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. The product category involves the various Metalic
Series, Solid Series, Peerless Series, Crinkle Series, Series and Shino Series.
Apart from the above there is a series in the development phase and it, being the Sand Finish
Series.
The present invention relates to a Sand Finish Series which is a unique kind of finish on the
aluminum coil that enhances the mechanical properties of the Aluminium Coated Panel
(ACP) adds a textured feel to the panel. It differentiates itself from a normal ACP in terms of
its mechanical or physical properties, antiglare, longevity, durability due to scratch free
surface. It also adds touch and depth to the surface. The series is a evolution of various ideas
to reduce the glare emitted from normal reflective paints used on ACP. The glare directly
affects the surrounding and adjacent buildings during sunlight, the same is avoided when
sand finish is used for internal / external applications.
Background of the invention
The construction industry is growing day by day. The panels form one of the important
components of this industry. Many metallic pigments are known which provide
electrochemical, electrical, thermal, barrier and other properties to compositions which are
used for protecting material such as metal from corrosion, maintaining electrical
conductivity, shielding equipment from electromagnetic fields, resisting elevated
temperatures, and providing protection from moisture. Silver, gold and other noble metal
pigments are used for their electrical conductivity and thermal conductivity properties. Zinc
and magnesium are used for their electrochemical properties. Aluminium is used for its
thermal and chemical barrier properties. Aluminium composite panels represent a relatively
new and modern material that is increasingly gaining larger market share and is often
preferred over other construction materials.
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A.J Aluminium composite panels are cut in any shape and dimension is needed. Their processing,
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cut - shaping, may take place 'by using conventional tools. Construction companies that use
composite panels, in order to create the final product cut all necessary pieces out from flat
composite panel sheets, which is the form the composite panels are disposed. Composite
panels are only available in flat sheets. Following the cut of the sheets in the dimensions
required it is reasonable that remnants of irregular dimensions and shapes are left over. These
residues are no longer usable.
An ACP is a panel with a Low Density PE core sandwiched between Ali~n~inurcno ils. 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.
Aluminium composite panels 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 lightweight
but very sturdy material in construction, particularly for transient structures like trade
show booths and similar temporary elements. It has recently also been adopted as a backing
material for mounting fine art photography, often with an acrylic finish using processes like
Diasec or other face-mounting techniques. ACP material has been used in famous structures
as Spaceship Earth, VanDusen Botanical Garden, the Leipzig branch of the German National
~ i b r a r ~ . [ ' ]
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.
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TECHNICAL FIELD :,,J ~
The present invention relates to the aluminium composite panel which is commonly used in
buiding .ACP is traditionally a composite sandwich panel sheets which consist of two
aluminium 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.
The embodiment of the present invention is a Composite Panel that is precisely sandwiched
non combustible or normal core between two superior alloy aluminium sheets, coated with
superior quality specialized paint ensuring enhanced durability and weather resistance.
SUMMARY OF THE INVENTION
The Sand Finish Series is unique natural look finish on the aluminum coil that enhances the
mechanical properties of the ACP, makes it a nature friendly surrounding, adds a textured
feel to the panel.
It differentiates itself from a normal ACP in terms of its appearance and anti glare surface as
each grain of paint has own orientation and depth to the surface. It avoids the strong glare
emitted by normal metallic / glossy finish panels, which affects the surroundings / buildings.
The series is a evolution of various ideas discussed and fine tuned by the management of
company with it's rich experience in newer products.
The sand finished Aluminium Composite Panels (ASF) can be shaped with ease for bends,
curves and cladding fabrication. This empowers the architects and designers to be more
creative while designing the buiding and its aesthetics in the most demanding market and
clientele.
The ASF Composite Panel is precisely sandwiched non combustible or normal core between
two superior alloy aluminium sheets, coated with superior quality specialized paint ensuring
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enhanced durability and weather resistance.
' Special features of sand finised u, panels are-
- Superior Scratch free antiglare, natural look surface
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. Perfect flatness and light weight.
