeycomb-cored panels for architectural cladding in many forms. Decorative bonded skins involving marble, granite, untreated or anodised aluminium (in colours or uncoloured) or coil coated laquers etc. make these lightweight panels suitable for all manner of building from a distribution centre to the most prestigious office block or leisure complex. In all cases, significant weight economies lead to cuts in the load bearing structure and in foundation work. These can mean big differences in the amounts of materials needed and the costs of construction. Honeycomb panels also add sound insulation properties to exterior cladding.

Signs and interior displays

Outstanding flatness makes alufoil-cored the natural choice for fascia panels and road signs. Aluminium honeycomb panels can be shaped and formed to make attractive curves and bends. Lightness helps in the handling and assembly, and durability means that signs and displays can be ‘installed and forgotten’. Maintenance, when required, is minimal.

For interior displays and exhibition stands, great savings are available to designers who incorporate lightweight, long life and durably finished honeycomb enclosure panels.

Transport

As with all aluminium applications in the transport sector, strong and durable honeycomb panels save deadweight and add to the amounts that can be carried. This, in turn, saves on vehicle usage, the fuel otherwise consumed and the emissions that result. Future low emission and alternative fuel systems are likely to depend on the construction of vehicles with an absolute minimum of weight. Aluminium foil honeycomb offers many solutions in this quest.

Impact protection

Aluminium honeycomb material can provide a high level of energy absorption when designed into impact protection components for vehicles. Studies carried out with car manufacturers have demonstrated that the honeycomb-based elements have a constant strength and a controlled level of deformation. In a longitudinal force experiment, the deformation elements were compressed to 30% of their original length and absorbed large amounts of impact energy, reducing the effects on other structural components.

The manufacture of honeycomb panels and structures

A wafer block of aluminium foil core material is stretched into a sheet of hexagonal structure on purpose designed computer-controlled equipment to give a consistent cell dimension. The walls of the cells can have micro perforations to allow movement of air between adjacent cells equalising pressure in environments with rapid temperature variation.

The expanded core is bonded to the outer facings with a two part adhesive which is applied in a dedicated computer controlled spray booth facility, which allows close monitoring of coat weights and accurate application to all substrates. The sandwich faces and core are laid up and accurately aligned prior to transferring by means of roller table to the press.

The final bonding process is done on a heated, hydraulically controlled, press to ensure uniformity of each panel and is closely controlled to ensure reliability of bond.

The cell size, depth of material, thickness of cell walls and aluminium alloy are all variable to suit specific requirements and tailored to impart the correct properties in the final manufactured units.

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