Continuous Manufacture of Metal Faced Sandwich Panels

General
Recommendations
The Continuous
Manufacture
of Metal Faced
Sandwich
Panels ...
... using the
Double-Belt
Process
Status: August 2012

Contents
Introduction Page 3
Delivering and Storing PU Intermediates Page 3
Discharging isocyanate from tankers Page 3
Discharging polyol from tankers Page 4
Storing PU and PIR intermediates Page 4
Facing Materials Page 5
Quality of inner and outer coatings Page 5
Cleanliness of facing materials Page 6
Corona treatment Page 6
Metallic sheet quality Page 7
Foaming Page 7
Processing parameters Page 7
Component dosing Page 7
Temperature control Page 10
Applying the reaction mixture Page 12
Nozzles Page 13
Application technology Page 13
Oscillation Page 14
Foaming process Page 15
Production parameters, operating

procedures and formulae Page 16
Effects of the individual

components on processing Page 17
Cooling, Subsequent Processing and Storing the Elements Page 19
General Recommendations »The Continuous Manufacture of Metalfaced Sandwich Panels ...«, (Status: August 2012) Page 2 of 20
Introduction
Metal-faced construction panels have been a popular
choice for many years, due to their low cost and their ease
and speed of assembly. The outstanding characteristics of
polyurethane (PUR) and polyisocyanurate (PIR) means that
they make up the largest proportion of thermal insulating
materials used in composite panel production. In contrast
to other thermal insulating materials, the auto-adhesive
qualities of PUR & PIR, enables a single step process to
achieve the necessary bond with the metallic facing mate-
rials. As well as the excellent thermal and mechanical
characteristics of the finished panels, the speed of produc-
tion cannot be achieved when other thermal insulators are
used as core material.
The following sections outline the most important steps

involved in the continuous production of sandwich panes
using Elastopor H PUR and Elastopir PIR rigid foams. If you
have questions that exceed the scope of this document,
please contact our technical service centers.
Delivering and Storing the Ingredients

The primary components, polyol and isocyanate, are deliv-
ered in bulk by road tanker or packaged in plastic IBCs.
Catalysts and other additives are delivered in plastic or
metal containers or flasks. It is important to note that PUR
and PIR intermediates are sensitive to high and low tem-
peratures (refer to the technical datasheets for the respec-
tive products), therefore the ideal storage temperature is
between 15 and 23 °C. It is essential that all PUR and PIR
precursor components are kept free of moisture.
Discharging isocyanate from tankers
All precursor components must be protected against water

ingress and/or exposure to moisture; however this is par-
ticularly important in the case of isocyanate as it reacts
with water to form carbon dioxide (CO2) and urea. The
latter is deposited as a solid and can lead to increased
maintenance costs and production down-times caused by
blockages in filters or nozzles. A range of measures are
available to prevent any intake of moisture while the
isocyanate is being discharged from the tanker and the
most important of these are described below:
The gas vapour recovery process:

Moisture intake is prevented by connecting a second hose
(balance line) in parallel to the one used to pump out the
isocyanate. This second hose allows the air in the storage
tank to be displaced, as the tank is filled, the displaced air
then returns to the road tanker, as it empties. This is a
closed system that prevents the entry of any moisture.
The procedure is emission free and is operated via the
discharge pump.
Dry air with a dew point below -20 °C:

This process prevents any condensation of water vapour in
the air during the discharge procedure, even in extremely
unfavourable atmospheric conditions. The discharge
process involves pressurising the tanker with dry air.
There are a variety of different methods for drying out
the air: refrigerators and adsorption driers provide more
consistent quality, while silica gel filters do not generally
provide sufficient drying capabilities and offer a limited
service life. Natural and synthetic zeolites, so called
molecular sieves, with a strong adsorption capacity, have
established as an alternative to silica gel filters in practice.
Nitrogen:
In this case, the tanker is pressurised using dry nitrogen
from pressurised gas cylinders and then discharged. If this
procedure is used, it is essential that the area around the
storage tank is adequately ventilated to prevent any risk of
asphyxiation caused by the accumulation of nitrogen.
Pressurised air generated using a compressor on the

road tanker must only be used for discharging purposes
in cases of extreme emergency and only if a functioning
silica-gel drier is available. Non-dried air from the
customer’s compressed-air ductwork system must not
be used.
The discharge hoses must also be checked. These generally

contain isocyanate residues, which can react with moisture
to form solid urea when the hoses are not in use and which
will then be flushed into the system the next time it is filled.
This can be avoided by sealing the hoses with closing caps
immediately after the discharging procedure is completed.
In practice it is impossible to guarantee 100% compliance

with the measures mentioned above due to a variety of
human as well as technical shortcomings, we recommend
that you install filters in the tanker’s output line, in the
output nozzle of the storage tank and ahead of the
isocyanate high-pressure machine pump.
Discharging polyol from tankers
The ingress of moisture must also be prevented when poly-

ol components are being discharged from road tankers, so
as to avoid problems during its subsequent processing into
PUR and PIR rigid foam. If a specific water content level in
the polyol component is exceeded as a result of improper
discharging and storage procedures, this may prevent its
further processing into PUR and PIR rigid foam and could
result in the loss of the entire product consignment.
Polyol components with a closed cup flash point below

