RU2327827C1 - Method of floor covering manufacture - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: said utility invention relates to floor coverings and may be used by individuals or in industry for floor covering in residential flats and industrial premises. The floor covering manufacture method involves operations of the application of PVC coatings using the air cushion for the preservation of the printed layer(s), levelling of the web edges, creation of stock of the floor covering rolled in the process of its coating, tensioning, drying, and cooling; along with a number of auxiliary operations related to the collection of excessive covering mass. The invention ensures cost effectiveness of the process, consisting in the selection of the most optimal operations of manufacture and inspection of the web proper, in the process of application of the coatings and the ultraviolet lacquer, the process of web tension synchronisation in various periods of its processing, the operations of linoleum web cooling, and other operations related to careful treatment of the covering, for example, during web rotation using the air cushion.

EFFECT: increased cost effectiveness of floor covering manufacture process.

1 ex

Description

The invention relates to floor coverings and can be used in individual or industrial use for flooring in residential apartments and in industrial premises.

A known analogue is DE 3233448, dated March 15, 1984, MKI D06N 1/00 - [1].

The disadvantages of the known method of manufacturing flooring [1] include the low information content of the process.

The objective of the new method of applying flooring is to increase technological capabilities in the manufacture of flooring.

This object is achieved in that a method of manufacturing a floor covering, including unwinding a base in the form of a needle-punched canvas or fiberglass with adjusting the coincidence of the edges of the previous and subsequent rolls, combining them by gluing with heat treatment or stitching with threads using a two-loop unwinding compensator to create a supply of the base, ensuring continuity the implementation of these stages, the subsequent direction of the subbase at a speed of 1-22 m / min under tension on the first alluvial mouth the primer layer for uniform application of polyvinyl chloride paste directly on the subbase or on the pump drum, ensuring that the subbase does not bend with the paste applied on it, which loses fluidity when passing under the infrared emitter, gelling the front layer of the subbase on the surface of the heat-sealing drum at 145-150 ° С, cooling up to 25 ° С of the base, applying to this front surface of the base of the front layer of PVC paste on the second application device with repeating these operations and applying on this front surface of the substrate of the print pattern with the corresponding color of printing ink with a thickness of 0.1-0.5 microns using 3-6 printing rollers, air drying in the chamber at 80-120 ° C, uniform double application of a transparent layer of flakes of polyvinyl chloride on the front surface substrates with subsequent heat treatment, the formation of the planned pattern and cooling, applying a layer of polyvinyl chloride on the back surface of the substrate, mechanical embossing and printing the back of the substrate with drying at 100-190 ° C, application on itsevuyu surface UV protection varnish, drying, cooling and packaging in rolls.

Description of the method.

A method of manufacturing a floor covering, consisting of technological operations of preparing the canvas and applying coatings, characterized in that:

- the base is made in the form of fiberglass or needle-punched fabric;

- before unwinding the roll, the substrates combine the edges of the previous and subsequent rolls;

- gluing the frontal areas of the fiberglass or needle-punched canvas with adhesive tape, heat treatment and stitching of the frontal areas of the previous and subsequent rolls with threads and with the necessary tension between the technological machines is carried out in two loop unwinding compensators, where they form the supply of the base needed for gluing and stitching;

- the subbase is centered along the axis of movement at a feed speed of 1-22 m / min;

- in a two-roll drying device, the substrate is dried and, with the necessary tension, it is fed to the first alluvial device of the primer layer, called the doctor blade;

- polyvinyl chloride paste is fed through a vibrating screen to a receiving container and pastor;

- PVC paste is applied to the subbase with a spreading shaft, taking into account the gap between the metal shaft or directly onto the base, the layer of PVC paste onto the base is regulated by a doctor blade and the rotation speed of the spreading shaft, the spreading spread or the PVC base paste is evenly distributed, smoothed and dosed on the base or spreading shaft when using the angle of inclination of the doctor blade support impregnation of the base, supporting this mode with the viscosity and fluidity of the PVC paste;

- collect the flowing down PVC paste, exclude the drainage of PVC paste onto the base of the spreading machine and ensure the collection of PVC paste contaminated with industrial waste;

- they do not allow sagging of the base, in the case of a technological interruption of the process, they provide directional movement to the PVC paste trough, do not allow the PVC paste to drain along the lateral edges of the base on the spreading shaft, feeding the base with the applied primer PVC primer layer;

- under the infrared emitter, they slow down the process of fluidity of the PVC paste on the subbase, providing an appropriate degree of drying with 1-8 rows of emitters; during the supply of the subbase, the position of the heat flux of the emitters is changed;

- the subbase with the face surface is pressed with a rubberized clamping shaft onto the surface of the thermal drum for gelation at a contact zone temperature of 144-151 ° С, which provides the maximum possible uniform impregnation of the PVC substrate with a paste in the thickness and width of the applied layer, gelation of the PVC paste renders the fluidity impossible by removing excess plasticizer from it, give the PVC paste the proper strength and elasticity;

- the surface of the drum polished to a mirror shine is smoothed over the adjacent side of the subbase and it is pulled away from the heat-sealing drum by the take-up roller, bringing the sub-base to contact cooling by a pair of rolls up to 25 ° C, the adhered PVC paste is removed by the knife blade during heat-sealing;

- the oil temperature regulator automatically changes the temperature of the heat-regulating drum, by automatically cooling the water, cooling the base;

- the tensioning device serves the basis for the second alluvial device for applying the PVC paste from the front side, the substrate is served on the external shaft forming a gap with the doctor blade, where the PVC paste from the pastor is dosed and fed to the substrate, the amount of PVC paste applied is adjusted with the doctor blade with a given angle the inclination of the cleaning knife and the selected speed of rotation of the spreading shaft, taking into account the gap between the edge of the blade of the doctor blade and the contact surface of the spreading shaft;

