Description:DESCRIPTION OF INVENTION
FIELD OF INVENTION
The present invention relates to advanced composite panel systems designed for diverse applications, including residential, commercial, and industrial use.
The invention particularly addresses the challenges of structural durability, environmental resistance, and aesthetic adaptability, combining innovative materials and manufacturing processes.
BACKGROUND OF THE INVENTION
Traditional panel and door systems, primarily constructed from wood-based materials, have long been the industry standard for residential, commercial, and industrial applications. While these materials offer a classic aesthetic appeal, they suffer from inherent limitations that compromise their performance, longevity, and structural integrity when exposed to harsh environmental conditions. The challenges associated with conventional wood-based panels have driven the need for alternative solutions that offer improved durability, moisture resistance, and fire safety without compromising on design flexibility or ease of installation.
One of the most significant drawbacks of traditional wood-based panels is their susceptibility to moisture absorption, which leads to swelling, warping, and eventual structural degradation. This issue is particularly prevalent in high-humidity environments such as kitchens, bathrooms, and exterior applications where wooden panels are exposed to rain or fluctuating temperature conditions. Prolonged moisture exposure also results in delamination, where the adhesive bonds holding the panel layers together weaken over time, causing separation and reducing the panel's lifespan.
In addition to moisture-related issues, biological degradation is another critical concern with traditional wood-based materials. Natural wood, as well as engineered wood products like plywood, Medium Density Fiberboard (MDF), and High-Density Fiberboard (HDF), remain highly vulnerable to fungal growth, mold, and termite infestations. Once compromised, these panels require extensive repairs or complete replacement, leading to increased maintenance costs and inconvenience for end users. Despite the application of chemical treatments and coatings to mitigate these issues, long-term protection remains a challenge, particularly in humid or tropical climates.
Another limitation of conventional wood and engineered panels is their poor structural integrity under heavy loads or impact forces. MDF and HDF, while offering better consistency in material composition than natural wood, are inherently brittle and susceptible to chipping, denting, and breakage when subjected to mechanical stress. This makes them unsuitable for high-traffic environments where doors and panels experience frequent usage, heavy impacts, or rough handling.
Fire resistance is another major concern in wood-based panel systems. Traditional wooden panels and their engineered counterparts exhibit low fire resistance, posing a significant safety risk in both residential and commercial buildings. While certain fire-retardant treatments are available, they often degrade over time or require specialized coatings that add to the overall manufacturing cost without completely mitigating the fire hazard.
To address some of these limitations, alternative materials such as aluminum composite panels (ACP), fiber-reinforced plastics (FRP), and steel-clad panels have been introduced in specific applications. While these materials offer improved durability and fire resistance, they come with their own set of challenges, including higher costs, complex installation procedures, limited design versatility, and inadequate thermal insulation properties. Many of these alternatives also suffer from weight-related constraints, making them difficult to transport and install, thereby increasing labor costs and limiting their widespread adoption.
Moreover, many modern panel systems fail to provide a comprehensive solution that integrates durability, moisture resistance, fire safety, aesthetic flexibility, and ease of installation. Most existing systems focus on addressing only one or two of these concerns, leading to compromises in other critical performance aspects. For instance, panels designed for high durability often lack aesthetic versatility, while those offering fire resistance may be significantly heavier and more difficult to install.
As a result, there remains a strong demand for an innovative panel system that combines structural strength, resistance to environmental degradation, lightweight design, ease of installation, and long-term durability, while also offering a wide range of aesthetic finishes to meet diverse architectural and design requirements. The need for a cost-effective and scalable solution that addresses these limitations while streamlining manufacturing and installation processes has driven the pursuit of advanced material integration and precision manufacturing techniques in the development of modern panel systems.
The present invention addresses the challenges with the existing state of the art and describes Advanced uPVC-Metal Composite Panel System with Reinforced Core and Precision Extrusion Manufacturing.
OBJECT OF THE INVENTION
The primary object of the invention is to provide a high-performance uPVC-metal composite panel system that overcomes the limitations of conventional wood-based panels, such as poor moisture resistance, structural weakness, and susceptibility to environmental degradation.