55 °C due to the presence of flammable catalysts and
blowing agents must be dealt with separately. The instruc-
tions contained in the product information and safety data
sheets must be adhered to.
Storing PU and PIR intermediates
General information
Specific PUR and PIR intermediates may carry hazardous
substance markings. It is essential that the product
information and safety datasheets be adhered to as they
contain detailed regulations regarding the handling and
storage of the products.
Tank farms
If the polyol and isocyanate components are stored in bulk
storage farms, care must be taken to ensure that the com-
ponents are stored in tanks that are physically separated
from one another. In the event of a leakage by either
component the separation of the tanks, will prevent them
from mixing and triggering a chemical reaction.
The storage conditions must also be configured in such a

way as to avoid extreme temperatures and the ingress of
moisture. Equally important is the ventilation/blanketing of
the tanks, which must be carried out using only dried air
(dew point -40 °C) or another inert gas, to prevent the
ingress of moisture.
Details regarding the correct storage procedures and

conditions can be found in the technical datasheets and
safety datasheets of the respective products.
Storing drums and containers

Intermediates delivered in drums and containers must be
stored well sealed, in a location that is free of extreme
temperature fluctuations. In the case of hazardous
substances, it may also be necessary to provide adequate
ventilation and to earth the containers.
Instructions regarding the correct storage conditions and

procedures are contained in the product information and
safety data sheets for the respective products.
Facing materials
Quality of inner and outer coatings
The manufacture of high-quality PUR/PIR sandwich

elements requires the maximum level of surface contact
between the facing materials and the rigid foam core.
To ensure this contact, metallic sheet that has a backing

coat that is compatible with PUR and PIR rigid foams
should be used.
Investigations demonstrate that a migration of paint

ingredients from the front side to the back side can occur
with metallic-sheet. For this reason, attention should also
be paid to the quality of the front side coating during the
process of selecting metallic sheet. If these recommenda-
tions are ignored, the occurrence of bubbles and voids,
that is, small or large gas pockets between the rigid foam
and facing material may be unavoidable under certain
circumstances.
An overwhelming majority of metallic sheet suppliers are

aware of this problem and have developed coating systems
to cope with it. When ordering coils of metallic sheet, it is
therefore essential that you order inner and outer coats
that are suitable for processing with PUR and PIR rigid
foams.
Cleanliness of the facing materials
Even small quantities of contaminates such as silicones,

fats, oils, acrylates, release agents and other substances
can lead to an irreversible breakdown of the foam
structure. Since they neutralise the effect of the foam
stabilisers present in all PUR and PIR rigid foam systems,
the effect of these substances can vary from a slightly
coarse cellular structure right up to complete collapse of
the foam, depending on the extent to which the facing ma-
terial is contaminated.
Provided that the personnel involved are informed of these

issues, numerous production problems can be avoided
simply by ensuring that they carry out a visual check on
the metallic sheet and that they exercise caution when
handling release agents, fats and oils.
It is also important to mention that not all contamination on

the surface of the facing materials is visible to the naked
eye. Should you encounter serious difficulties in conjunc-
tion with the processing of a specific length of metallic
sheet, switching to a different coil will frequently remedy
the problem.
Corona treatment
The wettability, that is, the ability to wet the entire surface
with PUR and PIR rigid foam is largely determined by the
surface tension of the backing coat to be covered. If the
surface tension is too low, this leads to the formation of
bubbles in the finished sandwich panel.
In the last few years, the use of the physical blowing agent
pentane, together with the continuing reduction in apparent
density of the foam, has increased the requirements with
regard to the surface quality of the metallic sheet. Using
commonly available metallic sheet and foam densities,
it is almost impossible to process pentane-blown systems
without the help of corona pre-treatment of the metal
facing material.
The corona treatment is generally carried out directly after

the uncoiling station and is provided in various perform-
ance configurations, whereby a higher performance
generally produces better results. The number and the
cleanliness of the electrodes are also of critical importance
with regard to the effectiveness of the treatment. Corona
systems should be cleaned at least once a month to ensure
that they operate to their maximum capability.
The effectiveness of the corona treatment, that is, the

change in the surface tension, can be determined quickly
and cost-effectively with the help of special inks.
Metallic sheet quality
The mechanical properties of sandwich panels are

influenced by a range of factors including the quality of the
metallic sheet used. The demands placed on the metallic
sheet can vary according to the static and dynamic design
of the sandwich panels.
The degree of tension in the metallic sheet is the most

important factor affecting the interaction between the
metallic sheet and the foam during the manufacturing
process. If the metallic sheet is subjected to too much
tension, this can lead to significant problems in the
shaping and foaming processes. This can cause ripples
that cannot be compensated for by the foam and that
result in a low quality product. Similar problems arise if the
metallic sheet is incorrectly pre-tensioned.
Metallic sheets affected by these types of quality defects

should not be used in the production of sandwich panels and
a complaint should be sent to the relevant manufacturer.
Foaming
The quality of sandwich panels is determined to a certain
degree by the mechanical properties of the foam core.
The following sections explain how these properties are
affected by processing parameters specific to each system
during the manufacturing process and the effects of the
properties themselves. In addition, aspects of the applica-
tion of the reaction mixture and of the foaming process are
examined in more detail.
Processing parameters
Component dosing
The process of manufacturing polyurethane sandwich