- with the spreading shaft and the base layer, the PVC paste is evenly distributed, smoothed and dosed, the angle of the working surface of the doctor blade ensures impregnation of the base, exclude the drainage of PVC paste on the base of the spreading machine and ensure the collection of PVC paste contaminated with industrial waste, do not allow sagging of the base, in case technological interruptions of the process provide directional movement of PVC paste into the trough, do not allow the PVC plate to run off along the lateral edges of the base on the spreading shaft;

- by feeding a base, coated with a paste of PVC of the front layer, under an infrared emitter, slow down the fluidity of the PVC paste on the base, providing an adequate degree of drying by 1-8 rows of radiators, during the supply of the substrate, the position of the heat flux of the emitters is changed;

- the subbase with the face surface is pressed with a rubberized clamping shaft onto the surface of the thermal drum for gelation heated with hot oil at a temperature of the contact zone from 144-151 ° С;

- provide the maximum possibility of uniform impregnation of the base of PVC paste with the thickness and width of the applied layer;

- by gelation, the PVC paste is deprived of fluidity by removing excess plasticizer from it, and the PVC paste is given adequate strength and elasticity;

- the surface of the drum polished to a mirror shine is smoothed over the adjacent side of the subbase and it is pulled away from the heat-sealing drum by the take-up roller, bringing the sub-base to contact cooling with four cooling rolls to 25 ° С;

- the adhered PVC paste is removed during the heat treatment by the knife blade, the cooled base is fed through the tensioner and the device to rotate the base 180 °, face down, sparging the front surface with air through the perforated shaft surface forms an air cushion between the shaft surface and the supplied base, making it easier coup;

- the centering again undergoes centering until it is aligned with the axis of movement of its feed, in which a pair of pulling rolls feed it into the print compartment for printing on the front side of the printed pattern;

- based on the entrance to the printing department, the stage of regulating the tension by the master shaft before and after itself, which is necessary for printing the picture, on the polyvinyl chloride surface of the front side of the base, passes;

- printing shafts, with a number from 3 to 6, prints of drawings with a thickness of 0.5 microns of all rubberized printing shafts of a given design;

- the drive controls the movement of the print rolls, provides a clear overlay of the pattern on the front side of the subbase, coincidence during the drawing process - rapport of control marks located on both edges of the ends of the print rolls, to evaluate the correctness of the pattern across the entire width and length of the base, the press is equipped with a drive, a printing shaft, a doctor blade, an ink supply pump, a printing ink bath, rubberized pressure rolls, load shafts, a drying chamber and a cooling shaft, a rubberized shaft;

- the subbase with the front side is pressed against the printing shaft during its rotation, the load shaft ensures uniform pressing of the rubberized shaft across the width of the base, it is not allowed to beat evenly without shells, scratches and swelling of the surface of the printing shaft, the pump stations in the bath create a constant circulation of ink to prevent its delamination , excess paint is removed from the surface of the print roll by a horizontally located doctor blade, which creates a condition due to reciprocating movements of the edge of the blade I raised stability and preserve the quality of the working area of the blade;

- after receiving the combined pattern on the front side of the base, the latter enters the drying chamber, where the drying process is carried out with warm air, which for intermediate dryers is heated in the oil heat exchanger of the thermal ignition compartment and fed by the fan through the air damper system, at a temperature in the drying chamber of 80 to 120 ° FROM;

- it bends around the refrigeration shaft and enters the next printing press, the printing presses are interconnected mechanically by drives and feed motion transmissions, which allow the position of the print rolls to be adjusted relative to each other to correct marks shift and allow the machines to operate in various feed motion modes;

- a pair of pulling rolls passes on a subbase with a final drawing, the device for regulating the tension of the subbase passes the separation wall and enters the flip device, where the subbase is face up;

- the subbase is oriented in the direction of the feed movement along the central axis, its tension is regulated and fed to a two-roll drying device, where the subbase is dried and fed with the necessary tension to the third spreading device, the polyvinyl chloride paste is fed through a vibrating screen to the receiving container and pastor distributor;

- PVC paste is applied to the subbase with a spreading shaft, taking into account the gap between the metal shaft or directly to the subbase, the layer of PVC paste onto the subbase is regulated with a doctor blade and the rotation speed of the spreading shaft;

- with a spreading shaft or a subbase, the PVC paste is evenly distributed, smoothed and dosed on the subbase or the spreading shaft using a tilt angle of the doctor blade to support the impregnation of the subbase, matching this regime with the viscosity and fluidity of the PVC paste;

- collect the flowing down PVC paste, exclude the drainage of PVC paste onto the base of the spreading machine and ensure the collection of PVC paste contaminated with industrial waste, prevent sagging of the substrate, in case of technological interruption of the process provide directional movement into the PVC paste trough, do not allow drainage of PVC pate along the side the edges of the base on the alluvial shaft;

- by feeding the base, coated with PVC paste, under the infrared emitter, the fluidity of the PVC paste on the substrate is slowed down, providing an appropriate degree of drying by 1-8 rows of radiators, during the process of feeding the base, the position of the heat flux of the emitters is changed;

- the subbase with the face surface is pressed with a rubberized clamping shaft onto the surface of the thermal drum for gelation at a contact zone temperature of 144-151 ° С, which provides the maximum possible uniform impregnation of the PVC substrate with a paste in the thickness and width of the applied layer, gelation of the PVC paste renders the fluidity impossible by removing excess plasticizer from it, give the PVC paste the proper strength and elasticity, the surface of the drum polished to a mirror shine smooths the adjacent side along the base and the take-up roll, it is pulled from the heat-sealing drum, bringing the base to contact cooling with four cooling rolls up to 25 ° C;

- the adhered PVC paste is removed during the heat treatment by the knife blade, the substrate with the transparent PVC coated paste is fed face down, onto the surface of the gelling drum that is heated to a temperature of 145-150 ° C with hot oil, the coated substrate through the take-up roll is pulled from the drum and sent to cool the base to 25 ° C;

