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Equipment Positioning & Core Process Challenges
The continuous press dedicated for manufacturing fire-rated panels (also known as High-Pressure Laminates/HPL or Continuous Pressure Laminates/CPL) is a highly specialized piece of equipment uniquely engineered for extreme process requirements including high pressure, high temperature, multi-stage exhaust, and precision tension control. Compared to standard panelboard (e.g., OSB, MDF) continuous presses, its core challenges lie in:
1. Material Specificity: It processes multiple layers of decorative and kraft papers impregnated with melamine or phenolic resins, which generate significant volatile gases during curing.
2. Demanding Aesthetic & Physical Requirements: The finished product must possess perfect surface gloss/texture clarity,high wear and scratch resistance, excellent chemical resistance, and A-class (non-combustible) fire performance.
3. High-Pressure Demand: Unit pressure requirements, necessary to achieve the desired density and physical strength, are significantly higher than for standard panels.
Therefore, this equipment is not a simple modification of a standard continuous press but rather a complete solution optimized for HPL/CPL craft from its design philosophy down to every subsystem.
The production of fireproof board (taking High-Pressure Decorative Laminate, HPL, as an example) is a process where multiple layers of resin-impregnated paper are permanently bonded through polycondensation under high temperature and pressure. In a continuous flat press, this process is dynamic and continuous, primarily divided into the following stages:
Stage 1: Material Preparation and Lay-up
Multiple layers of paper (including decorative paper, overlay paper, and multiple layers of core kraft paper) that have been impregnated with melamine or phenolic resin and dried to a "semi-cured" state are precisely aligned and stacked according to the product structure, forming a "wet lay-up."
Stage 2: Entry and Initial Exhaust (Low-Pressure Zone)
The stacked lay-up is fed into the continuous flat press by the infeed conveyor, entering the wedge-shaped opening formed by two large endless steel belts.
Key Action: The pressure at the inlet is precisely controlled at a low level (e.g., 50-150 N/cm²). Simultaneously, a high-frequency micro-vibration device activates, creating tiny vibrations in the stack to help expel trapped air between the layers.
Purpose: To prevent air from being trapped inside the board, which could cause bubbles or "dry flower" defects.
Stage 3: Heating, Pressurization, and Main Exhaust (Reaction Zone/High-Pressure Zone)
The lay-up moves with the steel belts into the main heating and pressing zone of the press. This is the core of the entire process.
Heating: The upper and lower hot press plates efficiently transfer heat through the steel belts to the lay-up. The resin begins to melt and enters the active polycondensation reaction phase.
Synchronous Pressurization and Exhaust: Driven by the hydraulic system, the pressure gradually increases along the machine length to its peak (typically 800-1000 N/cm² or higher). Throughout this process, the vacuum exhaust system distributed along both sides of the press operates continuously, acting like "straws" to constantly suck out volatile gases (water vapor, formaldehyde, phenol from phenolic resin, etc.) released from the melting resin.
Result: Under extremely high temperature and pressure, the resin fully cures, and the paper fibers are tightly compacted, forming a dense, homogeneous, high-strength board. Continuous vacuum exhaust is the key to ensuring the fireproof board is free of bubbles, has high transparency, excellent electrical properties, and stability.
Stage 4: Pressure Holding for Curing and Cooling for Setting (Holding/Cooling Zone)
Pressure Holding: After passing the peak pressure zone, the pressure is maintained over a certain length to ensure complete resin reaction and dimensional stability of the board.
Cooling: In the rear section of the press, the temperature of the hot press plates decreases or switches to cooling plates, beginning the controlled cooling of the formed board. This is a critical step to prevent the board from developing internal stress, warping, or delamination after exiting due to rapid cooling.
