XPS Foam Sandwich Panels for Trailer & Truck Bodies
XPS foam core sandwich panels have become one of the most commonly used panel materials for trailer and truck bodies, widely applied across various types of transportation vehicles. Common skin materials include FRP (fiberglass), aluminum, and coated steel plates, with FRP and aluminum being the most commonly used for their good strength, corrosion resistance, and lightweight properties, making them widely used in the exterior structure of the vehicle body.
XPS foam, as the core material, has unique physical properties that make it an ideal choice
The main advantages of XPS foam core sandwich panels lie in their exceptional light weight, water resistance, and excellent thermal insulation properties. Compared to other traditional materials, XPS foam has a lower density, which significantly reduces the overall vehicle weight. This not only helps increase the vehicle’s payload capacity but also improves fuel efficiency and reduces operating costs. In addition, the water-resistant nature of XPS foam makes it perform excellently in humid or rainy environments, preventing water penetration that could lead to structural damage or a decrease in thermal efficiency.
Specification of XPS Foam Core Sandwich Panels
| Composition | Skin | FRP/GRP: Glass fiber reinforced plastics. |
| CFRT: Continuous fiber reinforced thermoplastic . | ||
| Aluminum alloy. | ||
| Coated Steel. (GI, GL, PPGI, PPGL) | ||
| XPS Foam Core | Density: 35-50kg/m³. | |
| Thermal Conductivity: 0.025-0.035W/m·K. | ||
| Compressive Strength: 200-700 kPa. | ||
| Tensile Strength: 500–1000 kPa. | ||
| Water Absorption: <0.5%. | ||
| Dimensional Stability: <1.5%. | ||
| Flame Retardant Grade: B1-B2. | ||
| Operating Temperature Range: -50°C to +75°C. | ||
| Panel width | ≤ 3.2m. | |
| Panel length | ≤ 13m. | |
| Panel thickness | 10~150mm. | |
| Composite methods | Adhesive bonding.(Unsaturated polyester adhesive, polyurethane adhesive, etc） | |
| Added materials | Aluminum profiles, steel profiles, fiberglass profiles, wood, plywood, high-density PVC, high-density PU, etc. | |
Common Application Areas
- Refrigerated trucks/trailers.
- Dry cargo trucks/trailers.
- Container trucks/trailers.
- Ambulances/trailers.
- Freight container trucks.
- Special function vehicle bodies (e.g., mobile catering trucks, mobile office vehicles, etc.)
- Camping trucks/trailers (expedition vehicles, caravans, truck campers, etc.)
Structure of XPS Foam Core Sandwich Panels
The structure of XPS foam sandwich panel is not limited to the conventional three-layer structure; it can flexibly integrate various materials into the sandwich panel based on the specific needs of the vehicle, especially to enhance structural strength. For example, reinforcement layers or other composite materials can be added to the sandwich panel to improve impact resistance, corrosion resistance, thermal insulation, and other properties. This customized composite design allows the XPS foam sandwich panel to exhibit higher adaptability and performance in different types of transportation vehicles, particularly in applications that require resistance to high external forces or special environmental conditions. This flexible composite structure can meet the stringent requirements of materials for vehicles like refrigerated trucks, transport vehicles, ambulances, and other specialized vehicles.
Three-layer sandwich structure
Multi-layer sandwich structure
Skin Materials
FRP/GRP Sheets
FRP sheets are an ideal material for truck and trailer bodies due to their lightweight, high strength, corrosion resistance, good thermal insulation, and weather resistance, making them widely used in various transportation vehicles such as refrigerated trucks and dry cargo trucks. They not only effectively reduce vehicle weight and improve transportation efficiency, but also possess UV resistance, impact resistance, and low maintenance costs, ensuring long-term vehicle stability in harsh environments. Furthermore, the excellent mechanical properties and aesthetically pleasing design of FRP sheets make them an essential component of various commercial vehicles.
CFRT Sheets
CFRT sheets, as a new type of thermoplastic FRP material, offer highly reliable vehicle body solutions thanks to their advantages such as high strength, lightweight, high temperature resistance, impact resistance, and corrosion resistance. Whether for refrigerated trucks, dry cargo trucks, or special-purpose vehicles, CFRT sheets can improve vehicle safety, durability, and transportation efficiency, while reducing maintenance costs and extending vehicle lifespan.
Aluminum Alloy Sheets
Using aluminum alloy sheets for truck and trailer bodies provides numerous advantages, including a lightweight structure, high strength-to-weight ratio, corrosion resistance, and low maintenance. These benefits lead to improved fuel efficiency, increased payload capacity, and lower operational costs. Additionally, aluminum’s recyclability and ability to withstand extreme conditions make it an environmentally friendly and durable option for commercial vehicle manufacturers.
Coated Steel Sheets
Coated steel sheets offer a highly durable, cost-effective, and versatile body solution. They combine high strength, corrosion resistance, and aesthetic appeal, while providing long-term protection against environmental and mechanical stresses.
Our Customized Solutions
TOPOLO-TRUCK’s customized composite panel solutions help your vehicle projects achieve more efficient, safe, and flexible local production, enhancing overall operational efficiency. Customize prefabricated composite panel kits for your vehicle projects to enable localized, fast assembly.
Optimized Panel Structure
Depending on the specific needs of the vehicle, we use various composite materials to provide higher strength, durability, and lightweight designs. Whether it’s FRP, aluminum alloy, or other composite materials, we tailor the panels to ensure maximum performance and reliability.
High-Precision CNC Processing
Utilizing high-precision CNC machining, we ensure that every panel meets strict size and tolerance requirements.
Obtain XPS Foam Sandwich Panel Samples
We offer customized XPS foam sandwich panel samples based on your provided materials or specific requirements for testing purposes.