elements, with either PUR or PIR rigid foam cores, requires
that the processing parameters that apply to the foams and
to the production systems are adhered to. The following sec-
tion examines the processing equipment in greater detail.
Polyurethane rigid foam is created by mixing the system

components according to a specified foaming formula.
High-pressure machines have established themselves as
the main type of processing machinery used in this area,
while low-pressure machines are used predominantly for
low output performance. In the high-pressure process, the
various components are brought together at high pressure
(100 to 200 bar) in the mixing nozzle where they mix with
one another due to the high level of kinetic energy. Low
Pressure machines (< 40 bar) mix the components utilising
a dynamic or static mixer.
One factor that both processes have in common is that

the accuracy of the dosing of individual components is
extremely important. The number of components used
during processing depends on the dosing technology used.
For example, in the simplest case, only two ingredients are
mixed (premixed polyol components including catalysts and
blowing agents along with the isocyanate component).
However, state-of-the-art applications involve processing
of four to five components in the case of PUR systems or
five to six in the case of PIR systems. Although the latter
requires greater investment in machinery, it offers the
advantage of being able to produce a wider range of
products, since the output performance of the individual
components as well as the formulation vary depending on
the panel strength.
Irrespective of how many components are dosed, the

output performance of the pump must be calibrated at
regular intervals. For this purpose, each component must
be gauged in litres, this is carried out using a stopwatch
and a weighing scale. Once a constant discharge rate has
been achieved, the relevant component is allowed to run
into a container for between 20 and 60 seconds, depend-
ing on the output performance. Care must be taken to
ensure that the corresponding working pressure matches
the processing conditions. The quantity collected is then
weighed and compared with the value displayed by the
mass flow or volume flow meter. In the case of volatile
blowing agents, a pressurized gas cylinder should be used
as a collection vessel. The safety requirements governing
the handling of flammable blowing agents (pentane,
solkane 365mfc, etc.) must be observed. The primary
components may not deviate by more than +/- 1 percent,
while the additives may not deviate by more than +/- 2
percent. If the deviation exceeds these values, the
correction value of the flow meter must be adjusted (if
necessary, the relevant information must be obtained from
the manufacturer) and the calibration procedure repeated.
Experience has shown that the dosing accuracy of

frequency-controlled hydromatic pumps is at its greatest if
the normal output of the pump is specified at 80 to 90 %
of the target value and the motor is working in the middle
to lower speed range.
In terms of foam quality, it is extremely important that the

flow quantities specified in the foam formulation comply
with the relevant tolerance ranges. Even if they are not
apparent during processing, deviations can lead to
problems later on in the sandwich panel.
In the case of multi-component systems, the additives

(catalyst(s), chemical and physical blowing agents) are
metered into the polyol flow. The precise point at which
this occurs depends on the design of the individual system.
Older systems are generally equipped with a dynamic mixer
ahead of the high-pressure polyol pump, into which the
additives mentioned above are fed and mixed with the
polyol. The advantage of this approach is that the pumps
used as dosing pumps are more cost-effective and less
susceptible to malfunctions. The disadvantage is the
significantly longer time taken for a change in the dosing
performance to manifest itself in the application of the
reaction mixture.
Better still is the ability to dose the individual components
in the high-pressure area ahead of the mixing nozzle,
whereby a downstream static mixer is used to ensure the
required mixture of polyol components. These systems
frequently incorporate an intermediate solution in which
the components are metered into the mixture both in the
low-pressure and the high-pressure areas.
As well as the additives described above, air is also

frequently metered into the polyol flow to aid nucleation in
the foaming process. Rigid foams produced in this way
have a finer cell structure and a more homogenous
mixture. Furthermore, the introduction of air prolongs the
service life of the injection rake (refer to the section
»Application technology«, page 13). The quantity of air
used depends on the required insulation thickness and is
set by the service personnel for each foaming formula.
In general, the principle applied here is »As much as
necessary, as little as possible«, since, along with the
positive characteristics described here, a higher air loading
can increase the susceptibility to void formation. With
regard to the technology used in the various systems, there
are three main procedures used to carry out air dosing.
In some systems, the air is metered into the low-pressure
polyol stream and mixed with the polyol. In a separate
design, the metered dosing is carried out using a mixing
cone with a downstream Allweiler pump. In recent years
high pressure concepts for air dosing have been devel-
oped. Highly compressed air is dosed in the high pressure
part of the polyol line and homogenised by means of a
static mixer. Compared to other air dosing methods this
setup allows higher concentration of air in the polyol blend
and a faster responding behavior of the line.
In all cases, the pressure of the air being metered into

the mixture must be at least 1 bar higher than the feed
pressure of the polyol into which the air is being dosed.
The working pressure of the relevant components is also

an important factor during processing. To enable the addi-
tives to be introduced into the polyol stream, irrespective
of whether dosing occurs in the low-pressure or high-pres-
sure areas, the pressures of the respective components
must be greater than the polyol pressure.
The pressures of the primary components (polyol mixture

