DESC:ALUMINUM COMPOSITE PANEL AND A METHOD FOR PROVIDING THE SAME

Technical Field

[01] The present invention generally relates to the field of panels and more particularly to a method and system for providing an aluminum composite panel.The Aluminum Composite Panel (ACP) is a panel with a Low Density PE core sandwiched between Aluminum coils. It caters to the Building Material Industry and is applied in both interior and exterior application in buildings, signage and other various forms. It is available in various finishes and product categories.

Background of the Invention

[02] As is generally known in today’s world, the world of construction and interior design, materials play a pivotal role in bringing a vision to life. Among the multitude of options available, the timeless elegance of granite stands out, known for its unparalleled beauty and durability. However, replicating the sensory experience of sand and granite in a versatile and customizable form presented a challenge to overcome.

[03] The main technical problem existing in the industry is to develop a unique colour coating system that could emulate the texture and appearance of sand-infused granite. To realize this vision, a multifaceted approach is taken that encompassed both technological enhancements and a deep commitment to safety.
[04] In conclusion, there is a need for an improved aluminium composite panel which will require less maintenance and monitoring and which is compatible to various areas.

[05] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.

Summary of the Invention

[06] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

[07] The present invention is for a Granicia finish Aluminum Composite Panel (ACP) and the process for the same where, the ACP has a unique finish which increases the mechanical properties of the panels and adds aesthetic look to the panel. The Granicia finish ACP differentiates itself from a normal ACP in terms of its mechanical or physical properties like hardness, tensile strength, longevity, durability, and the like and also adds finesse, three dimensional view in two dimensional coating along with anti-corrosion properties. It is a moderate reflective panel, giving a distinct finish to the building exterior or interior. It is eco-friendly and soothing to the eye.
[08] According to embodiments illustrated herein, the present invention disclosesa methodmethod for manufacturing a Granicia finish Aluminum Composite Panel (ACP), the method comprising: an aluminum coil; a thinner coating; a plurality of granules with ash; an adhesive coating; and a protective film, wherein the ACP is non-combustible and being configured to be disposed as a normal core between two superior alloy aluminum sheets, coated with superior quality specialized paint, thereby ensuring enhanced durability and weather resistance.

[09] According to embodiments illustrated herein, there may be provided a system for a Granicia finish Aluminum Composite Panel (ACP); comprising:an aluminum coil;a thinner coating;a plurality of granules with ash;an adhesive coating; anda protective film, wherein the ACP is non-combustible and being configured to be disposed as a normal core between two superior alloy aluminum sheets, coated with superior quality specialized paint, thereby ensuring enhanced durability and weather resistance.

Brief Description of the Drawings

[010] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which:

[011] FIG. 1 is a schematicdiagram 100 that illustrates analuminum composite panel (ACP), in accordance with some embodiments of the present disclosure;

[012] FIG. 2 is a flow diagram 200 that illustrates an aluminum composite panel (ACP), in accordance with some embodiments of the present disclosure; and

[013] FIG. 3 is a schematic diagram 300 that illustrates an aluminum composite panel (ACP), in accordance with some embodiments of the present disclosure.

[014] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present subject matter. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in computer readable medium and executed by a computer or processor, whether or not such computer or processor is explicitly shown.

DETAILED DESCRIPTION

[015] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.

[016] Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.

[017] As used herein, the following terms have the following meanings:

[018] “A”, “an”, and “the” as used herein refers to both singular and plural referents unless the context clearly dictates otherwise. By way of example, “a compartment” refers to one or more than one compartment.

[019] “About” as used herein referring to a measurable value such as a parameter, an amount, a temporal duration, and the like, is meant to encompass variations of +/-20% or less, preferably +/-10% or less, more preferably +/-5% or less, even more preferably +/-1% or less, and still more preferably +/-0.1% or less of and from the specified value, in so far such variations are appropriate to perform in the disclosed invention. However, it is to be understood that the value to which the modifier “about” refers is itself also specifically disclosed.

[020] “Comprise”, “comprising”, and “comprises” and “comprised of” as used herein are synonymous with “include”, “including”, “includes” or “contain”, “containing”, “contains” and are inclusive or open-ended terms that specifies the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, features, element, members, steps, known in the art or disclosed therein.

