WO2018113326A1 - 压延机、发泡地板生产线及一次成型生产工艺 - Google Patents

压延机、发泡地板生产线及一次成型生产工艺 Download PDF

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Publication number
WO2018113326A1
WO2018113326A1 PCT/CN2017/097794 CN2017097794W WO2018113326A1 WO 2018113326 A1 WO2018113326 A1 WO 2018113326A1 CN 2017097794 W CN2017097794 W CN 2017097794W WO 2018113326 A1 WO2018113326 A1 WO 2018113326A1
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WO
WIPO (PCT)
Prior art keywords
roll
cooling
calender
roller
embossing
Prior art date
Application number
PCT/CN2017/097794
Other languages
English (en)
French (fr)
Inventor
周玉亮
Original Assignee
青岛三益塑料机械有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN201710580999.5A external-priority patent/CN107186937A/zh
Priority claimed from CN201720863810.9U external-priority patent/CN207290700U/zh
Priority claimed from CN201720867916.6U external-priority patent/CN207072074U/zh
Application filed by 青岛三益塑料机械有限公司 filed Critical 青岛三益塑料机械有限公司
Priority to KR1020177030360A priority Critical patent/KR102019446B1/ko
Priority to US15/855,533 priority patent/US20190016024A1/en
Publication of WO2018113326A1 publication Critical patent/WO2018113326A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/24—Calendering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/46—Rollers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/46—Rollers
    • B29C2043/461—Rollers the rollers having specific surface features
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/46—Rollers
    • B29C2043/461—Rollers the rollers having specific surface features
    • B29C2043/463—Rollers the rollers having specific surface features corrugated, patterned or embossed surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/46—Rollers
    • B29C2043/467—Rollers plurality of rollers arranged in a specific manner in relation to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/52—Heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/732—Floor coverings

Definitions

  • the present application relates to the field of mechanical manufacturing, and in particular relates to a one-step production process of a calender, a foamed floor production line and a foamed floor.
  • foamed flooring Compared with traditional wooden flooring, foamed flooring has the following advantages: (1) soft texture, good moisture-proof and waterproof performance, good elastic performance, good elastic recovery under heavy impact, and not easy to damage; (2) green and environmental protection Products that can be recycled by resources; (3) have good flame retardancy and high safety factor; (4) low cost, cheaper than wooden flooring; Based on the above, the foamed floor has a large development prospect and application space.
  • Foamed flooring is usually produced by multi-layer composite processing.
  • WPC wood-plastic composite flooring
  • it usually includes an intermediate foam layer covering a solid layer on both sides of the intermediate foam layer.
  • a non-slip layer may be disposed on the surface of a solid layer
  • a color film layer may be disposed on the surface of another solid layer as a decorative layer
  • a wear layer is provided to enhance the wear resistance of the floor and prolong its Service life.
  • the processing of foamed floor requires the use of a calender.
  • the calender usually comprises more than two rolls, which include mirror rolls, embossing rolls, anilox rolls, matting rolls, etc. Each roll has a different function, calendering
  • the machine completes the processing requirements of different materials to be processed through the combination of different rollers and the control of the temperature of the rolls.
  • the processing technology includes various processes such as thickness rolling, floor bottom grain rolling and floor surface pattern rolling. In the prior art, it is usually subjected to mirror calendering treatment by mirror roll, and then directly subjected to embossing and embossing treatment.
  • the temperature of the PVC foamed floor after being discharged by the mirror roll is high, it is affected by the foaming performance of the floor.
  • the embossing and embossing treatment is directly performed, the embossing effect of the embossing is not good, and the embossing effect on one side is not good, and the pattern is rebounded after embossing.
  • the production process of the foamed floor is as follows: extrusion substrate - sanding surface - gluing - lamination - stacking - cold pressing - health (constant temperature workshop placed for a period of time) - slitting - slotting - detection Packaging - begging - storage and packing.
  • extrusion substrate - sanding surface - gluing - lamination - stacking - cold pressing - health (constant temperature workshop placed for a period of time) - slitting - slotting - detection
  • Packaging - begging - storage and packing.
  • Chinese patent CN105459422A discloses a one-time processing polyvinyl chloride (PVC) floor forming mechanism, including a mixer, an extruder, a loading machine, a mold, a calender, and the like.
  • PVC polyvinyl chloride
  • the various powders are stirred and mixed and extruded, and the preforms processed by the mold directly enter the roller shaft assembly of the calender to complete processes such as calendering, laminating, embossing and the like.
  • the above conventional processing technique has the following problems: since the rolls of the calender are all in a high temperature state, After the finished product embryo is discharged from the high temperature mold, it directly enters the high temperature roller shaft. During the whole rolling and embossing process, the preform is always in a high temperature state, which will affect the calendering and embossing performance. Similar to the above-mentioned adverse effects, there is a problem that the embossing pressure does not rise, or the pattern bounces after the flower is pressed.
  • the purpose of the present application is to provide a calender, and at the same time, to solve the problems of the existing foamed floor production process, to provide a foamed floor production line, and to provide a foamed floor primary molding production process.
  • the present invention provides the following contents:
  • the calender comprises a machine base and a calender roll set arranged on the machine base; the calender roll set comprises a main calender roll set and an emboss roll set for embossing the material to be processed; the main calender roll set described herein It refers to a roller set consisting of a calender roll including a mirror roll.
  • the main calender roll group can be all mirror rolls, and other types of calender rolls can be selected according to requirements.
  • the configuration of the embossing roller set depends on the embossing requirements. For example, some materials are embossed on both sides, and some require only one-sided embossing, different requirements, and different configurations.
  • the main calender roll group completes one or several of the process steps of flattening, filming, extinction, and matte, and in order to ensure that the embossing effect is not destroyed, the embossing process is usually placed after the above process.
  • the calender roll group sequentially includes a main calender roll group and an emboss roll set for embossing the material to be processed.
  • the main calender roll set is spaced apart from the emboss roll set. Specifically, the discharge end of the main calender roll set is spaced apart from the feed end of the emboss roll set by a distance therebetween so that the material is in the distance.
  • One roll group can be cooled before entering another roll set.
  • the discharge end of the mirror roll set can be cooled before entering the feed end of the emboss roll set.
  • This distance is not a fixed distance, depending on the processing demand, for example, it may be 0.5 m, 0.8 m, 1 m, or the like.
  • a cooling roll set is disposed between the main calender roll set and the emboss roll set, for example, a cooling roll set is disposed between the final discharge end of the main calender roll set and the feed end of the emboss roll set.
  • the cooling roller group is not designed, the material is naturally cooled, and the auxiliary design of the cooling roller group can speed up the cooling rate of the material, so that the distance between the main calendering roller group and the embossing roller group can be correspondingly reduced.
  • the calender is more compact.
  • the calender includes, in order, a cooling sizing device, a main calender roll group, and an embossing roll group.
  • the cooling sizing device is used to shape the material by means of cooling.
  • the cooling sizing device comprises a first cooling component and a second cooling component arranged at intervals, and a gap between the first cooling component and the second cooling component can accommodate the passage of the material to be processed and ensure that the material to be processed passes through Both the first cooling component and the second cooling component are in contact to cool the shape.
  • the cooling sizing device comprises a first cooling roller and a second cooling roller arranged in pairs, or in pairs a first cooling sizing plate and a second cooling sizing plate disposed separately, or a first cooling roller and a second cooling roller disposed in pairs, and a first cooling sizing plate and a second cooling sizing plate disposed in pairs combination.
  • the first cooling roller and the second cooling roller disposed at intervals may be selected as a cooling sizing device, so that the material passes through the gap between the two rollers, and is cooled and shaped;
  • the first cooling sizing plate and the second cooling sizing plate may also be selected as the cooling sizing device to pass the material from the gap between the two sizing plates to cool the sizing; or alternatively, the first cooling roller and the second cooling may be included.
  • the roller which in turn comprises a combination of two sets of cooling devices of the structure of the first cooling sizing plate and the second cooling sizing plate, serves as a cooling sizing device for sequentially passing the materials through the two sets of cooling devices.
  • a cooling pipe for introducing a coolant is disposed in the first cooling roller and the second cooling roller; and a cooling pipe for introducing the coolant is also disposed in the first cooling shaping plate and the second cooling shaping plate. .
  • the first cooling roller and the second cooling roller, and/or the first cooling shaping plate and the second cooling shaping plate are connected with a cooling gap adjusting device, the cooling gap adjustment The device is used to adjust the gap between the two cooling rolls or between the two cooling plates for the passage of different size plates.
  • the cooling sizing device sequentially includes a first cooling sizing plate and a second cooling sizing plate disposed in pairs, and a first cooling roller and a second cooling roller disposed in pairs.
  • the combination of the cooling plate has a better setting effect than the combination of the cooling rolls.
  • the shape of the material has been basically formed, and then the auxiliary flattening is performed by the combination of the cooling rolls, so that a better flattening effect can be achieved.
  • the embossing roll set comprises a pattern roll or an anilox roll, or a combination of a pattern roll and an anilox roll, the pattern roll and the anilox roll being respectively arranged to be in contact with the material to be processed which is to be embossed.
  • the pattern roll is disposed on the side in contact with the top surface of the foamed floor
  • the anilox roll is disposed on the side that is connected to the bottom surface of the foamed floor.
  • the structure of the embossing roll set can also be improved according to the embossing requirements. For example, when only one-sided embossing is required, only the pattern roll or the anilox roll can be disposed.
  • the calender further includes a film winding mechanism, and a guide bonding mechanism for guiding the film wound by the film winding mechanism to the main calender roll group, the guide bonding mechanism including the guide wheel and the main rolling
  • the calender rolls in the roll set are laminating rolls provided with a gap.
  • the guide wheel may be a single guide wheel or a guide wheel set, and its function is to cooperate with the bonding roller to guide the film wound by the film winding mechanism to a desired position.
  • the laminating roller is disposed adjacent to the calendering roll in the main calender roll group to conform the desired film before passing the material through the gap between the calender rolls in the main calender roll group.
  • the main calender roll group may include a plurality of calender rolls, specifically to which calender roll position, depending on processing requirements.
  • the film winding mechanism includes a bottom film winding mechanism for winding the base film, and a color film roll for winding the color film.
  • a discharge mechanism for winding the base film
  • a wear-resistant film take-up mechanism for winding a wear-resistant film, or any combination of the three; and, if the base film take-up mechanism is configured to guide the base film to one side of the material,
  • the color film take-up mechanism and the wear-resistant film take-up mechanism are configured to direct the color film and the wear resistant film to the other side of the material.
  • Different processing needs, the type of film required will be different. For foamed floor processing, for example, one of the base film, color film or wear film may be required, or a combination of two or three, according to the demand.
  • the base film and the other two films are usually attached to different sides of the foamed floor, the base film is attached to the side close to the ground, and the color film and the abrasion resistant film are attached away from the ground. On one side, therefore, the position at which the film is directed is different.