and isocyanate) before they reach the nozzles have a direct
impact on the reaction behavior, mixture quality and cell
structure of the rigid foam. In practice, the working pres-
sures encountered in high-pressure systems range from
100 to 200 bar, in some cases even higher. In addition to
the nozzle type, nozzle size and the size of the mixing
nozzle, it is the required mixture quality of the foam that is
the decisive factor in determining the pressure to be used.
In general, an increase in pressure is associated with in-
creased kinetic energy when the isocyanate and polyol in-
gredients are combined in the mixing nozzle, which in turn
results in a more intense mixing process. At the same time,
the introduction of more energy causes increased heating
of the reaction mixture.
Temperature control
During the process of manufacturing PUR sandwich panels,

the influential variable of temperature affects not only the
reaction behaviour of the foam, but also influences the
working properties of the foam as well as the characteris-
tics of the finished panel. Therefore, temperature control
during the manufacturing process and later on when the
products are cooled down and stored is an extremely
important processing parameter.
Components
Heat exchangers are used in combination with water-

circulating temperature control units in order to maintain
the defined temperatures for the components. These
systems are integrated in the low-pressure stream of the
two primary components. Additives, which may be
introduced in the high-pressure stream, are not generally
subject to temperature control due to their low quantities.
Exceptions to this include the volatile blowing agents used
in some cases. The dosing of these blowing agents may be
problematic under certain conditions, on hot days in
particular. In these cases, an upstream cooler that cools
the blowing agent to 10 to 15 °C has proven to be
effective. The installation of high-pressure coolers in the
immediate vicinity of the mixing nozzle will guarantee de-
fined processing temperatures even on extremely hot days.
The temperature variable exerts a variety of influences on

the processing of the components. It determines the
reactivity of the reaction mixture. As the temperature rises,
so does the speed of reaction, with the result that the
processing times such as the start and curing times
specific to each type of foam are reduced. The catalyst
amount must be reduced as a necessary counter-measure,
although this has a negative impact on the curing process.
The temperature also affects the solubility of the physical
blowing agent used. In particular, excessive temperatures
can cause premature vaporisation of low-boiling blowing
agents, which in turn can lead to the formation of bubbles
in the foam. This phenomenon, which results in the
disturbance of the bow wave, causes defects in the foam.
The viscosity of each specific material is also dependent

on the temperature. Viscosity decreases as the tempera-
ture increases, i.e. the material becomes more fluid or
runny. Possible consequences include back-flow of the
reaction mixture under the injection rake as well as drifting
of the bow wave during the manufacture of thicker sand-
wich elements.
The component temperatures specified in the foaming

formulation have been worked out and optimised with
regard to the viscosity of the rigid foam system used and
the technical requirements of the relevant production
system and must be adhered to in accordance with
tolerance ranges.
Facing Materials
The upper and lower facing material is generally heated

by convection using heated air or by radiation. The most
important issue in both cases is to ensure that the
continuously fed metallic sheet is uniformly heated across
its entire width and that there is no significant temperature
difference between the edge and the middle of the sheet.
In the event of such a temperature difference, this has
direct consequences for the reaction behaviour of the
temperature-sensitive foam following the application of the
reaction mixture. The visible effect of this is the formation
of a non-uniform face of the foam in spite of the optimised
lay-down technique (refer to the section »Application
Technology, page 13«). Just as important as the tempera-
ture distribution across the width of the metallic sheet is
the constancy of the temperature applied. In the case of
radiant heating systems in particular, the temperature of
the metallic sheet frequently fluctuates for the first few
minutes after the system has been started up and before
the target value is achieved. This can frequently be
recognised by the fact that the face of the foam is drifting.
The temperature of the metallic sheet has consequences

for the susceptibility to undesirable defects. This applies in
particular to rigid foam systems in which a pentane-
blowing agent is used. Depending on its solubility in the
polyol and the length and temperature of the facing
material used, N-pentane with a boiling point of approxi-
mately 35 °C may vaporize too quickly. This leads to the
formation of large bubbles during the foaming process.
If the metallic sheet is removed, the underside of the
element no longer reveals the required smooth continuous
surface and displays areas of defects in the form of voids.
If the temperature of the facing material is too low, this

can lead to a reduction in the adhesion between the
metallic sheet and the foam. The ideal temperature
settings are specified by the service technicians in the
relevant processing formulae or are contained in the
production information for the foam system.
Double-Belt Systems
In practice, the sheet conveyor system is heated either

electrically or by convection, the latter being the most
commonly used option.
The polyurethane bonds with the facing materials in the

double-belt system and the control of temperature in this
curing section is instrumental in ensuring that this process
takes place. Depending on the foam system and blowing
agents in use, processing of PUR (Polyurethane) rigid foam
systems is carried out subject to a temperature range of
30 to 50 °C. Water-blown systems require the upper range
of this temperature window whereas systems that are
foamed using physical blowing agents such as n-pentane,
enovate 3000 or solkane 365mfc use the middle range.
R141b-blown systems can be processed at the lower end
of the temperature range. Refer to the product information
for the precise values.
In contrast to this, the processing of PIR (polyisocyanurate)
rigid foam systems requires a double-belt temperature of
approximately 60 °C. For both PU and for PIR systems, it
is very important that the lowest temperature achieved
(note – the temperature at the edge is frequently lower
than in the centre) corresponds at least to the value
specified in the foaming formula.
Cases where the lower of the two belts is advanced relative

to the upper belt, with the result that the reaction mixture
comes into contact with the higher temperature of the
double-belt earlier must also be taken into account. In
these systems, the temperature control for the underside
of the facing material must be adjusted accordingly.
Ambient temperature
State-of-the-art continuously running processing systems

