WO2021258609A1 - 一种连续发泡材料的定厚装置 - Google Patents

一种连续发泡材料的定厚装置 Download PDF

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Publication number
WO2021258609A1
WO2021258609A1 PCT/CN2020/127505 CN2020127505W WO2021258609A1 WO 2021258609 A1 WO2021258609 A1 WO 2021258609A1 CN 2020127505 W CN2020127505 W CN 2020127505W WO 2021258609 A1 WO2021258609 A1 WO 2021258609A1
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WO
WIPO (PCT)
Prior art keywords
roller
pressure roller
foaming material
foaming
setting device
Prior art date
Application number
PCT/CN2020/127505
Other languages
English (en)
French (fr)
Inventor
万立祥
杨庆锋
张镤
Original Assignee
浙江润阳新材料科技股份有限公司
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Publication of WO2021258609A1 publication Critical patent/WO2021258609A1/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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/203—Expanding the moulding material in a vertical channel
    • 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
    • B29C44/3415—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
    • B29C44/3442—Mixing, kneading or conveying the foamable material
    • 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
    • B29C44/60—Measuring, controlling or regulating
    • 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
    • B29C59/10—Surface shaping of articles, e.g. embossing; Apparatus therefor by electric discharge treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H23/00—Registering, tensioning, smoothing or guiding webs
    • B65H23/02—Registering, tensioning, smoothing or guiding webs transversely
    • B65H23/032—Controlling transverse register of web
    • B65H23/038—Controlling transverse register of web by rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H23/00—Registering, tensioning, smoothing or guiding webs
    • B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
    • B65H23/26—Registering, tensioning, smoothing or guiding webs longitudinally by transverse stationary or adjustable bars or rollers
    • 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
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets

Definitions

  • the invention belongs to the technical field of foaming material production equipment, and specifically relates to a thickness setting device for continuous foaming materials.
  • Sheet foaming refers to the process of heating a band-shaped polymer material in a foaming furnace.
  • the foaming agent decomposes at a high temperature to generate gas, which is filled inside the polymer material to produce a foaming material with closed pores.
  • the foaming material needs to be cooled and shaped by a cooling device, and then directly rewinded or rewinded after some post-processing procedures (such as trimming, embossing, cutting, etc.) to obtain the finished product.
  • some post-processing procedures such as trimming, embossing, cutting, etc.
  • cooling roller sets such as CN105599210B, CN209111359U located outside the foaming furnace, which have the following defects:
  • the cooling speed is slow. Although it can be improved by increasing the number of cooling rolls or increasing the pressure on the rolls, the former has high energy consumption and the latter is likely to over-squeeze or even break the sheet; more importantly, the current cooling setting only passes
  • the cooling roller cools the sheet to solidify it, and it is difficult to accurately control the thickness of the sheet, and the sheet is relatively thin (usually only 2-3mm), and it is easily deformed by external factors such as temperature, airflow, traction speed, etc. Therefore, the size of the finished product is difficult to control, and large deviations are prone to occur.
  • Foamed materials usually need to be laminated to other boards. Once the thickness of different parts has large deviations, it will directly affect the combination with the board, and then affect the board’s performance. Quality and performance.
  • the existing foaming equipment cannot accurately control the size of the foamed material, especially the thickness, so the finished product is prone to large size deviations, which affects the use effect.
  • the present invention proposes a continuous foaming material thickness setting device, which can realize accurate and rapid thickness setting, effectively reduce the deviation of the finished product size, and improve the quality of the finished product.
  • a device for fixing the thickness of a continuous foaming material comprising a foaming cavity and a thickness-locking part; the two ends of the foaming cavity are respectively provided with an inlet and an outlet, and the inner wall of the foaming cavity is conveyed along the foaming material
  • a number of heating elements are arranged in the direction; the thick lock part is arranged outside the discharge port, and the thick lock part includes a pressure roller and a steering roller that are arranged oppositely and communicate with the cooling medium pipeline, and the pressure roller and the steering roller are , At least one surface is provided with a cooling structure, and at least one is an active roller driven by a power device; the foamed material passes through the pressing area between the pressure roller and the steering roller in a manner of being attached to the surface of the steering roller Send out.
  • the invention accurately controls the size of the foamed material through a thickness setting device composed of a foaming cavity and a thick locking part, wherein the thick locking part is composed of a pressure roller and a steering wheel which are arranged oppositely with a cooling function and at least one surface has a cooling structure.
  • the roller composition, the cooling structure is a structure that can make the surface of the sheet after being rolled by the pressure roller and the turning roller to form a concave-convex appearance.
  • the sheet material is initially formed after foaming in the foaming cavity, and then vertically enters between the pressure roller and the turning roller.