[021] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order, unless specified. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

[022] The recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within that range, as well as the recited endpoints. The expression “% by weight”, “weight percent”, “%wt” or “wt%”, here and throughout the description unless otherwise defined, refers to the relative weight of the respective component based on the overall weight of the formulation.

[023] Whereas the terms “one or more” or “at least one”, such as one or more or at least one member(s) of a group of members, is clear per se, by means of further exemplification, the term encompasses inter alia a reference to any one of said members, or to any two or more of said members, such as, e.g., any =3, =4, =5, =6 or =7 etc. of said members, and up to all said members.

[024] Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, definitions for the terms used in the description are included to better appreciate the teaching of the present invention. The terms or definitions used herein are provided solely to aid in the understanding of the invention.

[025] Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to a person skilled in the art from this disclosure, in one or more embodiments. Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments may be used in any combination.

[026] It is desirable to have a new system and method that solves the above challenges as well as helps the users with a cost-effective, reliable and efficient way of managing the day to day work. FIG. 1 is a schematic diagram 100 that illustrates an aluminum composite panel (ACP), in accordance with some embodiments of the present disclosure. FIG. 3 is a schematic diagram 300 that illustrates an aluminum composite panel (ACP) with multicolor mechanical headers 302, in accordance with some embodiments of the present disclosure.According to embodiments illustrated herein, there may be provided a system for a Granicia finish Aluminum Composite Panel (ACP); comprising: an aluminum coil; a thinner coating; a plurality of granules with ash; an adhesive coating; and a protective film, wherein the ACP is non-combustible and being configured to be disposed as a normal core between two superior alloy aluminum sheets, coated with superior quality specialized paint, thereby ensuring enhanced durability and weather resistance.

[027] FIG. 2 is a flow diagram 200 that illustrates an aluminum composite panel (ACP), in accordance with some embodiments of the present disclosure. The method is performed at 202-212. According to embodiments illustrated herein, the present invention discloses a method method for manufacturing a Granicia finish Aluminum Composite Panel (ACP), the method comprising: an aluminum coil; a thinner coating; a plurality of granules with ash; an adhesive coating; and a protective film, wherein the ACP is non-combustible and being configured to be disposed as a normal core between two superior alloy aluminum sheets, coated with superior quality specialized paint, thereby ensuring enhanced durability and weather resistance.
[028] Color Coating System:A sophisticated color coating system is disclosed that could replicate the subtle variations found in natural granite. This system allowed us to offer a wide array of colors and Original patterns to cater to diverse design preferences.

[029] Machine Modification:A multicolor system is introduced that enabled precise color blending during production. By doing so, we could seamlessly integrate various shades to replicate the unpredictable erratic patterns. Moreover, we streamlined the manufacturing process, allowing all baking to occur in a single cycle, thereby enhancing efficiency and reducing production time.

[030] Exhaust System Enhancements: Safety has always been a paramount concern. As part of our commitment to safeguarding human beings during the manufacturing process, substantial enhancements are made to our exhaust system. These modifications ensured that harmful fumes and byproducts were effectively removed from the manufacturing environment, creating a safer workspace for the dedicated team members.

[031] The Birth of Granicia: After meticulous research, development, and countless iteration, Granicia emerged as a groundbreaking product. It embodied the rich aesthetics of granite while offering unparalleled versatility and customizability. With our color coating system, modified machinery, and improved safety measures in place, Granicia became a testament to innovation and excellence in the field of interior & exterior design materials application.5 to 15 numbers ofmulticolor mechanical systems are inbuilt into our CCL line for diffirent-2 colors and into this process. An ACP is a panel with a Low Density PE core sandwiched between Aluminum coils. It caters to the Building Material Industry and is applied in both interior and exterior application in buildings, signage and other various forms. It is available in various finishes and product categories. The ACPs have many advantages compared to conventional construction products and are, therefore, used in many applications. Some of the applications are architectural (aesthetic) coverings, coatings of internal /external walls, partitions, suspended ceilings, advertising hoardings, containers' construction, building renovations and external surfaces coatings, as well as in any construction work required. ACP has been used as a light-weight but very sturdy material in construction, particularly for transient structures like trade show booths and similar temporary elements. These structures made optimal use of ACP through its cost, durability and efficiency. Its flexibility, low weight and easy forming and processing allow for innovative design with increased rigidity and durability.

