As the core material for building a high standard dust-free environment, the cleanroom sandwich panel line integrates modern mechanical automation, material science, and environmental control technology. With the rapid development of industries such as semiconductor manufacturing, biomedicine, and precision electronics, the demand for clean environments is becoming increasingly strict, which has driven continuous innovation in sandwich panel production technology.
The cleanroom sandwich panel production line is a highly integrated production system, consisting of multiple functional modules working together to complete the entire production process from raw materials to finished products. These modular devices are linked through an intelligent control system to form a continuous and efficient automated production line.
Raw material processing system: As the starting point of the production line, the hydraulic unwinding machine is responsible for unfolding the metal coil, the leveling device eliminates internal stress in the material, and ensures the flatness of the substrate. The box board forming machine pre processes flat metal plates into components with specific cross-sectional shapes, preparing for subsequent composite. Advanced servo control systems have begun to intervene in this stage, providing precise positioning for material conveying.
Core composite system: including glue spraying devices (such as color steel plate glue spraying system, glass magnesium plate glue spraying system), transverse flipping mechanism, and hot press forming machine. The glue spraying system adopts quantitative screw rotation filling technology, with an error controlled within 0.01 grams, to ensure the uniformity of adhesive distribution. The hot press machine usually maintains a constant temperature of 60 ℃ and processes the board at a speed of 3 meters per minute. Each position needs to be continuously hot pressed for 4 minutes to achieve the best bonding effect.
Forming processing system: composed of angle cutting machine, molding machine, punching machine, bending machine, etc., responsible for fine processing of the composite sheet metal. The fully automatic cutting system (including band saws, disc saws, etc.) completes size precision machining according to preset parameters, meeting the size requirements of different application scenarios. The accuracy of this step directly affects the assembly and sealing performance of the sandwich panel.
Automated logistics system: including transport tracks, lifting and palletizing machines, plywood flipping machines, and end palletizing machines. The plywood flipping machine adopts a design with 4 suction cups set every 15cm ², which can stably process boards with specifications ranging from 300 × 600mm to 1200 × 7000mm. The end palletizer uses a servo system to locate the center of the board, automatically completes palletizing and packaging, and achieves the final processing of finished products before they are shipped out.
Environmental protection treatment system: Modern production lines are equipped with dust removal and exhaust gas treatment equipment, especially for non methane total hydrocarbon emissions that may occur in polyurethane production, to ensure that the production process meets environmental standards. Some high-end production lines have also integrated a scrap recycling system, which automatically classifies scrap with a width greater than 300mm into reuse areas.
The modern clean room sandwich panel line integrates multiple technological innovations, which not only improve production efficiency but also ensure the stability and consistency of product quality, meeting the stringent requirements of high-end clean environment construction.
Intelligent control system: Adopting the concept of centralized control, the control system of all moving components is integrated into a single process control console to achieve remote monitoring and parameter linkage. The production line is equipped with a fault self diagnosis system that can monitor equipment status in real time and provide timely warnings. The servo control system runs through various production processes, from width positioning to punching angle processing, with an accuracy error controlled within ± 0.1mm. The human-machine interface allows operators to flexibly set parameters such as cutting size and bending angle, and the same production line can quickly switch to produce products of different specifications.
Modular design concept: The entire line adopts a modular assembly scheme, and key components such as the forming host use precision servo lifting mechanisms without hydraulic pressure. This not only simplifies the thickness adjustment process (allowing for arbitrary adjustment of sheet thickness), but also avoids common leakage and maintenance problems in hydraulic systems. Modular design achieves a component exchange rate of over 85%, significantly reducing downtime for equipment maintenance and replacement. This design also enables flexible configuration of the production line, combining it into a production system suitable for different core materials such as polyurethane, rock wool, or glass magnesium board according to customer needs.
