Sandwich Panel Manufacturing Methods

Over the past 50 years, the Sandwich panel has emerged as a particularly economical construction method. The combined materials always consist of two face sheets (depending on the application, rigid metallic face material or flexible face sheets such as thin aluminum, paper, or membranes) and a core insulating material.

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Basically, there are two processes for Manufacturing panels:

• Continuous process:

All used materials are processed together and the finished formed panel is cut to the desired length without stopping the line.
This line has an average speed of about 14 meters per minute in the production of medium thickness panels (40-50 mm) with metal top layers. With an eight-hour shift per day for 220 days per year, production is about 1,180,000 meters per year, assuming an 80 percent efficiency.

• Discontinuous process:

The materials are processed separately, i.e. the face sheets are formed and cut to the desired length and then joined together in a press where the foam is injected.
Besides, this process has lower productivity that cannot be compared to that of the continuous process.
It is used today for products with shapes that do not allow the continuous process, or when the required production rate does not justify the investment in a continuous line.
This line with a 12-meter double press can achieve a production of about 100,000 meters per year under the same conditions with one shift per day.

In the polyurethane panels (PU -PIR) procedure, the foam is created starting from the required chemical components, which are dosed and mixed in the foaming machine. The resulting liquid mixture is evenly distributed over the lower metal sheet.
The metallic facings, the foam, and any side strips or gaskets are pressed in the double belt or continuous press. This machine must hold the metal sheets separated at the desired spacing while the foam expands.

Let&#;s Dig Into Continuous Panel Production line 

A typical continuous line has three sections:

1. The external layers processing section:The first section begins with the sheet decoilers and continues with all the equipment for
   forming the two sheets into the desired shape.
   This can be a panel for walls or for roofs. In a typical case of a Sandwich panel with the two outer
   surfaces made of sheet metal and an insulating core made of rigid polyurethane foam,
   Sandwich panels with flexible layers (aluminum, fiberglass sheets, asphalt paper) are
   not roll-formed. Then both surfaces of the finished panels are completely flat and their temperature is preheated as required
   (usually between 40 and 65 C), and then the insulating material is prepared.
   Temperature is again a critical parameter, this time for the reaction
   of the adhesive, i.e. for good adhesion of the inner sheet to the outer layers.
2. The insulating material processing section:in case the insulation material was mineral wool or expanded polystyrene,
   its inserted and bonded into the sheets in the form of mattresses
   which will be cut and shaped to the correct thickness before insertion.
3. Panels handling section:

The panel goes throw cutting, cooling, stacking, and wrapping with a plastic film.
Those last operations can be automatic or manual. Depending on the level of automation required by the customer for his production line.

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The complete set of equipment for polyurethane sandwich panel production line is mainly composed of uncoiling system, film cutting system, forming machine system, steel plate preheating furnace, high pressure foaming system, double track system, double track heating system, cutting system, horizontal cooling system, palletizing System, packaging system and other series of equipment, the main core equipment part is the molding machine system.

The production process of polyurethane sandwich panel
There are basically two ways to produce polyurethane sandwich panels: continuous production and discontinuous production. At present, the continuous production process is suitable for enterprises with high output requirements, while the discontinuous production process is suitable for products with special shapes that cannot be continuously produced, or the production volume is not enough to invest in continuous equipment.
In the continuous production process, the materials used to make the sandwich panels are processed together at high speed. The polyurethane foam is continuously sprayed between the upper and lower surface materials that have been formed at a constant speed, and there is a polymerization reaction there to produce different forms of Polyurethane sandwich panel. After the sandwich panel is fully formed, the cutting is performed at the expected length, and the production line of the cutting process does not stop.
In the non-continuous process, the materials are processed separately, which means that after the face material is formed, it is cut to the required length, then assembled together into the laminator, and the foam is injected between the face materials to generate a predetermined shape Polyurethane sandwich panel.

PU sandwich wall panel model type

PU sandwich roof panel model type

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