Mineral wool sandwich panel PIR edge-sealing production system and production process

Abstract

The present invention relates to a mineral wool sandwich panel PIR edge-sealing production system and production process. The production system comprises a polyol component (white material) storage tank, a pentane storage tank, an in-line shear precision mixer, a buffer tank, an isocyanate component (black material) storage tank, and mixing heads. Due to the amount of material consumed for edge sealing is relatively small, a mixing effect between a polyester polyol and pentane is adversely affected, and thus a high fire-resistant edge-sealed sandwich panel cannot be produced. In this system, the feed flow rate is increased and a polyol component and pentane undergo shearing, compression, impingement, and dispersion within the mixer, thereby improving the mixing effect. Because the rate of the pre-mixed polyol blend consumed by the mixing heads is relatively low, and material discharged from the mixing heads cannot be interrupted, there is a mismatch between the output rate of the pre-mixed polyol blend and the rate of the pre-mixed polyol blend consumed by the mixing heads. To achieve flow balance between the two, a strategy where "high-flow pre-mixed polyol blend + intermittent feeding" match "low flow in the mixing heads + continuous discharge" is employed. An intermediate transfer buffer device temporarily stores the pre-mixed polyol blend, ensuring uninterrupted discharge of the mixing heads for continuous production. This approach successfully overcomes the major challenge of being unable to perform in-line mixing and foaming due to low flow rates of the polyester polyol and pentane.

Description

A PIR edge banding production system and process for mineral wool sandwich panels Technical Field

[0001] This invention relates to the field of sandwich panel technology, and in particular to a PIR edge banding production system and process for mineral wool sandwich panels. Background Technology

[0002] Currently, the industry is facing a major headache regarding polyurethane edge-sealing foam products for rock wool sandwich panels. Previously, 141B was used as the foaming agent, as it has relatively good miscibility with polyester. However, with the approaching deadline for the final ban on 141B under the UN Montreal Protocol (starting January 1, 2026), replacing 141B is an urgent priority. Current alternatives include: 1) Water foaming (prone to shrinkage and powdering, low strength requiring high foam density to compensate, which cannot meet the quality requirements of sandwich panels); 2) 245 foaming: 245 is not an environmentally friendly material, has a high greenhouse effect, and is also a material the UN plans to phase out. It can be used temporarily, but the price is extremely high (RMB 40,000 / ton), making it unaffordable, and almost no one uses this material; 3) LBA foaming agent, currently priced at RMB 60,000 / ton, with extremely high costs, and no company in the industry uses this material.

[0003] Currently, a more economical alternative is polyether + cyclopentane. This is barely feasible for production, but it cannot produce high flame-retardant PIR foam. It can only be used to make sandwich panels with a fire resistance rating of B3. Furthermore, because cyclopentane has a high boiling point and volatilizes at 49°C, the pressure in the closed-cell core of the sandwich panel exposed to the atmosphere decreases (outdoor air temperature is usually below 49°C). As a result, the sandwich panel is flattened by atmospheric pressure (the thickness of the sandwich panel will shrink significantly). In addition, polyether material itself has low strength, and the combined effect of these two factors will result in very severe shrinkage of the sandwich panel.

[0004] The polyurethane sealing of rock wool sandwich panels is on both sides, and the rock wool in the middle does not shrink. This causes the panel surface to be uneven and the sides to collapse, which seriously affects the quality of the wall. This problem cannot be solved in the industry at present.

[0005] In the building insulation sandwich panel industry, rock wool and glass wool sandwich panels are widely used as insulation and fireproof building materials. However, because mineral wool, as an inorganic material, easily absorbs water, the strength of the panel decreases significantly after water absorption, greatly reducing the insulation effect, shortening the lifespan of the core material, and accelerating the corrosion of the inner coating layer of the steel plate, thus shortening the overall lifespan of the sandwich panel. The industry typically uses polyurethane edge sealing on the sides of the sandwich panel to improve its strength and waterproof performance. While edge sealing solves the waterproofing problem, it introduces a serious drawback: it doesn't provide fire resistance. This leads to two safety hazards with rock wool polyurethane edge-sealed sandwich panels. The first is that when exposed to open flame, the polyurethane edge sealing joints can burn down, causing the wall to collapse immediately. For example, as shown in Figure 1, a fire occurred on November 5, 2024, at Changzhou Jintan Chaofeng Company. The polyurethane edge sealing part of their rock wool polyurethane edge-sealed sandwich panel was a foam composed of 141B and polyether, with a fire resistance rating of B. 3. When exposed to fire, the edge sealing is quickly burned away, failing to connect and support the sandwich panels, leading to wall collapse. The second type of fire occurs when sparks from welding or abrasive cutting ignite during construction. For example, Figure 2 shows a fire caused during the construction of a temporary subway station in Jinan. This fire involved edge sealing foam made of polyether and cyclopentane, with a fire rating of B3. This presents a serious safety and quality hazard because the foam edge sealing lacks flame retardant properties and will ignite upon contact with any open flame.

[0006] In the production of PIR polyurethane edge-sealed rock wool sandwich panels, polyester and pentane are two completely immiscible materials. Current market mixing processes involve using a reactor / tank mixing method. The working principle is to weigh the polyester and pentane according to a specific ratio, transport them to the reactor, and then use a rotating propeller in the center of the reactor to mix the materials. This mixing process does not involve rapid cutting, dispersion, or impact between the two materials; it is a macroscopic mixing process. Once mixing stops, stratification immediately occurs, and the hazardous chemical pentane will overflow from the mixture. Because pentane has a lower density than polyester, it will float on the polyester surface, creating a serious safety hazard and making it unsuitable for producing PIR edge-sealed sandwich panels. Currently, only polyether and cyclopentane can be mixed, which can barely meet the mixing requirements using a reactor. However, polyether cannot produce high flame-retardant PIR foam; it can only produce ordinary, non-fireproof edge-sealing foam.

[0007] It should be noted that the information disclosed in the background section above is only for enhancing the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0008] To address the unresolved technological challenges in the current industry, this invention discloses a PIR edge banding production system and process for mineral wool sandwich panels, aiming to solve the critical problem of the inability to mix polyester and pentane online in PIR polyurethane edge banding.