Energy saving and environmental protection technology: The production line adopts high-power and low-energy consumption design, with energy consumption equivalent to only 40% of similar products. The unique internal insulation design enables the production line to heat up to the process temperature for no more than 1 hour at room temperature above 5 ℃, achieving all-weather production without the need for additional insulation rooms. For the polyurethane foaming process, environmentally friendly alternative technologies such as n-pentane foaming system have been developed to reduce reliance on traditional foaming agents. Although electrostatic purification methods have ozone emission issues, the new generation of equipment has controlled ozone concentration within a safe range through catalytic conversion technology.
Material processing innovation: The application of two-component polyurethane spraying machine solves the problem of uneven manual coating, ensuring the uniformity of bonding strength through precise control of ratio and adhesive amount. For multi-layer core material structures, the production line is equipped with multiple spraying stations to achieve precise control of interlayer bonding. The edge processing system automatically separates available edge materials into reuse areas through intelligent sorting, increasing material utilization by more than 15%. For sandwich panels with special requirements, such as those used in the semiconductor industry, the production line integrates a corona treatment system to enhance the bonding strength between the metal panel and the core material.
The performance of cleanroom sandwich panels directly affects the stability and reliability of the clean environment, and the combination of different materials can meet various requirements from basic dust prevention to ultra-high cleanliness. The advancement of cleanroom sandwich panel machine technology has made it possible to combine multiple materials, providing users with a wide range of choices.
Panel material: The most commonly used is color coated steel plate, with a thickness usually between 0.02-0.05mm and a surface coating or coating of about 0.15mm, which has good corrosion resistance and easy cleaning characteristics. High end clean rooms use stainless steel panels, especially suitable for occasions with extremely high hygiene requirements such as biopharmaceuticals. The panel processing technology includes processes such as reinforcement and corona discharge to enhance the bonding strength with the core material. The precision of panel forming directly affects the sealing performance of sandwich panels after assembly, and modern production lines can ensure that the straightness error of panel edges is within 1mm/m.
Core material type: Polyurethane (PU/PIR) core material has excellent insulation performance (thermal conductivity of 0.022-0.028W/(m · K)), and the fire rating can reach B1 level, making it an ideal choice for cold storage and temperature sensitive areas. Rock wool core material is widely used in places with strict fire protection requirements due to its A-level non combustible characteristics (fire resistance limit up to 2 hours) and good sound insulation effect. Magnesium oxychloride composite materials have the characteristics of fire resistance, moisture resistance, and anti delamination, and perform outstandingly in environments with high humidity. Emerging core materials such as glass magnesium board and aluminum honeycomb meet the needs of special application scenarios, such as anti-static and ultra-high strength.
Composite process: Different material combinations need to be matched with corresponding production processes. The polyurethane core material adopts continuous foaming technology, which directly foams between two layers of metal plates to form a sturdy overall structure. Fiber core materials such as rock wool and glass wool use a bonding agent composite process, relying on high-performance polyurethane adhesive to achieve permanent bonding between the panel and the core material. Magnesium oxychloride sandwich panels use special adhesives to prevent corrosion of metal panels by magnesium cement. The production line can switch between different core material production modes within 2 hours through a rapid mold changing system.
Function extension: To meet the needs of special industries, sandwich panels can integrate multiple functional layers. Anti static sandwich panels, with the addition of conductive fibers or coatings, have a surface resistance controlled between 10 ⁴ -10 ⁶ Ω, making them suitable for electronic manufacturing workshops. Antibacterial sandwich panels with added antibacterial agents such as silver ions on the surface layer have a bacterial inhibition rate of over 99%, and are used in pharmaceutical and food production. Radiation protection sandwich panels are made by adding barium sulfate and other components to the core material, and are used in medical radiology departments. The production line can be flexibly adjusted through modular design to meet the production needs of these special functional boards.
The products produced by the cleanroom sandwich panel manufacturing line play an irreplaceable role in many industries with strict environmental requirements due to their excellent physical properties and flexible designability. Different application scenarios have varying performance requirements for sandwich panels, prompting production lines to continuously develop towards customization and specialization.
