3-layer board
Innovative multilayer board with PIR core
with improved physical characteristics
3-layer board
The panel was created as part of the project 'R&D work on the development of WPW sandwich panel and core production technology' under Action 1.1 R&D projects of enterprises Sub-measure 1.1.1 Industrial research and development work carried out by enterprises of the Operational Programme Intelligent Development 2014-2020, co-financed by the European Regional Development Fund.
The aim of the project was to create an innovative multilayer board with unique mechanical properties, ready to meet even the highest demands of our customers.
Results of industrial research
As part of the ongoing project "R&D work on the development of a WPW sandwich panel and core technology", numerical tests using the finite element method were carried out for single-layer panels and simulation models corresponding to the designed three-layer panels were created, which showed that the introduction of additional layers with improved mechanical parameters would significantly improve the behaviour of the panel under load. The results of the numerical tests carried out provisionally confirmed the validity of implementing an innovative multilayer PIR core panel with improved physical parameters.
In the next stage of the research, optimum foam formulations were tested in the laboratory using a Foamat device, which met the established requirements for mechanical properties. The process times (i.e. rise time, gel time and dry face), the foam growth profile (i.e. growth speed over time, growth pressure) were determined during foam growth. On the basis of the analysis of the results obtained and the visual assessment, formulations meeting the criteria previously set were selected.
Once the formulations had been selected, suitable PIR foam samples were prepared using a high-pressure device, and the density, compressive strength, Young's modulus, tensile strength, thermal conductivity coefficient and adhesion to the cladding were tested. The results obtained indicated an improvement in the strength of the foams, which was found to be consistent with the results of the numerical tests carried out previously.
In the next step, assumptions were made and the relevant operating parameters of the dosing threads of the production line were determined for the individual layers of the three-layer board. Using 3D printing methods, a number of different mixing elements were designed and tested as part of the mixing system. As a result, a prototype of the proprietary mixing system was constructed, taking into account the existing relationships between the properties of the polyurethane foam and the cellular structure of the core.
Due to the challenges associated with dispensing the three layers, prototype spouts were designed and manufactured separately for each layer using 3D printing technology. Using the finished prototype mixing and dispensing system, samples were made and tested for mechanical properties and thermal conductivity in the laboratory. Mechanical tests carried out showed an improvement in the mechanical parameters of the obtained polyurethane foams consisting of three layers with respect to the reference values.
As a result of industrial research, a completely new, proprietary mixing and pouring section has been developed, which is currently being implemented on one of our polyurethane-core panel production lines. In the near future, we will present the finished product - a sandwich panel with a three-layer core.