[0009] The technical solution adopted in this invention is as follows:

[0010] A PIR edge-sealing production system for mineral wool sandwich panels includes a white material storage tank, a pentane storage tank, an online cutting precision mixer, a transfer device, a black material storage tank, and a mixing head. The white material storage tank is connected to the first feed end of the online cutting precision mixer via a first pipeline, and a white material metering pump is installed on the first pipeline to supply white material to the online cutting precision mixer. The pentane storage tank is connected to the second feed end of the online cutting precision mixer via a second pipeline, and a pentane metering pump is installed on the second pipeline to supply pentane to the online cutting precision mixer. The online cutting precision mixer cuts and mixes the white material and pentane. A premixed white material is obtained. The discharge end of the online cutting precision mixer is connected to the transfer device, and the online cutting precision mixer outputs the premixed white material to the transfer device. The transfer device is connected to the mixing head through a third pipe. A premixed white material metering pump is installed on the third pipe. The premixed white material metering pump continuously supplies the premixed white material to the mixing head. The feed rate of the transfer device is greater than the discharge rate of the premixed white material metering pump. The black material storage tank is connected to the mixing head through a fourth pipe. A black material metering pump is installed on the fourth pipe. The black material metering pump continuously supplies the black material to the mixing head. The premixed white material and the black material collide and mix in the mixing head.

[0011] A further technical solution is that the online cutting precision mixer is a dynamic mixer, which performs dynamic high-shear mixing and emulsification. The dynamic mixer includes a motor, a housing, a fixed blade disposed in the housing, a rotating blade that cooperates with the fixed blade, a shaft connecting the rotating blade and the output end of the motor, and a mechanical seal sleeved on the outside of the shaft. The mechanical seal is sealed to the end face of the housing. When the white material and pentane flow into the flow channel between the fixed blade and the rotating blade through the pressure of the pump, the output of the motor causes the rotating blade to rotate at a high speed of 3 to 20 m / s. The 0.1 to 0.5 mm gap between the rotating blade and the fixed blade shears against each other. The two different liquid phases, white material and pentane, which repel each other, are instantly exploded, cut, dispersed, and impacted to reach nanoscale fine particles and then recombine to form a stable continuous liquid phase.

[0012] A further technical solution involves an online precision mixer that is a static mixer. This static mixer is tubular, with fixed cutting blades featuring a spiral at a specific angle inside. As the liquid flows, it is gradually cut and mixed by these blades. The spiral shape of the blades reduces resistance as the liquid passes through and causes rotational motion along the length of the tube, improving the mixing effect. The cutting blades are arranged such that the number increases from the inlet to the outlet, the pore size decreases, and the thickness decreases. These blades cut the white material and pentane into 2 and 4 streams respectively at the initial feed, resulting in thousands of streams of mixed liquid at the outlet, achieving the premixing process requirements for PIR foam. The diameter of the mixing tube is determined based on the flow rates of polyester and pentane, ensuring a flow velocity of at least 3 m / s within the tube. A flow velocity of at least 3 m / s for pentane and polyester, combined with impact with the blades, results in a well-mixed liquid. This mixture typically does not precipitate within 24 hours, fully meeting the requirements for PIR edge sealing and foaming production.

[0013] A further technical solution is that the transfer device is a storage tank with a volume of 5L to 20L. The inlet of the storage tank is connected to an online cutting precision mixer via a pipeline, and the outlet of the storage tank is connected to a premixed white material metering pump via a third pipeline. A liquid level sensor is installed inside the storage tank. The lower limit of the liquid level sensor is the start of replenishment, and the upper limit of the liquid level sensor is the stop of replenishment.

[0014] A further technical solution is that the transfer device includes a movable container, a conveying device, and a storage tank. The premixed white material output from the dynamic mixer is input into the movable container. The conveying device transports the movable container to a sandwich panel production line in another location and loads it into the storage tank. The storage tank is connected to a third pipeline. The capacity of the movable container is generally between 200 kg and 1 t. The premixed white material metering pump continuously transports the premixed white material in the storage tank to the mixing head through the third pipeline.

[0015] A further technical solution is that the ratio of white material to pentane input into the online cutting precision mixer is 100:, where the pentane is n-pentane, cyclopentane, cycloisopentane, or n-isopentane; the mixing head is a low-pressure spiral cutting blade mixing tube, and the compressed air pressure input into the mixing tube is 0.5 Bar to 7 Bar; the black material and premixed white material in the mixing tube rely on the rapid flow of gas to drive the mixed white material and black material to be rapidly cut by the spiral blade to achieve the process mixing requirements; the mixing head can also adopt high-pressure mixing, where the black material and premixed white material are pressurized by their respective high-pressure metering pumps and then input into the mixing head, and their respective high-pressure switching valves are opened simultaneously and instantaneously. In the mixing chamber of the mixing head, the two materials collide with each other under high pressure to achieve high-pressure mixing. The high-pressure collision pressure in the mixing tube is 100 to 150 Bar, and high-pressure mixing can achieve sufficient mixing and emulsification.

[0016] The PIR edge banding process for mineral wool sandwich panels includes the following steps:

[0017] To obtain the emulsified mixed liquid, a process of increasing the premixed white material + intermittent feeding = small flow rate of the mixing head + continuous discharge is adopted to achieve flow balance. The intermediate transfer and transition device buffers the premixed white material to solve the problem of uninterrupted discharge from the mixing head and achieve continuous production. This successfully overcomes the major problem that the polyester and pentane cannot be mixed and foamed online due to the small flow rate.

[0018] Feeding: The white material metering pump intermittently delivers the white material from the white material storage tank to the online cutting precision mixer, while the pentane metering pump intermittently delivers the pentane from the pentane storage tank to the online cutting precision mixer;

[0019] High-flow-rate premixing: The white material and pentane are cut and mixed by an online precision mixer to obtain premixed white material;

[0020] Premixed white material buffer: The transfer and transition device receives the premixed white material intermittently input from the online cutting precision mixer;

[0021] Small-flow continuous mixing in the mixing head: The premixed white material metering pump continuously delivers the premixed white material from the transfer and transition device to the white material chamber of the mixing head. The feed rate of the transfer and transition device is greater than the discharge rate of the premixed white material metering pump. The black material metering pump continuously delivers the black material from the black material storage tank to the black material chamber of the mixing head. The premixed white material and the black material enter the mixing chamber after passing through their respective feed chambers, collide, and then enter the mixing pipe for mixing to obtain PIR polyurethane edge-sealing foam.