  • the method further includes an auxiliary bonding roller provided at a rear end of the bonding roller and disposed at the same calender roll as the bonding roller, and provided with a gap from the calendering roller.
  • the bonding roller first laminates the film, and the auxiliary bonding roller further performs auxiliary bonding to ensure a firmer bonding of the film.
  • the bonding roller and the auxiliary bonding roller are each connected to a gap adjusting device for adjusting a gap between the calendering roller and the calendering roller in the main calendering roller group.
  • the structure can adapt to different material thickness and processing requirements of different material thicknesses, adjust the gap between the bonding roller and the auxiliary bonding roller and the calendering roller to ensure the bonding quality and the material thickness processing requirements.
  • Foamed floor production line including the above calender.
  • the foaming floor one-time forming process is realized based on the above foamed floor production line, and includes the following steps: after the material is discharged by the main calender roll group, it is cooled by walking, and then enters the embossing roll group for embossing.
  • the temperature after cooling of the material is determined by the material characteristics and embossing requirements, and is not a fixed value.
  • the method further comprises the following steps: the material is first cooled and shaped by a cooling sizing device, and then enters the main calender roll group.
  • the purpose of cooling and setting is to avoid wavy bending of the material and to ensure the final processing quality.
  • the main calender roll group sequentially comprises, the first mirror roll, the intermediate mirror roll and the discharge end calender roll, and the temperature of the discharge end calender roll is higher than the temperature of the first mirror roll.
  • the first mirror roller is a calender roll near the discharge end of the cooling setting device in the processing flow; the calender roll at the discharge end is a calender roll near the embossing roll group in the processing flow; and the intermediate mirror roll is a material which is driven by the first mirror roll The transition calender roll that passes through the calender rolls at the discharge end.
  • the main calender roll group comprises, in order, a first mirror roll, an intermediate mirror roll set composed of at least two intermediate mirror rolls, and a discharge end calender roll, the first mirror roll and adjacent thereto
  • the temperature of the intermediate mirror roll is set to 30-90 ° C
  • the temperature of the calender roll at the discharge end is set to 150-190 ° C
  • the temperature of the intermediate mirror roll adjacent to the discharge end calender roll is set to 90-170 ° C.
  • the temperature of the pattern roll was set to 160-190 ° C
  • the temperature of the anilox roll was set to 160-190 ° C.
  • the production line further comprises a mixing machine and a feeding machine. After the material enters the mixing machine, the cold material is mixed and stirred again during the heating and stirring process, and then cooled to be sent to the loading machine.
  • the composition of the calender surface of the calender roll and the embossing roll are set.
  • the cooling roll can be designed for auxiliary cooling.
  • the properties of the material will change, which is conducive to the quality of subsequent processing. For example, in the process of foaming the floor, after the mirror roll group is discharged, after a certain distance, it enters the embossing roll group. In this process, the foamed floor temperature is lowered, and a better embossing embossing effect can be achieved.
  • This application has studied a set of temperature control strategies, through the setting of the temperature of the main calender roll group and the embossing roll set, combined with the structural design of the cooling section between the cooling device, the main calender roll set and the embossing roll set, The modification of the material during the process of high temperature and low can greatly improve the embossing effect of the finished product and reduce the scrap rate.
  • the process provided by the present application specifically includes: one-step molding-health-cutting-grooving-detecting packaging-setting-in-storage packing, which is omitted from the conventional production process, and the process omits the steps of coating, laminating and the like. , saving equipment and saving floor space. Since there is no need to apply glue, material can be saved; since sanding is not required, dust pollution can be reduced; the production line adopts flow-through operation, which can save labor costs.
  • FIG. 1 is a schematic structural view of the calender described in Embodiment 1;
  • Figure 2 is a schematic view showing the structure of a main calender roll group and an embossing roll set
  • FIG. 3 is a schematic structural view of a cooling sizing device
  • Figure 5 is a schematic structural view of the calender described in Embodiment 3.
  • FIG. 6 is a schematic structural view of a bottom film winding mechanism and a bottom film guiding and bonding mechanism in Embodiment 3;
  • FIG. 7 is a schematic structural view of a wear-resistant film winding mechanism and a wear-resistant film guiding and bonding mechanism in Embodiment 3;
  • FIG. 8 is a schematic structural view of a color film winding mechanism and a color film guiding and bonding mechanism in Embodiment 3;
  • Figure 9 is a schematic view showing the structure of the auxiliary bonding roller in the third embodiment.
  • Figure 10 is a schematic structural view of a production line of a foamed bottom plate
  • Figure 11 is a schematic plan view of the production line.
  • the “bottom surface” refers to the side that contacts the ground after the foamed floor is installed
  • the “top surface” refers to the side that contacts the user after the foamed floor is installed, and is not to be construed as limiting the present application.
  • the terms “first,” “second,” and “third” are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
  • the "traveling direction” and the “feeding direction” described in this embodiment are used to assist in the processing flow of the material, and the "front” and “front end” are used to indicate the first completed process in the processing flow, “rear” and “rear” “End” is used to indicate the process that is completed later in the process flow.
  • the embodiment provides a calender 1 which can complete embossing or embossing on both sides of the bottom surface and the top surface of the material to be processed.
  • the slab of the foamed floor is used as the material to be processed.
  • the material to be processed is not limited to the slab of the foamed floor.
  • the calender 1 includes a stand 11 and a calender roll set arranged on the stand 11.
  • the calender roll group sequentially comprises a main calender roll set 12 and a double-sided embossing for the slab of the foamed floor. Embossing roller set 13.
  • FIG. 1 A schematic diagram of an embodiment of a calender is described with reference to FIG. 1
  • the main calender roll group 12 refers to a roll group consisting of a calender roll including a mirror roll, and the main calender roll group may all be a mirror roll, and other types of calender rolls may be selected according to requirements.
  • the main calender roll group 12 includes a first mirror roll 1201 arranged in a gap, and an intermediate mirror surface composed of the intermediate mirror roll. The roll set and the discharge end calender roll, the slab of the foamed floor pass through the gap between each adjacent calender roll.
  • the initial feeding end of the main calender roll group; the feed end between the intermediate mirror rolls and between the intermediate mirror roll and the discharge end calender roll is the feed end between the rolls, the discharge roll at the discharge end and the middle adjacent thereto
  • the discharge end of the mirror roll is the final discharge end of the main calender roll set.
  • the discharge roller at the discharge end can be selected into various types of calender rolls depending on the processing requirements.
  • the main calender roll group 12 includes a first mirror roll 1201 disposed in a gap, a first intermediate mirror roll 1202, a second intermediate mirror roll 1203, and a matting roll 1204 (extinction
  • the roller 1204 is a discharge end calender roll, which may also be replaced by a mirror roll, a sanding roll or the like, and the first mirror roll 1201 and the first intermediate mirror roll 1202 are oriented toward the feed direction as the main calender roll.
  • the first mirror roller 1201 and the first intermediate mirror roller 1202 are each connected with a motion driving mechanism, and the rotation directions of the two are opposite (the rotation direction refers to the direction of the arrow in the drawing); the second intermediate mirror roller 1203 and the extinction roller 1204 are also connected. There is a motion drive mechanism, and the directions of rotation of the two are opposite (the direction of rotation refers to the direction of the arrow in the illustration).
  • the discharge ends of the second intermediate mirror roller 1203 and the extinction roller 1204 are the final discharge ends of the primary calender roll group 12.
  • the slab of the foamed floor enters the embossing roll set 13 through the final discharge end of the main calender roll set 12 to perform the embossing process.
  • the number of intermediate mirror rollers and the spacing between the mirror rollers can be configured in combination with the material condition and the need for mirror calendering.
  • three intermediate mirror rollers can also be used.
  • the more compact structure may be selected without the intermediate mirror roll and only the first mirror roll 1201 and the discharge end calender roll.
  • the embossing roll set 13 includes a pattern roll 1301 and an anilox roll 1302 disposed in a gap, and the pattern roll 1301 and the anilox roll 1302 are respectively disposed to be in contact with the material to be processed different from the embossed surface.
  • the anilox roll 1302 is disposed on the side in contact with the bottom surface of the slab of the foamed floor
  • the pattern roll 1301 is disposed on the side in contact with the top surface of the slab of the foamed floor.
  • the structure of the calender is explained by the double-sided embossing of the slab of the foamed floor.
  • the pattern roller 1301 may be omitted, and a mirror roller is disposed at one end in contact with the top surface of the slab of the foam floor instead of the pattern roller 1301;
  • the anilox roller 1302 may be omitted, and a mirror roller is disposed at one end in contact with the bottom surface of the slab of the foamed floor.
  • the temperature of the calender rolls in the main calender roll group 12 and the emboss roll set 13 is generally high, if the slab of the foamed floor directly enters the embossing roll set 13 from the final discharge end of the calender roll set 12, at a high temperature, The slab embryo of the foam floor has good elasticity and hot rise, and most of the pressed pattern will bounce, resulting in poor embossing effect.
  • the final discharge end of the main calender roll group 12 is spaced apart from the feed end of the emboss roll set 13 so that the slab of the foamed floor passes through the final discharge end of the main calender roll set 12 and
  • the feed end of the embossing roll set 13 can be cooled before.
  • This distance is set according to various parameters such as the performance and thickness of the slab of the foamed floor, and is not a fixed value.
  • the processing of the foamed floor is taken as an example, and the distance is 100 cm (it is necessary to explain that the distance is not too far, but it is only a little away from the embossing, and the pattern is too far or the cooling is too large.
  • the slab of the foamed floor before entering the embossing roll group 13 has been cooled, it has a cold shrinkage property and is subjected to high temperature embossing, and the pattern quality is high.
  • the processing of the foamed floor after walking for a certain distance, it is cooled to about 110-130 ° C, depending on the thickness of the wear-resistant film and the thickness of the foamed floor.
  • the desired embossing effect depends on the performance and needs of the slab of the foamed floor.
  • the slab of the foamed floor can be cooled by air by setting the main calender roll group 12 at a distance from the embossing roll set 13. For a better cooling effect, the cooling rate of the slab of the foamed floor is accelerated, and a chill roll set is provided between the final discharge end of the main calender roll group 12 and the feed end of the embossing roll set 13, the chill roll 14 having The function of cooling and guiding, the slab of the foamed floor walks above the chill roll 14, is further cooled by the chill roll 14, and enters the feed end of the embossing roll set 13.
  • the distance between the main calender roll group 12 and the emboss roll group 13 can be reduced, for example, in the present embodiment, this distance can be reduced to 80 cm. This is advantageous in reducing the volume of the entire calender.
  • the embossing guide mechanism is a guide wheel set consisting of a plurality of guide wheel arrangements.
  • the calender is usually processed in the form of a flat plate, usually by placing the hot extrudate into a calender.
  • the hot extrudate usually treated by the extruder and the mold does not guarantee good flatness, and is usually wavy and curved.
  • the calender 1 further comprises cooling in front of the initial feed end of the main calender roll group 12 for processing the material to be processed.
