The sandwich panels used did not meet the requirements of a manufacturer of horse transporters. Marks from the core material were visible and compromised the surface quality. At the same time, the composite exhibited weaknesses in the bond between the core and the facing. The problem was further exacerbated with dark paint finishes. Thermal stresses caused tension in the material. The conclusion was clear: the product was not marketable—either visually or technically—in the premium segment.
A sandwich panel with a continuously homogeneous core structure was used—manufactured using Corapan AL 85. The key difference lies in the manufacturing process. The core is not installed as a prefabricated element, but is instead poured as a bulk material directly between the face layers during the process and compressed. This results not in a segmented structure, but in a continuous core across the entire surface. There are no transitions. No joints. No structural weak points.
The homogeneous structure creates a stable bond between the core and the surface layers. The load is distributed evenly across the surface. Surface markings are prevented because there are no structural transitions.
Compared to traditional PUR solutions, it offers significantly higher structural integrity and a more stable bond throughout its entire service life.
The solution was implemented in several hundred vehicles per year and successfully integrated into mass production. The side panels feature a flawlessly smooth surface throughout—with no visible core marks. The composite remains stable even under thermal stress. Production is reproducible, quality is consistent, and the risk of customer complaints is significantly reduced.
Material combinations, fire safety requirements, and manufacturing processes can be evaluated early on.
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We specialize in sandwich plates 🥪—but this website also serves cookies 🍪. Not the kind you eat, but the digital kind. With your consent.