Further object of the present invention is to develop a reinforced composite panel system integrating extruded uPVC profiles, sheet metal surfaces, and high-strength core materials, ensuring superior load-bearing capacity and impact resistance;
Further object of the present invention is to provide a panel system with excellent moisture, termite, and fungal resistance, eliminating common issues such as warping, swelling, and degradation associated with traditional wood-based panels;
Further object of the present invention is to incorporate flame-retardant properties and materials that withstand high temperatures, ensuring safety compliance for residential, commercial, and industrial applications;
Further object of the present invention is to achieve high dimensional accuracy through a controlled extrusion process, optimized cooling techniques, and precise welding methods, ensuring minimal expansion, contraction, or deformation over time;
Further object of the present invention is to offer a modular panel system supporting various sizes, thicknesses, and surface finishes, including stone, acrylic, and metal, for aesthetic flexibility across different applications.
These objects collectively embody the purpose of the present invention, which is to provide a high-performance uPVC-metal composite panel system that surpasses traditional wood-based panels in structural strength, environmental resistance, fire safety, and design flexibility. This invention effectively addresses the limitations of MDF, HDF, and traditional panels, offering a next-generation solution that meets the evolving demands of modern construction and interior design.
SUMMARY OF THE INVENTION
Embodiments of the present disclosure present technological improvements as solution to one or more of the above-mentioned technical problems recognized by the inventor in conventional practices and existing state of the art.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. Further, while certain disadvantages of prior technologies may be noted or discussed herein, the claimed subject matter is not intended to be limited to implementations that may solve or address any or all of the disadvantages of those prior technologies.
The present invention discloses an advanced uPVC-metal composite panel system with reinforced core and precision extrusion manufacturing designed to overcome the limitations of traditional wood-based and MDF/HDF panel solutions.
According to an aspect of the present invention, the system integrates extruded unplasticized polyvinyl chloride (uPVC) profiles, reinforced sheet metal surfaces, and core materials such as foam injection or paper-based honeycomb structures, resulting in a durable, moisture-resistant, and structurally robust panel.
According to an aspect of the present invention, the manufacturing process involves precision-controlled uPVC extrusion, profile processing, and assembly integration to ensure dimensional stability, impact resistance, and longevity. The extrusion phase incorporates optimized process parameters such as extrusion speed, pressure range, cooling temperature, and pulling force, ensuring consistent quality across different panel sections. The profiles undergo miter cutting, strategic drilling, and high-strength welding, followed by the application of adhesive systems for metal sheet attachment and the incorporation of core materials for enhanced performance.
The uPVC-metal composite panel system provides superior resistance to moisture, thermal fluctuations, fungal growth, and environmental degradation, making it ideal for residential, commercial, and industrial applications. Additionally, its modular design allows for easy customization, installation, and replacement of components, reducing maintenance costs and improving operational efficiency.
Certified for RoHS compliance and validated through accelerated weathering tests, the system ensures safety, environmental sustainability, and long-term stability. By offering exceptional durability, design flexibility, and cost-effectiveness, the invention establishes a next-generation panel solution that significantly outperforms conventional alternatives.
The objects and the advantages of the invention are achieved by the process elaborated in the present disclosure.
BRIEF DESCRIPTION OF DRAWINGS:
The accompanying drawings constitute a part of this specification and illustrate one or more embodiments of the invention. Preferred embodiments of the invention are described in the following with reference to the drawings, which are for the purpose of illustrating the present preferred embodiments of the invention and not for the purpose of limiting the same.
For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the invention. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present invention. The same reference numerals in different figures denotes the same elements.
In the drawings:
Figure 1 illustrates the overall structure of the panel system, showcasing the integration of various components, including outer and inner extrusions, sheet metal surfaces, and reinforcement elements. The diagram provides a comprehensive view of the panel system’s configuration, highlighting the modular design approach that facilitates easy assembly and replacement of individual components.
