Polyurethane Composite Sandwich Panel Production Line

The polyurethane composite sandwich panel production line is a key equipment in the fields of building insulation, cold storage, industrial plants, etc. It uses high-pressure foaming technology to composite polyurethane materials with substrates such as color steel and rock wool, forming panels with fire resistance, thermal insulation, and sound insulation properties.

sandwich panel line

The pu composite sandwich panel production line is a specialized equipment system used in the modern construction industry to produce high-performance insulation panels. It combines metal panels (usually color steel plates or stainless steel plates) with polyurethane foam core materials through an automated process to form building panels with excellent insulation performance. This type of production line represents advanced technology in the current field of building materials manufacturing, which can meet the strict requirements of insulation, fire prevention, sound insulation, and other aspects in different building scenarios.

A complete polyurethane composite sandwich panel production line usually consists of multiple functional modules, including metal panel pretreatment system, polyurethane raw material storage and transportation system, foaming molding system, composite pressing system, cutting system, cooling and curing system, and finished product stacking system. These subsystems operate in a coordinated manner through precise automation control, ensuring the continuity of the production process and consistency in product quality.

Compared with traditional building material production lines, the polyurethane composite sandwich panel production line has the following significant characteristics: a high degree of automation reduces manual intervention, and the production speed can reach 5-15 meters per minute; Accurate temperature control and proportioning system ensure the quality of polyurethane foam; Flexible parameter adjustment capability can produce products with different thicknesses (usually 30-200mm), widths (standard 1000-1200mm), and performance requirements; The integrated environmental treatment system effectively controls the exhaust emissions during the production process.

The core of the polyurethane composite sandwich panel production line lies in its precise equipment configuration and coordinated operation mechanism. As the starting point of the production line, the uncoiler is usually equipped with a dual station design to achieve uninterrupted feeding. It can process metal coils with a width of up to 1300mm, a thickness range of 0.4-1.0mm, and a tension control system accuracy of ± 1%. The cleaning section adopts a combination of multi-stage chemical cleaning and physical brushing to ensure that the metal surface cleanliness meets the Sa2.5 standard, providing an ideal base for subsequent composite.

The forming machine is a key equipment that determines the quality of the panel. Modern production lines are equipped with 12-24 sets of roller molds, which ensure a forming accuracy of ± 0.1mm through CNC precision machining. They can produce dozens of different corrugated shapes of panels. The preheating furnace adopts infrared or hot air circulation heating, with a temperature control range of 50-80 ℃ and a temperature difference of ± 2 ℃, to ensure that the metal panel reaches the optimal composite temperature.

The polyurethane high-pressure foaming machine is the "heart" of the production line, with a working pressure usually reaching 120-200 bar. The mixing head adopts a self-cleaning design, and the switching time is less than 0.5 seconds. The raw material measurement accuracy is as high as ± 1%, and the temperature control is ± 1 ℃, ensuring that the polyurethane foaming reaction is sufficient and uniform. Modern foaming machines often use PLC control systems, which can store hundreds of formulas and adapt to different densities (30-60kg/m ³) and fire protection levels (such as B1, B2) requirements.

The dual belt press is the core of the composite process, with an adjustable pressure range of 0.5-5MPa and a length of 30-60 meters. It uses segmented heating (40-60 ℃) and cooling to control the foaming process. The advanced hydraulic system ensures even pressure distribution and a flatness error of less than 1mm/m ². The cutting system adopts high-speed circular saw or band saw, equipped with automatic length measuring device, with a cutting accuracy of ± 1mm and a bevel angle of up to 45 °.

The production process of polyurethane composite sandwich panels is a precision controlled continuous process. In the pre-treatment stage of metal panels, the coil is first unfolded by an uncoiler, leveled to eliminate internal stress, and then enters the cleaning section. Alkaline degreasing agents are used to remove surface oil and oxides, followed by drying treatment. The preprocessed metal plate enters the forming machine and gradually forms the designed ripple shape through multiple rolls. This process requires strict control of the forming speed and pressure to avoid material stretching and deformation.

In the composite section, the lower metal plate is preheated and enters the double belt press. At the same time, polyurethane raw materials (isocyanates and polyols) are mixed in precise proportions (usually 1:1 to 1:1.2) in the high-pressure foaming machine, and uniformly sprayed onto the lower panel through the mixing head. Subsequently, the upper metal plate is precisely aligned and covered, and enters the press to begin the foaming reaction. Temperature, pressure, and time control are crucial during this stage, with foaming time typically controlled between 3-8 minutes and temperature maintained within the range of 25-40 ℃.

In the maturation and post-treatment stage, the initially formed sheet enters the cooling section and the core material is completely cured through forced ventilation or water cooling. This process takes 10-30 minutes, depending on the thickness of the sheet and environmental conditions. After solidification, the board is automatically measured and cut by a high-speed sawing machine to the customer's specified length (usually 6-12 meters), and the cut is automatically trimmed to ensure flatness. After quality inspection (including thickness measurement, adhesive strength testing, and appearance inspection), the finished boards are automatically stacked and packaged. The packaging materials are usually made of moisture-proof plastic film and reinforced corner protection.

In the future, the production line of pu composite sandwich panels will pay more attention to green manufacturing throughout the entire lifecycle, from raw material selection to production process and product recycling, forming a closed-loop system. At the same time, personalized customization capabilities will be further enhanced, and efficient switching production of small batches and multiple varieties will be achieved through flexible manufacturing systems to meet the increasingly diverse needs of the construction industry.