[032] Applications and Impact: Granicia has found applications across a myriad of industries. Architects and designers have embraced this pioneering product for its ability to create stunning and durable surfaces. Whether it's a luxurious wall, facade in a high-end building, a dramatic facade solution in a commercial space, or an eye-catching accent wall in a hotel lobby, Granicia has redefined the possibilities of interior design. Beyond aesthetics, Granicia also contributes to sustainability efforts by reducing the demand for natural stone resources. Its lightweight nature and easy installation further decrease the environmental impact of construction projects.

[033] Looking Ahead: The journey to create Graniciashade card CCL's commitment to innovation, safety, and environmental responsibility. In conclusion, Granicia stands as a testament to the power of innovation and collaboration. Through a combination of cutting-edge technology, machine modifications, and safety enhancements, we have succeeded in replicating the sensation of sand-infused granite. This remarkable product has redefined the world of interior design, offering architects and designers an exciting canvas upon which to create timeless masterpieces. As we continue to look ahead, we are excited about the future possibilities and the positive impact Granicia will have on the world of design and construction.

[034] The present invention relates to a Granicia Series which is a unique kind of finish on the aluminum coil that enhances the mechanical properties of the Aluminum Composite Panel (ACP) adds a three dimensional view in two dimensional coating to the panel. It differentiates itself from a normal ACP in terms of its mechanical or physical properties, longevity, and durability due to scratch free surface. It also adds touch and depth to the surface. The series is an evolution of various ideas to improve upon the pattern offering on the ACP product. The present invention relates to the Aluminum composite panel which is commonly used in building. ACP is traditionally a composite sandwich panel sheets which consist of two aluminum sheets. Between them a polyethylene core is interposed. The composite panel deriving from this procedure is an extremely strong and rigid material used in various applications. It is available in flat sheets of different thicknesses.

[035] In an embodiment of the present disclosure, a Composite Panel that is sandwiched noncombustible or normal core between two superior alloy aluminum sheets, coated with superior quality specialized paint using a distinct process for enhanced durability and weather resistance is disclosed. The present invention precisely involves a Post Pre Treatment process, wherein the coil is loaded on to the Color Coating Line for Coating Process. The above mentioned Granicia Series is achieved at three coats to six coat finishes with a base coat 12-16micron, Ink Coat of 1-2 microns and clear coat of 14-15 microns. The Base coat is adequately mixed for 12 - 15 minutes to ensure adequate and proper paint adhesion to the aluminum substrate. The mixer used is of approx. 12 – 16 inches diameter and is rotated at the speed of approx. 120 – 130 rpm in a closed room with ambient temperature in the range 15 – 25o C.

[036] The paint is prepared at Aludecor by mixing different colors with the paint as received from the paint supplier – Akzonobel India Limited. The mixer used is of approx. 5 – 6 inches diameter and is rotated at a speed of approx. 120 – 130 rpm in a closed room with an ambient temperature in the range 15 - 25o C. The equipment, especially the coater rolls needs to be prepared prior to the coating of the Granicia series. The Granicia Series is unique natural look finish on the aluminum coil that enhances the mechanical properties of the ACP, makes it a nature friendly surrounding, improves its resistance to corrosion, improves its thickness uniformity across the surface of the panel and gives the panel a three dimensional look in two dimensional coating. It differentiates itself from a normal ACP in terms of its appearance. The Granicia finished Aluminum Composite Panels (ACP) can be shaped with ease for bends, curves and cladding fabrication. This empowers the architects and designers to be more creative while designing the building and its aesthetics in the most demanding market and clientele.