[0022] A further technical solution is that the step of the transfer device receiving the premixed white material intermittently input from the online cutting precision mixer includes:

[0023] Simultaneously turn on the white material metering pump, pentane metering pump, and online cutting precision mixer to replenish the storage tank until the liquid level sensor detects that the liquid level of the premixed white material in the storage tank has risen to the upper limit position, and then turn them off at the same time to keep the supplied material ratio completely consistent.

[0024] The mixing head operates continuously, supplying material continuously. As the material in the storage tank is gradually consumed, the level sensor detects that the level of the premixed white material in the storage tank has dropped to the lower limit position and sends a replenishment signal. The white material metering pump, pentane metering pump, and online cutting precision mixer are simultaneously turned on again to replenish the storage tank, completing one cycle.

[0025] A further technical solution is that the step of the premixed white material metering pump conveying the premixed white material in the transfer transition device to the white material chamber of the mixing head includes:

[0026] The premixed white material metering pump delivers the premixed white material from the storage tank to the white material chamber of the mixing head through a third pipeline.

[0027] A further technical solution is that the step of the premixed white material metering pump conveying the premixed white material in the transfer transition device to the white material chamber of the mixing head includes:

[0028] The output of the dynamic mixer is premixed white material and loaded into a movable container;

[0029] The conveying device transfers the movable container to a sandwich panel production line in another location and loads it into a storage tank. The storage tank is connected to a third pipeline, and the premixed white material metering pump continuously transports the premixed white material in the storage tank to the mixing head through the third pipeline.

[0030] The beneficial effects of the embodiments of the present invention are as follows:

[0031] (I) The mineral wool sandwich panel PIR edge banding production system of the present invention includes a white material storage tank, a pentane storage tank, an online cutting precision mixer, a transfer and transition device, a black material storage tank, and a mixing head. Because the amount of edge banding material used is very small, it affects the mixing effect of polyester and pentane, making it impossible to produce high-refractory edge banding sandwich panels. The present invention uses a large flow rate to fully compress and impact-mix the white material and pentane, achieving the mixing process for PIR foaming. Because the amount of premixed white material used in the mixing head is relatively small, and the output of the mixing head cannot be interrupted during continuous foaming production, the output of premixed white material in the front section is different from the amount of premixed white material consumed by the final mixing head in the back section. To achieve a balance between the two, the premixed white material in the front section is supplied with a large flow rate and intermittently, while the material in the back section is continuously discharged with a small flow rate. The intermediate transfer and transition device plays a connecting role between the front and the back. After the PIR rock wool sandwich panel is sealed, the fire resistance of the sandwich panel is improved by two levels, directly from B1 to B3. This eliminates the serious safety accident of the sandwich panel being ignited during construction and causing a fire. In the event of a fire, the fire resistance time of the wall is longer, which buys more time for rescue, escape, and property recovery, and can significantly reduce the damage caused by the fire.

[0032] (ii) Furthermore, since pentane is a hazardous chemical, when pentane vapor leaks and mixes with air at a ratio of 1.5% to 78%, it will explode when it comes into contact with an open flame or a temperature above 800°C. Therefore, it is very important to limit the volatilization of pentane gas during production, which greatly improves the safety factor in the production process.

[0033] 2.1 Elimination of hazardous gases at the foaming site: The mixing process path one of the present invention: The online cutting precision mixer adopts a dynamic mixer. The rotating blade and the fixed blade shear each other at a rotation speed of 10-20m / s and a gap of 0.1-0.5mm. The two different phase liquids of white material and pentane are burst, cut, dispersed and impacted to reach nanoscale particles and then recombine to form a stable continuous phase emulsion. This allows the polyester nanoparticles to encapsulate pentane, and the fine pentane nanoparticles dissolve in the polyester. In this way, when the material discharged from the mixing head is exposed to the air and injected into the continuous moving cavity of the sheet, the pentane is not easy to overflow and there is almost no leakage.

[0034] The second mixing process path of this invention: The online cutting precision mixer adopts a static mixing tube process. The inner diameter of the mixing tube is selected as 10mm. After increasing the flow rate, the flow velocity of the mixture of white material and pentane through the static mixer increases accordingly. The impact velocity of the cutting blade set between the material and the mixing tube also increases accordingly. Generally, the fluid velocity and the impact force of the blade should reach more than 3m / s. This can obtain premixed white material that will not precipitate in a short period of time, ensuring that the production process is safe and that the polyester and pentane are fully mixed and mutually encapsulated, meeting the production process of PIR.

[0035] 2.2 Savings in Raw Material and Equipment Investment Costs: This not only ensures safety but also reduces pentane volatilization emissions, saving raw materials. In conventional reactor mixing processes, a significant amount of organic waste gas volatilizes after the mixture exits the mixing head. Environmental requirements necessitate treatment methods such as carbon adsorption, catalytic combustion, or RTO incineration, all requiring substantial investment. This invention significantly limits the volatilization of organic waste gas, greatly reducing the cost of organic waste gas treatment and equipment investment. Furthermore, the absence of raw material volatilization saves on raw materials.

[0036] 2.3 Due to the use of polyester raw materials, which have high functionality, the resulting PIR foam has high compressive strength and does not shrink. Since the core of the sandwich panel is mineral wool, it does not shrink. However, the edge sealing currently used in the market is PUR foam, which shrinks. This results in the rock wool section of the core material protruding in the cross-section of the sandwich panel, while the PUR edge sealing section collapses. Currently, this phenomenon cannot be resolved. This invention uses PIR foam, which has high strength and is not easily shrunk, resulting in a sandwich panel where the rock wool section and the PIR polyurethane edge sealing section are flat.

[0037] 2.4 Investment in foaming equipment: Generally, sandwich panel production lines are capable of producing PIR high-flow-rate polyurethane core materials. However, when producing polyurethane edge sealing for rock wool core materials, a separate set of foaming equipment (equipment for polyether systems) is required. With the adoption of this invention, this set of foaming equipment dedicated to edge sealing can be greatly reduced, requiring only the output pump set at the back end. The equipment at the front end can be shared with the original foaming machine, significantly saving on equipment investment.

