FRP Skin PU Foam Sandwich Panels
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High-performance thermal insulation composite panels
Composite sandwich panels made of FRP (glass fiber reinforced plastic, also known as GRP or GFRP) and rigid PU (polyurethane) foam are high-performance thermal insulation materials. They combine the lightweight and excellent thermal insulation properties of polyurethane foam with the waterproofness of FRP, making them a highly reliable material for building insulated boxes.
Product Features
Lightweight
PU foam is a typical low-density foam with a general density below 50kg/m³, usually around 35kg/m³ or lower. Therefore, polyurethane foam sandwich panels are thicker but lighter, making them very convenient to transport and install.
Excellent Thermal Insulation Performance
PU foam is recognized as an excellent thermal insulation material and is known for its low thermal conductivity among existing foam systems. Its thermal conductivity coefficient is between 0.022-0.024W/(m.k), which can effectively reduce heat conduction and keep the temperature within a reasonable range for a long time.
High Impact Resistance
Rigid FRP sheets offer impact resistance comparable to that of metal sheets, absorbing and dissipating impact energy.
Waterproof, moisture-proof and chemical-resistant
The FRP surface is crafted with a unique gel coating, creating a smooth, non-porous surface that completely blocks moisture absorption. This makes it difficult for stains (such as dust, oil, and fingerprints) to penetrate and adhere. Regular dust can be removed by rinsing with clean water or wiping with a damp cloth. Stubborn stains can be quickly removed with a mild detergent.
Schematic Diagram
Specifications
| Facing | Gelcoat FRP sheet. (Thickness: 0.7-5.0mm) |
| Surface Treatment | Glossy, matte, embossed, etc. |
| Surface Color | RAL series. |
| Core | PU (Polyurethane) foam. (Density: 28-50kg/m³) |
| Composite Method | Unsaturated polyester adhesive, polyurethane adhesive, etc. |
| Thickness | 10-150mm |
| Length | ≤12000mm |
| Width | ≤3200mm |
| Additional Layers | Plywood, energy-absorbing layer, etc. |
| Frame Materials | Timbers, fiberglass profiles, aluminum profiles, sheet metal, etc. |
| Working Temperature | -40°C to 80°C |
PU Foam Core
- Density: 28-50kg/m³.
- Thermal conductivity: ≤0.024W/(m.k).
- Bonding strength: ≥100kPa.
- Rate of dimensional change(70ºCx48h): 1mm.
- Compressive strength: ≥160kPa.
- Tensile strength: ≥205kPa.
- Elongation at break: ≥10%.
- Porosity by closed pore: ≥92%.
- Water absorption: ≤3%.
- Water vapor permeability; ≤5Hg/(Pa.m.s).
- Anti-permeability(1000mmx24h)(1000mm water column X24h hydrostatic pressure): ≤5mm.
FRP Facing
Flat FRP panel is a high-strength material made of glass fiber and resin matrix through a composite process. It has excellent characteristics such as light weight, high strength, corrosion resistance and aging resistance. The surface of FRP can be processed into different colors and textures to meet the aesthetic and practical needs of different application fields.
How to Improve the Strength of PU Foam Sandwich Panels?
We know that PU foam is fragile and easily damaged. Relying solely on it as the core material for sandwich panels is insufficient to withstand higher strength challenges or meet the demands of diverse applications. Increasing the thickness of the foam core and skin to enhance structural strength is impractical. A common approach is to add a “skeleton” to the foam core. The unique feature of PU foam sandwich panels is that this “skeleton” is made of non-metallic, low-thermal-conductivity materials, such as waterproof wood and composite profiles. This ensures structural strength while also avoiding heat transfer issues.
Applications
FRP skin PU foam sandwich panels are used as wall panels, partition walls, and roof panels for various insulation facilities, such as:
- Refrigerated trucks.
- Refrigerated trailers.
- Recreational campers.
- Medical ambulances.
- Poultry transport trucks.
- Day-old chicken transport trucks.
- Refrigerated containers.
- Prefabricated homes.
- Temporary shelters.
- Cooling towers.
- Clean rooms.
- Industrial equipment insulation rooms, etc.
Production and Processing
We are the leading FRP sandwich panel manufacturer in China, providing building solutions for thermal insulation boxes. Our factory is equipped with industry-leading composite panel production lines with unique production processes to meet users’ high standards of quality demands. The size of the composite panel can reach 12mx3.2m. (The current maximum size of the container is 40 feet (12.03 meters)
- Weather-resistant FRP panels are resistant to sunlight and high-salt environments. They resist discoloration, fading, and chalking in outdoor environments for extended periods, and offer a service life of up to ten years.
- The foamed polyurethane foam is machined into uniform sizes.
- The strong adhesive is non-toxic, odorless and harmless to the human body.
- Unlike spray foam sandwich panels, our foam-core sandwich panels utilize an advanced one-piece composite panel process. These composite panels are bonded using adhesives and then formed in a high-pressure press, resulting in panels with superior surface flatness and bond strength.
- High-precision CNC processing meet any personalized design needs and maintain the consistency of product precision.
- The packaging is waterproof, fireproof, impact-resistant, drop-proof, and crush-resistant.
- Maximize container space utilization to reduce transportation costs.
- Equipped with unloading equipment to reduce operational difficulties during unloading.
We also supply FRP sandwich panels with XPS (Extruded Polystyrene), PET (Polyethylene Terephthalate), and PVC (Polyvinyl Chloride) foam cores. Please consult us for more information about our products.