- the base is fed to the device for applying PVC flakes on the front side of the base using 1-2 devices, the PVC flakes are applied to the front side of the base from the hopper of the distribution unit with a needle shaft or shaft with spikes with a feed of 20 to 300 g / m ² , doctor blade remove excess PVC flakes, which, falling on the surface of the base, adhere to the transparent PVC paste, forming a three-dimensional pattern, the sprinkled PVC flakes are recycled, and then reused, the substrate with the applied PVC paste and PVC flakes on the front surface is fed onto the surface of the thermal drum heated by hot oil to 145-150 ° C, the coated substrate is pulled from the thermal drum with a removable roller, the adhering PVC paste is cleaned with a scraper knife, it interacts with the tension sensor, which controls the tension of the base between the thermal drum and the smoothing unit, infrared heating, where heating elements, an infrared sensor and a transducer installed at the outlet of the unit are involved in the heating of the front surface An infrared heating system, the intensity of which is controlled by the number of lamps turned on, the intensity of the lamps and the change in light flux relative to the moving front of the subbase, which is fed to the smoothing unit, where the pressure rubber shaft and smoothing shaft, with a surface polished to a mirror finish, over the entire width of the base with the proper pressure necessary to press the PVC flakes into the transparent layer of the PVC paste, leveling and smoothing the front side of the surface subbases, pull from the smoothing shaft and measure the tension between the smoothing unit and cooling to 25 ° C;

- the sub-base is fed by rolls due to their contact interaction with it;

- the application of the second transparent layer on the substrate is performed in a two-roll drying device, where the substrate is dried and fed with the necessary tension to the fourth application of the primer layer, called the doctor blade, the polyvinyl chloride paste is fed through a vibrating screen to the receiving container and pastor;

- PVC paste is applied to the subbase with a spreading shaft, taking into account the gap between the metal shaft or directly onto the base, the layer of PVC paste onto the base is regulated by a doctor blade and the rotation speed of the spreading shaft, the spreading spread or the PVC base paste is evenly distributed, smoothed and dosed on the base or spreading shaft using the angles of inclination of the doctor blade;

- they support the impregnation of the base, matching this mode with the viscosity and fluidity of the PVC paste, collect the falling PVC paste, exclude the drainage of PVC paste onto the base of the spreading machine and ensure the collection of PVC paste contaminated with production waste, prevent the sagging of the base, in case of technological interruption of the process, ensure directional movement into the trough of PVC paste, do not allow the drainage of PVC paste along the lateral edges of the base on the spreading shaft;

- by feeding the base, coated with PVC paste, under the infrared emitter, the fluidity of the PVC paste on the base is slowed down, providing an adequate degree of drying by 1-8 rows of radiators, during the supply of the base, the position of the heat flux of the emitters is changed, the base is pressed with a rubberized compression shaft onto the heated with hot oil, the surface of the thermal drum for gelling at a contact zone temperature of 144-151 ° C, providing the maximum possible uniform impregnation of the base of the PVC paste with thick yin and the width of the applied layer, gelling PVC paste deprived of fluidity by removing therefrom excess plasticizer;

- they give the PVC paste the proper strength and elasticity, the surface of the drum polished to a mirror shine smoothes the adjacent side of the subbase and it is pulled away from the heat-sealing drum by the take-up roller, bringing the sub-base to contact cooling by a pair of rolls up to 25 ° C, the adhered PVC paste is removed by the knife blade during heat-sealing, the cooled web is turned upside down, the temperature of the heat-regulating drum is automatically changed by the oil temperature regulator, and automatic cooling is used waiting for water to cool the base;

- in a two-roll drying device, the substrate is dried and fed with the necessary tension to the fifth primer of the primer layer, called the doctor blade, the polyvinyl chloride paste is fed through a vibrating screen to the receiving container and the pastor, the PVC paste is applied to the substrate with the spreading shaft taking into account the gap between the metal shaft or directly on the substrate, the layer of PVC paste on the substrate is controlled by a doctor blade and the speed of rotation of the spreading shaft, while the spreading coating or the base of the PVC paste is uniformly they are distributed, smoothed and dosed on a subbase or slurry shaft using the tilt angle of the doctor blade, the impregnation of the subbase is maintained, matching this mode with the viscosity and fluidity of the PVC paste, collecting the flowing PVC paste, excluding the drainage of PVC paste on the base of the spreading machine and collecting PVC paste contaminated with industrial waste, do not allow sagging of the substrate, in case of technological interruption of the process, they provide directional movement of PVC paste into the trough, do not allow the PVC paste to drain sideways to the edges of the subbase on the spreading shaft, the PVC of the backing layer of the PVC through a vibrating screen with the help of a pneumatic pump enters the cube on the fifth spreading device and is dosed through the pastor to the moving base;

- the substrate with the PVC paste applied to it is fed into the heat chamber for gelling, where the gelling temperature for the top and bottom of the base is in the range from 165 to 200 ° C, the temperature of the heat-regulating drum is automatically changed by the oil thermostat;

- from the heat chamber, the subbase enters the cooling unit, which consists of eight cooling shafts with the interval of water temperature control of the substrate 25 and 14 ° C, a compact PVC layer is applied to the substrate on the back surface of the device containing the external shaft supporting the board and doctor blade in a twin roll the drying unit is dried and fed with the necessary tension to the sixth alluvial device of a compact layer of PVC, polyvinyl chloride paste is fed through a vibrating screen to a receiving container and pastorazdachi to;

- PVC paste is applied to the subbase with a spreading shaft, taking into account the gap between the metal shaft or directly onto the base, the layer of PVC paste onto the base is regulated by a doctor blade and the rotation speed of the spreading shaft, the spreading spread or the PVC base paste is evenly distributed, smoothed and dosed on the base or spreading shaft when using the angle of inclination of the doctor blade support impregnation of the base, supporting this mode with the viscosity and fluidity of the PVC paste;