  • the sizing cooling sizing device 15 includes a first cooling component and a second cooling component disposed at intervals, and a gap between the first cooling component and the second cooling component can accommodate the passage of the material to be processed and ensure that the material to be processed passes Both the first cooling component and the second cooling component are in contact.
  • the structure of the cooling sizing device 15 in this embodiment is as shown in FIG. 3, and the calender equipped with the cooling sizing device 15 is as shown in FIG.
  • the cooling sizing device 15 is disposed at the front end of the feeding end of the first mirror roller 1201 and the first intermediate mirror roller 1202 in the incoming direction, and includes a cooling roller group, specifically including a first cooling roller 1501 and a second cooling disposed in a gap.
  • a roller 1502 in which the first cooling roller 1501 and/or the second cooling roller 1502 are provided with a cooling pipe for adding a cooling liquid, that is, in order to enable the cooling roller to perform cooling, at least to ensure
  • a cooling line is arranged in one of the two cooling rolls, and in order to achieve a uniform cooling effect, a cooling line may be provided in both cooling rolls, and a cooling liquid is introduced into the cooling line to pass the cooling. The heat exchange between the liquid and the plate achieves the cooling of the plate.
  • the cooling line includes a coolant inlet and a coolant outlet, and the replacement of the coolant can be achieved.
  • the cooling member may adopt other forms of structure, such as a cooling setting plate disposed at a pair of intervals.
  • the first cooling roll 1501 and/or the second cooling roll 1502 are connected with a cooling gap adjusting device.
  • the first cooling roller 1501 is located above the second cooling roller 1502, and the first cooling roller 1501 is connected with a gap adjusting device for adjusting the cylinder 1503 for the first cooling gap.
  • the adjustment of the gap between the first cooling roller 1501 and the second cooling roller 1502 is achieved by the first cooling gap adjusting the expansion and contraction of the cylinder 1503.
  • the sheet to be processed passes through the gap between the first cooling roller 1501 and the second cooling roller 1502, and the cooling and shaping of the sheet to be processed can be completed.
  • the cooling sizing device 15 further includes a first cooling sizing plate 1504 and a second cooling sizing plate 1505 which are installed in pairs, spaced apart, and the gap between the sizing plates can accommodate the passage of the plates and ensure the passage of the plates. Contact with both sizing plates.
  • the shaping plate is in the form of a flat plate, and the flat plate can be pressed better than the cooling roll to shape the plate.
  • the first cooling sizing plate 1504 and the second cooling sizing plate 1505 are provided with a cooling pipe for adding a cooling liquid, and at least one cooling sizing plate is provided with a cooling gap adjusting device.
  • the first cooling sizing plate 1504 is located above the second cooling sizing plate 1505, and the first cooling sizing plate 1504 is mounted with a cooling lash adjusting device for adjusting the cylinder 1506 for the second cooling gap.
  • the cooling sizing plates 1504, 1505 are located at the front end of the chill roll group.
  • the direction indicated by the arrow in Fig. 3 is the direction in which the plate travels during the working process. That is, during the processing, the plate is first cooled by the cooling plate, and the plate is subjected to extrusion cooling and shaping, and then the cooling roller group is used for auxiliary extrusion cooling and setting. It then enters the main calender roll group 12. In order to ensure that the sheet can pass smoothly through the cooling sizing device 15, the gap between the first cooling roll 1501 and the second cooling roll 1502 is at the same level as the gap between the cooling sizing plates.
  • the combination of the first cooling roller 1501 and the second cooling roller 1502 may also be omitted depending on the needs of cooling setting or A combination of the first cooling sizing plate 1504 and the second cooling sizing plate 1505.
  • a calender having a film calendering function for a material to be processed is further provided.
  • the slab of the foamed floor is still used as the material to be processed to illustrate its structure and implementation process.
  • the calender 1 further includes a laminating film winding mechanism including a base film take-up mechanism 161, a wear-resistant film take-up mechanism 171, and a color film take-up mechanism 181, based on Embodiment 1 or Embodiment 2.
  • a laminating film reeling mechanism described herein includes two reeling wheels. During the winding and filming process, one performs the main work and the other performs the standby.
  • the film folding mechanism includes a bottom film winding mechanism 161 for winding a base film, a wear film winding mechanism 171 for winding a wear film, and a roll.
  • the calender 1 further includes a base film guiding and bonding mechanism 162 for guiding the base film to the feed end of the main calender roll group 12 for guiding the wear film to the main calender roll group 12 to feed between the rolls.
  • the end wear-resistant film guiding bonding mechanism 172, and the color film guiding bonding mechanism 182 for guiding the color film to the feeding end of the main calender roll group 12 between the rolls.
  • the wear-resistant film and the color film are both guided to the front of the feed end between the second intermediate mirror roll 1203 and the matte roll 1204; It is guided to the front of the feed end between the first intermediate mirror roll 1202 and the second intermediate mirror roll 1203 to achieve that the base film and the other two films are attached to different faces of the slab of the foamed floor.
  • the base film, the color film and the wear-resistant film are not limited to being guided to the above position, as long as the film can be applied according to the bonding surface, for example, the color film and the abrasion resistant film can also be used.
  • the base film Guided to the initial feed end of the main calender roll set 12, the base film can also be directed to the final discharge end of the main calender roll set 12.
  • FIG. 6 is a schematic view of the structure of the base film take-up mechanism 161 and the base film guide attaching mechanism 162 and its cooperation with the calender roll;
  • FIG. 7 is a wear-resistant film take-up mechanism 171 and a wear-resistant film guide lamination mechanism 172.
  • FIG. 8 is a schematic view showing the structure of the color film winding mechanism 181 and the color film guiding and bonding mechanism 182 and its cooperation with the calender roll.
  • the base film guiding and bonding mechanism 162 includes a base film guiding wheel 1621 and a base film bonding roller 1622 disposed in a gap with the first intermediate mirror roller 1202.
  • the base film bonding roller 1622 is connected to adjust the first intermediate mirror surface.
  • the first gap of the gap between the rollers 1202 adjusts the cylinder 1623.
  • the wear-resistant film guiding and bonding mechanism 172 includes a wear-resistant film guiding wheel 1721 and a wear-resistant film bonding roller 1722.
  • the color film guiding and bonding mechanism 182 includes a color film guiding wheel 1821 and a color film bonding roller 1822.
  • the wear-resistant film bonding roller 1722 and the color film bonding roller 1822 are respectively connected with a gap adjusting device for adjusting a gap between each of the intermediate mirror rollers (specifically, the second intermediate mirror roller 1203), wherein the wear-resistant film is attached.
  • the closing roller 1722 is connected with a second gap adjusting cylinder 1723, and the color film is attached.
  • the third roller adjusting cylinder 1823 is connected to the closing roller 1822. Since the surface of the color film is pasted with a wear-resistant film during the processing, the wear-resistant film bonding roller 1722 is located behind the color film bonding roller 1822, see FIG.
  • the calender 1 further includes an auxiliary bonding roller 19 which is disposed at the rear end of the bonding roller and disposed at the same calender roll as the bonding roller, and is provided with a gap from the calendering roller.
  • the auxiliary bonding roller 19 is disposed at the feed end between the rollers between the second intermediate mirror roller 1203 and the extinction roller 1204, and the auxiliary bonding roller 19 is located at the wear-resistant film bonding roller 1722. In the rear, the function is to further press and paste the attached color film and the wear-resistant film.
  • the auxiliary bonding roller 19 is connected to a gap adjusting device for adjusting the gap between the auxiliary bonding roller 19 and the calendering roller.
  • the fourth gap adjusting cylinder 1903 is provided.
  • the auxiliary bonding roller 19 may be disposed for the bonding of the base film, and as shown in FIG. 6, may be disposed behind the base film bonding roller 1622, the first intermediate roller 1202 and the second intermediate roller 1203. At the feed end.
  • the complete workflow is: after the slab of the foamed floor is cooled and shaped, the gap between the first mirror roll 1201 and the first intermediate mirror roll 1202 enters the main calender roll group 12, and then the "S" curve is formed along with the calender roll.
  • the bottom film is attached (the auxiliary bonding roller 19 auxiliary sticker can be selected or not)
  • the color film attached to the color film winding mechanism 181 is attached, and in the process, the color film bonding roller 1822 auxiliary bonding; subsequently, it is adhered to the wear-resistant film wound by the wear-resistant film winding mechanism 171, in the process, the wear-resistant film bonding roller 1722 assists the bonding; and then, the auxiliary bonding roller 19 will be pressed
  • the embossing of the wear-resistant film, the color film and the foamed floor after pressing, it enters between the second mirror roll 1203 and the matting roll 1204 for rolling.
  • the second intermediate mirror roller 1203 and the extinction roller 1204 are discharged from the discharge end, and then cooled to enter the embossing roller group 13, and the embossing and embossing process is completed. At this point, a complete film, bottom embossing and top embossing process can be completed.
  • the calender provided in this embodiment can complete the whole process material processing work of cooling setting, rolling shaping, double embossing and embossing.
  • This embodiment provides a foamed floor production line in which the calender 1 of Examples 1-3 is used for foamed floor production.
  • the mixing machine 2 is sequentially included (the mixing machine silo is shown in the figure to simplify the representation of the mixing machine), the loading machine 3, the extruder 4, and the mold 5
  • the calender 1 is the calender 1 according to any one of the embodiments 1-3, and the structure thereof will not be described again here.
  • the mixer 2 is used for the mixing of the powder, and various materials for producing the foamed floor are introduced into the mixer 2 to be stirred at a high speed.
  • the mixture after the agitation is placed in the silo of the feeder 3, and then fed by the feeder 3 to the hopper of the extruder 4.
  • the extruder 4 since the foamed floor is processed by multi-layer material composite processing, it is mainly composed of a foam layer and a solid layer on both sides of the foam layer. Before the extrusion into the mold 5, the discharge of the foam layer and the two solid layers is completed. Therefore, the extruder 4 includes two extruders, and each of the corresponding extruders corresponds to the respective mixer. And loading machine. The two extruders are arranged at an angle. In this embodiment, the angle between the two extruders is 60°, with reference to FIG.
  • the second extruder 402 is used to extrude a solid layer that covers both sides of the foam layer, respectively. Since the second extruder 402 is provided with a dispenser, the extrudate is a two-layer solid layer, and the two solid layers are respectively covered on both sides of the foam layer, and after preliminary bonding, enter the mold 5.
  • the mold 5 is used to process materials, specifically to the present embodiment, as a three-layer slab.
  • the calender 1 is located at the rear end of the mold. Since the temperature of the mold 5 is high, the three-layered slab is subject to wave bending after being discharged through the mold 5.
  • the front end of the calender 1 is provided with a cooling sizing device 15 for cooling and shaping the three-layer slab.