  • the foaming material uses the residual heat to make the cooling structure embedded in the surface, and at the same time, it is cooled and shaped under the action of the cooling medium;
  • the structure forms recessed parts on multiple parts of the foamed material surface, and because the recessed parts and the flat parts are alternately spaced, it will not affect its strength; the arrangement of the cooling structure not only increases the cooling contact area, but also enables the cooling process to be deepened quickly Into the foamed material, precise and rapid control of the thickness is realized, and the speed and sufficiency of the overall cooling of the sheet are improved.
  • the shaping effect is more effective.
  • the foamed material of the present invention is also sent out in a manner of being attached to the steering roller after the pressing is completed, so as to increase the cooling contact time, and protect and stabilize the lines formed by the cooling structure on the surface of the foamed material. . Therefore, the thick lock part of the present invention not only shapes the surface of the foamed material, but also can accurately shape it in the thickness direction, so that the deviation of the finished product size is small.
  • the cooling structure is a number of protrusions on the surface of the pressure roller/turning roller, and the shape and size of the protrusions can be diversified.
  • the protrusion is 0.1-0.5 mm higher than the surface of the pressure roller/turning roller.
  • the diameter of the roller of the turning roller is at least 1.2 times the diameter of the roller of the pressure roller.
  • the sending direction is at an acute angle with the conveying direction of the foam material in the foaming cavity.
  • the contact area between the foaming material and the steering roller is increased, so that the cooling and shaping of the foaming material are more sufficient, and the thickness locking effect is strengthened.
  • At least the pressing area on the pressure roller and the turning roller is directly opposite to the discharge port. Rolling is cooling at the same time, and the surface of the foamed material needs to form a concave-convex structure under the action of the cooling structure. Therefore, it is necessary to avoid premature cooling to overcome the difficulty of forming and directly affect the appearance.
  • At least the pressing area is set at a position directly opposite to the outlet of the foaming cavity, so that the pressing area and the foaming material are heated to a certain extent and will not be cooled immediately.
  • the pressure roller is located in an area directly facing the discharge port, and at least 70% of the turning roller is located outside the area directly facing the discharge port.
  • Such a position design can effectively slow down the cooling process of the pressing and cooling structure when it is laminated with the foam material to roll, and is beneficial to the formation of the concave-convex structure.
  • the foam material is attached to the steering roller and sent out, and the steering roller is less heated.
  • the thickness of the foam material can be quickly locked, so that the thickness of the locking part can ensure the aesthetics of the foam material without affecting the thickness of the locking effect.
  • the discharge port is rectangular, and the long sides are arranged in the same direction as the axial direction of the pressure roller and the steering roller, so that different parts of the foam material in the width direction are evenly heated, thereby avoiding inconsistent lock thickness processes caused by heat differences And increase the problem of the size deviation of the finished product.
  • the two ends of the roller shafts of the pressure roller and the steering roller are respectively provided with adjusting parts
  • the adjusting part includes a fixing frame and a bearing seat sleeved on the roller shaft and slidably connected to the fixing frame.
  • the adjusting part realizes the position adjustment, disassembly and replacement of the pressure roller and the steering roller through the sliding of the bearing seat on the fixed frame, and the operation is simple.
  • the adjusting part of the pressure roller is further provided with an air cylinder connected with the bearing seat to provide power for the movement of the bearing seat on the fixed frame, so that the disassembly and assembly of the pressure roller on the outer side is more convenient and faster.
  • the heating element is arranged in the middle of the inner wall of the foaming cavity, and a spreading roller with cooling function is arranged below the area where the heating element is arranged.
  • the sheet in the foaming cavity is foamed under the action of the heating element. After foaming, the sheet will expand and both sides will be curled. Therefore, an unwinding roll with cooling function is set in the non-heating zone. Flattening improves the flatness of the sheet.
  • the cooling effect of the spreading roller stops the foaming of the inside of the sheet completely, so as to prevent the thickness of the sheet from changing again after being flattened. The locking thickness of subsequent sheets provides a good structural foundation.
  • the present invention provides a winding assembly suitable for the above-mentioned setting device, including a deviation correction machine and a traction machine. Machine and winding rack. After the sheet is processed by the thickness setting device, it is directly reeled in the winding rack, which is prone to offset. Once the sheet is offset, the force on both sides of the sheet that is being locked will be unbalanced, which directly affects the setting effect.
  • the present invention is equipped with a correction machine in the winding assembly to avoid deviations in the thickness lock process; the setting of the tension machine provides a good buffer effect for the entire transmission process, and maintains a constant tension when the winding speed changes , So that the thickening process can be continued and stably carried out, further reducing the impact of the winding on the thickening process.
