CN114606643A - 一种多层材质隔音棉的自动化制备工艺 - Google Patents

一种多层材质隔音棉的自动化制备工艺 Download PDF

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CN114606643A
CN114606643A CN202210124196.XA CN202210124196A CN114606643A CN 114606643 A CN114606643 A CN 114606643A CN 202210124196 A CN202210124196 A CN 202210124196A CN 114606643 A CN114606643 A CN 114606643A
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毕凌云
陈强
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Anhui Langlitong New Material Application Co ltd
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Abstract

本发明公开了一种多层材质隔音棉的自动化制备工艺，涉及隔音阻燃材料制备技术领域，包括如下步骤：梳棉工序、熔喷成网工序、覆布工序、斜切涂胶工序以及整理打包。本发明通过在机架上设置斜切涂胶机构，制得的多层材质隔音棉为装配式的凸台状附胶结构，在安装过程中对应端面通过翻转即可以完成装配拼接，适应多种型号的空调及相应电器的隔音阻燃等使用，小体积拼接结构使得即使发生撕裂情况，裂纹延长至胶水粘结处即停止，隔音效果的降低得到缓解，同时维护时更换损坏小片隔音棉片即可，减低使用及维修成本。

Description

一种多层材质隔音棉的自动化制备工艺
技术领域
本发明涉及隔音阻燃材料制备技术领域，具体涉及一种多层材质隔音棉的自动化制备工艺。
背景技术
空调内通常铺设无妨纤维棉毡材质的隔音棉片材，其与PVC橡胶阻尼胶粘片单面或双面复合具有隔音、隔热、减震、降噪、阻燃等良好特性，现有的隔音棉为了更好地增强隔音阻燃等效果，采用多材质的多层直板结构，但传统工艺制备的直板式结构隔音棉片材，需要一体整片置于空调铺设层内，而在实际安装过程中，为了避让空调或电器内部线路，经常向周边延长的避让开口，导致运输及安装时沿着开口延伸方向发生撕裂现象，使得隔音效果降低，且一体式安装在长期的使用中也不易维护，一旦发生问题必须整片更换。
发明内容
本发明的目的在于提供一种多层材质隔音棉的自动化制备工艺，以解决现有技术中导致的上述缺陷。
一种多层材质隔音棉的自动化制备工艺，包括如下步骤：
S1：梳棉工序：将中空涤纶短纤经开包机开包，并经给棉机、梳棉机进行整理形成宽度为1.8cm、厚度为4.5cm的中空涤纶棉卷；
S2：熔喷成网工序：将固态聚丙烯液化后，以聚丙烯与中空涤纶棉卷为1：6的比例均匀熔喷在中空涤纶棉卷表面，使用成网机将熔喷聚丙烯后的中空涤纶棉卷进行成网加工；
S3：覆布工序：将固体的胶体液化后均匀喷涂在上述成网后的中空涤纶棉卷的表面，之后对喷胶后的中空涤纶棉卷进行覆布工序加工，即将无纺布覆在中空涤纶棉卷上，形成隔音棉卷材；
S4：斜切涂胶工序：对覆布工序完成后的隔音棉卷材通过输送带输送至机架内，所述机架上通过安装架设置斜切涂胶机构，通过斜切涂胶机构将隔音卷材分切为若干个均匀的梯形的装配式隔音棉片材，同时向两个相邻装配式隔音棉片材的斜侧端面涂抹胶水；
S5：整理打包：对涂抹胶水的装配式隔音棉片材有序放置，保证侧端斜面朝向一致，并经非涂胶侧端进行成捆打包。
优选的，所述斜切涂胶机构包括驱动电机、闩凸轮、顶推件以及切刀，所述驱动电机安装于安装架的侧端，驱动电机的输出端安装有辊轴，所述闩凸轮安装于辊轴上，辊轴上还安装有涂胶辊，安装架上固定连接有两个对称的固定杆，所述固定杆的上端部转动设置有限位头一，所述顶推件的中部转动设置于安装架的内侧壁上，顶推件的顶端转动设置有限位头二，所述限位头二与限位头一之间套设有弹簧，顶推件的一端抵靠于闩凸轮的端面上，所述切刀的端部固定安装于顶推件的另一端上。
优选的，所述输送带的输送方向与切刀的刀刃朝向相反。
优选的，所述涂胶辊为空腔结构，且与闩凸轮相配合的一侧半边为大外缘开口设置，涂胶辊上远离驱动电机的一侧安装有供胶泵。
优选的，所述闩凸轮的小径内缘与驱动电机的输出轴保持同轴。
本发明的优点在于：
通过在机架上设置斜切涂胶机构，由驱动电机的输出端经驱动电机，带动闩凸轮和涂胶辊同步转动，闩凸轮在顺时针转动的过程中，大径外缘推动顶推件的一侧沿着与安装架的转动点进行向上摆动，同时涂胶辊内部的海绵胶水回随着涂胶辊的转动，制得的多层材质隔音棉为装配式的凸台状附胶结构，在安装过程中对应端面通过翻转即可以完成装配拼接，适应多种型号的空调及相应电器的隔音阻燃等使用，小体积拼接结构使得即使发生撕裂情况，裂纹延长至胶水粘结处即停止，隔音效果的降低得到缓解，同时维护时更换损坏小片隔音棉片即可，减低使用及维修成本。
附图说明
图1为本发明的工艺流程图。
图2为本发明中斜切涂胶工序所用装置的结构示意图。
图3为本发明中斜切涂胶机构的部分结构示意图。
图4为本发明中斜切涂胶工序所用装置在工作状态的剖视图。