include a wide range of options for controlling the temper-
ature of the liquid components. They guarantee consistent
processing conditions within a specific temperature range.
In addition to this, extreme conditions in the lower and
higher temperature range that can cause problems with
processing and product quality can easily be detected.
For this reason it is important to ensure a minimum tem-

perature of 18 °C and a maximum temperature of 28 °C in
the building where processing is carried out. If the temper-
ature falls below this range, the increased viscosity of the
primary components is the greatest technical obstacle to
the production process. Given the accompanying increase
in frictional force, the loss of pressure is so great that the
process of feeding in the primary components becomes
extremely difficult or impossible. Even if dosing is possible,
the foaming process usually suffers from a poorer mixture.
Furthermore, the amount of catalyst added has to be
increased in order to adhere to the specified processing
times (refer to the section »Foaming process«, page 16).
If the temperatures are too high, the amount of catalyst

added has to be reduced. In this case, the curing behaviour
of the foam and the contour stability of the finished
sandwich elements require particular attention.
The temperature conditions applicable for the cool-off

stage and for storage are dealt with separately in the
section »Cooling, Subsequent Processing and Storaging
the Elements«.
Applying the reaction mixture
The consistency of the process of applying or injecting the

reaction mixture and the quality of the reaction mixture
itself can affect the quality of the sandwich elements pro-
duced. They also affect the working properties of the rigid
foam system in equal measure. In order to shed additional
light on these issues, this section deals with the topics of
nozzles, application technology and oscillation.
Nozzles
The polyurethane reaction is initiated by the process of

combining and mixing the polyol and isocyanate compo-
nents in the mixing nozzle. As mentioned earlier, mixing in
the high-pressure procedure occurs as the jets of compo-
nents are fired at one another at high pressure. The
amount of pressure and the formation of the stream is
controlled by the nozzle and determined by the size of the
nozzle. Needle and membrane nozzles have been well
proven in practice. These nozzle types generally operate at
pressures of 100 to 200 bar. They both feature an internal
pin whose position controls the opening of the discharge
aperture. Once the foaming process is started, the internal
pin is forced backwards by the working pressure of the
hydromatic pumps, against the direction of the closure
force exerted on it (generated by spring assemblies or by
a hydraulic or pneumatic system) and the mouth of the
nozzle is thus opened. The component pressure is set us-
ing the position of the pin and the resulting size of the
nozzle clearance area. While the pressure can be changed
during a production run in the case of a hydraulic or
pneumatic nozzle adjustment system, it is much more
difficult to make adjustments using spring assemblies and
production may have to be halted to facilitate this. When
choosing the type of nozzle to be used, it is important to
bear in mind that the size of the nozzle must be adjusted
to match the output performance. If the nozzles chosen are
too large, the nozzle clearance area may produce a stream
that is too widely dispersed because the pin is only pushed
back very slightly and the aperture is not fully opened. In
the reverse case, a solid stream is produced but there is
no longer any scope to adjust the working pressure be-
cause the pin has been pushed as far back as possible.
You must therefore check the relevant performance ranges
with the manufacturer. To ensure a good mixture, it is
important to use the correct nozzle size for the respective
performance range. You should also ensure that the noz-
zles are cleaned at regular intervals, at the very least when
the working pressure starts to increase without any adjust-
ments being made to the nozzle pin or when the reaction
mixture has started to deteriorate. Even the smallest
residues deposited between the pin and the nozzle
clearance area will result in a change in the geometry
of the stream and to a poorer mixture.
Application technology
Over the last decade, various traverse technologies have

been developed to apply the reaction mixture to the lower
facing. Along with the objective of distributing the reaction
product evenly across the width of the facing material, free
of air pockets, the service life and the cost of cleaning
were two additional selection criteria. Casting rakes and
flow-jet nozzles have proved to be by far the most
commonly used systems in practice. While casting rakes
offer advantages in relation to the uniform application of
the foam, flow-jet nozzles offer a longer service life and
lower cleaning costs.
The following sections will deal with the casting rake in
more detail since it is the most popular form of application
technology in use in Europe. The term casting rake is
understood to refer to a tube, the entire length of which is
covered by a series of holes. The correct design of the
casting rake is determined by the internal diameter of the
tube, the number, size and interval between the holes as
well as the wall thickness of the tube. Sandwich manufac-
turers use casting rake geometries that have been
specially optimized for the various output performances
and element types. In addition to the various output
performances, the viscosity, reactivity and foaming
behaviour of the reaction mixture, the type of blowing
agent used as well as a range of factors specific to the
system and processing technology used all exert an
influence on the configuration of the casting rake, with
the result that there is no single standard formula that can
be used to determine the design of a casting rake.
In casting rakes whose tube and hole diameters remain

constant along their entire length, the speed at which the
reaction mixture is discharged through the holes decreases
along the row of holes.
The process whereby the holes start to close up can be

attributed to the fact that the discharge speed falls below
a specific value and the reaction mixture starts to
accumulate on exposed surface areas and starts to react.
The casting rake then starts to clog up. As one hole starts
to close up, the rate of flow through the remaining holes
increases.
Sometimes the reaction mixture spatters in the area around

