The classical way in the market is to make an A2 core sheet first and place it in between the aluminum sheets with a film adhesive
Our method is to extrude a melted A2 core compound with the help of necessary equipment similar to classical PE-based ACP production or similar to B1 class Flame Retardant ACP production.
Easy to produce with classical lines having Internal mixers.
Very fast production compared to the Core sheet method. The production rate is 2.3 meters per minute. For 1500mm width means 3.5m2 per minute.
No water absorbtion.No effect of rain. The classical Core sheet method has a big problem with water absorption.
High bonding strength..3 times higher than the classical Core Sheet method.
Bonding Strength remains the same after water aging, whilst the Core Sheet method loses all the bonding force after the water immersion test.
No dust during cutting the sheets.
Flexible when making 90ᵒ corners. No break of corners and sides.
2 Internal mixers (Some classical lines already work with Internal mixer – Banbury system.).This is the most critical thing.
Conical Feeder with a big hopper
All other equipments are the same as B1 or PE line
A suitable screw for extruder (The type and design of screw will be supported from outside)
A2 compound (in pellet form) is mixed with MDH with a good heating Internal mixer (Banbury). The temperature of the final compound must reach to 230ᵒC. For a 100 – 120L mixer the total time must be below 15 minutes. Then the melt is transferred to a transfer hopper (Left picture) which is then fastly transferred to the extruder hopper. The melt temperature is 230ᵒC. It can be up to 250ᵒC.
Transferring the melt compound to the mixer hopper which is accomplished with a conical feeder.
The melt is transferred to the hopper of the extruder which has a conical feeder under.
The conical feeder feeds the melt continuously to the extruder and also slowly mixes the melt in the hopper. It is recommended that the conical feeder is heated…It is an extra advantage if the big hopper is heat isolated.
The hopper capacity is around 3 mixers, which means around 350 L
Extruding the melt from a Tdie (Like a simple PE or FR core)
The melt is carried to T-die with the extruder. The extruded melt is adhered to the Aluminum coils using a hot melt adhesive.
The hotmelt adhesive is the same adhesive that is used for FR or PE-based ACP production. The screws of the extruder must be a special one in which the design will be supported from outside.
The recommended extruder temperatures are 160 – 170 – 185 – 195, and around 210 – 220C for the T-die. Some lines may need different conditions. We will support you technically during trials.
The extrusion speed is around 2.3m/min. For 1500mm width it means 3.5 m2 per minute. All other steps are the same as for PE core panels.
We guarantee the final ACP will be A2 class and will be certified easily from international Institutes.
The heat value of the final core compound is between 2.60 – 2.75 J which is the most critical test. If the core compound passes the test the final Panel easily passes because the Aluminum will also be considered in the calculation, which decreases the heat value.
We have proven references for certificate examples which are available upon request.
– Polyolefin Halogen-Free Flame Retardant Compound –
FR-063 doesn’t emit toxic gases or halogen gases as the compound of polyolefin resin and inorganic filler based on Mineral Hydroxide , and also shows the excellent flame retardant property and very low smoke property. In addition, FR 063 can be easily processed through the single extruder. Its mechanical property and adhesion with adhesive layer are well
MI (@ 190℃,2.16kg)
Flame retarding rating
Class 2 (Class 1 : No Burn)
UL 94 Rating (3mm)
Low temp brittleness
* Adhesion strength (T-Peel strength)
– Test specimen preparation : press molding at 190℃, 2ton –
Test speed : 50mm/min
Because FR 063- has hygroscopic nature due to inorganic flame retardant, it should not be left open. If it is left open for a few days, pre-drying is recommended for extrusion. FR 063 should be dried in a dehumidified dryer or vacuum oven for about 4hrs at 70~80℃. Exposure to high relative humidity should be avoided, since moisture pick up may cause lots of voids in the extruded product.
In case FR-063 is extruded with the extruder for PE, its production speed may be reduced due to higher torque. To increase production speed, motor capacity should be raised, or CR should be lowered. Factors such as screw RPM and temperature of barrel, adapter and die zone influence melt temperature. It is desirable to maintain a melt temperature in the below-recommended range to achieve the best extrusion quality. After the processing of FR compounds, remaining material in the extruder barrel should be thoroughly purged with polyethylene so as to prevent carbonization on the surface of screw barrel.
General extruder specification for ACP (Al Composite Panel) with PE core layer is as follows:
30 : 1 ~ 32 : 1
22 : 1 ~ 24 : 1
3 : 1 ~ 3.5 : 1
1.5 : 1 ~ 2.5 : 1
Dulmage or maddock
200 ~ 250kw
200 ~ 250kw
1. Temperature Setting Refer to FR 063 brochure for temperature setting
2. Die gap tuning and balancing First, Start the side extruder for glue resin, and then gradually increase screw RPM of main extruder within the permitted limit of extruder torque and set it. At this time, adjust screw RPM of side extruder adequately so that the glue layer can be coated uniformly on both side of FR 063 core layer. And then,
Observe the shape of sheet coming out from T-die.
a) Sheet flow coming out from T-die may be unbalanced like the following cases;
Screw C/R, Flight angle
T-die structure and contour
Evenness of ACP
Production roll contour
Inlet-outlet temp. of prod. roll
Thickness profile of glue layer
(Al and core)