  • the cooling and setting process is as follows: after the three-layer slab is discharged through the mold 5, it first enters the cooling sizing device 15 for cooling and setting. Specifically, after discharging through the mold 5, first entering the gap between the first cooling shaping plate 1504 and the second cooling shaping plate 1505, the cooling shaping plate is in the form of a flat plate, and the inside is connected with the cooling liquid, and is exchanged with the three-layer slab. Heat is cooled to shape. After cooling the sizing plate, the three-layer slab has been substantially flat, and then enters the gap between the first chill roll 1501 and the second chill roll 1502 for auxiliary cooling setting.
  • the gap between the first cooling sizing plate 1504 and the second cooling sizing plate 1505, and between the first cooling roll 1501 and the second cooling roll 1502 may be adjusted according to the requirements for the thickness of the three-layer slab. If the two gaps are large, the thickness of the three-layer slab after discharge is large, and if the gap is small, the thickness of the three-layer slab after discharge is small.
  • the three-layer blank After discharging through the first cooling roll 1501 and the second cooling roll 1502, the three-layer blank will enter the initial feed end of the main calender roll set 12, passing through the film, bottom embossing and top surface described in Example 3. After the embossed workflow, proceed to the subsequent processing steps.
  • a cooling bracket 6, a tractor 7, an arch bracket 8, a precision shearing machine 9, a conveying bracket 20, an automatic lifting machine 21, etc. are provided. Complete the process of cooling, shaping, cutting, etc. of the foamed floor.
  • the embodiment provides a processing technology for forming a foamed floor at a time. Compared with the conventional processing technology, the process omits the steps of coating, laminating, etc., thereby saving equipment and occupying space.
  • the one-time forming process specifically includes the following steps:
  • the equipment with temperature working such as the mixer 2, the feeder 3, the extruder 4, and the mold 5 is provided. Preheating before warming and keeping warm.
  • the preheating time depends on the demand. In this embodiment, the warm-up time is 2 hours.
  • the purpose of warming is to start the mixing, extrusion and other work after the material is changed from the previous powder to the solution.
  • the preheating temperature is between 150 and 180 ° C. In this embodiment, preheating is performed at 150 ° C, 160 ° C and 180 ° C, respectively, and the difference in work performance is not large. If the temperature is not enough to start the work, it is easy to damage the screw of the feeder 3 and the reducer of the mixer 2 and the extruder 4, which affects the service life of the equipment.
  • the powder and auxiliary materials are poured into the mixing machine 2 for high-speed stirring.
  • the stirring temperature reaches 115 ° C
  • the cold material is cooled and stirred again.
  • the stirred powder is put into the feeding.
  • the silo of the machine 3 is then rotated by the feeder 3 to the hopper of the extruder 4.
  • the powder described in this step includes a powder for producing a foamed floor foam layer and a powder for producing a solid layer covering both sides of the foam layer, the extruder 4 including for extrusion foaming
  • the first extruder 401 of the layer and the second extruder 402 for extruding the solid layer.
  • the mixer 2 and the loading machine 3 are also configured with two sets, one for the mixing and feeding of the foam layer production, and the other for the mixing and feeding of the solid layer production.
  • the material is advanced by the screw rotation of the extruder 4 with the animal material. It should be noted that the two extruders 4 are operated at the same time, the first extruder 401 extrudes the foam layer, and the second extruder 402 extrudes two solid layers covering both surfaces of the foam layer.
  • the extruded material enters the cavity of the mold 5 and is extruded to form a slab of foamed floor.
  • the slab of the foamed floor which has passed through the mold 5 is wavy, is cooled and shaped by the cooling sizing device 15, and then enters the initial feed end of the main calender roll group 12. Tests have shown that although the calender roll is still shaped during the process of passing through the main calender roll group 12, if the front end cooling setting step is omitted, the slab embryo setting effect of the foamed floor is not good, and the embossing effect is also affected.
  • the main calender roll group 12 includes, in order, the first mirror roll 1201, the intermediate mirror roll, and the discharge end calender roll, and the temperature of the discharge end calender roll is higher than the temperature of the first mirror roll 1201.
  • the first mirror roll 1201 is a calender roll near the discharge end of the cooling setting device 15 in the processing flow; the discharge end calender roll is a calender roll adjacent to the emboss roll group 13 in the processing flow; and the intermediate mirror roll is a foamed floor.
  • the slab is moved from the first mirror roll 1201 to the transition calender roll through which the discharge roller of the discharge end passes.
  • the intermediate mirror roller is used to assist in the filming process. The number of intermediate mirror rollers depends on the demand.
  • the non-fixed value can be one, two or three.
  • the slab of the foamed floor is gradually heated after being cooled and shaped, and the slab of the foamed floor is gradually modified to ensure that the slab of the foamed floor is sufficiently softened and the flatness is ensured before the embossing process is performed. Sex.
  • the main calender roll set 12 includes, in order, a first mirror roll 1201, an intermediate mirror roll set consisting of at least two intermediate mirror rolls, and a discharge end calender roll, the temperature design of each calender roll Strict standards must be followed to ensure foaming and embossing quality.
  • the temperature of the first mirror roller 1201 and the intermediate mirror roller adjacent thereto is set to 30-90 ° C
  • the temperature of the calender roll at the discharge end is set to 150-190 ° C
  • the temperature of the intermediate mirror roll adjacent to the discharge end calender roll is set to 90-170 ° C
  • the temperature of the pattern roll 1301 is set to At 160-190 ° C
  • the temperature of the anilox roll 1302 is set to 160-190 ° C.
  • the temperature of each calender roll is explained by the structure of the calender roll in Example 1: wherein the temperatures of the first mirror roll 1201 and the first intermediate mirror roll 1202 are set to 30-90 ° C; the temperature of the second intermediate mirror roll 1203 is set.
  • the temperature is set to 90-170 ° C; the temperature of the matting roll 1204 is set to 150-190 ° C; the temperature of the pattern roll 1301 is set to 160-190 ° C, and the temperature of the anilox roll 1302 is set to 160-190 ° C.
  • each calendering roll is related to factors such as the thickness of the foamed floor and the thickness of the wear layer.
  • Production process 1 foaming floor thickness is 5mm, wear layer thickness is 0.15mm; mold 5 temperature is 170 ° C, first mirror roll 1201 temperature is 30 ° C, first intermediate mirror roll 1202 temperature is 30 ° C, the first The temperature of the second intermediate mirror roller 1203 is set to 130 ° C, the temperature of the matting roller 1204 is set to 165 ° C, the temperature of the pattern roller 1301 is set to 165 ° C, and the temperature of the anilox roller 1302 is set to 165 ° C; The slab is discharged through the second intermediate mirror roller 1203 and the matting roller 1204, and then cooled to 110 ° C to enter the embossing roller group 13.
  • Production process 2 foamed floor thickness is 7mm, wear layer thickness is 0.3mm; mold 5 temperature is 175 ° C, first mirror roll 1201 temperature is 60 ° C, first intermediate mirror roll 1202 temperature is 50 ° C, the first The temperature of the second intermediate mirror roller 1203 is set to 90 ° C, the temperature of the matting roller 1204 is set to 150 ° C, the temperature of the pattern roller 1301 is set to 160 ° C, and the temperature of the anilox roller 1302 is set to 160 ° C; The slab is discharged through the second intermediate mirror roller 1203 and the extinction roller 1204, and then cooled to 120 ° C to enter the embossing roller group 13.
  • Production process 3 foamed floor thickness is 8mm, wear layer thickness is 0.2mm; mold 5 temperature is 180 ° C, first mirror roll 1201 temperature is 70 ° C, first intermediate mirror roll 1202 temperature is 80 ° C, the first The temperature of the second intermediate mirror roller 1203 is set to 160 ° C, the temperature of the matting roller 1204 is set to 185 ° C, the temperature of the pattern roller 1301 is set to 170 ° C, and the temperature of the anilox roller 1302 is set to 170 ° C; The slab is discharged through the second intermediate mirror roller 1203 and the matting roller 1204, and then cooled to 125 ° C to enter the embossing roller group 13.
  • Production process 4 foamed floor thickness is 11mm, wear layer thickness is 0.5mm; mold 5 temperature is 175 ° C, first mirror roll 1201 temperature is 90 ° C, first intermediate mirror roll 1202 temperature is 90 ° C, the first The temperature of the second intermediate mirror roller 1203 is set to 170 ° C, the temperature of the matting roller 1204 is set to 190 ° C, the temperature of the pattern roller 1301 is set to 190 ° C, and the temperature of the anilox roller 1302 is set to 190 ° C; The slab is discharged through the second intermediate mirror roller 1203 and the matting roller 1204, and then cooled to 130 ° C to enter the embossing roller group 13.
  • the temperature of the pattern roller 1301 and the anilox roller 1302 is mainly related to the thickness of the wear layer, and the second center mirror roller 1203 and the matting roller 1204 which are in contact with the wear layer mainly mold the wear layer.
  • the effect is to suppress the pattern on the basis of plasticization. If the temperature of the pattern roll 1301 and the anilox roll 1302 is too low, the embossing and embossing effects are not good.
  • the slab of the foamed floor is embossed and then discharged from the embossing roll group 13, and after passing through the cooling bracket 6, enters the tractor 7 (the main function of the tractor 7 is to advance the animal material evenly) after passing through the tractor 7
  • the arch bracket 8 the length is about 2000mm, it is processed by the precision shearing machine 9 longitudinally trimming, and cut to the desired ideal size. After cutting, it enters the conveying bracket 20, and the cutting material is also cut at the same time.
  • the device with the edge trimming on both sides of the frame 20 is transported to the position grabbed by the robot through the transport frame, and is taken by the robot and sent to the tray. When the robot reaches a certain height, the robot alarms, and then forks the forklift and puts it into a new tray. .
  • the foamed floor is completed and ready for sale.

