DBP-ACM

Alumax provides DBP-ACM, which is a new system for FR-A2/FR-B1 flame-retardant aluminum composite material production line, and is the best solution to effectively reduce the cost of core materials. Different from the traditional A2-ACP production line, the A2 core coil is used. First, the core is heated at high temperature and then laminated with a special adhesive film, and then bonded with the upper and lower aluminum alloy strip to form an A2- ACP panels.
The DBP-ACM production line can directly use FR-A2 or FR-B1 fine particles, these fine granules are fed into the press feeding unit through the dispenser, then heated and pressed to make a core and then bonded with conventional type adhesive film and aluminum alloy strips on both sides to form an FR-A2 or FR-B1 aluminum composite panels , Compared with the A2/FR core material used in the traditional ACP line, the core material cost can save about one million US dollars per year.

The FR-A2 core material used in the DBP-ACM production line belongs to Polymer/Copolymer Based compound granules. These fine granules enter the feeding unit of the press through the dispenser are heated and pressed in stages to make FR-A2 core, and are then bonded with conventional EVA film (DuPont/Bynel 30E753) and the metal strips on the upper and lower sides Made of FR-A2 metal composite panels of five layers.
Different from the traditional A2-ACP line, an A2 core coil is used, which is heated at a high temperature and then bonded with an expensive special adhesive film and composited aluminum alloy strips on the upper and lower sides to form an A2-aluminum composite panel. Comparing the cost of two cores, the material cost of the core used by the DBP line can be saved by more than 30%.
The manufacturing process of FR-B1 Panels in the DBP production line is the same as that of FR-A2 Panels. Compared with FR flame-retardant pellets used in traditional production lines, FR-B1 core material can save more than 45% in material costs.

At present, most of the A2 grade aluminum composite panels are produced by the transformation of the traditional ACP production line. They use the prefabricated A2 core coil to be heated to a high temperature, and then bonded with a special adhesive film and composites aluminum alloy strips on the upper and lower sides to form an A2-ACP panel.
Most of these core coils are made of VAE Copolymer emulsion (water dispersion) and a preset ratio of mineral fillers. After mixing and stirring, the initial stage is a moisture-containing mortar mud, which is rolled into a core shape by a rolls stand and covered with PP /PE non-woven on the surface. It's used as the carrier of the mud-like core shape to prevent the structure from loosening its strength and after the hot air drying process removes the water contents from it and it’s finally wound into A2 core coils.
These types of core absorb moisture easily, and if it is exposed to a harsh external environment with a lot of humidity, high temperature, and the difference between cold and hot for a long time, it will not only be prone to aging, but what is most worrying is that maybe the bonding strength between the prefabricated core and aluminum strips will gradually degrade???
The DBP-ACM production line uses hot melt polymers or copolymers compounded with a preset ratio of ATH/MDH mineral fillers to make fine granules. The particles have high-strength polymer chains and hydrophobic properties between them. The core material is continuously heated and pressed to produce a mineral-filled core, which is then laminated with conventional adhesive films and aluminum strips to produce A2 composite panels.
A hot-melt polymer or copolymer mineral-filled core will neither absorb moisture nor weaken the core's strength, will not degrade bonding strength between the adhesive layers of the composite panel, and will last even in harsh hot and cold weather.

FR-A2 Fine Granule

FR-A2 core

The main advantage of the DBP-ACM line is that it produces zero waste in the FR-A2 and FR-B1 grade ACP panel manufacturing cycles by recycling excess core material from edge trimming during the pressing stage, 100% of the waste is recovered during DBP-ACM panel manufacturing through the core material recovery system. Recycled core waste is dry crushed until a suitable size of granulate is achieved and mixed directly with fresh granulate in the dispenser.
The conventional A2-ACP production line using A2 core coils is processed into an aluminum composite panel, and the excess core material on both sides of the edge must be cut off. These trimming materials cannot be recycled, and they will become waste and pollute the environment which is not friendly to the environment.

The main process of the DBP-ACM production line is divided into the stages of dispenser, heating, pressing, and composite. It is completely different from the conventional ACP production line production method. The process is simple and easy to operate, especially for the production of FR-B1 grade ACP panels. At the same time, because there is no process of extruding the core plate, there is no problem with the replacement of the screw and barrel of the extruder, the maintenance cost of the DBP line is low and the replacement of parts is easy.

DBP uses a high speed of 3-6 meters per minute to produce panels. It is a high capacity ACM production line. Compared with the conventional ACM production line with the same amount of output, the energy consumption for producing FR-A2 Panels can be reduced by about 30-40%. The energy consumption required to manufacture FR-B1 Panels can be reduced by more than 60%。

The DBP line’s most unique benefit is its production capacity. The DBP line can realize the production of FR-A2 and FR-B1 composite panels with a daily output of 4,500 - 10,000 square meters. In addition to having a production capacity 2-3 times higher than conventional production lines, it also has excellent performance in reducing labor costs, energy consumption costs, occupied plant area and plant construction costs.

The DBP line can be connected and compatible with the latest prime technology industry 4.0 standards.

For more details of A2 grade Aluminum Composited Panel (ACP) Line, please contact us.