- collect the flowing down PVC paste, exclude the drainage of PVC paste onto the base of the spreading machine and ensure the collection of PVC paste contaminated with industrial waste, prevent sagging of the substrate, in case of technological interruption of the process provide directional movement into the PVC paste trough, do not allow drainage of PVC pate along the side the edges of the subbase on the spreading shaft, feeding the subbase, coated with a compact layer of PVC paste;

- under the infrared emitter, the fluidity of the PVC paste on the sub-base is slowed down, they provide an adequate degree of drying by 1-8 rows of emitters, during the supply of the sub-base, the position of the heat flux of the emitters is changed, the sub-base is pressed with a rubberized pressure roller onto the surface of the thermal drum for gelation at a contact temperature zones from 144-151 ° С, providing the maximum possible uniform impregnation of the base with a compact PVC layer of paste in thickness and width of the applied layer oy, by gelation, the PVC paste is deprived of fluidity by removing excess plasticizer from it, and the PVC paste is given adequate strength and elasticity;

- the surface of the drum polished to a mirror shine is smoothed over the adjacent side of the subbase and it is pulled away from the heat-sealing drum by the take-up roller, bringing the sub-base to contact cooling by a pair of rolls up to 25 ° C, the adhered PVC paste is removed by the knife blade in the process of heat-sealing, the temperature of the fourth thermo-drum is automatically controlled by the oil thermostat , use automatic water cooling, with which they cool the base;

- the tensioning device serves the base on the mechanical embossing unit face up, the mechanical embossing on the front surface of the subbase is carried out by an embossing unit containing an infrared field, an embossing shaft, a rubberized and cooling shaft, whereby the infrared field undergoes heating at least 140 ° C, the subbase with the face side is pressed against the embossing shaft, the pressure during mechanical embossing is selected and manually adjusted using a hydraulic pressure valve, at a cutoff temperature the shaft from 14 to 17 ° C, a relief pattern is applied on the embossing shaft, the height of which reaches 1-3 microns, a double cooling jacket with a temperature of 14-17 and 20-25 ° C is provided in the embossing shaft; the substrate from the embossing shaft is removed to the cooling shaft, the embossed support is fed to two shafts with a tension sensor and a cooling unit if it has four cooling shafts to a temperature of 20-25 ° C;

- the substrate is fed to the tension control device and the back side is printed, which is applied by nine printing machines with the printing ink of the pattern engraved on the printing shaft onto the polyvinyl chloride surface of the substrate with a print profile height of 0.5 microns, the integrity of the pattern is perceived only after the printing has passed all the printed substrates shafts of a given design with the appropriate tension of the base before and after passing through the places of raster printing;

- the base is centered until it is aligned with the axis of movement of its feed, in which a pair of pulling rollers feed it to the print compartment for printing on the back of the printed pattern, on the polyvinyl chloride surface of the back of the base, printing shafts, from 3 to 6, print the patterns 0.5 microns thick of all rubberized printing rolls of a given design;

- the drive controls the movement of the print rolls, a clear overlay of the pattern on the back side of the subbase, coincidence during the drawing of patterns of check marks located on both edges of the ends of the print rolls to assess the correctness of the pattern across the entire width and length of the base;

- the printing machine is equipped with a drive, a printing shaft, a doctor blade, an ink supply pump, a printing ink bath, rubberized compression shafts, load shafts, a drying chamber and a refrigerated shaft, a rubberized shaft, the face is pressed against the printing shaft during rotation, the shaft loads ensure uniform pressing of the rubberized shaft across the width of the base, it is not allowed to beat evenly without sinks, scratches and swelling of the surface of the printing shaft, pumping stations in the bath create a constant circus lation paint to prevent it from peeling, excessive ink from the surface of the printing shaft disposed horizontally removed cleaning blade which due to the reciprocating movements of the blade edge creates conditions of increased stability and maintain the quality of the working zone of the blade;

- printing machines are interconnected mechanically by drives and feed motion transmissions, which allow the position of the printing shafts relative to each other to correct rapport shifts and allow the machines to operate in different feed motion modes, after receiving the combined pattern on the front side of the base, the latter enters the drying chamber, where the process is carried out by drying with warm air, which for intermediate dryers is heated in the oil heat exchanger of the thermal burn compartment and is fed to ntilyatorom through damper system, at a temperature in the drying chamber of from 100 to 190 ° C;

- the subbase is guided through a shaft with a tension sensor, where it bends around the bypass shafts and enters the ultraviolet (UV) protection varnish application unit with the front side, the rubberized shaft, the front side substrate is pressed against the gummed shaft, which is used to apply UV protection varnish of a dosage thickness, and which the master shaft, rotating in the varnish bath, receives a dosed layer of UV protection varnish, the spread station creates a constant circulation of the varnish volume required for the work process, based on the UV protection varnish applied on it s enters for preliminary drying of the varnish layer into the drying chamber with a drying temperature of 80-100 ° С, then it is fed into the ultraviolet drying chamber with a maximum radiation power for fixing the varnish in three-dimensional space;

- after drying, the substrate with varnish UV protection enters the cooling device through a series of bypass rolls and devices for tensioning the substrate as a finished product, which ensure the continuity of the process in a small compensator;

- the substrate is centered and fed to the edge trimming device, which is packaged and sold in the production process, rolls the coils in the expansion joint, from where the flooring enters the technological department, where its presentation is determined, finished flooring rolls are packed and marked.