Figure 2 illustrates the corner welding assembly of the panel system, showcasing the precise alignment and joining of various structural components. The outer extrusion (1) and inner extrusion (3) are positioned and welded at the corner to ensure a seamless connection. The top sheet metal layer (2) and bottom sheet metal layer (5) are securely bonded, while the filler material (4) is enclosed within the structure. The diagram highlights the butt welding and corner welding techniques used to reinforce the frame, ensuring a high-strength, airtight, and watertight joint.
Figure 3 illustrates a detailed side view of the panel system, depicting the integration of key structural components working together to create a durable, modular, and high-performance panel system: Outer Extrusions H & V (1 & 2, uPVC) form the primary structural framework, providing rigidity and modular connectivity for panel assembly; Inner Extrusions H, V1, V2, V3 (3, 4, 8, 9, uPVC) are strategically placed to distribute mechanical loads, improve impact resistance, and support panel integrity; L-Brackets Small & Big (5, 12, PP) enhance the panel’s structural stability by reinforcing corner joints and critical load-bearing points; Straight Brackets Small & Big (10, 11, PP): These components are used for reinforcing flat panel sections, ensuring uniform strength and resistance to bending or warping; Top & Bottom Sheet Metal (6, 7, PPGI-Steel) are outermost layers protecting against environmental damage, including moisture, impact, and corrosion, ensuring long-term durability; and Filler (13, Foam) forms core insulating material that contributes to thermal and acoustic insulation while maintaining lightweight characteristics.
Figure 4 presents a cross-sectional view of the panel system utilizing Outer Extrusion Type-A (1). The diagram highlights the multi-layered composition of the panel, showcasing the structural and insulation components. The top sheet metal layer (PPGI-Steel) (2) provides an impact-resistant and corrosion-resistant exterior surface. The inner extrusion (3) reinforces the core structure, distributing mechanical loads efficiently. The filler material (foam) (4) enhances thermal insulation, acoustic damping, and weight reduction. The bottom sheet metal layer (PPGI-Steel) (5) complements the structural integrity, providing a rigid base to prevent panel deformation. The inclusion of Outer Extrusion Type-A ensures a precise fit for modular assembly, making it suitable for various architectural and industrial applications. The cross-section view distinctly illustrates how each layer is integrated, demonstrating the panel’s balance of strength, lightweight design, and functional efficiency.
Figure 5 illustrates a cross-sectional illustration of the panel system, similar to Figure 4 but incorporating Outer Extrusion Type-B (1). The Outer Extrusion Type-B features a modified profile design, potentially enhancing structural flexibility, weight optimization, or installation ease. The top sheet metal (PPGI-Steel) (2) and bottom sheet metal (PPGI-Steel) (5) remain critical structural elements, offering surface protection and mechanical strength. The inner extrusion (3) reinforces the internal load-bearing structure, ensuring panel stability. The foam-based filler (4) continues to play a crucial role in providing thermal insulation and reducing the overall weight of the panel. The distinction between Outer Extrusion Type-A and Type-B allows for customization based on application-specific requirements, such as higher load capacity, better flexibility, or optimized aesthetic integration.
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description illustrates embodiments of the present disclosure and ways in which the disclosed embodiments can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practising the present disclosure are also possible.
The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in brackets in the following description.
The present invention describes an advanced uPVC (Unplasticized Polyvinyl Chloride) metal composite panel system with reinforced core and precision extrusion manufacturing.
The said uPVC-metal composite panel system integrates advanced materials and innovative manufacturing processes to create a highly durable and efficient panel solution. This system is designed to overcome the limitations of conventional wood-based panels by utilizing a combination of extruded unplasticized polyvinyl chloride (uPVC) profiles, reinforced metal layers, and a structurally optimized core. The integration of these components ensures superior structural integrity, flame resistance, and moisture protection while maintaining aesthetic appeal.
The said uPVC-metal composite panel system comprises three key components:
1. Outer and Inner Frames: These frames are manufactured using uPVC extrusions (1, 2, 3, 4, 8, 9) that offer excellent stability and durability. The structural design of these frames ensures the panel's longevity and resistance to environmental degradation.
2. Surface Layers: The external surfaces of the panel are made from sheet metal components (6, 7), providing both durability and an aesthetically pleasing finish.