Abstract

一种压延机(1)、发泡地板生产线及一次成型加工工艺，包括机座(11)及排列设置在机座(11)上的压延辊组，所述压延辊组包括主压延辊组(12)及用于对待加工物料进行压纹的压纹辊组(13)，所述主压延辊组(12)与压纹辊组(13)间隔一定距离以使物料由一个辊组进入到另一个辊组前，可以冷却。该压延机(1)可以实现更好的压纹压花效果。将该压延机(1)用于发泡地板的生产，可以实现发泡地板一体化生产。

Description

压延机、发泡地板生产线及一次成型生产工艺 技术领域
本申请涉及机械制造领域，具体涉及一种压延机、发泡地板生产线及发泡地板的一次成型生产工艺。
背景技术
较传统的木质地板，发泡地板具有以下优点：(1)质地柔软，防潮防水性能好，弹性性能好，在重物冲击下有着良好的弹性恢复，不易损坏；(2)绿色环保、是一种可资源回收利用的产品；(3)具有较好的阻燃性，安全系数高；(4)造价低，较木质地板价格便宜；等。基于以上，发泡地板具有较大的发展前景和应用空间。
发泡地板通常是由多层材料复合加工生产而成，例如，以木塑复合地板(WPC)发泡地板为例，通常包括中间发泡层，覆于中间发泡层两侧的实心层，根据加工需求，在一个实心层的表面还可以设置一层防滑层，在另一个实心层的表面还可以设置彩膜层作为装饰层，同时设置耐磨层以增强地板的耐磨性，延长其使用寿命。
发泡地板的加工需要用到压延机，压延机通常包括两个以上的辊筒，辊筒包括镜面辊、压花辊、网纹辊、消光辊等，每种辊筒具有不同的功能，压延机通过不同辊筒的组合及辊筒温度的控制，完成不同的对待加工物料的加工需求。以PVC发泡地板的加工为例，其加工工艺包括厚度压延、地板底面网纹压延和地板表面花纹压延等多种工艺。现有技术中，通常是通过镜面辊进行镜面压延处理后，直接对其进行压纹压花处理，由于PVC发泡地板经镜面辊出料后温度较高，受地板发泡性能的影响，此时直接进行压纹压花处理通常压纹压花效果不好会造成一侧压纹效果不佳，出现压花后花纹又反弹起的现象。
现有技术中，发泡地板的生产工艺如下：挤出基材—砂光表面—涂胶—贴合—堆码—冷压—养生(恒温车间放置一段时间)—分切—开槽—检测包装—打托—入库装箱。一方面，各层复合材料之间是通过粘胶贴合在一起的，不环保；另一方面，各个流程是分段进行的，每个流程都需要专门的机器专人进行操作，费事费力。
为了实现流水化作业，现有技术中出现了发泡地板生产线。例如，中国专利CN105459422A公开了一种一次加工聚氯乙烯(PVC)地板成型机构，包括混料机、挤出机、上料机、模具、压光机等。将各种粉料搅拌混合后挤出，经模具加工成的料胚，直接进入压光机的辊轴组件，完成例如压光、贴膜、压花等工艺过程。
采用以上这种传统的加工工艺存在以下的问题：由于压延机的各个辊轴都是高温状态， 本成品料胚由高温模具出料后，直接又进入高温辊轴，在整个压延和压花的过程中，料胚一直处于高温状态，会影响压延及压花性能。与上文所述的不良效果相似，出现压花压不上，或压好花后花纹反弹起等问题。
发明内容
本申请的目的在于提供一种压延机，同时，针对现有发泡地板生产工艺的问题，提供一种发泡地板生产线，以及，提供一种发泡地板一次成型生产工艺。
为实现以上目的，本发明的提供以下内容：
压延机，包括机座及排列设置在机座上的压延辊组；压延辊组包括主压延辊组及用以对待加工物料进行压纹的压纹辊组；此处所述的主压延辊组是指由包括镜面辊在内的压延辊组成的辊组，主压延辊组可以全部是镜面辊，也可以根据需求选择其他类型的压延辊。压纹辊组的配置视压纹需求而定，例如，有些物料是要进行双面压纹的，而有些只需要单面压纹即可，需求不同，配置不同。按加工需求，主压延辊组完成的是压平、贴膜、消光、磨砂等工序流程中的一项或几项，而为了保证压纹效果不被破坏，压纹流程通常是放在以上工序之后完成的，因此，按物料的加工流程，压延辊组顺次包括主压延辊组及用以对待加工物料进行压纹的压纹辊组。所述主压延辊组与压纹辊组间隔设置，具体的说为主压延辊组的出料端与压纹辊组的进料端间隔一个距离设置，二者间隔一个距离以使物料在由一个辊组进入另一个辊组前，可以冷却。例如，按常见的加工流程，为由镜面辊组的出料端进入压纹辊组的进料端前可以冷却。这个距离并非是固定的距离，视加工需求而定，例如，可以为0.5m、0.8m、1m等。
优选为：主压延辊组与压纹辊组之间设置有冷却辊组，例如，主压延辊组的最终出料端与压纹辊组的入料端之间设置有冷却辊组。对于不设计冷却辊组的结构，物料是自然冷却的，而辅助设计冷却辊组，可以加快物料的冷却速度，这样就可以相应的减少主压延辊组与压纹辊组之间的距离，使压延机结构更紧凑。
优选为：沿物料加工流程，所述压延机顺次包括冷却定型装置、主压延辊组和压纹辊组。其中冷却定型装置用于通过冷却的方式对物料进行定型。
优选为：所述冷却定型装置包括间隔设置的第一冷却部件和第二冷却部件，第一冷却部件和第二冷却部件之间的间隙可容纳待加工物料通过，且保证待加工物料通过时与第一冷却部件和第二冷却部件均接触，以冷却定型。
优选为：冷却定型装置包括成对间隔设置的第一冷却辊筒和第二冷却辊筒，或，成对间 隔设置的第一冷却定型板和第二冷却定型板，或，成对间隔设置的第一冷却辊筒和第二冷却辊筒和成对间隔设置第一冷却定型板和第二冷却定型板的组合。具体的说，根据不同加工物料的冷却定型需求，可以选择间隔设置的第一冷却辊筒和第二冷却辊筒作为冷却定型装置，使物料从两个辊筒之间的间隙通过，冷却定型；也可以选择第一冷却定型板和第二冷却定型板作为冷却定型装置，使物料从两个定型板之间的间隙通过，冷却定型；或者可以选择，即包括第一冷却辊筒和第二冷却辊筒，又包括第一冷却定型板和第二冷却定型板的结构的两组冷却装置的组合作为冷却定型装置，使物料依次通过两组冷却装置。第一冷却辊筒和第二冷却辊筒内均配置有用以通入冷却液的冷却管路；第一冷却定型板和第二冷却定型板内也均配置有用以通入冷却液的冷却管路。
优选为：所述第一冷却辊筒和所述第二冷却辊筒，和/或，所述第一冷却定型板和所述第二冷却定型板连接有冷却间隙调整装置，所述冷却间隙调整装置用于调整两冷却辊筒之间或两冷却定型板之间的间隙，以供不同尺寸板材的通过。
优选为：沿物料加工流程，冷却定型装置顺次包括成对间隔设置第一冷却定型板和第二冷却定型板，和，成对间隔设置的第一冷却辊筒和第二冷却辊筒。对于加工需求为平面型的物料，冷却定型板的组合相比冷却辊筒的组合具有更好的定型效果。先经过冷却定型板进行冷却压平后，物料形状已经基本成型，再经过冷却辊筒的组合进行辅助压平，可以实现更佳的压平效果。
优选为：所述压纹辊组包括花纹辊或网纹辊，或花纹辊与网纹辊的组合，所述花纹辊与网纹辊分别被配置为与待加工物料不同待压纹面相接触。以发泡地板加工为例，所述花纹辊设置在与发泡地板顶面相接触的一侧，网纹辊设置在与发泡地板底面接出的一侧。根据压纹需求，也可以改进压纹辊组的结构，例如，当仅需要单面压纹时，只配置花纹辊或网纹辊即可。
优选为：压延机进一步包括贴膜卷放机构，以及，用以将贴膜卷放机构卷放的贴膜导向至主压延辊组的导向贴合机构，所述导向贴合机构包括导向轮及与主压延辊组中压延辊呈间隙设置的贴合辊。导向轮可以为单个导向轮也可以为导向轮组，其作用是配合贴合辊，将贴膜卷放机构卷放的贴膜导向至所需要的位置。贴合辊被设置在靠近主压延辊组中压延辊的位置，使物料经过主压延辊组中压延辊之间的间隙前，贴合所需的贴膜。主压延辊组中是可以包括多个压延辊的，具体导向至哪一个压延辊的位置，视加工需求而定。
优选为：所述贴膜卷放机构包括用于卷放底膜的底膜卷放机构、用以卷放彩膜的彩膜卷 放机构、用以卷放耐磨膜的耐磨膜卷放机构三者之一，或三者的任意组合；且，若底膜卷放机构被配置为将底膜导向至物料的一面，则彩膜卷放机构和耐磨膜卷放机构被配置为将彩膜和耐磨膜导向至物料的另一面。加工需求不同，所需贴膜的种类会不同，以发泡地板加工为例，可能会需要贴合底膜、彩膜或耐磨膜中的一种，或两种或三种的组合，根据需求，配置相应的贴膜卷放机构。而由于底膜和另外两种贴膜(彩膜和耐磨膜)通常是被贴在发泡地板的不同的面的，底膜贴在靠近地的一面，彩膜和耐磨膜贴在远离地的一面，因此，膜被导向至的位置是不同的。
优选为：进一步包括设置在贴合辊后端，与贴合辊配置在同一压延辊处，且与该压延辊呈间隙设置的辅助贴合辊。贴合辊先将贴膜进行贴合，辅助贴合辊进一步进行辅助贴合，保证贴膜贴合的更牢固。
优选为：贴合辊和辅助贴合辊各自均连接有用以调整其与主压延辊组中压延辊之间间隙的间隙调整装置。这种结构可以适应物料厚度的不同和不同物料厚度的加工要求，调整贴合辊以及辅助贴合辊与压延辊之间的间隙，保证贴合质量和物料厚度加工的要求。
发泡地板生产线，包括上述压延机。
发泡地板一次成型加工工艺，基于上述发泡地板生产线而实现，包括以下步骤：物料经主压延辊组出料后，行走冷却，随后进入压纹辊组进行压纹。物料冷却后的温度视物料特性和压纹需求而决定，非固定值。
优选为：进一步包括以下步骤：物料先经过冷却定型装置进行冷却定型，随后再进入主压延辊组。冷却定型的目的是避免物料发生波浪形的弯曲，保证最终加工质量。
优选为：按加工流程，所述主压延辊组顺次包括，第一镜面辊、中间镜面辊和出料端压延辊，出料端压延辊的温度高于第一镜面辊的温度。其中第一镜面辊为在加工流程上靠近冷却定型装置出料端的压延辊；出料端压延辊为在加工流程上靠近压纹辊组的压延辊；中间镜面辊为物料由第一镜面辊行走至出料端压延辊所经过的过渡压延辊。
优选为：按加工流程，所述主压延辊组顺次包括，第一镜面辊、由至少两个中间镜面辊组成的中间镜面辊组和出料端压延辊，第一镜面辊及与其相邻的中间镜面辊的温度设定为30-90℃，出料端压延辊的温度设定为150-190℃，与出料端压延辊相邻的中间镜面辊的温度设定为90-170℃，花纹辊的温度设定为160-190℃，网纹辊的温度设定为160-190℃。
优选为：生产线进一步包括混料机、上料机，物料进入混料机后，加热搅拌过程中混入冷料再次搅拌，降温后送至上料机。
本申请的有益效果为：