the first holes as it hits the facing material. The overall
effect of the closing up of the casting rake is to reduce the
width and quality of the reaction mixture applied. In order
to guarantee application to the entire surface area, the
oscillation speed has to be increased.
The metering in of air has a beneficial effect on the

service life of the rake. Another consequence of using an
unsuitable casting rake is the deterioration in the mix
quality of the reaction mixture.
In addition to a shorter service life, the use of an

incorrectly designed casting rake can cause problems in
relation to processing and product quality such as a poor
quality of the mixture applied or injected, the inclusion of
air, the formation of bubbles and voids in the foam as well
as the increased formation of bubbles on the upper surface
of the element.
Oscillation
The uniform distribution of the reaction mixture across the

width of the element is achieved using an oscillating move-
ment of the mixing nozzle. This oscillation is pneumatically,
hydraulically or electrically actuated. The oscillation speed
can be adjusted according to the processing speed of the
equipment used. The latest application stations feature
oscillation programs that allow you to vary the speed of the
mixing nozzle across the width of the element. This allows
the application of greater quantities of material at the
various turning points to be minimized. The formation of
the bow wave and the uniform expansion of the reaction
mixture are significant factors that determine the formation
of bubbles and voids below the upper facing material. The
relationship can be explained as follows: if the foam starts
to expand unevenly due to non-uniform distribution across
the width of the element (more material is frequently
applied at the edges), it will meet the upper layer facing of
material earlier in these areas.
If, in addition to this, this expansion of the foam is very

wavy due to the uneven application of the reaction mixture,
the air above the foam in the middle may become trapped,
resulting in occlusions. In practice, slightly more material
should be applied in the centre so that the bow wave
displays a slightly sickle-shaped orientation to the band
opening, if viewed from above.
In some cases, an increased incidence of voids occurs

even without too much material having been applied to the
sides. The uniform expansion of the reaction mixture is
therefore also a significant factor. Options for influencing
this problem include selecting the correct casting rake and
the appropriate oscillation speed. The latter is dependent
on the speed of production and the length of the casting
rake. In practice, this is referred to as »simple double
overlapping« or »two-fold double overlapping« and the
terms are used to describe how often the casting rake
oscillates over reaction mixture that has already been
applied or injected. In the former case, the casting rake
passes over the entire width of the element twice and in
the latter case, four times. When setting the oscillation
speed, it is important to note that the number of cycles to
and fro per minute (a cycle to and fro is the distance
travelled by the mixing nozzle from one side to the other
and back again) should not exceed 60, since higher speeds
will result in more material being applied at the side areas
due to the abrupt change of direction and the inertia of the
reaction mixture. The type of overlapping that will deliver
the best results must be determined empirically. However,
you must select either simple or two-fold double overlap-
ping, as experience has shown that 1.5 double overlapping
delivers poor results with regard to the incidence of
bubbles and voids at the upper facing layer.
Static Poker
Some years ago BASF started the development of an alter-

native application technology, which has been introduced at
many sandwich panel producers. When compared to oscil-
lating application technologies the static poker offers a
variety of advantages: Foam lay-down is improved enhanc-
ing the quality and homogeneity, this leads to improved sur-
face quality of the sandwich panels. The improved surface
quality has the potential to reduce customer claims and
furthermore, decrease the thickness of the (metal)sheet in
certain cases. Improved mechanical properties of the
foamed PU core permit a noticeable decrease of the foam
density without deterioration of the foam properties.
As a rule it is possible to apply the static poker on lines
with an oscillation mixing head without huge investments.
Please check with our technical service department if and
under which circumstances it is possible to use the static
poker on your line.
Foaming process
Particular attention should be devoted to this section. As

mentioned above, the quality of a metal-faced composite
panel is largely determined by the rigid foam core inside.
In addition to the system-specific characteristics of the
rigid foam material used, over which the production
personnel have no influence, it is critically important that
the specified formula is strictly adhered to and that the
parameters governing the manufacturing process are
complied with.
Regular checks on all the parameters that apply to the

manufacturing process are an essential prerequisite in
guaranteeing the production of high-quality sandwich
elements, especially in the case of continuous production.
Sandwich elements, which normally display excellent
mechanical properties, can easily be rendered unsalable if
they are not properly manufactured.
Production parameters, operating procedures

and formulae
The relevant technical specifications relating to the

continuous production of sandwich elements are deter-
mined by the service technicians in consultation with the
software manufacturers and recorded on process run
sheets. These are specific to each product and ensure that
high-quality sandwich elements can be produced subject to
the specified manufacturing conditions being adhered to. In
addition to the total discharge and dosages of the
individual components, the process run sheets specifies
manufacturing-relevant parameters such as the curing and
contact times and the speed of the production belt.
Specifications regarding the temperature control of the
facing material, of the components and of the double-belt
systems are also included, as are instructions governing
the component pressures and the application techniques to
be used. Since we have already discussed the influence of
temperature and pressure on the foaming process, the
following sections deal with the manufacturing parameters
of curing and contact time in greater detail.
The string time indicates the time that passes from the
point at which the foam is mixed until it forms a foam
matrix (in practice, this is determined by repeatedly
sticking a rod into the foam until it pulls out threads), the
contact time refers to the period that elapses from the time
that the reaction mixture is applied to the time that it
reaches the upper facing layer. The adherence to these two
times, or in other words, the difference between both times
is extremely important and is frequently underestimated in
practice. To ensure that the element to be produced is
completely filled with foam, the contact time must always
be shorter than the string time. This requirement is taken
into account in virtually all cases, as this would otherwise
lead to panels that were not completely filled. Cases where
the contact time is significantly shorter than the string
time can frequently be attributed to a lack of understand-
ing of this issue, since the elements leave the production
line well filled, that is, they appear to be normal. However,
this is a misinterpretation. Even if an initial inspection does
not reveal any obvious flaws or defects, the mechanical
properties of the rigid foam when it is subjected to
pressure are significantly lower and its susceptibility
towards voids is increased. In extreme cases, this may
even result in the foam core starting to shrink within a
matter of days after production. The problem can usually
be easily detected by examining a cross-sectional area.
The finished elements may frequently display what are