其中，1-机架，2-输送带，3-安装架，4-斜切涂胶机构，401-驱动电机，402-闩凸轮，403-顶推件，404-切刀，405-辊轴，406-涂胶辊，407-固定杆，408-限位头一，409-限位头二，410-弹簧，411-供胶泵。
具体实施方式
为使本发明实现的技术手段、创作特征、达成目的与功效易于明白了解，下面结合具体实施方式，进一步阐述本发明。
如图1至图4所示，一种多层材质隔音棉的自动化制备工艺，包括如下步骤：
S1：梳棉工序：将中空涤纶短纤经开包机开包，并经给棉机、梳棉机进行整理形成宽度为1.8cm、厚度为4.5cm的中空涤纶棉卷；
S2：熔喷成网工序：将固态聚丙烯液化后，以聚丙烯与中空涤纶棉卷为1：6的比例均匀熔喷在中空涤纶棉卷表面，使用成网机将熔喷聚丙烯后的中空涤纶棉卷进行成网加工；
S3：覆布工序：将固体的胶体液化后均匀喷涂在上述成网后的中空涤纶棉卷的表面，之后对喷胶后的中空涤纶棉卷进行覆布工序加工，即将无纺布覆在中空涤纶棉卷上，形成隔音棉卷材；
S4：斜切涂胶工序：对覆布工序完成后的隔音棉卷材通过输送带2输送至机架1内，所述机架1上通过安装架3设置斜切涂胶机构4，通过斜切涂胶机构4将隔音卷材分切为若干个均匀的梯形的装配式隔音棉片材，同时向两个相邻装配式隔音棉片材的斜侧端面涂抹胶水；
S5：整理打包：对涂抹胶水的装配式隔音棉片材有序放置，保证侧端斜面朝向一致，并经非涂胶侧端进行成捆打包。
在本实施例中，所述斜切涂胶机构4包括驱动电机401、闩凸轮402、顶推件403以及切刀404，所述驱动电机401安装于安装架3的侧端，驱动电机401的输出端安装有辊轴405，所述闩凸轮402安装于辊轴405上，辊轴405上还安装有涂胶辊406，安装架3上固定连接有两个对称的固定杆407，所述固定杆407的上端部转动设置有限位头一408，所述顶推件403的中部转动设置于安装架3的内侧壁上，顶推件403的顶端转动设置有限位头二409，所述限位头二409与限位头一408之间套设有弹簧410，顶推件403的一端抵靠于闩凸轮402的端面上，所述切刀404的端部固定安装于顶推件403的另一端上。
需要说明的是，所述驱动电机401为伺服电机，且闩凸轮的小径内缘与大径外缘均为半圆结构，对应的涂胶辊凸起也为半圆结构，所述涂胶辊406为空腔结构，且与闩凸轮402相配合的一侧半边为大外缘开口设置，涂胶辊406上远离驱动电机401的一侧安装有供胶泵411。
在本实施例中，所述输送带2的输送方向与切刀404的刀刃朝向相反，以保证隔音棉卷材在输送过程中完成端面的斜向裁切。
此外，所述闩凸轮402的小径内缘与驱动电机401的输出轴保持同轴。
工作过程及原理：本发明在使用过程中，按工序依次进行梳棉工序、熔喷成网工序、覆布工序、斜切涂胶工序以及整理打包，在斜切涂胶的工序过程，首先将隔音棉卷材通过输送带2按照相反于切刀404的刀刃朝向反向进行输送，输送至机架1内后，开启驱动电机401使其输出端带动辊轴405转动，进而带动闩凸轮402转动，闩凸轮402在顺时针转动的过程中，大径外缘推动顶推件403的一侧沿着与安装架3的转动点进行向上摆动，通过设置于限位头一408和限位头二409之间的弹簧410的自身弹力作用下，抵紧顶推件403始终与闩凸轮402的端面相抵靠，此过程使得顶推件403的另一端带动切刀404向斜下方翻转，配合输送带2上多层材质隔音棉的输送，完成对其一侧端面的斜向裁切，随着闩凸轮402的继续顺时针转动，顶推件403的端部与闩凸轮402的抵接处于大径外缘至小径内缘的过渡，同样在弹簧410自身的弹力作用下，顶推件403的另一端带动切刀404向斜上方抬升，进而完成隔音棉另一侧的斜向裁切；
在裁切阶段的同时，随着辊轴405的转动，还会带动涂胶辊406和闩凸轮402同步转动，涂胶辊406内部的海绵胶水回随着涂胶辊406的转动，从其上的半边大外缘开口流出，并通过控制驱动电机401的转动速度可以刚好使得对应的半边流出胶水全部涂覆于隔音棉的一侧斜切端面上，转动至隔音棉的上端面位置时，则胶水刚好处于非开口结构位置，从而停止胶水的涂覆供给，最终斜切涂胶工序完成后的隔音棉经输送带2的末端导出。
基于上述，本发明通过在机架1上设置斜切涂胶机构4，由驱动电机401的输出端经驱动电机401，带动闩凸轮402和涂胶辊406同步转动，闩凸轮402在顺时针转动的过程中，大径外缘推动顶推件403的一侧沿着与安装架3的转动点进行向上摆动，使得顶推件403的另一端带动切刀404向斜下方翻转，对隔音棉一侧端面的斜向裁切，同时涂胶辊406内部的海绵胶水回随着涂胶辊406的转动，从其上的半边大外缘开口流出，并通过控制驱动电机401的转动速度可以刚好使得对应的半边流出胶水全部涂覆于隔音棉的一侧斜切端面上；
制得的多层材质隔音棉为装配式的凸台状附胶结构，在安装过程中对应端面通过翻转即可以完成装配拼接，适应多种型号的空调及相应电器的隔音阻燃等使用，小体积拼接结构使得即使发生撕裂情况，裂纹延长至胶水粘结处即停止，隔音效果的降低得到缓解，同时维护时更换损坏小片隔音棉片即可，减低使用及维修成本。
由技术常识可知，本发明可以通过其它的不脱离其精神实质或必要特征的实施方案来实现。因此，上述公开的实施方案，就各方面而言，都只是举例说明，并不是仅有的。所有在本发明范围内或在等同于本发明的范围内的改变均被本发明包含。