Stage 5: Pressure Release and Continuous Board Exit
After sufficient cooling, the pressure gradually drops to zero, and the board is smoothly discharged from the end of the steel belts. What emerges is an endless, fully cured "strip" of fireproof board. Subsequently, an online cross-cut saw cuts it to set lengths, followed by sanding, trimming, and other processes to become the finished product.
Core Characteristic of the Production Process: "Continuous high-pressure lamination under dynamic exhaust." All process parameters (temperature profile, pressure profile, line speed, exhaust vacuum) must be precisely coordinated and controlled based on paper type, resin formula, and board thickness.
Core Working Principle
The working principle of a continuous flat press can be summarized as follows: Utilizing two endless, high-strength steel belts to clamp the mat material, continuously passing it through a long pressure chamber formed by multiple sets of heating plates (and cooling plates). Within the chamber, a hydraulic system applies immense pressure perpendicular to the board surface from outside the belts, while the heating plates provide the heat necessary for curing, enabling the material to complete the entire process of pressing, heating, curing, and cooling while in motion.
Simple Analogy: It is like an extremely long, horizontal "iron," but the "soleplate" (hot press plates) of the iron is stationary, while the "fabric" being ironed (the mat) is clamped and pulled through at a constant speed by the upper and lower "conveyor belts" (steel belts), being continuously heated and pressed into shape during passage.
Main Components
A continuous flat press dedicated for fireproof board production mainly consists of the following seven major systems:
1. Main Frame
Function: The skeleton of the entire equipment, bearing the full working pressure (up to thousands of tons).
Features: Made of a pre-stressed frame welded from high-quality steel plates in a box-type or column-type design, optimized through finite element analysis to ensure minimal deformation under extreme pressure, forming the foundation for uniform board thickness.
2. Steel Belt System - The "Flexible Mold" and Pressure Transfer Medium
Composition: Two parallel, endless high-strength alloy steel belts (or special stainless steel belts).
Function:
Acts as the pressure transfer medium, uniformly distributing the hydraulic cylinder pressure across the entire width of the mat.
Acts as the conveyor belt, clamping and pulling the mat continuously through the press.
Acts as an isolation layer, protecting the surface of the precision hot press plates from contamination, while its high surface finish directly determines the surface quality of the finished board.
Auxiliary Devices: Include drive rollers, tension rollers, steering systems, support rollers, cleaning and polishing devices to ensure stable, centered, and clean belt operation.
3. Heating and Pressure System - The "Source of Energy and Force"
Heating Plates: Made of special alloy steel with internal flow channels for high-temperature thermal oil (mainstream, for precise temperature control) or steam, providing heat for the process. Typically divided into dozens of independently controlled temperature zones along the length.
Hydraulic System: Consists of an oil tank, high-pressure pumps, servo valves, accumulators, and numerous working cylinders. The cylinders are distributed in groups, enabling zone-specific pressure control along the length and width of the press to create complex pressure profiles.
4. Exhaust System - The "Soul" of the Fireproof Board Press
Function: Specifically designed to extract volatile gases generated during the resin curing reaction.
Composition: Includes mechanical exhaust devices (micro-vibration mechanisms) at the press inlet, and vacuum exhaust pipes and powerful vacuum pump groups distributed along both sides of the press.
Principle: While the mat is being pressed but not yet completely sealed, the vacuum system continuously draws air from the mat edges, creating negative pressure to "pull" out internal gases.
5. Infeed and Outfeed System
Infeed End: Equipped with precision forming, alignment, and pre-pressing devices to ensure the multi-layer impregnated papers are fed flat, aligned, and wrinkle-free into the nip of the steel belts.
Outfeed End: Smoothly guides the cured and cooled continuous board strip out and conveys it to the subsequent cutting saw.
6. Control System - The "Brain"
Function: Utilizes an advanced DCS/PLC system, integrating thousands of monitoring points for temperature, pressure, speed, tension, exhaust vacuum, etc.
Role: Conducts fully automatic, closed-loop control of the entire machine based on preset "process recipes," adjusts parameters in real-time to ensure stable quality, and enables fault diagnosis, data logging, and recipe management.