3. Core Materials: The core structure plays a crucial role in determining the panel's performance characteristics. Two core options are available:
o Foam Injection Core: This option provides a lightweight construction with excellent thermal insulation properties (13).
o Paper-Based Honeycomb Core: This core offers an exceptional strength-to-weight ratio, making it ideal for high-load applications.
Component Architecture
Primary Components
The composite panel system of the present invention comprises two fundamental elements: the outer and inner frames. These frames (1, 2, 3, 4, 8, 9) are produced using high-precision uPVC extrusion technology, ensuring consistency in structure and performance. The frames are reinforced with joining mechanisms such as L-brackets (5, 12) or welded joints, depending on specific application requirements..
Surface and Core Materials
The external sheet metal surfaces (6, 7) are carefully selected to provide both durability and aesthetic appeal. The internal core structure varies based on the application, offering two main options:
• Foam Injection Core: This provides a lightweight solution with excellent thermal insulation properties (13).
• Paper-Based Honeycomb Core: This configuration enhances strength while maintaining a lightweight profile, making it particularly useful for demanding structural applications.
Manufacturing Process
Extrusion Phase
The manufacturing process begins with the extrusion of raw uPVC material through precision-engineered dies. This step involves meticulous temperature control and monitoring to ensure consistent quality. The extruded profiles (1, 2, 3, 4, 8, 9) then undergo controlled cooling using either water-based or air-based systems to maintain optimal structural integrity. The table below details key parameters of the extrusion process:
Parameter Outer Edge Band Inner Frame Remarks
Material uPVC with stabilizers and pigments Reinforced uPVC with impact modifiers Section 1 prioritizes aesthetics, Section 2 prioritizes rigidity.
Extruder Model SJZ55/110 SJZ55/110 Same extruder for both sections.
Extrusion Speed 1.5 - 2.0 m/min 1.2 - 1.5 m/min Section 2 requires a slower speed for greater thickness.
Temperature Zones 170°C - 190°C 170°C - 190°C Consistent across both sections.
Die Exit Temperature 170°C - 180°C 170°C - 180°C Ensures proper material flow and prevents premature cooling.
Pressure Range 10 - 20 MPa 15 - 25 MPa Higher pressure for Section 2 due to its larger cross-section.
Cooling Temperature 10°C - 15°C 10°C - 15°C Ensures dimensional stability.
Pulling Force 150 - 200 N 200 - 250 N Higher pulling force required for the inner frame due to increased weight.
Weight 80 - 160 g/m 450 - 650 g/m Reflects the design's application-specific requirements.
Straightness Tolerance ±0.3 mm/m ±0.5 mm/m Consistent precision across both sections.
Surface Quality RA 0.2 - 0.6 RA 0.6 - 0.8 The outer edge band emphasizes a smoother finish.

Profile Processing
Once the extrusion phase is complete, the profiles undergo precise cutting using specialized miter saws. This ensures accurate angles of either 45° or 90°, depending on the specific assembly requirements. In addition, strategic drilling operations are performed to create mounting points, facilitating efficient hardware installation.
Assembly Integration
The assembly process consists of several critical steps that ensure the structural integrity and aesthetic quality of the final panel. These steps include:
1. Butt Welding: The internal profiles (3,4,8,9) undergo precision welding techniques that reinforce structural stability and joint integrity.
2. Corner Assembly: The uPVC corner welding process is carried out using specialized welding equipment, ensuring airtight and seamless joints.
3. Surface Adhesion: High-strength adhesive systems are applied to securely bond the sheet metal components (6,7) to the panel's frame.
4. Core Installation: Based on the specific design requirements, either a foam injection (13) or paper-based honeycomb core is inserted, providing the desired mechanical and thermal properties.
5. Edge Finishing: The final stage of assembly involves the installation of edge banding components (10, 11, 12), which complete the panel’s structural and aesthetic features.
Performance Characteristics
Structural Integrity
The combination of advanced materials and precise manufacturing processes results in a panel system with superior structural stability. Unlike traditional wood-based panels, the Xteel Panel System is highly resistant to impact, warping, and surface wear.