(1)压延机镜面辊组和压纹辊组分开设置，当物料在两个镜面辊组间运动过程中，可自然冷却，也可以设计冷却辊，进行辅助冷却。冷却过程中，物料的性能会发生变化，有利于保证后续加工质量。例如，发泡地板加工过程中，经镜面辊组出料后，经过一定距离后再进入压纹辊组。在这一过程中，发泡地板温度会降低，可以实现更好的压纹压花效果。
(2)本申请研究了一套温度控制策略，通过主压延辊组、压纹辊组的温度的设置，配合冷却装置、主压延辊组与压纹辊组之间冷却段的结构设计，在温度高低过程中配合物料改性，可以极大的提高成品压花效果，降低废品率。
(3)本申请提供的工艺具体包括：一步成型—养生—分切—开槽—检测包装—打托—入库装箱，较传统的生产工艺，本工艺省略了涂胶、贴合等步骤，节省了设备，同时可以节省占地空间。由于不需要涂胶，可节省材料；由于不需要砂光，可降低粉尘污染；生产线采用流水化作业，可节省人工成本。
附图说明
图1为实施例1中所述压延机的结构示意图；
图2为主压延辊组及压纹辊组的结构示意图；
图3为冷却定型装置的结构示意图；
图4为实施例2中所述压延机的结构示意图；
图5为实施例3中所述压延机的结构示意图；
图6为实施例3中底膜卷放机构和底膜导向贴合机构的结构示意图；
图7为实施例3中耐磨膜卷放机构和耐磨膜导向贴合机构的结构示意图；
图8为实施例3中彩膜卷放机构和彩膜导向贴合机构的结构示意图；
图9为实施例3中辅助贴合辊的结构示意图；
图10为发泡底板生产线结构示意图；
图11为生产线俯视结构示意图。
其中：1-压延机；11-机座；12-主压延辊组；1201-第一镜面辊；1202-第一中间镜面辊；1203-第二中间镜面辊；1204-消光辊；13-压纹辊组；1301-花纹辊；1302-网纹辊；14-冷却辊；15-冷却定型装置；1501-第一冷却辊筒；1502-第二冷却辊筒；1503-第一冷却间隙调节气缸；1504-第一冷却定型板；1505-第二冷却定型板；1506-第二冷却间隙调节气缸；161-底膜卷放机构；162-底膜导向贴合机构；1621-底膜导向轮；1622-底膜贴合辊；1623-第一间 隙调节气缸；171-耐磨膜卷放机构；172-耐磨膜导向贴合机构；1721-耐磨膜导向轮；1722-耐磨膜贴合辊；1723-第二间隙调节气缸；181-彩膜卷放机构；182-彩膜导向贴合机构；1821-彩膜导向轮；1822-彩膜贴合辊；1823-第三间隙调节气缸；19-辅助贴合辊；1903-第四间隙调节气缸；2-混料机；201-第一混料机；202-第二混料机；3-上料机；301-第一上料机；302-第二上料机；4-挤出机；5-模具；6-冷却托架；7-牵引机；8-拱形托架；9-精密剪板机；20-输送托架；21-自动抬板机。
具体实施方式
以下将结合附图对本申请的具体实施方式进行清楚完整地描述。显然，具体实施方式所描述的实施例仅为本申请的一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动的前提下所获得的所有其他实施例，都属于本申请的保护范围。
需要说明的是，本实施例中“底面”是指发泡地板安装后与地面接触的一面，“顶面”是指发泡地板安装后与用户接触的一面，不能理解为对本申请的限制。此外，术语“第一”、“第二”、“第三”仅用于描述目的，而不能理解为指示或暗示相对重要性。本实施例所述的“行走方向”、“来料方向”用以辅助表示物料的加工流程，“前方”、“前端”用以表示在加工流程上首先完成的工序，“后方”、“后端”用以表示在加工流程上在后完成的工序。
实施例1
本实施例提供了一种压延机1，该压延机1可以完成对待加工物料底面和顶面双侧的压纹或压花。本实施例以发泡地板的板胚作为待加工物料，实际应用过程中，待加工物料不限于发泡地板的板胚。
压延机1，包括机座11及排列设置在机座11上的压延辊组。按物料加工流程(本实施例中所述物料为发泡地板的板胚)，所述压延辊组顺次包括主压延辊组12及用以对发泡地板的板胚进行双面压纹的压纹辊组13。
一种压延机实施方式的示意图参考图1。
其中，主压延辊组12是指由包括镜面辊在内的压延辊组成的辊组，主压延辊组可以全部是镜面辊，也可以根据需求选择其他类型的压延辊。按加工流程(发泡地板的板胚在主压延辊组压延辊之间的行走顺序)，主压延辊组12包括顺次呈间隙设置的第一镜面辊1201、由中间镜面辊组成的中间镜面辊组和出料端压延辊，发泡地板的板胚在各相邻压延辊之间的间隙内通过。与发泡地板的板胚相接触的第一镜面辊1201与和其相邻的中间镜面辊之间的入料端 为主压延辊组的初始入料端；中间镜面辊之间及中间镜面辊与出料端压延辊之间的入料端为辊间入料端，出料端压延辊和与其相邻的中间镜面辊的出料端为主压延辊组的最终出料端。出料端压延辊可以选择为各种形式的压延辊，视加工需求而定。
以一种具体的实施结构为例，本实施例中，主压延辊组12包括呈间隙设置的第一镜面辊1201、第一中间镜面辊1202、第二中间镜面辊1203和消光辊1204(消光辊1204为出料端压延辊，其也可以采用镜面辊、磨砂辊等其他类型的压延辊来代替)，第一镜面辊1201和第一中间镜面辊1202迎向来料方向的一端为主压延辊组12的初始入料端，发泡地板的板胚从入料端进入后，从第一镜面辊1201和第一中间镜面辊1202的间隙内通过，随后进入第一中间镜面辊1202和第二中间镜面辊1203之间的间隙。第一镜面辊1201和第一中间镜面辊1202均连接有运动驱动机构，二者的转动方向相反(转动方向参考图示中的箭头方向)；第二中间镜面辊1203和消光辊1204也均连接有运动驱动机构，二者的转动方向相反(转动方向参考图示中的箭头方向)。第二中间镜面辊1203和消光辊1204的出料端为主压延辊组12的最终出料端。发泡地板的板胚经主压延辊组12的最终出料端进入压纹辊组13执行压纹流程。
实际应用过程中，可以结合物料情况以及镜面压延的需求，配置中间镜面辊的数量及各个镜面辊之间的间距，例如还可以采用三个中间镜面辊。或者，更精简的结构也可以不配置中间镜面辊而只选择设置第一镜面辊1201和出料端压延辊。
压纹辊组13包括呈间隙设置的花纹辊1301及网纹辊1302，花纹辊1301与网纹辊1302被分别配置为与待加工物料不同待压纹面相接触。具体的说，本实施例中，网纹辊1302设置在与发泡地板的板胚的底面相接触的一侧，花纹辊1301设置在与发泡地板的板胚的顶面接触的一侧。发泡地板的板胚从主压延辊组12的最终出料端出料后，进入花纹辊1301及网纹辊1302之间的间隙，花纹辊1301及网纹辊1302分别完成对发泡地板的板胚表面的双面压纹处理。
需要说明的是，本实施例是以发泡地板的板胚需要双面压纹来说明压延机的结构的。实际应用过程中，若不需要顶面压花纹，可以省略花纹辊1301，而在与发泡地板的板胚的顶面接触的一端配置镜面辊来代替花纹辊1301；若不需要底面压网纹，可以省略网纹辊1302，而在与发泡地板的板胚的底面接触的一端配置镜面辊来代替网纹辊1302。
由于主压延辊组12和压纹辊组13中压延辊的温度通常较高，如果发泡地板的板胚从压延辊组12的最终出料端直接进入压纹辊组13，高温下，发泡地板的板胚弹性好且具有热涨性，压出的花纹大部分会弹起，造成压纹效果不好。
为了解决这问题，使主压延辊组12的最终出料端与压纹辊组13的进料端间隔一定距离，以使发泡地板的板胚经主压延辊组12的最终出料端与压纹辊组13的进料端前可以冷却。具体参考图2。这个距离是根据发泡地板的板胚的性能、厚度等多种参数来设定的，并不是固定值。例如，本实施例以发泡地板的加工为例，这个距离采用100cm(需要说明，这个距离不能太远，只是离开一点距离再压纹即可，距离太远或者冷却太大后压出来的花纹纹路没有质感)。由于进入压纹辊组13前发泡地板的板胚经过了冷却，具有冷缩性，再经过高温压花，花纹质量高。以发泡地板的加工为例，行走一段距离后，使其冷却到110-130℃左右，具体视耐磨膜的厚度以及发泡地板的厚度而定。所需的压花效果，具体视发泡地板的板胚的性能和需求而定。
通过将主压延辊组12与压纹辊组13间隔一段距离设置可以通过空气冷却发泡地板的板胚。为了更好的冷却效果，加快发泡地板的板胚的冷却速度，在主压延辊组12的最终出料端与压纹辊组13的进料端之间设置冷却辊组，冷却辊14具有冷却兼导向的作用，发泡地板的板胚在冷却辊14上方行走，由冷却辊14进一步冷却后进入压纹辊组13的进料端。设置冷却辊14后，可以减小主压延辊组12与压纹辊组13之间的间距，例如，本实施例中，可以将这个距离减小到80cm。这有利于减小整个压延机的体积。
作为辅助设计，为了保证发泡地板的板胚可以顺利的由主压延辊组12运行到压纹辊组13，进一步包括用以将发泡地板的板胚由主压延辊组12的最终出料端处导向至压纹辊组13的压纹导向机构。例如，压纹导向机构为由多个导向轮排列组成的导向轮组。
实施例2
在生产过程过程中，还有一个问题会导致产品质量不高，也会影响压花质量。压延机处理的通常都是平板形的材料，通常是将热挤出料放入压延机加工。但，通常经挤出机和模具处理后的热挤出料并不能保证良好的平整性，通常是波浪形弯曲状的。
为了使物料在进入压延机之前就有较好的平整性，按物料加工流程，基于实施例1，压延机1进一步包括设置在主压延辊组12初始入料端前方的用以对待加工物料冷却定型的冷却定型装置15，其包括间隔设置的第一冷却部件和第二冷却部件，第一冷却部件和第二冷却部件之间的间隙可容纳待加工物料通过，且保证待加工物料通过时与第一冷却部件和第二冷却部件均接触。
本实施例中冷却定型装置15的结构如图3所示，配置有该冷却定型装置15的压延机如图4所示。
冷却定型装置15，沿来料方向设置在第一镜面辊1201和第一中间镜面辊1202入料端前端，包括冷却辊筒组，具体包括呈间隙设置的第一冷却辊筒1501和第二冷却辊筒1502，所述第一冷却辊筒1501和/或第二冷却辊筒1502内设置有用以加入冷却液的冷却管路，也就是说，为了能够使冷却辊筒发挥冷却作用，至少要保证两个冷却辊筒中的一个内设置有冷却管路，同时，为了实现均匀的冷却效果，也可以将两个冷却辊筒内均设置冷却管路，在冷却管路内通入冷却液，通过冷却液与板材之间的换热实现板材的冷却。此处，冷却管路包括冷却液入口和冷却液出口，可以实现冷却液的更换。