7. Thermal Energy System and Environmental Interface
Thermal Energy Center: Provides heat source (possibly natural gas, electricity, or biomass) for the thermal oil heater or steam boiler.
Environmental Interface: The extracted exhaust gases (rich in VOCs) are directed to a downstream thermal oxidizer for high-temperature oxidation treatment before being discharged to meet stringent environmental regulations.
In summary, a continuous flat press dedicated for fireproof board production is a highly complex system integrating mechanical, hydraulic, thermal, vacuum, and automation technologies. Its core value lies in achieving precise control over the high pressure, high temperature, and exhaust requirements—traditionally associated with "batch" processes—through continuous production, thereby reaching levels of efficiency and quality unattainable by traditional multi-opening presses.
Produces High-Quality Class A Fire-Rated Panels
Exceptional Surface & Physical Properties
High Material Yield & Low Reject Rate
Production Flexibility & Efficiency
Environmental & Safety Compliance
Applicable Products: High-Pressure Decorative Laminates (HPL), Continuous Pressure Laminates (CPL)
Working Width: 1300mm, 1450mm, 1600mm, 1850mm (Standard industrial widths)
Design Line Speed: 5 - 25 meters/minute (Depending on panel thickness and resin type)
Maximum Working Pressure: 800 - 1200 N/cm²
Heating Method: Thermal Oil Heating (Mainstream, for precise control) or Electric Heating
Operating Temperature Range: 180°C - 230°C
Exhaust System: Multi-zone Controlled Vacuum Exhaust
Steel Belt Specification: High-strength Polished Stainless Steel Belt, Thickness 1.2 - 1.8mm
Control System: Fully Digital Integrated Control System based on Industrial PC
Power Supply: 3-Phase, 380-415V, 50Hz / 60Hz
For more information, welcome contact us, we will reply you quickly and offer working videos with you.
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
Equipment Positioning & Core Process Challenges
The continuous press dedicated for manufacturing fire-rated panels (also known as High-Pressure Laminates/HPL or Continuous Pressure Laminates/CPL) is a highly specialized piece of equipment uniquely engineered for extreme process requirements including high pressure, high temperature, multi-stage exhaust, and precision tension control. Compared to standard panelboard (e.g., OSB, MDF) continuous presses, its core challenges lie in:
1. Material Specificity: It processes multiple layers of decorative and kraft papers impregnated with melamine or phenolic resins, which generate significant volatile gases during curing.
2. Demanding Aesthetic & Physical Requirements: The finished product must possess perfect surface gloss/texture clarity,high wear and scratch resistance, excellent chemical resistance, and A-class (non-combustible) fire performance.
3. High-Pressure Demand: Unit pressure requirements, necessary to achieve the desired density and physical strength, are significantly higher than for standard panels.
Therefore, this equipment is not a simple modification of a standard continuous press but rather a complete solution optimized for HPL/CPL craft from its design philosophy down to every subsystem.
The production of fireproof board (taking High-Pressure Decorative Laminate, HPL, as an example) is a process where multiple layers of resin-impregnated paper are permanently bonded through polycondensation under high temperature and pressure. In a continuous flat press, this process is dynamic and continuous, primarily divided into the following stages:
Stage 1: Material Preparation and Lay-up
Multiple layers of paper (including decorative paper, overlay paper, and multiple layers of core kraft paper) that have been impregnated with melamine or phenolic resin and dried to a "semi-cured" state are precisely aligned and stacked according to the product structure, forming a "wet lay-up."
Stage 2: Entry and Initial Exhaust (Low-Pressure Zone)
The stacked lay-up is fed into the continuous flat press by the infeed conveyor, entering the wedge-shaped opening formed by two large endless steel belts.