I - Additional ridigity & density of the sheets.
- Long lasting against weather1 atmosphere 1 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 colours blending with natural surroundings.
I Recyclable, environmental friendly, green building product.
~ : Advantages
~ Advantages and positive effects of the invention:
(1) unique core sandwich structures and materials provided by the invention by the
characteristics of the panels.
(2) the panel surface texture and the core material in this way the present invention, by
metallurgical bonding, such that the material has a long life.
(3) The method for manufacturing aluminum sandwich panel of the present invention
with sand finish can be used to manufacture shaped metal component.
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Description of the invention
The present invention as per the description involves the main steps as-
Main extruder for PE core
T-Die
Up Coil Car(Feed Roll)
Polishing Roll
Cooling
Trimming
Dryer
Making and Taping
Cutting
Stacker
The process can be divided in two main steps -
Coil Coating
ACP Production
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 & Primer
Pre Treatment Process - Coil
: Mixing - Primer
Mixing - Paint
Application - Primer
Application - Paint
- - - - - - --- - - -
The details in relation to the entire process are mentioned in Annexure 1.
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Raw Material Specifications - Mill Finished Coil & Paint & Primer
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. He Pre Treatment process ensures that the unwanted particles and grease is
removed and hence the adhesion properties of the coil are increased.
Mixing - Primer
Post Pre Treatment process, the coil is loaded on to tlie Color Coating Line for Coating
Process. The Sand Finish Series is a two coat finish with a 5 - 6 micron Primer Coat & 16 -
18 micron paint coat. The Primer is adequately mixed for 12 - 15 minutes to ensure adequate
and proper paint adhesion to the aluminium substrate. The mixer used is of approx 5 - 6
inches diameter and is rotated at the speed of approx 120 - 130 rpm in a closed room with
ambient temperature in the range 15 - 25' C.
Mixing - Paint
The paint is received from the supplier is filtered using a 100 mesh nylon filter cloth so as to
ensure adequate filtration of tiny particles that provides the sand finish texture and touch to
the coated coil and later the Panel. This process also ensures removal of larger particles and
impurities in the paint thus providing a uniform feel to the panel. The Paint is adequately
mixed for 12 - 15 minutes to ensure adequate and proper paint adhesion to the primer
substrate. The mixer used is of 5 - 6 inches diameter and is rotated at the speed of approx 120
- 130 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 - Primer
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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). The coil coating
Application - Paint
Once the primer coat is applied the coil moves on to Top Coat section for application of the
sand finish paint. The Company uses PU roll for application of paint. But for the purpose of
Sand finish series, the rolls are changed and steel roll is used for the purpose of application.
The roll speed for application of Paint along with approximate WFT (Wet Film Thickness) &
DFT (Dry Film Thickness) has been mentioned in Table 6. The unique thermosetting
property of this paint gives a textured finish similar to sand grains while getting cured at 230
deg in the oven- IMP.
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 given
Process Operation Procedures
The ACP manufacturing process is a continuous process which includes various machines (as
mentioned in table 5a and 5b. The details in relation to the entire process are mentioned in
Annexure 2.
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 vaccum pressure is adjusted gradually.
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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 upto 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, aluminuni 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 (Sand 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 sand 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 propeicomposition
between the extruded PE core and the top and-bottom--coils. This process also- -
flattens the granular structure, making it unique anti glare, and closer to natural feel of sand
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' finished buildings- IMP. Post this composition process, the composite is moved on to th ~ chilling/cooling section where it is cooled before Protective Film integration.
1 . Protective Film Lamination Unit
The composite board moves protective film integration section post cooling. The Sand
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.

We claim
1. A Sand finish Aluminium Composite panel comprising a aluminium coil, thinner
coating , granules with ash, adhesive coating and an protective film.
2. A process for Sand finish aluminium Composite panel comprising the steps of
kluminium Coil Coating and ACP production is a sand finish wherein the glare of
normal finish panels is avoided and is more acceptable to surrounding environment.