[0038] 2.5 Raw Material Procurement: A typical production line can produce both PIR polyurethane sandwich panels and rock wool polyurethane edge-sealed sandwich panels. However, these two materials are different systems; the former is a PIR system, and the latter is a PUR system. Using this invention, sandwich panel manufacturers no longer need to purchase two different chemical materials; they only need to purchase polyester white material, which greatly simplifies management, procurement, and warehousing, saving internal costs.

[0039] 2.6 When the premixing head output of the front section and the mixing head output of the back section are produced separately in different locations, a transfer and transition device is used to connect the front and back sections. The premixing front section can be set up at the chemical raw material supplier, and the transfer and transition device can be distributed to multiple sandwich panel manufacturers in a centralized material supply method, which greatly reduces the equipment investment of sandwich panels.

[0040] (III) Furthermore, the transfer device is a storage tank. The premixed white material metering pump transports the premixed white material in the storage tank to the mixing head through a third pipeline, which can meet the online production needs of PIR polyurethane. The transfer device includes a movable container, a conveying device, and a storage tank. The discharge end of the dynamic mixer is loaded into the movable container. The conveying device transfers the movable container to a sandwich panel production line at another location and loads it into the storage tank. The storage tank is connected to the third pipeline. The premixed white material metering pump continuously transports the premixed white material in the storage tank to the mixing head through the third pipeline, which can meet the off-site production needs of PIR polyurethane. Attached Figure Description

[0041] Figure 1 is a schematic diagram showing the rapid collapse of a sandwich panel wall panel from a certain manufacturer after a fire.

[0042] Figure 2 is a schematic diagram showing a sandwich panel wall panel from a certain manufacturer being ignited by sparks from electric welding during construction.

[0043] Figure 3 is a schematic diagram of the PIR edge banding production system for mineral wool sandwich panels according to the first embodiment of the present invention.

[0044] Figure 4 is a schematic diagram of the PIR edge banding production system for mineral wool sandwich panels according to the third embodiment of the present invention.

[0045] Figure 5 shows a cross-sectional view of a 50mm thick sandwich panel.

[0046] Figure 6 shows a cross-sectional view of a 200mm thick sandwich panel.

[0047] Figure 7 shows the fire resistance test results of the PIR edge banding of the mineral wool sandwich panel of the present invention. Figure 7(a) is a schematic diagram of the combustion test of commercially available PUR polyurethane edge banding and the PIR polyurethane edge banding prepared according to the fourth embodiment of the present invention. Figure 7(b) is a schematic diagram of the combustion cessation of commercially available PUR polyurethane edge banding and the PIR polyurethane edge banding prepared according to the fourth embodiment of the present invention. The left side of Figure 7(c) shows a schematic diagram of the internal structure of commercially available PUR polyurethane edge banding after combustion, and the right side of Figure 7(c) shows a schematic diagram of the internal structure of the PIR polyurethane edge banding prepared according to the fourth embodiment of the present invention after combustion.

[0048] In the diagram: 1. White material storage tank; 11. First pipeline; 12. White material metering pump; 2. Pentane storage tank; 21. Second pipeline; 22. Pentane metering pump; 3. In-line cutting precision mixer; 4. Transfer device; 41. Third pipeline; 42. Premixed white material metering pump; 43. Liquid level sensor; 5. Black material storage tank; 51. Fourth pipeline; 52. Black material metering pump; 6. Mixing head; 61. Mixing pipe; 62. White material chamber; 63. Black material chamber; 7. Filter; 8. Heat exchanger. Detailed Implementation

[0049] The specific embodiments of the present invention will now be described with reference to the accompanying drawings.

[0050] To make the objectives, technical solutions, and advantages of this invention clearer, the device proposed by this invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The advantages and features of this invention will become clearer from the following description. It should be noted that the drawings are in a very simplified form and use non-precise proportions, only for the purpose of conveniently and clearly illustrating the embodiments of this invention. Please refer to the accompanying drawings to make the objectives, features, and advantages of this invention more apparent and understandable. It should be understood that the structures, proportions, sizes, etc., depicted in the accompanying drawings are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the implementation conditions of this invention. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportional relationships, or adjustments to the size, without affecting the effects and objectives achieved by this invention, should still fall within the scope of the technical content disclosed in this invention.

[0051] First embodiment:

[0052] This embodiment discloses a PIR edge banding production system for mineral wool sandwich panels.

[0053] As shown in Figure 3, the mineral wool sandwich panel PIR edge banding production system includes a white material storage tank 1, a pentane storage tank 2, an online cutting precision mixer 3, a transfer and transition device 4, a black material storage tank 5, and a mixing head 6.

[0054] The white material storage tank 1 is connected to the first feed end of the online cutting precision mixer 3 through the first pipe 11. The white material metering pump 12 is installed on the first pipe 11, and the white material metering pump 12 intermittently supplies white material to the online cutting precision mixer 3.

[0055] The pentane storage tank 2 is connected to the second feed end of the online cutting precision mixer 3 via the second pipeline 21. The second pipeline 21 is equipped with a pentane metering pump 22, which intermittently supplies pentane to the online cutting precision mixer 3.

[0056] The in-line precision mixer 3 cuts and mixes the white material with pentane to obtain a premixed white material. The discharge end of the in-line precision mixer 3 is connected to a transfer device 4. For example, the ratio of white material to pentane input into the in-line precision mixer 3 is 100:6 to 12, and the pentane is n-pentane, cyclopentane, cycloisopentane, or n-isopentane. The in-line precision mixer 3 is a dynamic mixer, such as an emulsion pump. The dynamic mixer includes a motor, a housing, a fixed blade housed within the housing, a rotating blade that cooperates with the fixed blade, a shaft connecting the rotating blade and the motor output, and a mechanical seal fitted on the outside of the shaft. The mechanical seal is sealed to the end face of the housing. When the white material and pentane flow into the flow channel between the fixed blade and the rotating blade under the pressure of the metering pump, the motor output causes the rotating blade to rotate at a high speed of 3 to 20 m / s. The 0.1 to 0.5 mm gap between the rotating blade and the fixed blade shears against each other. The two different liquid phases, white material and pentane, which repel each other, are instantly burst, cut, dispersed, and impacted to reach nanoscale fine particles before recombinating to form a stable continuous liquid phase.