An example of a method of manufacturing a floor covering consists of: 1.1-1.4. unwinding of the base; 2.1-2.9. applying a primer PVC layer; 3.1-3.8. applying the front PVC layer; 4.1-4.7. printing; 5.1-5.8. applying a transparent PVC layer; 6.1-6.2. applying PVC flakes (chips); 7.1-7.7. applying a second transparent PVC layer; 8.1-8.8. applying a back PVC layer; 9.1-9.3. mechanical embossing; 10.1-10.5 back print; 11.1-11.2. applying varnish UV protection; 12. winding of the flooring, and more fully stated in accordance with the above positions:

1.1. the base is made in the form of fiberglass or needle-punched fabric;

1.2. before unwinding the roll, the substrates combine the edges of the previous and subsequent rolls;

1.3. gluing the near-end zones of fiberglass cloths or needle-punched cloth with adhesive tape, heat treatment and stitching of the second-hand zones of the previous and subsequent rolls with threads and with the necessary tension between the technological machines are sent to two loop unwinding compensators, where they form the supply of the base needed for gluing and stitching;

1.4. the subbase is centered along the axis of movement at a feed speed of 1-22 m / min;

2.1. in a two-roll drying device, the substrate is dried and, with the necessary tension, it is fed to the first alluvial device of the primer layer, called the doctor blade;

2.2. polyvinyl chloride paste is fed through a vibrating screen to a receiving container and a pastor;

2.3. PVC paste is applied to the subbase with a spreading shaft, taking into account the gap between the metal shaft or directly onto the base, the layer of PVC paste onto the base is regulated by a doctor blade and the rotation speed of the spreading shaft, the spreading spread or the base of the PVC paste is evenly distributed, smoothed and dosed on the base or spreading shaft when using the angle of inclination of the doctor blade support the impregnation of the base, matching this mode with the viscosity and fluidity of the PVC paste;

2.4. collect the falling PVC paste, exclude the drainage of PVC paste onto the base of the spreading machine and ensure the collection of PVC paste contaminated with industrial waste;

2.5. do not allow sagging of the base, in case of technological interruption of the process, provide directional movement to the PVC paste trough, do not allow the PVC paste to drain along the lateral edges of the base on the spreading shaft, by feeding the base, with the applied primer PVC primer layer;

2.6. under the infrared emitter, the fluidity of the PVC paste on the substrate is slowed down, providing an adequate degree of drying by 1-8 rows of emitters; during the supply of the substrate, the position of the heat flux of the emitters is changed;

2.7. the subbase with the front surface is pressed with a rubberized clamping shaft onto the surface of the thermal drum for gelation at a contact zone temperature of 144-151 ° C, providing the maximum possible uniform impregnation of the PVC substrate with the paste in the thickness and width of the applied layer, gelation of the PVC paste renders the fluidity impossible due to removal from excess plasticizer, give the PVC paste the proper strength and elasticity;

2.8. the surface of the drum polished to a mirror shine is smoothed over the adjacent side of the subbase and is pulled away from the heat-sealing drum by a take-up roller, bringing the sub-base to contact cooling with a pair of rolls up to 25 ° С, the adhered PVC paste is removed by the knife blade during heat-sealing;

2.9. with an oil temperature regulator, the temperature of the heat-regulating drum is automatically changed, the subbase is cooled by automatic water cooling;

3.1. the tensioner feeds the substrate onto the second alluvial device for applying the PVC paste from the front side, the substrate is fed to the applicator shaft, forming a gap with the doctor blade, where the PVC paste from the pastor is dosed and fed to the substrate, the amount of PVC paste applied is adjusted with the doctor blade with a given angle a cleaning knife and a selected speed of rotation of the spreading shaft, taking into account the gap between the edge of the blade of the doctor blade and the contact surface of the spreading shaft;

3.2. with the spreading shaft and the base layer, the PVC paste is evenly distributed, smoothed and dosed, the angle of the working surface of the doctor blade ensures impregnation of the substrate, exclude the drainage of PVC paste onto the base of the spreading machine and ensure the collection of PVC paste contaminated with production waste, do not allow sagging of the substrate in case of technological interruptions of the process provide directional movement of PVC paste into the trough, do not allow the PVC plate to run off along the lateral edges of the base on the spreading shaft;

3.3. by feeding a base, coated with PVC front layer paste, under an infrared emitter, slow down the fluidity of the PVC paste on the base, providing an adequate degree of drying by 1-8 rows of radiators, during the process of feeding the base, the position of the heat flux of the emitters is changed;

3.4. the subbase with the face surface is pressed with a rubberized clamping shaft onto the surface of the thermal drum for gelation heated with hot oil at a temperature of the contact zone from 144-151 ° С;

3.5. provide the maximum possibility of uniform impregnation of the base of PVC paste with the thickness and width of the applied layer;

3.6. by gelation, the PVC paste is deprived of fluidity by removing excess plasticizer from it, and the PVC paste is given adequate strength and elasticity;

3.7. the surface of the drum polished to a mirror shine is smoothed over the adjacent side of the subbase and it is pulled away from the heat-sealing drum by a take-up roller, bringing the sub-base to contact cooling with four cooling rolls to 25 ° С;

3.8. the adhered PVC paste is removed during the heat treatment by the knife blade, the cooled substrate is fed through the tensioner and the device to rotate the substrate 180 °, face down, sparging the air with the air through the perforated surface of the shaft forms an air cushion between the shaft surface and the supplied substrate, facilitating the process of its revolution ;

4.1. the sub-base again undergoes centering to align with the axis of movement of its feed, in which a pair of pulling rollers feed the sub-base into the print compartment for drawing on the front side of the printed pattern;

4.2. on the basis of the entrance to the printing department, the stage of regulating the tension by the master shaft before and after itself, necessary for printing the picture, on the polyvinyl chloride surface of the front side of the subbase, passes;

4.3. printing shafts, with a number from 3 to 6, prints of drawings with a thickness of 0.5 microns of all rubberized printing shafts of a given design;