Claims (5)

1.一种多层材质隔音棉的自动化制备工艺，其特征在于，包括如下步骤：
S1：梳棉工序：将中空涤纶短纤经开包机开包，并经给棉机、梳棉机进行整理形成宽度为1.8cm、厚度为4.5cm的中空涤纶棉卷；
S2：熔喷成网工序：将固态聚丙烯液化后，以聚丙烯与中空涤纶棉卷为1：6的比例均匀熔喷在中空涤纶棉卷表面，使用成网机将熔喷聚丙烯后的中空涤纶棉卷进行成网加工；
S3：覆布工序：将固体的胶体液化后均匀喷涂在上述成网后的中空涤纶棉卷的表面，之后对喷胶后的中空涤纶棉卷进行覆布工序加工，即将无纺布覆在中空涤纶棉卷上，形成隔音棉卷材；
S4：斜切涂胶工序：对覆布工序完成后的隔音棉卷材通过输送带(2)输送至机架(1)内，所述机架(1)上通过安装架(3)设置斜切涂胶机构(4)，通过斜切涂胶机构(4)将隔音卷材分切为若干个均匀的梯形的装配式隔音棉片材，同时向两个相邻装配式隔音棉片材的斜侧端面涂抹胶水；
S5：整理打包：对涂抹胶水的装配式隔音棉片材有序放置，保证侧端斜面朝向一致，并经非涂胶侧端进行成捆打包。
2.根据权利要求1所述的一种多层材质隔音棉的自动化制备工艺，其特征在于：所述斜切涂胶机构(4)包括驱动电机(401)、闩凸轮(402)、顶推件(403)以及切刀(404)，所述驱动电机(401)安装于安装架(3)的侧端，驱动电机(401)的输出端安装有辊轴(405)，所述闩凸轮(402)安装于辊轴(405)上，辊轴(405)上还安装有涂胶辊(406)，安装架(3)上固定连接有两个对称的固定杆(407)，所述固定杆(407)的上端部转动设置有限位头一(408)，所述顶推件(403)的中部转动设置于安装架(3)的内侧壁上，顶推件(403)的顶端转动设置有限位头二(409)，所述限位头二(409)与限位头一(408)之间套设有弹簧(410)，顶推件(403)的一端抵靠于闩凸轮(402)的端面上，所述切刀(404)的端部固定安装于顶推件(403)的另一端上。
3.根据权利要求1所述的一种多层材质隔音棉的自动化制备工艺，其特征在于：所述输送带(2)的输送方向与切刀(404)的刀刃朝向相反。
4.根据权利要求2所述的一种多层材质隔音棉的自动化制备工艺，其特征在于：所述涂胶辊(406)为空腔结构，且与闩凸轮(402)相配合的一侧半边为大外缘开口设置，涂胶辊(406)上远离驱动电机(401)的一侧安装有供胶泵(411)。
5.根据权利要求2所述的一种多层材质隔音棉的自动化制备工艺，其特征在于：所述闩凸轮(402)的小径内缘与驱动电机(401)的输出轴保持同轴。
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