需要说明的是，除了采用冷却辊筒外，冷却部件还可以采用其他形式的结构，例如成对间隔设置的冷却定型板等。
更进一步，由于板材厚度尺寸不同，为了能使各种厚度尺寸的板材均通过冷却装置之间的间隙，第一冷却辊筒1501和/或第二冷却辊筒1502连接有冷却间隙调整装置。本实施例中，第一冷却辊筒1501位于第二冷却辊筒1502的上方，第一冷却辊筒1501连接有间隙调整装置，为第一冷却间隙调节气缸1503。通过第一冷却间隙调节气缸1503的伸缩作用，实现第一冷却辊筒1501和第二冷却辊筒1502之间间隙的调整。
工作过程中，待加工板材通过第一冷却辊筒1501和第二冷却辊筒1502之间的间隙，可以完成对待加工板材的冷却定型。
为了实现更好的定型效果，冷却定型装置15进一步包括成对、间隔安装的第一冷却定型板1504、第二冷却定型板1505，定型板之间的间隙可容纳板材通过，且保证板材通过时与两个定型板均接触。定型板为平板状，相比于冷却辊筒，可以更好的压平板材，以进行板材的定型。同样的，第一冷却定型板1504、第冷却二定型板1505内设置有用以加入冷却液的冷却管路，且至少一个冷却定型板安装有冷却间隙调整装置。本实施例中，第一冷却定型板1504位于第二冷却定型板1505的上方，第一冷却定型板1504安装有冷却间隙调节装置，为第二冷却间隙调节气缸1506。
沿来料方向，冷却定型板1504、1505位于冷却辊筒组的前端。图3中箭头所示的方向为工作过程中板材行走的方向，即加工过程中，板材首先经过冷却定型板，对板材进行挤压冷却定型，再经过冷却辊筒组进行辅助挤压冷却定型，随后进入主压延辊组12。为了保证板材可以顺利通过冷却定型装置15，第一冷却辊筒1501和第二冷却辊筒1502之间的间隙与冷却定型板之间的间隙位于同一水平面。
根据冷却定型的需求，也可以省略第一冷却辊筒1501和第二冷却辊筒1502的组合或者 第一冷却定型板1504和第二冷却定型板1505的组合。
实施例3
以下，进一步提供另一种压延机的结构。为一种具有对待加工物料进行贴膜压延功能的压延机。仍采用发泡地板的板胚作为待加工物料来说明其结构和实施过程。
基于实施例1或实施例2，压延机1进一步包括贴合膜卷放机构，贴合膜卷放机构包括底膜卷放机构161、耐磨膜卷放机构171和彩膜卷放机构181中的一个或几个。本文所述的贴合膜卷放机构均包括两个卷放轮，卷放贴膜过程中，一个做主要工作，另一个做备用。
如图5所示，本实施例中贴合膜卷放机构包括用以卷放底膜的底膜卷放机构161、用以卷放耐磨膜的耐磨膜卷放机构171和用以卷放彩膜的彩膜卷放机构181。压延机1进一步包括，用以将底膜导向输送至主压延辊组12辊间入料端的底膜导向贴合机构162，用以将耐磨膜导向输送至主压延辊组12辊间入料端的耐磨膜导向贴合机构172，以及，用以将彩膜导向输送至主压延辊组12辊间入料端的彩膜导向贴合机构182。
具体的说，参考上述压延机1中主压延辊组12的机构，耐磨膜和彩膜均被导向至第二中间镜面辊1203和消光辊1204之间的辊间入料端的前方；底膜被导向至第一中间镜面辊1202和第二中间镜面辊1203辊间入料端的前方，以实现底膜和另外两种膜被贴合到发泡地板的板胚的不同面。
需要说明的是，实际应用过程中，不限于将底膜、彩膜和耐磨膜导向至上述位置，只要可以实现按贴合面覆膜即可，例如，也可以将彩膜和耐磨膜导向至主压延辊组12的初始入料端处，也可以将底膜导向至主压延辊组12的最终出料端处。
为了更清晰地展示各部件的组成及配合关系，进一步分别提供了各部件的示意图。其中，图6为底膜卷放机构161、底膜导向贴合机构162的结构及其与压延辊的配合的示意图；图7为耐磨膜卷放机构171、耐磨膜导向贴合机构172的结构及其与压延辊配合的示意图；图8为彩膜卷放机构181、彩膜导向贴合机构182的结构及其与压延辊配合的示意图。所述底膜导向贴合机构162包括底膜导向轮1621、与第一中间镜面辊1202呈间隙设置的底膜贴合辊1622，底膜贴合辊1622连接有用于调整其与第一中间镜面辊1202之间间隙的第一间隙调节气缸1623。所述的耐磨膜导向贴合机构172包括耐磨膜导向轮1721和耐磨膜贴合辊1722，所述彩膜导向贴合机构182包括彩膜导向轮1821及彩膜贴合辊1822，所述耐磨膜贴合辊1722和彩膜贴合辊1822均连接有用于调整各自与中间镜面辊(具体为第二中间镜面辊1203)之间间隙的间隙调整装置，其中，耐磨膜贴合辊1722连接有第二间隙调节气缸1723，彩膜贴 合辊1822连接有第三间隙调节气缸1823。由于加工过程中，首先贴彩膜，在彩膜的表面贴上耐磨膜，因此沿加工物料输送方向，耐磨膜贴合辊1722位于彩膜贴合辊1822的后方，参见图9。按加工流程，压延机1进一步包括设置在贴合辊后端，与贴合辊配置在同一压延辊处，且与该压延辊呈间隙设置的辅助贴合辊19。
进一步参见图9，本实施例中，辅助贴合辊19设置在第二中间镜面辊1203和消光辊1204之间的辊间入料端，辅助贴合辊19位于耐磨膜贴合辊1722的后方，其作用是将贴好的彩膜和耐磨膜进行进一步的压紧贴合。所述辅助贴合辊19连接有用以调节辅助贴合辊19与压延辊间隙的间隙调整装置，本实施例中，为第四间隙调节气缸1903。
除了以上结构外，也可以为底膜的贴合配置辅助贴合辊19，如图6所示，可以配置在底膜贴合辊1622的后方，第一中间辊1202和第二中间辊1203的入料端处。
完整工作流程为：发泡地板的板胚经冷却定型后，由第一镜面辊1201和第一中间镜面辊1202之间的间隙进入主压延辊组12，随后随压延辊做“S”形曲线运动，从第一镜面辊1201和第一中间镜面辊1202出料进入第一中间镜面辊1202与第二中间镜面辊1203的间隙之前，贴底膜(可以选择是否设置辅助贴合辊19辅助贴合)；运动到第二中间镜面辊1203和消光辊1204之间的辊间入料端之前，首先与彩膜卷放机构181卷放的彩膜贴合，此过程中，彩膜贴合辊1822辅助贴合；随后，与耐磨膜卷放机构171卷放的耐磨膜贴合，此过程中，耐磨膜贴合辊1722辅助贴合；再随后，辅助贴合辊19将压贴耐磨膜、彩膜和发泡地板的板胚；压贴后进入第二镜面辊1203和消光辊1204之间进行压延。经第二中间镜面辊1203和消光辊1204出料端出料，随后冷却，进入压纹辊组13，完成压花、压纹的流程。至此，可以完成一个完整的贴膜、底面压纹和顶面压花的过程。
本实施例提供的压延机可以完成冷却定型、压延定型、双侧压纹、压花的全流程物料加工工作。
实施例4
本实施例提供了一种将实施例1-3中的压延机1用于发泡地板生产的发泡地板生产线。
具体参考图10，按产品生产流程，顺次包括混料机2(图中所示为混料机料仓，用以简化表示混料机)、上料机3、挤出机4、模具5及压延机1，所述压延机1为实施例1-3中任一项所述的压延机1，此处不再对其结构进行赘述。
混料机2用于粉料的混合，用于生产发泡地板的各种材料被导入混料机2内高速搅拌混合。搅拌之后的混合料放入上料机3的料仓，然后由上料机3旋转上料到挤出机4的料斗中。
此处需要说明的是，由于发泡地板是由多层材料复合加工而成的，即主要由发泡层和发泡层两侧的实心层构成。在进入模具5挤压之前，要完成发泡层与两层实心层的出料，因此，挤出机4包括两个挤出机，相应的每一台挤出机均对应各自的混料机和上料机。两个挤出机呈夹角排列设置，本实施例中，两台挤出机之间的夹角为60°，参考图11。具体包括用于挤出发泡层的第一挤出机401(对应第一混料机201和第一上料机301)，以及，配置有分配器的第二挤出机402(对应第二混料机202和第二上料机302)，第二挤出机402用于挤出分别覆盖在发泡层两侧的实心层。由于第二挤出机402配置有分配器，其挤出料为两层实心层，所述两层实心层分别覆盖在发泡层的两个侧面，初步贴合后，进入模具5。
模具5用以加工物料，具体到本实施例，为三层板胚。按生产加工流程，位于模具后端的为压延机1。由于模具5温度较高，经模具5出料后，三层板胚会出现波浪弯曲的现象，为解决这一问题，压延机1的前端设置冷却定型装置15进行三层板胚的冷却定型。
冷却定型流程为：三层板胚经模具5出料后，首先进入冷却定型装置15进行冷却定型。具体的说，经模具5出料后，首先进入第一冷却定型板1504和第二冷却定型板1505之间的间隙，冷却定型板为平板状，内部通入冷却液，与三层板胚换热以冷却定型。经冷却定型板冷却后，三层板胚已经基本上为平板状了，随后进入第一冷却辊筒1501和第二冷却辊筒1502之间的间隙，进行辅助冷却定型。冷却定型过程中，可以根据对三层板胚定型厚度的需求调整第一冷却定型板1504和第二冷却定型板1505、以及第一冷却辊筒1501和第二冷却辊筒1502之间的间隙。若两个间隙大，则出料后三层板胚厚度大，若间隙小，则出料后三层板胚厚度小。
经第一冷却辊筒1501和第二冷却辊筒1502出料后，三层板胚将进入主压延辊组12的初始入料端，经过实施例3所述的贴膜、底面压纹和顶面压花的工作流程后，进入后续加工步骤。
后续加工步骤由设置在压延机1之后的设备完成。按产品生产流程和加工需求，在压延机1之后还设置有冷却托架6、牵引机7，拱形托架8，精密剪板机9、输送托架20、自动抬板机21等，以完成发泡地板的冷却定型、剪裁等流程。
实施例5
本实施例提供了一种发泡地板一次成型的加工工艺，较传统的加工工艺，本工艺省略了涂胶、贴合等步骤，节省了设备及占地空间。所述一次成型加工工艺具体包括以下步骤：
生产线启动运行之前，将混料机2、上料机3、挤出机4、模具5等带温度工作的设备提 前预热加温、保温。预热的时间视需求而定，本实施例中，预热时间为2小时。加温的目的是让物料由之前的粉末变成溶体后再启动混料、挤出等工作。预热的温度为150-180℃之间，本实施例中，分别采用150℃、160℃和180℃进行预热，工作性能差异不大。如果温度不到就开机执行工作的话，容易对上料机3螺杆和混料机2、挤出机4的减速箱造成损伤，影响设备的使用寿命。
