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Introduction to aluminum honeycomb panels
Aluminum honeycomb panels are widely used in civil construction, automotive, and marine applications. These panels represent the adaptation of advanced aerospace materials for use in everyday building environments. The panel is primarily constructed using high-quality 3003H24 or 5052AH14 aluminum alloys as the base material, with a thickness ranging from 0.8 to 1.5 mm. It is coated with fluorocarbon paint or color-resistant coatings that offer excellent resistance to scratches, acid rain, and corrosion—outperforming PVDF in terms of cleanliness. The bottom plate has a thickness of 0.6 to 1.0 mm, and the total thickness of the panel is 25 mm.
The core material consists of hexagonal-shaped 3003 aluminum honeycomb, with an aluminum foil thickness of 0.04 to 0.06 mm and a cell size of 5 to 6 mm. The front and back skins are formed using roll forming technology, and the entire assembly is completed by fully automatic machines that ensure tight bonding. The manufacturing process takes place in a modern factory using hot press forming technology. Due to the high thermal conductivity between the aluminum skin and the honeycomb, the expansion and contraction of the inner and outer layers occur in sync. The small holes in the honeycomb allow internal air to circulate freely, while the sliding mounting buckle system prevents structural deformation during thermal changes, ensuring exceptional flatness.
A two-component polyurethane adhesive, cured at high temperatures, is used to bond the honeycomb layer. This ensures strong adhesion and eliminates the brittleness often found in traditional bonding methods. The inner layer features a special hexagonal aluminum honeycomb made from H19-hardness aluminum alloy, which acts as a core within the sandwich structure. Pressure is applied in the tangential direction, creating densely packed cells that function like miniature I-beams. These cells distribute pressure evenly across the panel, maintaining high flatness even over large areas.
The installation process avoids mechanical damage, and the sliding mounting system allows for thermal movement without distortion. Anti-slip buckles on the bottom of the panel control expansion direction, while the 25mm hidden glue seam system offers both aesthetic appeal and self-cleaning properties. After production, the inner and outer panels and the honeycomb structure form a unified unit. The hollow honeycomb design significantly reduces thermal expansion, making the panels highly resistant to wind pressure, shock absorption, sound insulation, heat retention, and fire resistance.
Since the 1960s, this material has been widely adopted in various civil applications and has seen rapid development. In recent years, China has increasingly applied cellular technology in the civil industry. Aluminum honeycomb panels have become popular in high-rise building façades due to their lightweight, high strength, and rigidity. With a total thickness of 15 mm, the 1.0 mm thick aluminum bottom plate weighs only 6 kg/m².
Compared to aluminum veneer and steel plates, these honeycomb panels achieve the same stiffness while weighing just 1/5 of aluminum veneer and 1/10 of steel. The interconnected honeycomb core functions like thousands of I-beams, stabilizing the panel and improving its wind resistance. They are not easily deformed and maintain excellent flatness, even with larger cell sizes. This makes them the preferred choice for lightweight construction materials in the building industry.