4.4. the drive controls the movement of the printing shafts, provides a clear overlay of the pattern on the front side of the base, coincidence during the drawing process - rapport of check marks located on both edges of the ends of the print shafts, to evaluate the correctness of the pattern along the entire width and length of the base, the printing machine is equipped with a drive, a printing a shaft, a doctor blade, a pump for supplying ink, a bathtub for printing ink, pressure rubberized shafts, load shafts, a drying chamber and a refrigerating shaft, a rubberized shaft;

4.5. the subbase with the face side is pressed against the printing shaft during its rotation, the load shaft ensures uniform pressure of the rubberized shaft across the width of the base, preventing beats even without sinks, scratches and swelling of the surface of the printing shaft, pump stations in the bath create a constant circulation of ink to prevent its delamination, excess paint is removed from the surface of the print roll by a horizontally located doctor blade, which creates conditions for the reciprocating movements of the edge of the blade increased durability and maintaining the quality of the working area of the blade;

4.6. after receiving the combined pattern on the front side of the base, the latter enters the drying chamber, where the drying process is carried out with warm air, which for intermediate dryers is heated in an oil heat exchanger of the thermal ignition compartment and fed by a fan through a system of air dampers, at a temperature in the drying chamber from 80 to 120 ° С ;

4.7. it bends around the refrigeration shaft and enters the next printing press, the printing presses are interconnected mechanically by drives and feed motion transmissions, which allow the position of the print rolls to be adjusted relative to each other to correct marks shift and allow the machines to operate in different feed motion modes;

5.1. a pair of pulling rolls passes under the final drawing with the drawing; the device for regulating the tension of the subbase passes the dividing wall and enters the flip device, where the base is placed face up;

5.2. the subbase is oriented in the direction of the feed movement along the central axis, its tension is regulated and fed to a two-roll drying device, where the subbase is dried and fed with the necessary tension to the third spreading device, PVC paste is fed through a vibrating screen to the receiving container and the pastor;

5.3. PVC paste is applied to the subbase with a spreading shaft, taking into account the gap between the metal shaft or directly onto the subbase, the layer of PVC paste onto the subbase is controlled with a doctor blade and the rotation speed of the spreading shaft;

5.4. with a spreading shaft or a subbase, the PVC paste is evenly distributed, smoothed and dosed on the subbase or the spreading shaft, using the angle of inclination of the doctor blade, the substrate is impregnated, matching this mode with the viscosity and fluidity of the PVC paste;

5.5. collect the flowing down PVC paste, exclude the drainage of the PVC paste onto the base of the spreading machine and ensure the collection of the PVC paste contaminated with industrial waste, prevent sagging of the substrate, in case of technological interruption of the process provide directional movement into the trough of the PVC paste, do not allow the drainage of the PVC paste along the side edges subbases on an alluvial shaft;

5.6. by feeding a substrate with PVC paste applied under an infrared emitter, the fluidity of the PVC paste on the substrate is slowed down, providing an adequate degree of drying with 1-8 rows of emitters; during the process of feeding the substrate, the position of the heat flux of the emitters is changed;

5.7. the subbase with the front surface is pressed with a rubberized clamping shaft onto the surface of the thermal drum for gelation at a contact zone temperature of 144-151 ° C, providing the maximum possible uniform impregnation of the PVC substrate with the paste in the thickness and width of the applied layer, gelation of the PVC paste renders the fluidity impossible due to removal from excess plasticizer, give the PVC paste the proper strength and elasticity, the surface of the drum polished to a mirror shine smooths the adjacent side under the base and the take-up roll it is pulled from the heat-sealing drum, bringing the base to contact cooling with four cooling rolls up to 25 ° C;

5.8. the adhered PVC paste is removed by a knife blade during heat treatment, the substrate with the transparent PVC coated paste is fed face down, onto the surface of the gelling drum heated to a temperature of 145-150 ° C with hot oil, the coated substrate through the take-up roll is pulled from the thermal drum and guided for cooling the base to 25 ° C;

6.1. the substrate is fed to the device for applying PVC flakes on the front side of the base using 1-2 devices, the PVC flakes are applied to the front side of the base from the hopper of the distribution unit with a needle shaft or shaft with spikes with a feed of 20 to 300 g / m ² , the doctor blade is removed excess PVC flakes, which, falling on the surface of the base, adhere to the transparent PVC paste, forming a three-dimensional pattern, the sprinkled PVC flakes are recycled, and then reused, the substrate with the applied PVC paste and PVC flakes on the front surface is fed onto the surface of the thermo-drum heated with hot oil to 145-150 ° С, the coated substrate is pulled from the thermo-drum by a removable roller, the adhered PVC paste is cleaned with a scraper knife, it interacts with the tension sensor, which controls the tension of the substrate between the thermal drum and the smoothing unit, the sub-assembly passes infrared heating, where heating elements, an infrared sensor and a converter installed at the outlet of the mouth are involved in the heating of the front surface They are heated by infrared radiation, the intensity of which is controlled by the number of lamps turned on, the intensity of the incandescent lamps and the change in light flux relative to the moving front side of the subbase, which is fed to the smoothing unit, where the pressure rubber shaft and smoothing shaft, with a surface polished to a mirror shine, over the entire width of the base with the proper pressure necessary to press the PVC flakes into the transparent layer of the PVC paste, leveling and smoothing the front side of the surface odosnovy, is pulled off the shaft and smoothing tension measured between node smoothing and cooling to 25 ° C;

6.2. the substrate is fed by rolls due to their contact interaction with it;

7.1. applying the second transparent layer to the substrate is carried out in a two-roll drying device, where the substrate is dried and fed with the necessary tension to the fourth application of the primer layer, referred to as a doctor blade, the polyvinyl chloride paste is fed through a vibrating screen to a receiving container and pastor;