[037] The ACP is precisely sandwiched non-combustible or normal core between two superior alloy aluminum sheets, coated with superior quality specialized paint ensuring enhanced durability and weather resistance. Granicia Series is achieved at three coat finish with a base coat 12-16micron, Ink Coat of 1-2 microns and clear coat of 14-15 microns. The Base coat is adequately mixed for 12 - 15 minutes to ensure adequate and proper paint adhesion to the aluminum substrate. The mixer used is of approx. 12 – 16 inches diameter and is rotated at the speed of approx. 120 – 130 rpm in a closed room with ambient temperature in the range 15 – 25o C.The paint is prepared at Aludecor by mixing inorganic pigments into super durable. The mixer used is of approx. 5 – 6 inches diameter and is rotated at a speed of approx. 120 – 150 rpm in a closed room with an ambient temperature in the range 15 - 25o C. The equipment, especially the coater rolls needs to be prepared prior to the coating of the Granicia series.Due to the introduction of the Granicia series, treatment the resultant product obtained has the following advantages and positive effects:
(1) Unique core sandwich structures and materials provided by the invention.
(2) The panel surface look and the core material in the present invention are by metallurgical bonding, such that the material has a long life.
(3) The method for manufacturing aluminum sandwich panel of the present invention with Granicia finish can be used to manufacture shaped metal component.

[038] The steps involved in ACP production are T-Die, Up Coil Car (Feed Roll), Polishing Roll, Cooling, Trimming, Dryer, Making and Taping, Cutting, Stacker.Further below the said invention is elaborately explained with the help of different table’s illustrating the specific materials, conditions and annexures required in conjunction with the above mentioned invention.
1. Raw Material Required
The list of Raw materials (along with the mechanical properties/composition) required for manufacturing a Granicia Finish ACP are as follows:
Table 1: Raw Materials required for Coil Coating
Sl No. Raw Material Property Property Description Unit / Specification Measure
A.1
Aluminum Coil Mechanical Property Grade - AA1100
Mechanical Property Tensile Strength N/m2 130 – 165 MPa
Mechanical Property Hardness - H16 & H28
Mechanical Property T Bend - 2T
A.2 Thinner Mechanical Property Specific Gravity @ 30° C 0.87 - 0.93
A.3 Paint Mechanical Property Viscosity Ford Cup (BS 3900) 110 - 120 sec
Mechanical Property Fineness of grind Microns < 40 microns
Mechanical Property Specific Gravity @ 30° C 1.12 - 1.18
Mechanical Property Volume Solids % 44 – 46
Mechanical Property Gloss at 60° angle 90-95
Mechanical Property Cupping 4.5mm - 5.5mm
Mechanical Property T Bend 2T
Composition * Polyester resin % 40 – 50
Composition * Amino Resin % 7 – 12
Composition * Pigment (Organic/Inorganic) % 10 – 17
Composition * Solvents (Hydrocarbon/Polar) % 30 – 45
Composition * Paint Additives % 2 – 3
A.4 Multicolor paint Mechanical Property Viscosity Ford Cup (BS 3900) 70 - 80 secs
Mechanical Property Specific Gravity @ 30° C 1.14 - 1.18
Mechanical Property Volume Solids % 15 – 20
Mechanical Property Fineness of grind Microns < 15 Micron
A5. Clear Coat Mechanical Property Viscosity Ford Cup (BS 3900) 110 - 120 sec
Mechanical Property Fineness of grind Microns < 40 microns
Mechanical Property Specific Gravity @ 30° C 1.03 - 1.07
Mechanical Property Volume Solids % 44 – 45
Mechanical Property Gloss at 60° angle 90-95
Mechanical Property Cupping 4.5mm-5.5mm
Mechanical Property T Bend 2T

Table 2: Raw Materials required for ACP production
Sl No. Raw Material Property Property Description Unit / Specification Measure
B.1 Granules Mechanical Property Melt Flow Index gms per min 0.60 - 1.00
Mechanical Property Density - 0.93 - 1.03
Mechanical Property Elongation % > 100%
Mechanical Property Ash Content % 5 – 10
B.2 Adhesive Film Mechanical Property Density - 0.90 - 0.95
Mechanical Property Thickness Microns 48 – 55
Mechanical Property Adhesive Strength
B.3 Protective Film Mechanical Property Density - 0.90 - 0.95
Mechanical Property Clarity / Color - White
Mechanical Property Thickness Microns 70 – 85
Mechanical Property Adhesive Strength N/25mm 1.4 – 1.6

