Can two different core materials (e.g., XPS and PU) be mixed to make functionally graded sandwich panels?

Yes – this is called a functionally graded foam core sandwich panel. Typical application: using a PU layer near the outer surface for insulation and a PET layer near the inner surface for load-bearing, bonded with PU adhesive. The manufacturing challenge is the differential thermal expansion coefficients (PU≈80, PET≈65) during cooling after lamination, which can cause bending. Solutions: 1) Co-cure process – continuously foam PU and superimpose PET sheets before full curing; 2) Use a flexible adhesive layer (modulus <10 MPa) as a buffer; 3) Stepwise transition (e.g., from PU to low-density PET to high-density PET). Engineering validation shows such hybrid core panels can achieve 40% higher flexural stiffness than single PU core panels with only 8% loss in insulation performance.

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Can two different core materials (e.g., XPS and PU) be mixed to make functionally graded sandwich panels?

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