Sandwich panel is one of the best and most useful building materials made in the last century.
This durable and useful structure has solved many problems of building engineers in the field of design and construction of sheds, prefabricated buildings, refrigerators and cold storages, and so on. A huge change that made food trucks better equipped and more principled to carry out their missions for distribution systems. Drug trucks work better and in the warehousing process; the fruits that were available to the world’s farmers to stay healthier and more useful.
Simplified storage conditions and significantly assisted energy engineering to make energy storage easier. Although sandwich panels have been introduced to the world of industry for several decades, nothing has yet been able to replace this construction product in principle. The advancement of science and knowledge, instead of obsolete this product and replacing it with something new, came to its aid and made it more optimized every day. Production and design engineers came up with new ideas every day to improve the quality of sandwich panels, and the collaboration of mechanical design engineers and chemical engineers always kept this product alive and dynamic.
The sandwich panel consists of two or three elemental combinations, but in general, the performance of the product in each case is similar to each other.
This structure consists of two levels of metal or non-metal (composite, fabric, paper, foil, etc.) and a volume of insulation (polystyrene – rock wool – glass wool – polyurethane).
Wall surfaces, which are generally metal (iron – Aluzinc – aluminum) are formed by roll forming machines to reach the required strength and accept the installation conditions together.
Different production methods and technological progress have created different categories in this product.
Types of sandwich panels:
A- Classification based on the base wall level:
1- Iron double sided sandwich panels
2. Sandwich panels on one side of iron and one side of non-iron
3. Sandwich panels on both sides of the composite
4- Aluminum surface sandwich panels
5- Acoustic sandwich panels
B- Classification based on insulation volume
1- Pu polyurethane sandwich panels
2. EPS polystyrene sandwich panels
3. xps sandwich panels
4- Rock wool sandwich panels
5- Fiberglass sandwich panels
6- Sandwich panels of shells and mineral materials
C- Classification based on the production process
1- Production of sandwich panels by manual method (Batch to Batch)
2- Production of sandwich panel by automatic method (Sandwich panel production line)
مقایسه انواع ساندویچ پنل با یکدیگر
امروز بهترین و مقرون به صرفه ترین نوع ساندویچ پنل ، محصولات تولیده شده با خطوط کانتینیوز یا اتوماتیک و فوم پلی اورتان است.
این محصول استقامت وضریب انتقال حرارت بسیار مناسبی دارد و هزینه تولید در این نوع خطوط تولید نسبت به مابقی خطوط به مراتب پایین تر و رقابتی تر است. در سایر خطوط تولید هزینه ها به سادگی قابل مدیریت نیست و نهایتاً شرایط رقابت پذیری در بازار سخت تراست. لذا توضیح دادن در خصوص محصولات دیگر (روشهای تولید دیگر) خیلی ضروری وبجا نیست.
The components of the Pooya Boresh sandwich panel production line are:
1- Sheet coil holder:
This machine usually requires 2 or 4 meters per production line. The capacity of each device is 10 to 15 tons and they work in the form of automatic charging.
One or two coil holders feed the lower production line and one or two coil holders feed the high production line.
2. Roll forming:
Depending on the type of customer order and product variety, a number of roll forming machines should be installed in the production line. If the line wants to produce ceiling and wall products, at least 3 roll forming machines should be installed in the production line.
3. Primary cutting systems
To angle or correct the edges of the sheet, between the coil holder and the roll forming, a percussion or rotating guillotine is usually placed. If the customer needs, two separate devices are installed for the top line and the bottom line.
4- Preheat
The formed sheet must pass through the bottom of the preheating cutting system to receive the initial heat to prepare the foam injection. Preheating systems operate in two ways: 1- Heating with electric element 2- Heating with fossil fuels such as city gas.
The temperature of the sheet before injecting the foam has a significant effect on the adhesion of the foam and increases the homogeneous volume (puff curing) and finally the density of the foam.
5- Foam injection machine
Polyurethane foam injection mechanisms in production lines are usually 2-part or 4-part. 4-component systems are more expensive and require more initial capital, but are instead more accurate and controllable.
These devices are able to inject foam materials consisting of isocyanate, polyol and gases such as R141B and catalyst with more controllable and precisely adjustable ratios.
6- Press or double bound
This is one of the most important and accurate parts of the product line. This machine is very influential in the quality and variety of the product.
The main and effective feature of this device is the effective length of the machine. This device is usually not made in less than 10 meters because the low lengths in this device have a very low efficiency and effectiveness. 3 factors in the production line determine the length of this machine 1- Technical specifications of foam and model of injection machine 2- Speed required by the customer for the production line (production capacity) 3- Geographical area and location of the production factory, our experts based on these 3 factors Will present to the customer.
7. The final cutting system
Cutting machines are made in 2 types; A – Cutting tape B – Disc cutting
The company has the ability to build both types of cutting systems, but the customer’s choice based on the benefits of each system causes the production line to be equipped with a disc or tape cutting system.
8- Cooling system
The cooling system has two main functions: 1- Moving the product from one side of the production line to the other (in halls with a length of less than 150 meters) 2- Giving time to the product for heat homogenization in the depth of foam and the product surface Makes a work agreeable in two numerical (butterfly) ways. Capacity of cooling systems is not a requirement of the production line, but in some grades of foam, lack of cooling and accelerated packaging may cause volume changes in the foam and the final product.
9- Stacker system
Stackers are used to stack and arrange production parts on top of each other. In cases where the ceiling product is on the production line, in addition to moving the product one by one, the stacker rotates the products so that they can be stacked more regularly and take up less space. Stackers are made in three types of hydraulic – pneumatic and mechanical with tow wire.
10- Packing:
This machine is the final station of production. We usually stack the panels up to a height of one meter and wrap them in nylon at this station. The cellophane operation is performed by the machine in such a way that the cellophane or nylon is wrapped in a spiral around the manufactured products.