Key Action: The pressure at the inlet is precisely controlled at a low level (e.g., 50-150 N/cm²). Simultaneously, a high-frequency micro-vibration device activates, creating tiny vibrations in the stack to help expel trapped air between the layers.
Purpose: To prevent air from being trapped inside the board, which could cause bubbles or "dry flower" defects.
Stage 3: Heating, Pressurization, and Main Exhaust (Reaction Zone/High-Pressure Zone)
The lay-up moves with the steel belts into the main heating and pressing zone of the press. This is the core of the entire process.
Heating: The upper and lower hot press plates efficiently transfer heat through the steel belts to the lay-up. The resin begins to melt and enters the active polycondensation reaction phase.
Synchronous Pressurization and Exhaust: Driven by the hydraulic system, the pressure gradually increases along the machine length to its peak (typically 800-1000 N/cm² or higher). Throughout this process, the vacuum exhaust system distributed along both sides of the press operates continuously, acting like "straws" to constantly suck out volatile gases (water vapor, formaldehyde, phenol from phenolic resin, etc.) released from the melting resin.
Result: Under extremely high temperature and pressure, the resin fully cures, and the paper fibers are tightly compacted, forming a dense, homogeneous, high-strength board. Continuous vacuum exhaust is the key to ensuring the fireproof board is free of bubbles, has high transparency, excellent electrical properties, and stability.
Stage 4: Pressure Holding for Curing and Cooling for Setting (Holding/Cooling Zone)
Pressure Holding: After passing the peak pressure zone, the pressure is maintained over a certain length to ensure complete resin reaction and dimensional stability of the board.
Cooling: In the rear section of the press, the temperature of the hot press plates decreases or switches to cooling plates, beginning the controlled cooling of the formed board. This is a critical step to prevent the board from developing internal stress, warping, or delamination after exiting due to rapid cooling.
Stage 5: Pressure Release and Continuous Board Exit
After sufficient cooling, the pressure gradually drops to zero, and the board is smoothly discharged from the end of the steel belts. What emerges is an endless, fully cured "strip" of fireproof board. Subsequently, an online cross-cut saw cuts it to set lengths, followed by sanding, trimming, and other processes to become the finished product.
Core Characteristic of the Production Process: "Continuous high-pressure lamination under dynamic exhaust." All process parameters (temperature profile, pressure profile, line speed, exhaust vacuum) must be precisely coordinated and controlled based on paper type, resin formula, and board thickness.
Core Working Principle
The working principle of a continuous flat press can be summarized as follows: Utilizing two endless, high-strength steel belts to clamp the mat material, continuously passing it through a long pressure chamber formed by multiple sets of heating plates (and cooling plates). Within the chamber, a hydraulic system applies immense pressure perpendicular to the board surface from outside the belts, while the heating plates provide the heat necessary for curing, enabling the material to complete the entire process of pressing, heating, curing, and cooling while in motion.
Simple Analogy: It is like an extremely long, horizontal "iron," but the "soleplate" (hot press plates) of the iron is stationary, while the "fabric" being ironed (the mat) is clamped and pulled through at a constant speed by the upper and lower "conveyor belts" (steel belts), being continuously heated and pressed into shape during passage.
Main Components
A continuous flat press dedicated for fireproof board production mainly consists of the following seven major systems:
1. Main Frame
Function: The skeleton of the entire equipment, bearing the full working pressure (up to thousands of tons).
Features: Made of a pre-stressed frame welded from high-quality steel plates in a box-type or column-type design, optimized through finite element analysis to ensure minimal deformation under extreme pressure, forming the foundation for uniform board thickness.
2. Steel Belt System - The "Flexible Mold" and Pressure Transfer Medium
Composition: Two parallel, endless high-strength alloy steel belts (or special stainless steel belts).
Function:
Acts as the pressure transfer medium, uniformly distributing the hydraulic cylinder pressure across the entire width of the mat.
Acts as the conveyor belt, clamping and pulling the mat continuously through the press.