[0057] The online precision mixer 3 outputs premixed white material to the transfer device 4. The transfer device 4 is connected to the mixing head 6 via a third pipe 41. A premixed white material metering pump 42 is installed on the third pipe 41, continuously supplying premixed white material to the mixing head 6. The feed rate of the transfer device 4 is greater than the discharge rate of the premixed white material metering pump 42. For example, the transfer device 4 is a storage tank with a volume of 5L to 20L, which increases to 200kg to 1t during off-site transfers. The feed end of the storage tank is connected to the online precision mixer 3 via a pipeline, and the discharge end is connected to the premixed white material metering pump 42 via the third pipe 41. A level sensor 43 is installed inside the storage tank to detect the upper and lower limits of the liquid level and control the feeding stop and feeding start of the white material metering pump 12, the pentane metering pump 22, and the online precision mixer 3, respectively. Of course, in other embodiments of the present invention, the balance between the feeding and discharging of premixed white material can also be achieved by setting the on-time and off-time, and the present invention does not impose further limitations on this.

[0058] The black material storage tank 5 is connected to the mixing head 6 via a fourth pipe 51. A black material metering pump 52 is installed on the fourth pipe 51, which continuously supplies black material to the mixing head 6. The premixed white material and the black material collide and mix in the mixing head 6. For example, the black material metering pump 52 continuously pumps the black material, and the feeding speed of the black material metering pump 52 is [missing information]. The mixing head 6 is a low-pressure spiral cutting blade mixing tube 61, and the pressure inside the mixing tube 61 is 0.5 Bar to 7 Bar. The black material and the premixed white material in the mixing tube 61 rely on gas flow to increase the impact force of the two materials and the spiral cutting blades in the mixing tube 61 to achieve cutting and mixing. In other embodiments of the present invention, the mixing head 6 can also adopt high-pressure mixing. After the black material and the premixed white material are pressurized by their respective high-pressure metering pumps, they are input into the mixing chamber of the mixing head 6 and collide with each other under high pressure to achieve high-pressure mixing. The high-pressure collision pressure inside the mixing tube 61 is 100 to 150 Bar, and high-pressure mixing can achieve sufficient mixing and emulsification.

[0059] In this embodiment, the mixing head 6 has four sets: a male-side mixing head 6, a female-side mixing head 6, and two corrugated crest mixing heads 6. The number of mixing heads 6 can be adjusted according to actual production needs.

[0060] Furthermore, filters 7 and heat exchangers 8 are respectively installed on the first pipe 11, the second pipe 21 and the fourth pipe 51. The filters 7 filter impurities in the white material, pentane and black material, and the heat exchangers 8 control the feed temperature of the white material, pentane and black material.

[0061] In this embodiment, the small amount of edge banding material affects the mixing effect of polyester and pentane, making it impossible to produce high-refractory edge-banded sandwich panels. This system uses a large flow rate to fully compress and impact-mix the white material and pentane to achieve the mixing process of PIR foaming. Since the amount of premixed white material used in mixing head 6 is relatively small, and the output of mixing head 6 cannot be interrupted during continuous foaming production, the output of premixed white material in the front section is different from the amount of premixed white material consumed by the final mixing head 6 in the back section. To achieve a balance between the two, the premixed white material in the front section is supplied with a large flow rate and intermittently, while the back section is supplied with a small flow rate and continuously. The intermediate transfer and transition device 4 plays a connecting role between the front and back sections.

[0062] Second embodiment:

[0063] Based on the first embodiment, the second embodiment further optimizes and refines the online cutting precision mixer 3 of the first embodiment.

[0064] The online precision mixer 3 is a static mixing tube. The static mixer is tubular, and a cutting blade with a certain angle spiral is fixedly installed inside the tube. When the liquid flows, it is gradually cut and mixed by the cutting blade. The cutting blade is in a fluid spiral shape to reduce the resistance when the liquid passes through and to make the liquid rotate during the movement along the length of the tube, thereby improving the mixing effect. The cutting blade is arranged so that the number of blades increases from the inlet to the outlet, the pores decrease from large to small, and the thickness decreases from thick to thin. The cutting blade cuts the white material and pentane into 2 and 4 strands at the beginning of the feeding, and then into thousands of strands of mixed liquid at the outlet to meet the premixing process requirements of PIR foam.

[0065] Third embodiment:

[0066] Based on the first embodiment, the third embodiment further optimizes and refines the transfer device of the first embodiment.

[0067] As shown in Figure 4, the transfer device 4 includes a movable container, a conveying device, and a storage tank. The premixed white material output from the dynamic mixer is input into the movable container. The conveying device transports the movable container to a sandwich panel production line in another location and loads it into the storage tank. The storage tank is connected to a third pipeline 41. The premixed white material metering pump 42 continuously transports the premixed white material in the storage tank to the mixing head 6 through the third pipeline 41.

[0068] For example, in this embodiment, a dynamic mixer is used to produce premixed white material. The conveying device can be a conveyor belt, AGV, truck, or tanker, etc. The movable container is filled with material through the live joint at the discharge end of the precision mixer 3 and conveyed through the live joint at the end of the third pipe 41.

[0069] Fourth embodiment:

[0070] This embodiment also discloses the production process of high flame-retardant PIR polyurethane edge sealing for rock wool and glass fiber sandwich panels, including the following steps:

[0071] Step S1, feeding: The white material metering pump 12 intermittently delivers the white material in the white material storage tank 1 to the online cutting precision mixer 3, while the pentane metering pump 22 intermittently delivers the pentane in the pentane storage tank 2 to the online cutting precision mixer 3.

[0072] Step S2, high-flow-rate premixing: the online cutting precision mixer 3 cuts and mixes the white material and pentane to obtain the premixed white material.

[0073] Step S3, Premixed White Material Buffer: The transfer device 4 receives the premixed white material intermittently input from the online cutting precision mixer 3.