7.2. PVC paste is applied to the subbase with a spreading shaft taking into account the gap between the metal shaft or directly onto the base, the layer of PVC paste onto the base is controlled by a doctor blade and the speed of rotation of the spreading shaft, the spreading spread or smoothing PVC paste is evenly distributed, smoothed and dosed on the base or spreading shaft, using the angles of inclination of the doctor blade;

7.3. they support the impregnation of the base, matching this mode with the viscosity and fluidity of the PVC paste, collect the falling PVC paste, exclude the drainage of PVC paste onto the base of the spreading machine and ensure the collection of PVC paste contaminated with production waste, prevent the sagging of the base, in case of technological interruption of the process, provide directional the movement in the trough of PVC paste, do not allow the drainage of PVC paste along the lateral edges of the base on the spreading shaft;

7.4. by feeding a substrate with PVC paste applied under an infrared emitter, the fluidity of the PVC paste on the substrate is slowed down, providing an adequate degree of drying with 1-8 rows of emitters; during the process of feeding the substrate, the position of the heat flux of the emitters is changed;

7.5. the subbase with the front surface is pressed with a rubberized clamping shaft onto the surface of the thermal drum for gelation at a contact zone temperature of 144-151 ° C, providing the maximum possible uniform impregnation of the PVC substrate with the paste in the thickness and width of the applied layer, gelation of the PVC paste renders the fluidity impossible due to removal from excess plasticizer;

7.6. they give the PVC paste the proper strength and elasticity, the surface of the drum polished to a mirror shine smoothes the adjacent side of the subbase and is pulled away from the heat-sealing drum by a take-up roller, bringing the sub-base to contact cooling by a pair of rolls up to 25 ° C, the adhered PVC paste is removed by the knife blade during the heat-treatment;

7.7. the cooled web is turned face down, the temperature of the heat-regulating drum is automatically changed by the oil temperature regulator, automatic cooling of the water is used, which cool the base;

8.1. in a two-roll drying device, the base is dried and fed with the necessary tension to the fifth primer of the primer, called the doctor blade, the polyvinyl chloride paste is fed through a vibrating screen to the receiving container and the paste distributor, the PVC paste is applied to the substrate by the spread shaft taking into account the gap between the metal shaft or directly on the subbase, the layer of PVC paste on the subbase is regulated by a doctor blade and the speed of rotation of the spreading shaft, while the spreading shaft or the base of the PVC paste is evenly They identify, smooth and dose on a subbase or slurry shaft using the tilt angle of the doctor blade, support the impregnation of the subbase, matching this regime with the viscosity and fluidity of the PVC paste, collect the PVC flowing paste, exclude the PVC paste from dripping onto the base of the spreading machine and ensure the collection of PVC paste contaminated with industrial waste, do not allow sagging of the substrate, in the case of technological interruption of the process, they provide directional movement of PVC paste into the trough, do not allow the drainage of PVC pate on the sides m to the edges of the base on the spreading shaft, the PVC of the back layer through the vibrating screen with the help of a pneumatic pump enters the cube on the fifth spreading device and is dosed through the pastor on the moving base;

8.2. based on a paste of PVC applied to it, it enters the heat chamber for gelling, where the gelling temperature for the top or bottom of the base is in the range from 165 to 200 ° C, the temperature of the heat-regulating drum is automatically changed by the oil temperature regulator;

8.3. from the heat chamber, the subbase arrives at a cooling unit consisting of eight cooling shafts with a water temperature control interval of a substrate of 25 and 14 ° C, a compact layer of PVC is applied to the substrate on the back surface of the device containing the external shaft supporting the board and doctor blade;

8.4. in a two-roll drying device, the substrate is dried and, with the necessary tension, it is fed to the sixth alluvial device of the compact PVC layer, the polyvinyl chloride paste is fed through a vibrating screen to the receiving container and the pastor;

8.5. PVC paste is applied to the subbase with a spreading shaft, taking into account the gap between the metal shaft or directly onto the base, the layer of PVC paste onto the base is regulated by a doctor blade and the rotation speed of the spreading shaft, the spreading spread or the base of the PVC paste is evenly distributed, smoothed and dosed on the base or spreading shaft when using the angle of inclination of the doctor blade support the impregnation of the base, matching this mode with the viscosity and fluidity of the PVC paste;

8.6. collect the flowing down PVC paste, exclude the drainage of the PVC paste onto the base of the spreading machine and ensure the collection of the PVC paste contaminated with industrial waste, prevent sagging of the substrate, in the case of technological interruption of the process, provide directional movement into the trough of the PVC paste, do not allow the drainage of PVC pate along the side edges subbases on the spreading shaft, by feeding the subbase, with a compacted PVC layer applied;

8.7. under the infrared emitter slow down the process of fluidity of the PVC paste on the subbase, provide an adequate degree of drying by 1-8 rows of emitters, during the supply of the subbase, the position of the heat flux of the emitters is changed, the subbase is pressed with a rubberized pressure roller onto the surface of the thermal drum for gelation at a contact zone temperature, heated with hot oil from 144-151 ° С, providing the maximum possible uniform impregnation of the base with a compact PVC layer of paste in the thickness and width of the applied layer I, by gelation, PVC paste is deprived of fluidity by removing excess plasticizer from it, and PVC paste is given adequate strength and elasticity;

8.8. the surface of the drum polished to a mirror shine is smoothed over the adjacent side of the base and is pulled away from the heat-sealing drum by a take-up roller, bringing the base to contact cooling by a pair of rolls up to 25 ° C, the adhered PVC paste is removed by the knife blade during heat-sealing, the temperature of the fourth heat-regulating drum is automatically changed by the oil temperature regulator use automatic water cooling, with which they cool the base;

9.1. the tensioner serves the base on the mechanical embossing unit face up, the mechanical embossing on the front surface of the subbase is carried out by the embossing unit containing an infrared field, an embossing shaft, a rubberized and cooling shaft, and the infrared field undergoes a baseline in which the heating reaches a minimum of 140 ° C;