2. Coil Coating Process
The processes involved in the color coating department can be bifurcated into the following sub processes:
• Raw Material Specifications – Mill Finished Coil, Paint paint, Super Durable paint & Super Durable Lacquer.
• Pre Treatment Process - Coil
• Mixing – Super Durable Paint &multicolor
• Mixing – Super Durable lacquer
• Application – Super durable Paint & Multi color paint
• Application – Super Durable lacquer

• Raw Material Specifications – Mill Finished Coil & Paint & Primer & Clear Coat
For the coating of Aluminum Coil in the Color Coating Line, the requisite raw materials along with required specifications have been listed in Table 1.
• Pre Treatment Process - Coil
The Coil received for suppliers is pre-treated to remove dust, grease, oil or other impurities deposited on the coil. The Pre Treatment process is largely similar for all types of Coils depending on its thickness. The coil passes through a series of water spray rinsing tanks and other chemicals. The Pre Treatment process ensures that the unwanted particles and grease is removed and hence the adhesion properties of the coil are increased.
• Mixing – Super Durable Paint
Post Pre Treatment process, the coil is loaded on to the Color Coating Line for Coating Process. The Granicia Series is a three to six coat finish with super durable paint 15 - 16 micron;multi-color 1-3 micron & super durable lacquer 15-26 microns. The Paint is adequately mixed for 12 - 15 minutes to ensure adequate and proper paint adhesion to the aluminum substrate. The mixer used is of approx. 5 – 6 inches diameter and is rotated at the speed of approx. 500 – 600 rpm in a closed room with ambient temperature in the range 24 – 28o C.
• Mixing – Super Durable multicolor
The paint is received from the supplier is filtered using a 2000 mesh nylon filter cloth so as to ensure adequate filtration of tiny particles that provides the Granicia finish to the coated coil and later the Panel. This process also ensures removal of larger particles and impurities in the paint thus providing a distribution of multicolor grains. The Paint is adequately mixed for 20 - 25 minutes to ensure adequate and proper paint adhesion to the coated substrate. The mixer used is of 5 – 6 inches diameter and is rotated at the speed of approx. 120-150 rpm in a closed room with ambient temperature in the range similar to that of the primer (as researched by Aludecor in house). Moreover, the paint is mixed in two directions at appropriate intervals (as researched by Aludecor in house) so as to ensure adequate and appropriate coverage and maintain the required viscosity levels. Also thinner is mixed in a specific ratio to get the viscosity at the desired level.
Mixing – Super Durable Lacquers
The Super Durable lacquer is received from the supplier is filtered using a 600 mesh nylon filter cloth so as to ensure adequate filtration of tiny particles that help in uniform distribution of Granicia finish texture in two dimensional coating. This process also ensures removal of impurities in the lacquers thus providing a uniform distribution of grains. The lacquer is adequately mixed for 12 - 15 minutes to ensure adequate and proper paint adhesion to the super durable paint coated substrate. The mixer used is of 5 – 6 inches diameter and is rotated at the speed of approx. 500 – 600 rpm in a closed room with ambient temperature in the range similar to that of the primer (as researched by Aludecor in house). Moreover, the paint is mixed in two directions at appropriate intervals (as researched by Aludecor in house) so as to ensure adequate and appropriate coverage and maintain the required viscosity levels. Also thinner is mixed in a specific ratio to get the viscosity at the desired level.
• Application – Super Durable paint
The Pre Treated Coil is loaded on to the Uncoiler within 180 to 240 minutes from the coil being pre-treated. The tension control on the Uncoiler is set based on a pre-determined range (as per the Coil thickness as per Table 3 below).
Table 3: Tension Control for Granicia Finish Series Coil
Coil Thickness Range (mm) Line Speed (Mtr/Min.) Uncoiler Back Tension (Kgf) Recoiler Main tension (Kgf)
0.05 - 0.08 17-20 10-12 200-210
0.10 - 0.15 17-20 22-24 220-225
0.18 - 0.21 15-17 28-30 230-232
0.40 - 0.45 15-17 40-42 240-245