referred to as pressure zones just above the lower layer of
facing material, which can be recognized by the darker
colour of the foam. Alternatively, the underside may be
affected by the formation of voids in the foam (the reaction
mixture has shifted). The string and contact time must be
recorded separately for each panel type. Adherence to the
specified string and contact times must be verified by a
system of regular checks.
If PIR systems are processed, BASF strongly recommends

the application of an adhesion promoter, that is applied on
the bottom sheet immediately before the application of the
liquid foam. In practice, a low pressure machine with a
static mixing head has proved to be more suitable for this
purpose. The distribution of the reaction mix is carried out
mostly by a rotating disc. Here it is essential to ensure a
sufficient wetting, especially close to the border areas of
the bottom sheet. BASF recommends to link the adhesion
promoter machine electronically to the control of the
double belt line in order to ensure maximum safety
regarding processing. Our service technicians will provide
advice on a suitable adhesion promoter and necessary
processing parameters.
Effects of the individual components on

Processing
The aim of this section is to outline the possible

consequences of changing the dosing quantities of the
individual components. It should be noted that only
fundamental interrelationships are addressed.
Assuming that you are using a 5-component system, the

personnel operating the production equipment can control
the content of three auxiliary components in addition to the
polyol and isocyanate. In the case of the manufacturing of
PU systems, these generally include a catalyst, an additive
(for example, a water-polyol mixture) and a physical
blowing agent (for example, n-pentane).
The content of polyol and isocyanate, that is, the mixing

ratio of the two ingredients relative to one another, is set
by the service technicians in such a way that a complete
conversion into polyurethane will result in a surplus of the
NCO groups of isocyanate. This is described by the
characteristic number, which specifies the ratio of the NCO
groups actually used compared with the NCO groups
theoretically required to ensure 100% conversion.
The characteristic number in PU systems (also referred to
as the index) is normally between 110 and 130. Variation
in the polyol or isocyanate discharge amount therefore
changes the characteristic number directly. In the case of
characteristic numbers lower than 100, cross-linking does
not occur to a sufficient degree and the foam can shrink.
Values significantly above 130 will cause the foam to be-
come more brittle because the excess isocyanate reacts to
form strongly cross-linked structures such as allophanates,
biurets or dimers. It should be noted at this point that
these products are also formed in the characteristic
number range between 110 and 130, however in lower
quantities. The characteristic number applicable to the
production of PIR foams is above 180. In this case, specific
catalysts are used to convert excess isocyanate into poly-
isocyanurate (where three isocyanate molecules react to
form one Isocyanurate molecule).
Changes to the catalyst content during the foaming

process, while all other conditions remain the same will
have an immediate effect on the speed of the reaction.
Increasing the proportion of the catalyst will shorten the
cream and string times, with the result that the foam
hardens faster. However, what appears at first to be a
desirable outcome can only be implemented to a limited
degree in practice. The shorter cream time results in
poorer pre-distribution due to the poorer flow characteris-
tics of the reaction mixture. Furthermore, the activation
process becomes more turbulent with the result that the
occurrence of bubbles and voids between the upper facing
layer and the foam may increase.
Conversely, if the dosage of catalyst is too low, it is the

hardening behaviour that is the first to suffer with the
result that the foam continues to expand significantly after
it has left the double-belt system. This subsequent
expansion can be so extensive that diagonal cracks may be
visible at the end of a section if it is cut in two.
As mentioned above, the sandwich panels remain for a

time in the double-belt system to allow the foam to harden
sufficiently so that the metal-faced composite panel retains
an adequate level of dimensional stability after it has
completely cooled down. As the thickness of the insulating
core increases, so does the necessary retention time in the
double-belt system and it must be specified for the
respective element type in accordance with the require-
ments of the processor.
Changes to the dosing of the blowing agent, irrespective of

whether it is a chemical or physical blowing agent, have a
direct impact on the speed of the production line. An
increase in the amount of blowing agent triggers an
increase in the speed of the manufacturing process and
vice versa. If more blowing agents are added to a foam
system, the expansion behaviour becomes more active,
that is, the bulk density of the foam is reduced for a given
input quantity. If the speed of the manufacturing process is
not adjusted in this context, then the contact time is
shortened, the bow wave migrates forward and the front of
the foam tends to shift. Faults on the lower and upper
sides can be expected. Furthermore, cracks may also
appear in the foam and the profile of mechanical charac-
teristics will degrade significantly. In contrast, the reverse
applies if the amount of blowing agent is reduced. The bow
wave retreats. If the speed of the production line remains
the same, this causes the contact and curing times to
converge, with the result that the sandwich element is no
longer completely filled. The effect of chemical blowing
agents is generally many times greater than that of
physical blowing agents. For this reason, larger dosing
fluctuations are problematic, especially in conjunction with
chemical blowing agents. The dosing instructions contained
in the formulation provided by the foam supplier must
always be adhered to.
Cooling, Subsequent Processing and Storing the Elements