Acts as an isolation layer, protecting the surface of the precision hot press plates from contamination, while its high surface finish directly determines the surface quality of the finished board.
Auxiliary Devices: Include drive rollers, tension rollers, steering systems, support rollers, cleaning and polishing devices to ensure stable, centered, and clean belt operation.
3. Heating and Pressure System - The "Source of Energy and Force"
Heating Plates: Made of special alloy steel with internal flow channels for high-temperature thermal oil (mainstream, for precise temperature control) or steam, providing heat for the process. Typically divided into dozens of independently controlled temperature zones along the length.
Hydraulic System: Consists of an oil tank, high-pressure pumps, servo valves, accumulators, and numerous working cylinders. The cylinders are distributed in groups, enabling zone-specific pressure control along the length and width of the press to create complex pressure profiles.
4. Exhaust System - The "Soul" of the Fireproof Board Press
Function: Specifically designed to extract volatile gases generated during the resin curing reaction.
Composition: Includes mechanical exhaust devices (micro-vibration mechanisms) at the press inlet, and vacuum exhaust pipes and powerful vacuum pump groups distributed along both sides of the press.
Principle: While the mat is being pressed but not yet completely sealed, the vacuum system continuously draws air from the mat edges, creating negative pressure to "pull" out internal gases.
5. Infeed and Outfeed System
Infeed End: Equipped with precision forming, alignment, and pre-pressing devices to ensure the multi-layer impregnated papers are fed flat, aligned, and wrinkle-free into the nip of the steel belts.
Outfeed End: Smoothly guides the cured and cooled continuous board strip out and conveys it to the subsequent cutting saw.
6. Control System - The "Brain"
Function: Utilizes an advanced DCS/PLC system, integrating thousands of monitoring points for temperature, pressure, speed, tension, exhaust vacuum, etc.
Role: Conducts fully automatic, closed-loop control of the entire machine based on preset "process recipes," adjusts parameters in real-time to ensure stable quality, and enables fault diagnosis, data logging, and recipe management.
7. Thermal Energy System and Environmental Interface
Thermal Energy Center: Provides heat source (possibly natural gas, electricity, or biomass) for the thermal oil heater or steam boiler.
Environmental Interface: The extracted exhaust gases (rich in VOCs) are directed to a downstream thermal oxidizer for high-temperature oxidation treatment before being discharged to meet stringent environmental regulations.
In summary, a continuous flat press dedicated for fireproof board production is a highly complex system integrating mechanical, hydraulic, thermal, vacuum, and automation technologies. Its core value lies in achieving precise control over the high pressure, high temperature, and exhaust requirements—traditionally associated with "batch" processes—through continuous production, thereby reaching levels of efficiency and quality unattainable by traditional multi-opening presses.
Produces High-Quality Class A Fire-Rated Panels
Exceptional Surface & Physical Properties
High Material Yield & Low Reject Rate
Production Flexibility & Efficiency
Environmental & Safety Compliance
Applicable Products: High-Pressure Decorative Laminates (HPL), Continuous Pressure Laminates (CPL)
Working Width: 1300mm, 1450mm, 1600mm, 1850mm (Standard industrial widths)
Design Line Speed: 5 - 25 meters/minute (Depending on panel thickness and resin type)
Maximum Working Pressure: 800 - 1200 N/cm²
Heating Method: Thermal Oil Heating (Mainstream, for precise control) or Electric Heating
Operating Temperature Range: 180°C - 230°C
Exhaust System: Multi-zone Controlled Vacuum Exhaust
Steel Belt Specification: High-strength Polished Stainless Steel Belt, Thickness 1.2 - 1.8mm
Control System: Fully Digital Integrated Control System based on Industrial PC
Power Supply: 3-Phase, 380-415V, 50Hz / 60Hz
For more information, welcome contact us, we will reply you quickly and offer working videos with you.
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