Table 4: Line / Roll parameters for Super Durable Paint Coating
Coil Thickness Range (mm) Line Speed (Mtr/Min.) Pickup Roll Speed (RPM) Doctor Roll Speed (RPM) Applicator Roll Speed (RPM) WFT(µm) DFT(µm)
0.05 - 0.08 17-20 7-9 1-3 21 – 24 60 - 65 15-16
0.10 - 0.15 17-20 7-9 1-3 21 – 24 60 - 65 15-16
0.18 - 0.21 18-20 8-10 1-3 23 – 26 60 - 65 15-16
0.40 - 0.45 18-20 8-10 1-3 23 – 26 60 - 65 15-16

The details in relation to the Burner Temperatures is mentioned below –
Table 5: Temperature of various Burner Zones
Coil Thickness Range (mm) Line Speed (Mtr/Min.) Burner-Zone1 Temperature(°C) Burner-Zone2 Temperature(°C) Burner-Zone3 Temperature(°C)
0.05 - 0.08 17-20 175 – 185 230 – 240 245 – 255
0.10 - 0.15 17-20 175 – 185 230 – 240 245 – 255
0.18 - 0.21 15-17 185 – 195 240 – 250 250 – 260
0.40 - 0.45 15-17 185 – 195 250 – 260 260 – 270

• Application – Super Durable multicolour Paint
Once the Super durable paint is applied the coil moves on to Top Coat section for application of the super Durable multicolor finish paint. Then, 4 to 20 spray application of paint is used. But for the purpose of natural look of Granicia finish series, the colors are changed for the purpose of application.

[039] A unique spray application method is devised, integrating multicolored layers to replicate the desired effect. This innovative approach allows seamless color transitions that precisely match our product specifications. The result is a stunning Granicia finish that captivates with its authenticity and aesthetic appeal. This breakthrough underscores our commitment to pushing the boundaries of creativity and technology, delivering exceptional coated sheets that redefine the possibilities in architectural and design applications.The roll speed for application of Paint along with approximate WFT (Wet Film Thickness) & DFT (Dry Film Thickness) has been mentioned in Table 6.
Table 6: Line / Roll parameters for Super Durable paint coating
Coil Thickness Range (mm) Line Speed (Mtr/Min.) Pickup Roll Speed (RPM) Doctor Roll Speed (RPM) Applicator Roll Speed (RPM) WFT (µm) DFT (µm)
0.05 - 0.08 17-20 7-9 1-3 23-26 60-65 15-16
0.10 - 0.15 17-20 7-9 1-3 23-26 60-65 15-16
0.18 - 0.21 13-15 8-10 1-3 21-24 60-65 15-16
0.40 - 0.45 13-15 8-10 1-3 21-24 60-65 15-16

The details in relation to the Burner Temperatures is mentioned below –
Table 7: Temperature of various Burner Zones for the top coat curing
Coil Thickness Range (mm) Line Speed (Mtr/Min.) Burner-Zone 4 Temperature(°C) Burner -Zone 5 Temperature(°C) Burner -Zone 6 Temperature(°C)
0.05 - 0.08 17-20 175 – 185 210 – 220 220 – 230
0.10 - 0.15 17-20 175 – 185 210 – 220 220 – 230
0.18 - 0.21 13-15 185 – 195 230 – 240 240 – 250
0.40 - 0.45 13-15 185 – 195 230 – 240 240 – 250

• Application – Lacquer Paint
Once the super durable paint coat is applied the coil ready for the lacquer application of the Granicia finish substrate to improve its appeal & ensure the life of coating. Then, PU roll is used for application of paint. But for the purpose of lacquering for Granicia finish series, the rolls are changed and mirror finish steel roll is used for the purpose of application.
The matt finish material requires the Guard film during coating at CCL line to avoid the very small scratches from bottom side of coil during coating winding.
Table 8: Line / Roll parameters for super Durable Lacquering
Coil Thickness Range (mm) Line Speed (Mtr/Min.) Pickup Roll Speed (RPM) Doctor Roll Speed (RPM) Applicator Roll Speed (RPM) WFT (µm) DFT (µm)
0.05 - 0.08 17-20 7-9 1-3 23-26 45-50 14-16
0.10 - 0.15 17-20 7-9 1-3 23-26 35-40 14-16
0.18 - 0.21 13-15 8-10 1-3 21-24 35-40 14-16
0.40 - 0.45 13-15 8-10 1-3 21-24 35-40 14-16
The details in relation to the Burner Temperatures is mentioned below –
Table 9: Temperature of various Burner Zones for the top coat curing
Coil Thickness Range Line Speed (Mtr/Min.) Burner-Zone 4 Temperature(°C) Burner -Zone 5 Temperature(°C) Burner -Zone 6 Temperature(°C)
0.05 0.08 17-20 175 – 185 210 – 215 220 – 225
0.10 - 0.15 17-20 175 – 185 210 – 215 220 – 225
0.18 - 0.21 13-15 185 – 195 220 – 225 225 – 230
0.40 - 0.45 13-15 185 – 195 220 – 225 225 – 230

