PANEL PRODUCTION

MOTULAB

The production cycle we have proposed for the realization of this type of panel foresees the use of machine presses built with materials which can easily be found, such as sheet-metal, chipboards, marine plywood, etc., that when put together, enable its creation.

Step 1 . machine presses creation

Fig.1

MOTULAB

Fig.2-3 Different kind of machin presses

MOTULAB

The next step in creating the panels is choosing the panel skin. These are cut to size and set down on the press base.

Step 2 . skins

Fig.4

MOTULAB

Fig. Examples of possible skins

MOTULAB

At the same time, a mix of recycled materials and polyurethane is prepared according to the technical characteristics previously established. Whether the two products are mixed together using sifters, other machinery or simply by hand within the mould itself, the same result will be obtained.

Step 3 . mixture

Fig.5

MOTULAB

Fig.6 Sifter at work for creating mixture

MOTULAB

The mixture is then transferred onto the panel skin, previously placed onto the press base, and is carefully spread as uniformly as possible over the available surface. The closing panel skin is then placed and the top press is lowered and clamped down.

Step 4 . panel assembly Fig.7

MOTULAB

The closing panel skin is then placed and the top press is lowered (fig.8) and clamped down(fig.9)

Step 5 . closure

Fig.8

Fig.9

MOTULAB

The polymerization of polyurethane varies according to quantity but doesn’t generally exceed a few minutes. Once the materials are dry, the clamps are removed and the panel extracted.

Step 6 . Final extraction

Fig.10

MOTULAB

The density of the mixture (polyurethane and recycled materials) varies based on the mechanical characteristics needed. These characteristics are limited to and depend on the natural properties of the base materials used (well-know for polyurethane, variable for the recycled materials). In producing these panels using our production cycle, it is vital to know the end-user’s purpose.

Some considerations

MOTULAB

Our methods allow for the variation of the mechanical characteristics by simply modifying the ratios of the mixture used and the type of panel skin chosen which can guarantee better mechanical characteristics and better fire resistance while the equipment remains identical.

Some considerations

Fig.11

MOTULAB

Experimental Panels produced for Acciona Group cost

• Skins Aluminum : 3,50 €/kg• Recycled materials : 0,15 €/kg

• Polyurethane : 4,00 €/kg• Hourly labor cost : 25,00 €/h

For one panel 1500 x 1000 x 50 mm (as the example tested from Acciona),it has been used the following materials :

• Skins Aluminum : 8,00 kg (2 skins) /mq• Recycled materials : 18,00 kg / mq• Polyurethane : 4,50 kg / mq• Time : 20 minutes

Example of costs

MOTULAB

• The desired product can be made to fit specific needs. It is necessary that all partners involved do minimal market research to identify competitors;

• Polyurethane panels that are particularly fire resistant do not exist and this is where the panel skins play an integral role.

Conclusions