9.2. the subbase with the face side is pressed against the embossing shaft, the pressure during mechanical embossing is selected and manually adjusted using a hydraulic pressure valve, at a temperature of the rubberized shaft from 14 to 17 ° C, a relief pattern is applied on the embossing shaft, the height of which reaches 1-3 microns, in the embossing the shaft provides for a double cooling jacket with a temperature of 14-17 and 20-25 ° C;

9.3. the substrate from the embossing shaft is removed to the cooling shaft, the embossed support is fed to two shafts with a tension sensor and a cooling unit if it has four cooling shafts to a temperature of 20-25 ° C;

10.1. the substrate is fed to the device for regulating the tension and printing of the back side, which is applied by nine printing machines with the printing ink of the pattern engraved on the printing shaft onto the polyvinyl chloride surface of the substrate with the profile profile height of a print of 0.5 μm, the integrity of the pattern is perceived only after passing all printing shafts of a given design with the appropriate tension of the base before and after passing through the places of raster printing;

10.2. on the basis of centering, it is aligned with the axis of movement of its feed, in which a pair of pulling rolls feed it to the print compartment for printing on the back of the printed pattern, on the polyvinyl chloride surface of the back of the base, with print shafts, from 3 to 6, prints of patterns with a thickness of 0.5 microns of all rubberized printing rolls of a given design;

10.3. the drive controls the movement of the print rolls, a clear overlay of the pattern on the back side of the subbase, coincidence during the drawing of patterns of control marks located on both edges of the ends of the print rolls to assess the correctness of the pattern across the entire width and length of the base;

10.4. the printing machine is equipped with a drive, a printing shaft, a doctor blade, an ink supply pump, a printing ink bath, rubberized compression shafts, load shafts, a drying chamber and a refrigerated shaft, a rubberized shaft, the face is pressed against the printing shaft during rotation, the load shaft provide uniform pressing of the rubberized shaft across the width of the base, it is not allowed to beat evenly without sinks, scratches and swelling of the surface of the printing shaft, pumping stations in the bath create a constant circulation yatsiyu paint to prevent it from peeling, excessive ink from the surface of the printing shaft disposed horizontally removed cleaning blade which due to the reciprocating movements of the blade edge creates conditions of increased stability and maintain the quality of the working zone of the blade;

10.5. the printing machines are interconnected mechanically by drives and feed motion transmissions, which allow the position of the printing shafts relative to each other to correct rapport shifts and allow the machines to operate in different feed motion modes, after receiving the combined pattern on the front side of the base, the latter enters the drying chamber, where the process is carried out by drying with warm air, which for intermediate dryers is heated in the oil heat exchanger of the thermal burn compartment and supplied tilyatorom through damper system, at a temperature in the drying chamber of from 100 to 190 ° C;

11.1. the subbase is guided through a shaft with a tension sensor, where it bends around the bypass shafts and enters the ultraviolet (UV) protection varnish application unit with the front side, a rubberized shaft and the front side is pressed against the gummed shaft, which is used to apply UV protection varnish of a dosed thickness, and which is applied by the master - a shaft rotating in a bathtub with varnish receives a dosed layer of UV protection varnish, a stationary station creates a constant circulation of the varnish volume required for the work process, based on UV varnish applied on a varnish stumble in for preliminary drying lacquer layer in the drying chamber with a drying temperature 80-100 ° C, then fed into the drying chamber ultraviolet radiation with a maximum capacity for fixing the nail in the three-dimensional space;

11.2. after drying, the substrate with the varnish UV protection enters the cooling device through a series of bypass rolls and devices for tensioning the substrate as a finished product, which ensures the continuity of the process in a small compensator;

12. The support is centered and fed to the edge trimming device, which is packaged and sold in the production process, rolls the coils in the expansion joint, from where the flooring enters the technological department, where its presentation is determined, and the finished flooring coils are packed and marked.

The materials used in the implementation of the method are presented in the table.

The industrial usefulness of the new technical solution lies in more complete information and a description of the technological operations of linoleum, new in structure, related to floor coverings and used in industrial and domestic operating conditions.

The economic efficiency of the method consists in choosing the most optimal operations for the manufacture and control of the substrate, in the process of applying coatings of ultraviolet varnish, tensioning the substrate in different periods of its processing, the cooling operation of the linoleum canvas and other operations associated with a careful attitude to PVC paste, chips, when turning airbags.

Claims (1)

A method of manufacturing a floor covering, including unwinding of subbase rolls in the form of fiberglass or needle-punched fabric with adjustment of the coincidence of the edges of the previous and subsequent rolls, combining them by gluing with heat treatment or stitching with threads using a two-loop unwinding compensator to create a supply of the subbase, ensuring the continuity of these stages, the subsequent the direction of the subbase with a speed of 1-22 m / min under tension on the first application of the primer layer for ra the uniform application of polyvinyl chloride paste directly on a subbase or on a slurry drum, ensuring that the subbase does not bend with a paste that loses fluidity when passing under an infrared emitter, gelling the face layer of the subbase on the surface of the heat-sealing drum at 145-150 ° C, cooling to 25 ° C of the base, applying to this face surface the subbases of the face layer of polyvinyl chloride paste on the second application device, repeating the above operations and applying to this face surface l the basis of the print pattern with the corresponding color of printing ink with a thickness of 0.1-0.5 microns using 3-6 printing rollers, air drying in the chamber at 80-120 ° C, uniform double application of a transparent layer of polyvinyl chloride flakes on the front surface of the base with subsequent heat treatment, the formation of the planned pattern and cooling, applying a layer of polyvinyl chloride on the back surface of the subbase, mechanical embossing and printing of the back side of the subbase with drying at 100-190 ° C, applying varnish to the front surface and UV protection, drying, cooling and packaging in rolls.