Continuous PU Sandwich Panel Line For Color Steel Sheet

The color steel sheet continuous pu sandwich panel production line is an automated production system used in modern construction industry for mass production of high-quality insulation composite panels. The color steel sheet continuous polyurethane sandwich panel line uses color coated steel plate as the surface material and polyurethane (PU) as the core material. Through continuous foaming process, it is formed into a sandwich structure composite panel with excellent thermal insulation performance.

sandwich panel line

Working principle and process:

• The feeding system automatically uncovers the color steel sheet coil and sends it to the production line
  

• Clean and chemically treat the surface of steel plates through pre-treatment equipment
  

• The forming unit rolls the flat plate into the designed waveform or flat shape
  

• After positioning the upper and lower materials, they enter the continuous foaming zone
  

• The high-pressure mixing head precisely injects polyurethane raw materials between the two sides of the material
  

• Complete the foaming and curing process in a temperature controlled environment
  

• After entering the curing zone, the board completes the final strength formation
  

• The automatic cutting system precisely cuts according to the set length
  

• Finished products are stacked and packaged before entering the warehousing process

Core equipment composition and technical parameters

• Open book and pre-processing system
  Dual station automatic unwinding machine: with a carrying capacity of 10-20 tons, equipped with EPC automatic correction device
  Cleaning and drying unit: using multi-stage chemical cleaning+high-pressure water washing+hot air drying process
  Pre treatment equipment: Roll coating chemical treatment to form chromized or zirconized conversion film

• Forming unit
  Multi pass progressive forming technology: 12-24 sets of rolling rolls are gradually formed
  Servo drive system: positioning accuracy ± 0.1mm
  Removable mold design: supports quick switching of over 30 board types

• Polyurethane foaming system
  High pressure foaming machine: mixing pressure of 120-200bar, output of 30-300kg/min
  Temperature control system: raw material temperature control accuracy ± 0.5 ℃
  Two component ratio control: measurement error ≤± 1%

• Continuous foaming production line
  Double belt press: adjustable pressure range of 0.1-0.5MPa
  Temperature zoning control: 6-8 temperature zones, temperature control accuracy ± 1 ℃
  Operating speed: adjustable from 3-15m/min

• Post processing system
  Flying saw cutting machine: cutting accuracy ± 1mm, maximum cutting thickness 300mm
  Automatic stacker crane: carrying capacity of 5 tons, positioning accuracy ± 2mm
  Packaging line: automatic laminating+bundling, processing speed 10-20 pieces/minute

Innovation points in process technology

• Intelligent temperature control foaming technology
  Adopting multi-stage temperature field control, precise temperature control of each stage of the foaming process is achieved through infrared temperature measurement and dynamic adjustment system. Innovatively developed a temperature curve of "high in front and low in back", which makes the foaming reaction more complete, the cell structure more uniform, and the thermal conductivity of the product can be reduced to 0.018-0.022W/(m · K).

• Micro pressure continuous forming process
  Breaking through the limitations of traditional high-pressure foaming, we have developed a 0.15-0.25MPa low-pressure continuous forming technology, which reduces energy consumption by about 30% while ensuring bonding strength, and improves the flatness of the board to ≤ 1mm/m.

• Digital closed-loop control system
  Integrate PLC+SCADA control system to achieve:
  Raw material measurement accuracy reaches 99.5%
  Speed synchronization error<0.1%
  Online quality inspection (thickness, density, bonding strength)
  Big data analysis optimizes process parameters

• Environmentally friendly production process
  Innovation points include:
  Fully enclosed raw material conveying system, VOC emissions<30mg/m ³
  Online recycling, crushing, and reuse of waste materials
  Application of water-based release agents to replace traditional oil-based products
  The utilization rate of thermal energy recovery is over 65%

Product performance advantages

The color steel polyurethane sandwich panels produced by this production line have significant performance advantages:

• Thermal insulation performance: thermal conductivity of 0.018-0.024W/(m · K), superior to similar products by 15-20%
  

• Structural strength: Bonding strength ≥ 0.12MPa, flexural bearing capacity increased by 30%
  

• Fire safety: Passed GB8624 B1 certification, smoke density level ≤ 50
  

• Durability: Weather resistance test for 3000 hours without powdering, with a service life of over 25 years
  

• Dimensional accuracy: Length tolerance ± 2mm, width tolerance ± 1mm, flatness ≤ 1mm/m

Expansion of application areas

With the advancement of technology, modern color steel polyurethane sandwich panels have broken through the traditional application scope:

• Ultra low temperature field: -196 ℃ liquid nitrogen storage tank insulation layer
  

• Cleanroom Engineering: Semiconductor Factory Cleanroom Wall System
  

• Modular building: integrated bathroom, medical shelter unit
  

• Transportation sector: high-speed rail carriages, refrigerated container bodies
  

• New energy facilities: Building Integrated Photovoltaics (BIPV) substrate

The color steel sheet continuous pu sandwich panel line represents the highest level of current composite panel manufacturing for construction. Its technological innovation not only improves product performance, but also promotes the development of the entire construction industry towards high efficiency, energy conservation, and green environmental protection. With the promotion of the "dual carbon" strategy, the production line of color steel polyurethane sandwich panels will play a more important role in the future process of building industrialization.