Composite Materials

Rigid polyester foam, Styrofoam, rigid urethane?

Who knows, with some information.

Why are yuo using carbon fiber if you want cheap panels?

I am interested in C fiber because its high strenght and low weight.

Polystyrene or isocyanurate are good core materials.

As an aside, other insulated panel manufacturers use PVDF (polyvinylidene fluoride) as skins. It is resistant to solvents, acids, and bases, and has low smoke generation in a fire event. It is low cost, low density, and pretty durable.

Have you considered honeycomb core material?

Honeycomb Core Material - Image Results

It even comes in paper.

Boy there's a good thought.

Some of the steel door manufacturers use a honeycomb kraft paper core. It is amazing how tough that stuff is after it is laminated between two skins.

It's interesting to watch them make the the honeycomb material, too.

I was just thinking of aluminium honeycomb too. Good strength and flexibility but low compression, so I guess it really depends on the application.

Extruded architectural polyethylene is a good material too.

But, you have a basic problem with the core foam or such. Neither divinycell, nor rohacell is expensive if used properly. Additionally, their qualities are different from polyethylene or polystirol.

Additionally: did you even think of what adhesive you can use with a different core? I guess, you did not. Stress testing, and delamination? I guess, you did not.

Other than that, and maybe for a dozen more, I have no problem with your fishing expedition, none at all.

It depends entirely on the use.
I'd favour plywood and paper honeycomb maybe impregnated with some polyeurathane varnish or some such.
Or
Maybe sheets of Lasagne with minced beef and tomato sauce in between?
Del

Not spahgetti, then?

Maybe an icecream and wafer composite?
Del

How about a ciabatta skin with a core of prosciutto and mozzarella (olive oil, pepper and origano optional)?

Polyurethane foam is commonly used as a core material in industrial/architectural panels (eg. roof panels). Whilst it is relatively strong and inexpensive, it is usually injected in liquid form, and the equipment to do this does not come cheap. Maybe you can find someone to do this for you, or the foam can be bought in slab form.

maybe philo dough, with some honey adhesive, and a center core of walnut kernals placed in a concentric pattern, say, 1 per square inch. Now, if you you are thinking of using this in a moisture laden area, all bets are off.

Take a look to this web side: www.euro-composites.com and find all about sandwiches with a honeycomb core made of paper, aluminum, Nomex, Kevlar and glas. I´m sure that you´ll find your solution.

There are quite a few composites companies that sell a wide variety of core materials. I would look for maybe excess or cut off pieces from manufacturing companies. I know that ACP Composites sell a wide stock of honeycomb and foam, but also offer some excess pieces of rohacell and honeycomb.