Environmental Resistance
The panel system exhibits excellent resistance to moisture, eliminating problems such as fungal growth and material degradation. Additionally, its flame-resistant properties provide an added layer of safety for both residential and commercial applications.
Installation Efficiency
The modular design of the system allows for quick and precise installation, reducing labor costs and ensuring uniform quality across different applications.
Performance Validation and Test Results
To ensure the structural integrity, durability, and reliability of the uPVC-metal composite panel system, rigorous testing procedures were conducted. These tests focused on evaluating welding efficiency, core material performance, and adhesive composition, which are critical factors in maintaining the panel's mechanical strength, environmental resistance, and long-term stability. The results of these tests are detailed below.
Welding Performance Evaluation
The welding parameters were optimized to ensure seamless joint formation, high bonding strength, and air-tight sealing, which are essential for maintaining the panel's load-bearing capacity and resistance to mechanical stress. The key welding specifications are as follows:
Parameter Value
Input Voltage 220V, 50Hz
Input Power 2.5kW
Working Air Pressure 0.5 - 0.8 MPa
Air Consumption 60 L/min
Welding Height 15 - 120 mm
Max Welding Width 120 mm
Welding Size 150 - 3500 mm
These welding parameters ensure high-precision assembly, eliminating the risk of weak joints or structural deformities, which commonly occur in traditional panel manufacturing techniques.
Paper-Based Core Material Testing
To achieve optimal strength-to-weight ratio, impact resistance, and thermal efficiency, the core material was evaluated based on its composition, cell structure, and weight characteristics. The test results for the paper-based honeycomb core material are presented below:
Parameter Value
Type AALS-140
Cell Size 8
Paper Weight 140 GSM
Paper Width 1250 mm
The high-density honeycomb structure provides enhanced structural rigidity while maintaining a lightweight profile, making it suitable for applications requiring load-bearing efficiency without excessive weight.
Adhesive Performance Testing
A specialized adhesive formulation was developed to ensure high bonding strength, thermal stability, and resistance to environmental degradation. The adhesive composition was tested for optimal adhesion properties, with the following results:
Component CAS No Percentage (%)
Polychloroprene Rubber 9010-98-4 10 - 20
Phenolic Resin 9003-35-4 10 - 20
Toluene 108-88-3 40 - 50
Ethyl Acetate 141-78-6 20 - 25
The tested adhesive composition ensures superior bonding strength between the panel components, significantly enhancing the overall mechanical performance and longevity of the system. The presence of phenolic resin and polychloroprene rubber contributes to high-impact resistance, while toluene and ethyl acetate facilitate efficient application and curing.
These test results validate the robust construction and superior performance of the uPVC-metal composite panel system, demonstrating its suitability for demanding architectural and industrial applications.
Advantages of the uPVC-Metal Composite Panel System
Design Flexibility
The uPVC-metal composite panel system offers extensive design flexibility, allowing for the customization of panel sizes and configurations to meet diverse architectural and functional requirements. Whether for residential, commercial, or industrial applications, the system supports a range of surface finishes, including stone, acrylic, and steel, ensuring aesthetic versatility. This adaptability makes it suitable for various interior and exterior installations, seamlessly integrating with different design themes and structural layouts.
Structural Benefits
The integration of reinforced sheet metal layers (6,7) significantly enhances the strength and durability of the panels, making them highly resistant to physical impacts, warping, and environmental stressors. Unlike traditional wood-based solutions, these composite panels maintain their structural integrity over extended periods. Additionally, the modular design facilitates easy replacement of individual components, allowing for quick repairs or upgrades without the need for extensive dismantling, thereby improving long-term usability and sustainability.
Economic Value
One of the primary advantages of this system is its cost-effective manufacturing process, which optimizes material usage and reduces production costs without compromising quality. The long service life of the panels, coupled with minimal maintenance requirements, further enhances their economic value. Unlike conventional panels that require frequent refinishing or replacement due to environmental damage, the uPVC-metal composite panels retain their performance and appearance over time, reducing overall lifecycle costs for users.