[0074] Specifically, the step of receiving the premixed white material intermittently input from the online cutting precision mixer 3 by the transfer device 4 includes:

[0075] In step S31, the white material metering pump 12, the pentane metering pump 22, and the online cutting precision mixer 3 are turned on simultaneously to replenish the storage tank until the liquid level sensor 43 detects that the liquid level of the premixed white material in the storage tank has risen to the upper limit position, and then the pump is turned off, so as to keep the supplied material ratio completely consistent.

[0076] In step S32, the mixing head 6 operates continuously, supplying material continuously. As the material in the storage tank is gradually consumed, the liquid level sensor 43 detects that the liquid level of the premixed white material in the storage tank has dropped to the lower limit position. Then, the white material metering pump 12, the pentane metering pump 22, and the online cutting precision mixer 3 are simultaneously turned on to replenish the storage tank, completing one cycle.

[0077] Step S4, continuous mixing at low flow rate in mixing head 6: Premixed white material metering pump 42 continuously delivers premixed white material from transfer device 4 to white material chamber 62 of mixing head 6. The feed rate of transfer device 4 is greater than the discharge rate of premixed white material metering pump 42. Black material metering pump 52 continuously delivers black material from black material storage tank 5 to black material chamber 63 of mixing head 6. After the premixed white material and black material pass through their respective feed chambers, they merge into the mixing chamber and collide before entering the mixing pipe 61 for mixing, thus obtaining PIR polyurethane edge-sealing foam.

[0078] Specifically, the step of the premixed white material metering pump 42 conveying the premixed white material in the transfer device 4 to the white material chamber 62 of the mixing head 6 includes:

[0079] The premixed white material metering pump 42 transports the premixed white material in the storage tank to the white material chamber 62 of the mixing head 6 through the third pipeline 41.

[0080] In this embodiment, in order to obtain an emulsified mixed liquid, a process of increasing the premixed white material + intermittent feeding = small flow rate of mixing head 6 + continuous discharge is adopted to achieve flow balance. The intermediate transfer device 4 buffers the premixed white material to solve the problem of uninterrupted discharge of the mixing head and realize continuous production. This successfully overcomes the major problem that the polyester and pentane cannot be mixed and foamed online due to the small flow rate.

[0081] Fifth embodiment:

[0082] Based on the fourth embodiment, the fifth embodiment further optimizes and refines the transfer steps of the third embodiment.

[0083] The steps by which the premixed white material metering pump 42 conveys the premixed white material in the transfer device 4 to the white material chamber 62 of the mixing head 6 include:

[0084] Step S41: The premixed white material output from the dynamic mixer is loaded into a movable container.

[0085] In step S42, the conveying device transfers the movable container to the sandwich panel production line in another location and loads it into the storage tank. The storage tank is connected to the third pipeline 41, and the premixed white material metering pump 42 continuously conveys the premixed white material in the storage tank to the mixing head 6 through the third pipeline 41.

[0086] Sixth Embodiment

[0087] As shown in Figure 5, the production of 50mm thick sandwich panels is taken as an example.

[0088] The sandwich panel has male and female edges of the same size on both sides. The female edge sealing section is 0.0014 m². The production line speed is 8 m / min, and the material conveying speed is 0.0014 m² * 8 m / min = 0.0112 m / min. 3 / min, the total feeding rate is 0.0112m 3 / min×core material density 50kg / m 3 =0.56kg / min =560g / min.

[0089] The ratio of black pigment to premixed white pigment is 165:110. The feeding rate of black pigment = 560g / min * 165 ÷ (165 + 110) = 336g / min = 5.6g / s; the feeding rate of premixed white pigment = 560g / min * 110 ÷ (165 + 110) = 224g / min = 3.7g / s;

[0090] Since the amount of premixed white material used on the male and female sides of the sandwich panel is the same, the total feeding speed of the premixed white material for both male and female sides is 3.7g / s*2=7.4g / s.

[0091] A 20L storage tank is used. Feeding is initiated when the liquid level reaches 3L and stopped when the liquid level reaches 15L. Each feeding operation involves 12L × 1.1g / cm³. 3 =13200g.

[0092] 13200g ÷ 448g / min = 29.5min, meaning that feeding begins after 29.5min. Mixing head 6 consumes 7.4g / s * 45.5s = 340g per second. Each feeding amount is 13200g + 340g = 13540g. The actual feeding rate is 298g / s, and the feeding time is 13540g ÷ 298g / s = 45.5s, meaning each feeding session lasts 45.5 seconds.

[0093] Find the cutting speed of the premixed white material and the cutting blade of the static mixer:

[0094] If a mixing process is adopted where the premixing flow rate at the front end is the same as the consumption rate at the back end, the discharge rate of the premixed white material is 7.4 g / s, which translates to a volume of 7.4 g / s ÷ 1.1 g / cm³. 3 =6.73cm 3 / s=6730mm 3 / s. The diameter of the static mixing tube is 10mm, and the cutting speed is 6730mm / s. 3 / s÷(5mm 2 *3.14)=85.7mm / s. When pentane and polyester move at a speed of 85.7mm / s and the blades in the static mixing tube are cutting, there is almost no impact force, and it is impossible to obtain mixed emulsified premixed polyester white material. Thus, it is impossible to lay the foundation for the later production of PIR foam.

[0095] If the mixing process of this invention with increased flow rate is used, the discharge rate of the premixed white material is 298 g / s, which translates to a volume of 298 g / s ÷ 1.1 g / cm³. 3 =270cm 3 / s=270909mm 3 / s. The diameter of the static mixing tube is 10mm, and the cutting speed is 6730mm / s. 3 / s÷(5mm 2 *3.14)=3.45m / s.

[0096] In summary: Through high-flow-rate mixing, the discharge rate of the premixed white material is 298 g / s, and the cutting speed of the premixed white material with the cutting blade of the static mixer is 3.45 m / s. Without using a mixing process that increases the flow rate, the cutting speed of the premixed white material with the cutting blade of the static mixer is 85.7 mm / s.

[0097] Seventh Embodiment

[0098] As shown in Figure 6, the production of 200mm thick sandwich panels is taken as an example.

[0099] The sandwich panel has male and female edges of the same size on both sides. The female edge sealing section is 0.00645㎡. The production line speed is 4m / min, and the material conveying speed is 0.00645㎡ * 4m / min = 0.0258m. 3 / min, the total feeding rate is 0.0258m 3 / min×core material density 50kg / m 3 =1.29kg / min =1290g / min.