3. ACP Production Process
Machine Start Up
The process is initiated by switching on the heating zones of the Extruder for the granules extrusion. The temperature of die and extruder is set in accordance to the table below:
Table 10: ACP Line 1 – Temperature Chart (Extruder Zone 9 to 15)
Die Zone 9th 10th 11th 12th 13th 14th 15th
Temperature(°C) 190-210 200-220 175-195 180-200 185-205 180-200 175-195

After heating 9th to 15th zone for approx. 25-35 minutes, the temperature control of 1st to 8th zone on electrical control cabinet is set as per table below:

Table 11: ACP Line 1 – Temperature Chart (Extruder Zone 1 to 8)
Zone 1st 2nd 3rd 4th 5th 6th 7th 8th
Temperature(°C) 120-140 130-150 140-160 270-290 150-170 155-175 160-180 160-180

The water circulation system of the three-roller calendar is switched on along with the water pump and heating system. The following temperatures are set:

Table 12: ACP Line 1 – Temperature Chart (Calendar Rolls)
Calendar Roll Upper Middle Lower
Temperature(°C) 55-75 65-85 80-100

Simultaneously, the heat conduction oil heating system is switched on with the 1st to 8th zones are being heated, ensuring adequate thermal oil with following set temperatures:
Table 13: ACP Line 1 – Temperature Chart (Composite Rolls)
Group 1st 2nd 3rd 4th 5th
Temperature(°C) 205-225 210-230 215-235 215-235 125-145

Process Operation Procedures
The ACP manufacturing process is a continuous process which includes various machines (as mentioned in table 5a and 5b.
Extruder Unit
As soon as the set temperatures at the Extruder is achieved and soaked for 15-25 minutes, the material (granules) mixer and dryer is switched on for material mixing, loading & feeding the hopper Unit. Once the hopper Unit is adequately filled to feed the Extruder, the main motor of the Extruder is switched on with gradual acceleration to the set desired speed with metered flow and current load of the main motor. The vacuum pressure is adjusted gradually.

Calendaring Unit
After receipt of melt from extruder and T die, the three-roller calendaring unit is started to extrude continuous rolled core in sheet form. The speed of extruder, calendar rolls and MTD roll is appropriately synchronized to get a uniform thickness and continuous sheet of the core. This hot sheet then travels on conveyor up to the composite roller to avoid sticking on the calendar roll surface.
Adhesive Film Lamination Unit
The Adhesive Film of appropriate thickness is loaded on to the top and bottom Adhesive Film Integration units. The respective adhesive films are un-winded with proper tension and air pressure. The width of core, aluminum coils and adhesive is matched and aligned properly. (Refer Raw Material specifications table for the details of Adhesive Film used)

Coil Holding Unit
The top (Granicia Finished Coated coil – as received post Coil coating) and the bottom coated coils are pre-loaded on to the top and bottom uncoiler respectively. The start ends of both coils should be unwinded and positioned at the composite rollers. The top press roller should be pressed to grip these start ends as per the speed of the composite rollers. The unwinding tension of each coil is adjusted for flatness and edge guide alignment. (Refer Raw Material specifications table for the details of top and bottom coil used)

Composite Section
The extruded granules, with adhesive film (both side – top and bottom), the Granicia finish coated coil (top side) and the bottom coated coil are moved on to the Composite Section. The pressure and gap is set appropriately for the respective Composite sections to ensure proper composition between the extruded PE core and the top and bottom coils. Post this composition process, the composite is moved on to the chilling/cooling section where it is cooled before Protective Film integration.