Certified Performance
The panel system meets stringent safety and environmental standards, as confirmed by its Restriction of Hazardous Substances (RoHS) Certification, which ensures that the materials used are free from harmful substances such as lead, mercury, and other toxic elements. Additionally, accelerated weathering test results validate the long-term stability of the panels, confirming their resistance to color fading, deformation, and environmental wear. These certifications provide assurance of durability, safety, and compliance with global industry standards.
By addressing key limitations of traditional panel materials, the uPVC-metal composite panel system stands out as a superior alternative, delivering unmatched performance, sustainability, and design adaptability.
These embodiments are provided to demonstrate the various aspects and features of the durable and customizable modular cabinet system. The invention is not limited to these specific embodiments and can be implemented in different configurations and variations without departing from the scope of the invention as defined in the claims.
, Claims:CLAIMS:
We Claim:
1. An advanced uPVC-metal composite panel system with reinforced core and precision extrusion manufacturing, the said composite panel system comprising:
- an outer extrusion (1, 2) and an inner extrusion (3, 4, 8, 9) made of unplasticized polyvinyl chloride (uPVC) forming a modular frame;
- sheet metal layers (6, 7) made of PPGI steel, bonded to the outer and inner extrusions, providing structural reinforcement and protection;
- core material (13), selected from a foam injection core for thermal insulation and a paper-based honeycomb core for enhanced strength-to-weight ratio;
- reinforcement elements, including L-brackets (5, 12) and straight brackets (10, 11), positioned at critical load-bearing points for improved mechanical stability;
- corner welding assembly, wherein the outer extrusion (1) and inner extrusion (3) are joined using butt and corner welding techniques to form an airtight and watertight joint.;
wherein the panel system is manufactured using precision extrusion technology to achieve consistent dimensional accuracy, structural reinforcement, and high-performance characteristics suitable for architectural and industrial applications; and
wherein the panel’s environmental resistance is enhanced by moisture-proof, flame-resistant, and corrosion-resistant properties, making it suitable for diverse architectural and industrial applications.
2. The composite panel system as claimed in Claim 1, wherein the core material (13) is enclosed between the top sheet metal layer (6) and the bottom sheet metal layer (7), forming a lightweight, thermally insulated, and acoustically dampened structure
3. The composite panel system as claimed in Claim 1, wherein the uPVC extrusion process ensures a straightness tolerance of ±0.3 mm/m and a surface finish with an RA value ranging from 0.2 to 0.8.
4. The composite panel system as claimed in Claim 1, wherein the adhesive composition selected from the group of polychloroprene rubber, phenolic resin, toluene, and ethyl acetate, providing enhanced bonding strength and durability under environmental stress conditions.
5. The composite panel system as claimed in Claim 1, wherein the edge finishing includes the integration of edge banding components (10, 11, 12) for improved structural integrity and aesthetic appeal.
6. The composite panel system as claimed in Claim 1, wherein the outer extrusion is configured as type-A (1) as well as type-B (1) to provide structural flexibility and weight optimization.
7. A method for manufacturing a uPVC-metal composite panel system with reinforced core and precision extrusion manufacturing, the said method comprising steps of:
- extruding uPVC profiles for outer and inner frames under controlled conditions, including a temperature range of 170°C to 190°C, extrusion speeds of 1.5-2.0 m/min for outer frames and 1.2-1.5 m/min for inner frames, die exit temperatures between 170°C and 180°C, and a pulling force of 150-250 N based on profile weight;
- cooling the extruded profiles using water or air systems at a temperature range of 10°C to 15°C to ensure dimensional stability;
- cutting the extruded profiles using miter saws to achieve precise angles and dimensions for frame assembly;
- welding the profiles using butt and corner welding techniques to create seamless joints;
- bonding sheet metal surface layers to the frames using an adhesive composition comprising polychloroprene rubber, phenolic resin, toluene, and ethyl acetate;
- installing core materials selected from foam injection or paper-based honeycomb between the surface layers to enhance structural performance;
- applying edge banding components to finalize the structural and aesthetic features of the panel;
wherein the assembled panels are subjected to accelerated weathering tests to validate environmental resistance, dimensional stability, and structural integrity.