[0100] The ratio of black pigment to premixed white pigment is 165:110. The feeding rate of black pigment = 1290g / min * 165 ÷ (165 + 110) = 774g / min = 12.9g / s; the feeding rate of premixed white pigment = 1290g / min * 110 ÷ (165 + 110) = 516g / min = 8.6g / s;

[0101] Since the amount of premixed white material used on the male and female sides of the sandwich panel is the same, the total feeding speed of the premixed white material for both male and female sides is 8.6g / s*2=17.2g / s=1032g / min.

[0102] A 20L storage tank is used. Feeding is initiated when the liquid level reaches 3L and stopped when the liquid level reaches 15L. Each feeding operation involves 12L × 1.1g / cm³. 3 =13200g.

[0103] 13200g ÷ 1032g / min = 12.8min, meaning that feeding begins after 12.8min. Mixing head 6 consumes 17.2g / s * 45.5s = 783g per second. Each feeding amount is 13200g + 783g = 13983g. The actual feeding rate is 307g / s, and the feeding time is 13983g ÷ 307g / s = 45.5s, meaning each feeding session lasts 45.5 seconds.

[0104] Find the cutting speed of the premixed white material and the cutting blade of the static mixer:

[0105] If a mixing process with the same premixing flow rate at the front end and the same consumption rate at the back end is adopted, the discharge velocity of the premixed white material is 17.2 g / s, which translates to a volume of 17.2 g / s ÷ 1.1 g / cm³. 3 =15.63cm 3 / s=15636mm 3 / s. The diameter of the static mixing tube is 10mm, and the cutting speed is 15636mm. 3 / s÷(5mm 2 *3.14)=199mm / s.

[0106] If the mixing process of this invention with increased flow rate is adopted, the discharge rate of the premixed white material is 307 g / s, which translates to a volume of 307 g / s ÷ 1.1 g / cm³. 3 =279.09cm 3 / s=279090mm 3 / s. The diameter of the static mixing tube is 10mm, and the cutting speed is 279090mm. 3 / s÷(5mm 2 *3.14)=3.55m / s.

[0107] In summary: Through high-flow mixing, the discharge rate of the premixed white material is 307 g / s, and the cutting speed of the premixed white material and the cutting blade of the static mixer is 3.55 m / s.

[0108] Without using a mixing process that increases flow rate, the cutting speed of the premixed white material and the static mixer cutting blade is 199 mm / s.

[0109] Experimental example:

[0110] The premixed white and black isocyanates prepared in the fourth embodiment were mixed and injected into the side cavity of the sandwich panel for curing to form a PIR rigid foam edge seal. Commercially available PUR foam was purchased and injected into the side cavity of the sandwich panel for curing to form a PUR rigid foam edge seal. Fire resistance tests were conducted. A flame of 1200°C was held perpendicular to the panel surface at equal intervals, and both the PUR and PIR rigid foam edge seals of the sandwich panel were burned for 2 minutes. The test results are shown in Figure 7. In Figure 7(b), the PUR polyurethane edge seal on the right continued burning after the flame source was removed, while the PIR polyurethane edge seal on the left stopped burning immediately after the flame source was removed. In Figure 7(c), the interior of the PUR polyurethane edge seal on the left was completely carbonized, losing its supporting strength. In Figure 7(c), the PIR polyurethane edge seal on the right only had a small amount of carbonization on the outer surface, while the interior remained intact, still possessing supporting strength, indicating better fire resistance.

[0111] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0112] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A PIR edge banding production system for mineral wool sandwich panels, characterized in that, The production system includes a white material storage tank (1), a pentane storage tank (2), an online cutting precision mixer (3), a transfer device (4), a black material storage tank (5), and a mixing head (6); the white material storage tank (1) is connected to the first feed end of the online cutting precision mixer (3) through a first pipe (11), and a white material metering pump (12) is installed on the first pipe (11), which supplies white material to the online cutting precision mixer (3); the pentane storage tank (2) is connected to the second feed end of the online cutting precision mixer (3) through a second pipe (21), and a pentane metering pump (22) is installed on the second pipe (21), which supplies pentane to the online cutting precision mixer (3); the online cutting precision mixer (3) cuts and mixes the white material with pentane to obtain premixed white material. The discharge end of the online cutting precision mixer (3) is connected to the transfer transition device (4), and the online cutting precision mixer (3) outputs premixed white material to the transfer transition device (4); the transfer transition device (4) is connected to the mixing head (6) through a third pipe (41), and a premixed white material metering pump (42) is installed on the third pipe (41). The premixed white material metering pump (42) continuously delivers premixed white material to the mixing head (6), and the feeding speed of the transfer transition device (4) is greater than the discharge speed of the premixed white material metering pump (42); the black material storage tank (5) is connected to the mixing head (6) through a fourth pipe (51), and a black material metering pump (52) is installed on the fourth pipe (51). The black material metering pump (52) continuously delivers black material to the mixing head (6), and the premixed white material and black material collide and mix in the mixing head (6).

2. The mineral wool sandwich panel PIR edge banding production system according to claim 1, characterized in that: The online cutting precision mixer (3) is a dynamic mixer. The dynamic mixer performs dynamic high-shear mixing and emulsification. The dynamic mixer includes a motor, a housing, a fixed blade set in the housing, a rotating blade that cooperates with the fixed blade, a shaft connecting the rotating blade and the output end of the motor, and a mechanical seal sleeved on the outside of the shaft. The mechanical seal is sealed to the end face of the housing. When the white material and pentane flow into the flow channel between the fixed blade and the rotating blade through the pressure of the metering pump, the output of the motor causes the rotating blade to rotate at a high speed of 3 to 20 m / s. The gap of 0.1 to 0.5 mm between the rotating blade and the fixed blade shears each other. The two different liquid phases, white material and pentane, which repel each other, are burst, cut, dispersed, and impacted to reach nanoscale fine particles in an instant and then recombine to form a stable continuous liquid phase.