Protective Film Lamination Unit
The composite board moves protective film integration section post cooling. The Granicia finished composite is covered with a protective film to safeguard the top coated side till final installation at site. The protective is un-winded and adheres to the composite panel, with proper tension and wrinkle free positioning.

Trimming & Cutting
The continuously produced panels are now cut to specific sizes based on the requirement. The above mentioned product has the following Special features over the existing art:

- Superior Scratch free, natural look surface
- Perfect flatness and light weight.
- Additional rigidity& density of the sheets.
- Long lasting against weather/ atmosphere / UV rays due to granular surface.
- Acid and Alkali resistance
- Proven heat & Sound insulation
- Easily processed and fabricated at sites.
- Quick installation with regular skills.
- Unique & distinguished colors blending with natural surroundings.
- Recyclable, environmental friendly, green building product.
- Three dimensional look in two dimensional coating.

[040] In light of the above mentioned advantages and the technical advancements provided by the disclosed method and system, the claimed steps as discussed above are not routine, conventional, or well understood in the art, as the claimed steps enable the following solutions to the existing problems in conventional technologies. Further, the claimed steps clearly bring an improvement in the functioning of the device itself as the claimed steps provide a technical solution to a technical problem.

[041] A description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention.

[042] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.

[043] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

[044] A person with ordinary skills in the art will appreciate that the systems, modules, and sub-modules have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.Those skilled in the art will appreciate that any of the aforementioned steps and/or system modules may be suitably replaced, reordered, or removed, and additional steps and/or system modules may be inserted, depending on the needs of a particular application.

[045] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.
,CLAIMS:We claim:

1. A Granicia finish Aluminum Composite Panel (ACP) (100); comprising:
- an aluminum coil;
- a thinner coating;
- a plurality of granules with ash;
- an adhesive coating; and
- a protective film, wherein the ACP is non-combustibleand being configured to be disposed as a normal core between two superior alloy aluminum sheets, coated with superior quality specialized paint, thereby ensuring enhanced durability and weather resistance.

2. TheAluminum Composite panel (ACP) (100) as claimed in claim 1, wherein the ACP is a composite panel sheets consisting of two aluminum sheets and between them a polyethylene core/non-combustible core is interposed.

3. A method (200) for manufacturing a Granicia finish Aluminum Composite Panel (ACP), the method (200) comprising:
- an aluminum coil;
- a thinner coating;
- a plurality of granules with ash;
- an adhesive coating; and
- a protective film, wherein the ACP is non-combustible and being configured to be disposed as a normal core between two superior alloy aluminum sheets, coated with superior quality specialized paint, thereby ensuring enhanced durability and weather resistance.

4. The method (200) as claimed in claim 3, wherein the ACP is a composite panel sheets consisting of two aluminum sheets and between them a polyethylene core/non-combustible core is interposed.

5. The method (200) as claimed in claim 3, wherein the steps of Aluminum Coil Coating and ACP production is a Granicia finish, wherein the glare of normal finish panel is avoided and is more acceptable to surrounding environment.

6. The method (200) as claimed in claim 3, wherein the Coil Coating process comprises the step of pretreatment of the aluminum coil to remove impurities, the 3 step coating for Granicia finish coating, mixing of the paint and thinner and the top coat and clear coat of the Granicia finish paint.

7. The method (200) as claimed in claim 3, wherein the Granicia Finish Coating or Series is achieved at three to six coat finish with a 15 - 16 micron super durable paint Coat & 1 - 3 micron multicolor paint coat & 14-16 micron clear coat.

8. The method (200) as claimed in claim 3, wherein the ACP production process includes: the granules are extruded in extruder zone and in the composite section the extruded granules, the adhesive film, Granicia finish coated coil and bottom coated coil in presence of adequate pressure and gap ensure proper composition between the extruded PE core and the top and bottom coils.

9. The ACP (100) as claimed in claim 1 such as hereinbefore described with reference to the ongoing description and examples.

10. The method (200) as claimed in claim 3 such as herein before described with reference to ongoing description and examples.