Views: 89 Author: Site Editor Publish Time: 2026-07-20 Origin: Site
Initially, we focused solely on the production of plastic honeycomb panels—a lightweight, high-strength, and cost-effective structural material widely used in applications such as architectural partitions and curtain wall backing panels. However, customer feedback made us realize that a single structural function was no longer sufficient to meet market demands. This was particularly true in tropical countries, where there was a strong demand for a new type of thermal insulation material, as this directly impacts indoor comfort and air conditioning energy consumption.
Through our research, we have learned that aerogel—often referred to as “solid smoke”—is currently the solid material with the lowest known thermal conductivity; its nanoporous structure effectively suppresses both thermal conduction and convection. Combining it with a honeycomb structure could, in theory, achieve an integrated “structural + thermal insulation” solution that retains the mechanical advantages of honeycomb panels while endowing them with superior thermal insulation properties. However, the problem is that we have never worked with aerogel composite manufacturing processes.
To fulfill our commitment to our customers, we did not back down. Our team visited more than ten domestic new materials companies, high-efficiency laboratories, and building materials research institutes to systematically study the properties of aerogel, its forming methods, and the challenges of composite manufacturing. We discovered that aerogel is inherently brittle and cannot be used directly as a core material; traditional insulation materials such as polystyrene boards and rock wool, while inexpensive, have poor fire resistance and are too thick; Although aerogel felts and coatings are already available on the market, there is still no mature solution for hot-pressing them with plastic honeycomb panels; during high-temperature hot-pressing, aerogel tends to pulverize; and the plastic substrate is prone to deformation, resulting in weak interfacial bonding.
Faced with these challenges, we decided to independently develop a composite process. After three months of repeated testing—adjusting temperature, pressure, adhesive type, and aerogel pretreatment methods—we finally established a viable solution involving low-temperature hot pressing combined with the embedding of flexible aerogel felt. We cut custom-made silica aerogel felt to the dimensions of the honeycomb cells, precisely embedded it into the honeycomb cavities between the upper and lower plastic panels, and achieved a strong bond using eco-friendly hot-melt adhesive.
Third-party testing of the final samples showed that the thermal conductivity was significantly lower than that of traditional honeycomb panels, while maintaining Class A fire resistance, low water absorption, and good compressive strength. After conducting on-site testing in India, the client reported: “In a high-temperature environment of 45°C, this panel reduced the indoor temperature difference by 8–10°C, significantly lowering the air conditioning load.” More importantly, despite being only 3–5 mm thicker, the product achieved the same cooling effect that traditionally required 50 mm of rock wool, resulting in significant savings in building space.
This development process was free of grandiose slogans; instead, it involved post-failure reviews, repeated fine-tuning of parameters, and a relentless focus on detail. We understand that true technological innovation does not come from working in isolation, but rather from addressing real-world problems based on actual scenarios. Today, this aerogel-composite plastic honeycomb panel has entered the small-batch production phase.