  • the number of the tension machine is two
  • the winding assembly includes a rectifying machine, a first tension machine, a tractor, a second tension machine, and a winding frame arranged in sequence.
  • the setting of two tension machines can effectively improve the production efficiency.
  • the two tension machines work together to provide a certain adjustment time and improve the previous foaming in a short time.
  • the thickness locking process will not affect, so continuous production can be realized; and the setting of two tension machines can effectively reduce the deviation of the foam material and the degree of deviation, and reduce the deviation correction set at the front end of the first tension machine
  • the present invention also provides a foaming material production system including the above-mentioned setting device and winding assembly.
  • a foaming material production system including the above-mentioned setting device and winding assembly.
  • it also includes a side of the steering roller for further A cooling roller for cooling the foamed material and a corona machine between the cooling roller and the rectifier.
  • the corona treatment is performed on the foamed material through the setting of the corona machine to increase the surface roughness, thereby improving the wettability and adhesion of the surface, and improving the compatibility with the adhesive during subsequent use; through the cooling roller
  • the setting ensures complete cooling of the foamed material, improves its dimensional stability, and obtains a good corona effect.
  • the foaming material production system can continuously and stably produce various sheet-shaped foaming materials, with high production efficiency, small size deviations of the produced foaming materials, and good combination with other plates.
  • the size of the foamed material is accurately controlled by a thickness setting device composed of a foaming cavity and a thick lock part.
  • the thick lock part is composed of a pressure roller and a steering roller with a cooling function arranged oppositely, and at least the pressure roller and the One of the steering rollers has a surface cooling structure; the sheet is initially formed after foaming in the foaming cavity, and the thickness of the lock is matched with the cooling structure to complete the surface and the thickness direction to accurately determine the shape.
  • the shape is finalized Faster and fuller, the finished product size deviation is small (can be controlled within 10%).
  • the cooling structure can form lines on the surface of the sheet, and its style can be designed according to user needs. It can improve the aesthetics without subsequent processing and effectively reduce the cost.
  • the pressure roller in the area directly facing the discharge port, and at least 70% of the steering roller is located outside the area directly facing the discharge port, to ensure the smooth formation of the foamed material's concave and convex structure, and to achieve rapid Cooling to obtain a good thickness locking effect; by setting the discharge port to a rectangular shape, the foam material is heated uniformly in the width direction, and the consistency of the thickness locking effect at different positions is improved.
  • the position adjustment, disassembly and replacement of the two rollers are realized by setting adjustment parts at both ends of the pressure roller and the steering roller.
  • the adjustment part includes a fixing frame and a bearing seat sleeved on the roller shaft and slidably connected to the fixing frame. The operation is simple. When the cooling structure on the surface of the roller is worn out or when a different style of cooling structure is required, the replacement of the roller can be completed quickly and work efficiency is improved.
  • the expansion roll with cooling function is arranged in the non-heating area under the heating element to flatten the expanded sheet and stop foaming inside the sheet to avoid further changes in thickness, which is the lock thickness of the subsequent sheet Provide a good structural foundation.
  • the setting of the cooling structure in the thick lock part makes the surface of the foam material present a concave-convex structure, which is beneficial to the combination with the adhesive during subsequent use.
  • the present invention uses a corona machine to complete the shaping of the foam material. Corona can increase the surface roughness of the foamed material, improve the wettability and adhesion of the surface, and further improve the compatibility of the foamed material with the adhesive.
  • the present invention can carry out continuous production of foaming materials such as IXPE, XPE, EVA, etc.
  • the foaming cavity can be vertical or horizontal, with wide application range and good application prospects.
  • Figure 1 A schematic diagram of the structure of the thickness setting device described in Example 1.
  • Figure 2 A three-dimensional structural view of the thick lock portion of the embodiment 1.
  • Figure 3 A schematic diagram of the structure of the thickness setting device described in Example 3.
  • Figure 4 A schematic diagram of the structure of the winding assembly described in Embodiment 4.
  • Figure 5 A three-dimensional structural diagram of the tension machine described in Example 4.
  • Figure 6 A schematic diagram of the structure of the continuous foaming material production system described in Example 6.
  • Fig. 7 A schematic diagram of the structure of the feed roller of the corona machine described in Example 6.
  • a continuous foaming material thickness setting device as shown in Figure 1, includes a foaming cavity 1 and a thick lock part 2.
  • the foaming cavity 1 is a vertical foaming cavity, and the upper and lower ends are respectively provided There are a feeding port 11 and a discharging port 12.
  • the inner wall of the foaming cavity 1 is provided with a number of heating elements 13 along the conveying direction of the foaming material, and the heating elements 13 are arranged in the middle of the inner wall of the foaming furnace 1.
