What is Polyurethane Sheet
Polyurethane sheets are normally used to insulate buildings and are now becoming increasingly popular in construction. Due to their unique chemical composition, they have an unmatched low weight to strength ratio.
Polyurethanes, also known as polycarbamates are polymers that are made up of repeating units called monomers. They are long-chain molecules with attached side-groups. They belong to Carbamate groups known as -NHCO2 in their molecular structure.
How is Polyurethane Sheet Made
Polyurethane sheets are produced when polyols and diisocyanates in a strict ratio of 1:2 are made to react together. Polyols and Diisocyanates are both derived from crude oil, though polyols may also be derived from natural oils from renewable sources. The Diisocynate used in the production of Polyurethane is Toluene Diisocyanate (TDI).
The whole production process is computer controlled. In the start of the production line the polyols, diisocyanates, pigments and other additives are mixed together in the mixing head. They are kept in liquid forms with the help of agitators in the tanks. After this the reacting ingredients are pushed into pipelines, they pass via a heat exchanger. The temperature is adjusted to the reactive level by the exchanger. The polymerization reaction takes place inside the pipes. The polyurethane has already formed by the time the polymerizing liquid reaches the end of the pipe. A dispensing head for the polymer is located on the end of the pipe. The polymer is then poured on to a rolling conveyor belt where it starts to foam.
The polymer is passed over a baking paper and as the polymer is dispensed it keeps on rising like foam, after the expansion a second layer of paper is passed on the polymer. The paper gives it the shape of sheets. The rising foam forms a block along the conveyor belt. As the polymer travels to the end of the production lines it dries. In the end the sheets are cut with an automatic saw in the length or shape required. Normally a block is cut into sections of 120 meters in length and is then cooled for up to 24 hours before transporting to storage houses. In storage houses the foam is cut in to customized shapes.
These sheets are manufactured using several other methods including compression moulding, open casting, and centrifugal casting.
Polyurethane foam can be transformed into a variety of products using high precision cutting equipment the foam can be cut from the shape of blocks into 120-meter-long sheets that are as thin as 1mm. During the cutting process the sheets can also be combined with other materials like fiber glass, glass, steel, and graphite to give it added strength and load bearing qualities.
With variation in density, hardness and resilience polyurethane can be used to make materials as soft as kitchen sponges or mattresses. Polyurethane sheets can be made into any desired products depending upon the art of production. All through the production process the foam is tested for its conformity to requirements.
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