The chemical synthesis of PUR and PIR rigid foams involves
the release of heat. Depending on the thickness of the rigid
foam core, temperatures of up to 180 °C may be measured
in the panel over an extended period. The outstanding heat
insulation properties of PUR and PIR rigid foams ensure
that the temperature reduction process takes place
extremely slowly, this means that the panels need to be
sufficiently cool before being sent for subsequent
processing, sorting and packaging. The duration of the
cooling phase is in an approximately quadratic relationship
to the thickness of the panels. Doubling the insulation
thickness will theoretically involve quadrupling the cooling
time.
The actual duration to be selected for the cooling period

depends on the quality requirement of the respective
manufacturer. For a panel with an insulating core measur-
ing 200 mm, BASF recommends a cooling duration of three
hours. The manufacturers of double-belt systems provide
upright coolers for cooling the elements.
After it has been cooled in the upright cooler, the foam has
reached a sufficient level of dimensional stability to allow
it to be sent for subsequent processing, for example,
milling. If the elements are stacked and packed too soon,
this can lead to an accumulation of heat within a package
that can cause damage to the sandwich panels.
Once the elements have cooled down in the upright cooler,

they should be stored for a further 20 hours at tempera-
tures above 15 °C, so that the rigid foam can cool off com-
pletely and stabilise. Only after this period of time is it
safe to store the elements outside at temperatures below
15 °C.
If the elements are subjected to a significant temperature

shock sooner than 24 hours following production, this can
cause deformation of the foam and of the sandwich panels.
®= Registered trademark of BASF GmbH
BASF Polyurethanes GmbH

The data contained in this publication is based on our current
European Business Management knowledge and experience. In view of the many factors that may
Insulation affect processing and application of our product, this data does
not relieve processors from carrying out their own investigations
Elastogranstraße 60 and tests; neither does this data imply any guarantee of certain
MA, 12-2539/12 GB
49448 Lemförde properties, or the suitability of the product for a specific purpo-
se. Any descriptions, drawings, photographs, data, proportions,
Germany weights etc. given herein may change without prior notice and
Telephone +49 (54 43) 12-27 21 do not constitute the agreed contractual quality of the product.
It is the responsibility of the recipient of our products to ensure
Telefax +49 (54 43) 12-20 14 that any proprietary rights and existing laws and legislation are
www.pu.BASF.de observed. (05/06)

Continuous Manufacture of Metal Faced Sandwich Panels

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Continuous Manufacture of Metal Faced Sandwich Panels

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General

Status: August 2012

Delivering and Storing PU Intermediates Page 3

Discharging isocyanate from tankers Page 3

Discharging polyol from tankers Page 4

Storing PU and PIR intermediates Page 4

Facing Materials Page 5

Quality of inner and outer coatings Page 5

Cleanliness of facing materials Page 6

Corona treatment Page 6

Metallic sheet quality Page 7

Processing parameters Page 7

Component dosing Page 7

Temperature control Page 10

Applying the reaction mixture Page 12

Application technology Page 13

Foaming process Page 15

Production parameters, operating

Effects of the individual

Cooling, Subsequent Processing and Storing the Elements Page 19

The following sections outline the most important steps

Delivering and Storing the Ingredients

Discharging isocyanate from tankers

All precursor components must be protected against water

The gas vapour recovery process:

Dry air with a dew point below -20 °C:

Pressurised air generated using a compressor on the

The discharge hoses must also be checked. These generally

In practice it is impossible to guarantee 100% compliance

Discharging polyol from tankers

The ingress of moisture must also be prevented when poly-

Polyol components with a closed cup flash point below

Storing PU and PIR intermediates

The storage conditions must also be configured in such a

Details regarding the correct storage procedures and

Storing drums and containers

Instructions regarding the correct storage conditions and

The manufacture of high-quality PUR/PIR sandwich

To ensure this contact, metallic sheet that has a backing

Investigations demonstrate that a migration of paint

An overwhelming majority of metallic sheet suppliers are

Even small quantities of contaminates such as silicones,

Provided that the personnel involved are informed of these

It is also important to mention that not all contamination on

The corona treatment is generally carried out directly after

The effectiveness of the corona treatment, that is, the

The mechanical properties of sandwich panels are

The degree of tension in the metallic sheet is the most

Metallic sheets affected by these types of quality defects

The process of manufacturing polyurethane sandwich

Polyurethane rigid foam is created by mixing the system

One factor that both processes have in common is that

Irrespective of how many components are dosed, the

Experience has shown that the dosing accuracy of

In terms of foam quality, it is extremely important that the

In the case of multi-component systems, the additives

As well as the additives described above, air is also

In all cases, the pressure of the air being metered into

The working pressure of the relevant components is also

The pressures of the primary components (polyol mixture

During the process of manufacturing PUR sandwich panels,

Heat exchangers are used in combination with water-

The temperature variable exerts a variety of influences on

The viscosity of each specific material is also dependent