首先将粉料和辅料倒入混料机2里高速搅拌，搅拌温度到了115℃的时候放入冷料再次冷却搅拌，搅拌温度降到30℃左右后，将搅拌好的料粉放入上料机3的料仓，然后由上料机3旋转上料到挤出机4的料斗。此步骤中所述的料粉包括制造发泡地板发泡层的料粉以及用于制造覆盖在发泡层两侧面的实心层的料粉，所述挤出机4包括用于挤出发泡层的第一挤出机401和用于挤出实心层的第二挤出机402。混料机2和上料机3相应的也是配置两套的，一套用于发泡层生产的混料和上料，另一套用于实心层生产的混料和上料。
物料由挤出机4螺杆旋转带动物料往前推进。需要说明的是，两台挤出机4是同时工作的，第一挤出机401挤出发泡层，第二挤出机402挤出覆盖在发泡层两表面的两个实心层。
挤出后的物料进入模具5腔内进行挤压制成发泡地板的板胚。
由于模具5的温度较高，经模具5出来的发泡地板的板胚是呈波浪状的，经过冷却定型装置15进行冷却定型，随后再进入主压延辊组12的初始入料端。试验表明，虽然在经过主压延辊组12过程中也会经压延辊压延定型，如果省略前端冷却定型这个步骤，发泡地板的板胚定型效果不好，压花效果也受影响。
按加工流程，所述主压延辊组12顺次包括，第一镜面辊1201、中间镜面辊和出料端压延辊，出料端压延辊的温度高于第一镜面辊1201的温度。其中第一镜面辊1201为在加工流程上靠近冷却定型装置15出料端的压延辊；出料端压延辊为在加工流程上靠近压纹辊组13的压延辊；中间镜面辊为发泡地板的板胚由第一镜面辊1201行走至出料端压延辊所经过的过渡压延辊。中间镜面辊用以辅助完成贴膜工作，中间镜面辊的数量视需求而定，非固定值，可以为一个、两个或三个。如此，使发泡地板的板胚经过冷却定型后逐步升温，发泡地板的板胚逐步改性，保证在压花工艺执行前，发泡地板的板胚已被足够软化，且保证良好的平整性。
一种更优的实施方式，主压延辊组12顺次包括，第一镜面辊1201、由至少两个中间镜面辊组成的中间镜面辊组和出料端压延辊，每个压延辊的温度设计都要遵循严格的标准，才能保证发泡和压花质量。其中，第一镜面辊1201及与其相邻的中间镜面辊的温度设定为 30-90℃，出料端压延辊的温度设定为150-190℃，与出料端压延辊相邻的中间镜面辊的温度设定为90-170℃，花纹辊1301的温度设定为160-190℃，网纹辊1302的温度设定为160-190℃。采用实施例1中压延辊的结构来说明各个压延辊的温度：其中，第一镜面辊1201及第一中间镜面辊1202的温度设定为30-90℃；第二中间镜面辊1203的温度设定为90-170℃；消光辊1204的温度设定为150-190℃；花纹辊1301的温度设定为160-190℃，网纹辊1302的温度设定为160-190℃。
各个压延辊温度的高低与发泡地板厚度、耐磨层的厚度等因素有关。
以下为几组具体的生产过程数据：
生产过程一：发泡地板厚度为5mm，耐磨层厚度为0.15mm；模具5温度为170℃，第一镜面辊1201的温度为30℃，第一中间镜面辊1202的温度为30℃，第二中间镜面辊1203的温度设定为130℃，消光辊1204的温度设定为165℃，花纹辊1301的温度设定为165℃，网纹辊1302的温度设定为165℃；发泡地板的板胚经第二中间镜面辊1203和消光辊1204出料后，冷却至110℃后进入压纹辊组13。
生产过程二：发泡地板厚度为7mm，耐磨层厚度为0.3mm；模具5温度为175℃，第一镜面辊1201的温度为60℃，第一中间镜面辊1202的温度为50℃，第二中间镜面辊1203的温度设定为90℃，消光辊1204的温度设定为150℃，花纹辊1301的温度设定为160℃，网纹辊1302的温度设定为160℃；发泡地板的板胚经第二中间镜面辊1203和消光辊1204出料后，冷却至120℃后进入压纹辊组13。
生产过程三：发泡地板厚度为8mm，耐磨层厚度为0.2mm；模具5温度为180℃，第一镜面辊1201的温度为70℃，第一中间镜面辊1202的温度为80℃，第二中间镜面辊1203的温度设定为160℃，消光辊1204的温度设定为185℃，花纹辊1301的温度设定为170℃，网纹辊1302的温度设定为170℃；发泡地板的板胚经第二中间镜面辊1203和消光辊1204出料后，冷却至125℃后进入压纹辊组13。
生产过程四：发泡地板厚度为11mm，耐磨层厚度为0.5mm；模具5温度为175℃，第一镜面辊1201的温度为90℃，第一中间镜面辊1202的温度为90℃，第二中间镜面辊1203的温度设定为170℃，消光辊1204的温度设定为190℃，花纹辊1301的温度设定为190℃，网纹辊1302的温度设定为190℃；发泡地板的板胚经第二中间镜面辊1203和消光辊1204出料后，冷却至130℃后进入压纹辊组13。
试验结果表明，以上几个生产过程发泡、压花及压纹效果均良好。
需要说明的是，花纹辊1301和网纹辊1302的温度主要是与耐磨层的厚度有关，由于与耐磨层相接触的第二中心镜面辊1203和消光辊1204主要对耐磨层起塑化作用，在塑化的基础上压制花纹，若花纹辊1301和网纹辊1302温度过低，压花、压纹效果并不好。
发泡地板的板胚经过压花成型后从压纹辊组13出料，经过冷却托架6后，进入牵引机7(牵引机7主要作用就是牵动物料均匀的往前进)经过牵引机7后进入拱形托架8后(长度为2000mm左右，由精密剪板机9纵向裁边处理，裁到想要的理想尺寸。裁断后进入输送托架20，裁断的同时边角料也被裁断，输送托架20两边带有接边角料的装置，经过输送架输送到机械手抓取的位置，由机械手抓取后送到托盘处，到达一定的高度时机械手报警，然后用叉车叉走后放入新的托盘。
经上述一次成型加工工艺后，再经过养生、分切、开槽、检测包装、打托、入库装箱后，发泡地板生产完成，即可销售。

Claims (19)

  1. 压延机，包括机座及排列设置在机座上的压延辊组，其特征在于：所述压延辊组包括主压延辊组及用以对待加工物料进行压纹的压纹辊组，所述主压延辊组与压纹辊组间隔一定距离以使物料由一个辊组进入到另一个辊组前，可以冷却。
  2. 如权利要求1所述的压延机，其特征在于：主压延辊组与压纹辊组之间设置有冷却辊组。
  3. 如权利要求1所述的压延机，其特征在于：按加工流程，所述压延机顺次包括冷却定型装置、主压延辊组和压纹辊组。
  4. 如权利要求3所述的压延机，其特征在于：所述冷却定型装置包括间隔设置的第一冷却部件和第二冷却部件，第一冷却部件和第二冷却部件之间的间隙可容纳待加工物料通过，且保证待加工物料通过时与第一冷却部件和第二冷却部件均接触。
  5. 如权利要求3所述的压延机，其特征在于：所述冷却定型装置包括成对间隔设置的第一冷却辊筒和第二冷却辊筒，和/或，成对间隔设置的第一冷却定型板和第二冷却定型板。
  6. 如权利要求5所述的压延机，其特征在于：所述第一冷却辊筒和所述第二冷却辊筒，和/或，所述第一冷却定型板和所述第二冷却定型板内设置有用以加入冷却液的冷却管路。
  7. 如权利要求5所述的压延机，其特征在于：所述第一冷却辊筒和/或所述第二冷却辊筒，和/或，所述第一冷却定型板和/或所述第二冷却定型板连接有冷却间隙调整装置。
  8. 如权利要求5所述的压延机，其特征在于：按加工流程，冷却定型装置顺次包括成对间隔设置第一冷却定型板和第二冷却定型板，和，成对间隔设置的第一冷却辊筒和第二冷却辊筒。
  9. 如权利要求1所述的压延机，其特征在于：所述压纹辊组包括花纹辊和/或网纹辊，所述花纹辊与网纹辊被配置为与物料不同待压纹面相接触。
  10. 如权利要求1所述的压延机，其特征在于：所述压延机进一步包括贴膜卷放机构，以及，用以将贴膜卷放机构卷放的贴膜导向至主压延辊组的导向贴合机构，所述导向贴合机构包括导向轮及与主压延辊组中压延辊呈间隙设置的贴合辊。
  11. 如权利要求10所述的压延机，其特征在于：所述贴膜卷放机构包括用于卷放底膜 的底膜卷放机构、用以卷放彩膜的彩膜卷放机构、用以卷放耐磨膜的耐磨膜卷放机构三者之一，或三者的任意组合；且，若底膜卷放机构被配置为将底膜导向至物料的一面，则彩膜卷放机构和耐磨膜卷放机构被配置为将彩膜和耐磨膜导向至物料的另一面。
  12. 如权利要求10所述的压延机，其特征在于：按加工流程，进一步包括设置在贴合辊后端，与贴合辊配置在同一压延辊处，且与该压延辊呈间隙设置的辅助贴合辊。
  13. 如权利要求12所述的压延机，其特征在于：所述贴合辊和辅助贴合辊各自均连接有用以调整其与主压延辊组中压延辊之间间隙的间隙调整装置。
  14. 发泡地板生产线，其特征在于：包括权利要求1-13中任意一项所述的压延机。
  15. 发泡地板一次成型加工工艺，其特征在于：基于权利要求14所述的发泡地板生产线而实现，包括以下步骤：物料经主压延辊组出料后，行走冷却，随后进入压纹辊组进行压纹。
  16. 如权利要求15所述的发泡地板一次成型加工工艺，其特征在于：进一步包括以下步骤：物料先经过冷却定型装置进行冷却定型，随后再进入主压延辊组。
  17. 如权利要求15所述的发泡地板一次成型加工工艺，其特征在于：按加工流程，所述主压延辊组顺次包括，第一镜面辊、中间镜面辊和出料端压延辊，出料端压延辊的温度高于第一镜面辊的温度。
  18. 如权利要求17所述的发泡地板一次成型加工工艺，其特征在于：按加工流程，所述主压延辊组顺次包括，第一镜面辊、由至少两个中间镜面辊组成的中间镜面辊组和出料端压延辊，第一镜面辊及与其相邻的中间镜面辊的温度设定为30-90℃，出料端压延辊的温度设定为150-190℃，与出料端压延辊相邻的中间镜面辊的温度设定为90-170℃。
  19. 如权利要求17或18所述的发泡地板一次成型加工工艺，其特征在于：所述压纹辊组包括花纹辊或网纹辊，或花纹辊与网纹辊的组合，花纹辊的温度设定为160-190℃，网纹辊的温度设定为160-190℃。
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