3. The mineral wool sandwich panel PIR edge banding production system according to claim 1, characterized in that: The online cutting precision mixer (3) is a static mixer. The static mixer is tubular, and a cutting blade with a certain angle spiral is fixedly installed inside the tube. When the liquid flows, it is continuously cut and mixed by the cutting blade. The cutting blade is in the shape of a fluid spiral to reduce the resistance when the liquid passes through and to make the liquid rotate during the linear movement along the length of the tube, thereby improving the mixing effect. The cutting blade is arranged so that the number of blades increases from the inlet to the outlet, the pores decrease from large to small, and the thickness decreases. The cutting blade cuts the white material and pentane into 2 and 4 strands from the beginning of the feed and into thousands or tens of thousands of strands of mixed liquid at the outlet to meet the premixing process requirements of PIR foam. The diameter of the mixing tube is determined according to the pump flow rate. The flow velocity in the tube must reach more than 3 m / s. When the flow velocity of pentane and polyester reaches more than 3 m / s and impacts the blade in the tube, a better mixture will be obtained. This mixture will not have any sedimentation within 24 hours, which can fully meet the requirements of PIR edge sealing foam production.

4. The mineral wool sandwich panel PIR edge banding production system according to any one of claims 1 to 3, characterized in that: The transfer device (4) is a storage tank with a volume of 5L to 20L. The inlet of the storage tank is connected to the online cutting precision mixer (3) through a pipeline. The outlet of the storage tank is connected to the premixed white material metering pump (42) through a third pipeline (41). A liquid level sensor (43) is installed inside the storage tank. The lower limit of the liquid level sensor (43) is the start of replenishment, and the upper limit of the liquid level sensor (43) is the stop of replenishment.

5. The mineral wool sandwich panel PIR edge banding production system according to claim 2, characterized in that: The transfer device (4) includes a movable container, a conveying device, and a storage tank. The premixed white material output by the dynamic mixer is input into the movable container. The conveying device transports the movable container to a sandwich panel production line in another location and loads it into the storage tank. The storage tank is connected to a third pipeline (41). The premixed white material metering pump (42) continuously transports the premixed white material in the storage tank to the mixing head (6) through the third pipeline (41).

6. The mineral wool sandwich panel PIR edge banding production system according to claim 1, characterized in that: The ratio of white material to pentane input into the online cutting precision mixer (3) is 100:(6-12), and the pentane is n-pentane, cyclopentane, cycloisopentane, or n-isopentane; the mixing head (6) is a low-pressure spiral cutting blade mixing tube (61), and the compressed air pressure input into the mixing tube (61) is 0.5 Bar to 7 Bar; the black material and premixed white material in the mixing tube (61) rely on the rapid flow of gas to drive the mixed white material and black material to be rapidly cut by the spiral blade to achieve the process mixing requirements; the mixing head (6) can also adopt high-pressure mixing. After the black material and premixed white material establish pressure through their respective high-pressure metering pumps, they are input into the mixing chamber of the mixing head (6). The two materials collide with each other under high pressure to achieve high-pressure mixing. The high-pressure collision pressure in the mixing tube (61) is 100-150 Bar. High-pressure mixing can fully achieve mixing and emulsification.

7. The PIR edge banding production process for mineral wool sandwich panels, characterized in that, Includes the following steps: To obtain emulsified mixed liquid, the process of increasing the premixed white material + intermittent feeding = mixing head (6) small flow rate + continuous discharge is adopted to achieve flow balance. The intermediate transfer device (4) buffers the premixed white material to solve the problem of uninterrupted discharge from the mixing head to achieve continuous production. This successfully overcomes the major problem that polyester and pentane cannot be mixed and foamed online due to their small flow rates. Feeding: The white material metering pump (12) intermittently transports the white material in the white material storage tank (1) to the online cutting precision mixer (3), while the pentane metering pump (22) intermittently transports the pentane in the pentane storage tank (2) to the online cutting precision mixer (3); High-flow-rate premixing: The online cutting precision mixer (3) cuts and mixes the white material and pentane to obtain the premixed white material; Premixed white material buffer: Transfer device (4) receives premixed white material intermittently input from online cutting precision mixer (3); Mixing head (6) for continuous mixing at low flow rate: The premixed white material metering pump (42) continuously transports the premixed white material in the transfer transition device (4) to the white material chamber (62) of the mixing head (6). The feeding speed of the transfer transition device (4) is greater than the discharge speed of the premixed white material metering pump (42). The black material metering pump (52) continuously transports the black material in the black material storage tank (5) to the black material chamber (63) of the mixing head (6). The premixed white material and the black material enter the mixing chamber after passing through their respective feeding chambers and collide before entering the mixing pipe (61) to mix, thus obtaining PIR polyurethane edge-sealing foam.

8. The PIR edge banding production process for mineral wool sandwich panels according to claim 7, characterized in that, The step of the transfer device (4) receiving the premixed white material intermittently input from the online cutting precision mixer (3) includes: Simultaneously turn on the white material metering pump (12), pentane metering pump (22) and online cutting precision mixer (3) to replenish the storage tank until the liquid level sensor (43) detects that the liquid level of the premixed white material in the storage tank has risen to the upper limit position, and then turn them off at the same time to keep the supplied material ratio completely consistent. The mixing head (61) works continuously, and the material in the storage tank is gradually consumed. After the liquid level sensor (43) detects that the liquid level of the premixed white material in the storage tank drops to the lower limit position, it sends a replenishment signal and simultaneously turns on the white material metering pump (12), pentane metering pump (22) and online cutting precision mixer (3) to replenish the storage tank, completing one cycle.

9. The PIR edge banding production process for mineral wool sandwich panels according to claim 7, characterized in that, The step of the premixed white material metering pump (42) conveying the premixed white material in the transfer device (4) to the white material chamber (62) of the mixing head (6) includes: The premixed white material metering pump (42) delivers the premixed white material in the storage tank to the white material chamber (62) of the mixing head (6) through the third pipeline (41).

10. The PIR edge-sealing production process for mineral wool sandwich panels according to claim 7, characterized in that, The step of the premixed white material metering pump (42) conveying the premixed white material in the transfer device (4) to the white material chamber (62) of the mixing head (6) includes: The output of the dynamic mixer is premixed white material and loaded into a movable container; The conveying device transfers the movable container to the sandwich panel production line in another location and loads it into the storage tank. The storage tank is connected to the third pipeline (41). The premixed white material metering pump (42) continuously conveys the premixed white material in the storage tank to the mixing head (6) through the third pipeline (41).

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