  • the heating elements 13 are arranged
  • An unfolding roller 14 is provided below the area, and the inside of the unfolding roller 14 is hollow and provided with a cooling water port.
  • the thick lock portion 2 is provided on the outside of the discharge port 12, as shown in Figs. 1-2, including a pressure roller 21 and a steering roller 22 which are provided with a cooling structure 23 on the opposite surfaces communicating with the cooling water pipeline.
  • the steering roller 22 is an active roller driven by a motor; the cooling structure 23 is a number of protrusions arranged on the surface of the pressure roller 21 and the steering roller 22, the protrusions are higher than the pressure roller 21 / steering roller
  • the surface of the 22 is 0.1-0.5mm (the shape, size, and style of the protrusions provided on the surface of the pressure roller 21 and the steering roller 22 can be the same or different); the roller diameter of the steering roller 22 is at least the pressure roller 21 is 1.2 times the diameter of the roller; the foamed material passes through the pressing area between the pressure roller 21 and the steering roller 22, and then is sent out in a manner of being attached to the surface of the steering roller 22, and the sending direction is the same as that of the foaming material.
  • the conveying direction of the bubble cavity 1 is at an acute angle; the pressure roller 21 is located in the area directly opposite the outlet 12, the pressing area on the steering roller 22 is directly opposite to the outlet 12, and at least 70% of the steering roller 22 is located at the outlet Outside the area directly facing the material port 12; the pressing area of the pressure roller 21 and the turning roller 22 is 0.2-0.35m away from the discharge port 12; the discharge port 12 is rectangular, and the long side is set in the same direction as the pressure roller 21
  • the axial direction of the steering roller 22 is the same.
  • the first adjustment portion 24 includes a first fixing frame 241, a first bearing seat 242 slidably connected to the first fixing frame 241 on both sides by a first slide rail 243, and a first bearing seat sleeved on the first bearing seat
  • the cylinder 244 at the bottom of 242, the cylinder 244 is also threadedly connected to the first fixing frame 241 through a fixing plate 245;
  • the second adjusting portion 25 includes a second fixing frame 251 and two sides slide through the second slide rails 253
  • the second bearing seat 252 is connected to the second fixing frame 251, and one side of the second fixing frame 251 is opened; when the pressure roller 21 needs to be replaced, the cylinder 244 is loosened, and then the fixing plate 245 and the first The screws connected to the fixing frame 24
  • a production equipment for continuous foaming material The basic structure is the same as that of Embodiment 1. The difference is that this embodiment is only provided with a cooling structure 23 on the surface of the pressure roller 21.
  • a production equipment for continuous foaming materials The basic structure is the same as that of Example 1. The difference is: the foaming cavity 1 of this embodiment is a horizontal foaming cavity. As shown in Figure 3, the left and right ends of the foaming cavity 1 are respectively provided with The feeding port 11 and the discharging port 12, the embossing roller 21 and the turning roller 22 are arranged opposite to each other up and down, and the rest of the structure is the same as that of the first embodiment.
  • this embodiment provides an optimized winding assembly suitable for the thickness setting device of the present invention, as shown in FIG. 52a, tractor 53, second tensioner 52b, and winding frame 54; the two tensioners in the winding assembly 5 are set on the basis of maintaining a constant tension, which can also avoid the impact of the subsequent winding process on the locking process. Realize continuous production and improve production efficiency.
  • the correcting machine 51 includes a frame and four rollers fixed to the frame.
  • the correcting machine 51 checks the correctness of the position with an infrared detector, and adjusts the frame direction through an automatic controller to correct the foaming material conveying direction. This prevents the deviation of the foam material from affecting the locking effect.
  • the structure of the first tensioner 52a and the second tensioner 52b are the same, as shown in FIG.
  • the roller 521, the guide roller 521 and the float 522 are parallel to each other; the two ends of the float roller 522 are provided with a transmission part 524, in this embodiment, the transmission part 524 is a sprocket chain mechanism, the sprocket chain mechanism includes a vertical arrangement A chain and a sprocket for the chain to be wound around, the sprocket is driven by a motor, one end of the chain is fixedly connected with a balance weight 523 for reducing the lifting resistance of the floating roller 522, and the other end is fixedly connected to the floating roller 522
  • the two ends of the floating roller 522 are also sleeved in a vertical guide rod 525, the guide rod 525 can effectively avoid the lifting of the floating roller 522 deviation, thereby avoiding the deviation of the foam material in the tension control process;
  • the chain drives the floating roller 522 to move up and down on
  • the spring 526 can reduce the impact force generated when the floating roller 522 touches the bottom and improve the stability of adjustment.
  • the floating roller 522 is also electrically connected with a potentiometer. When the winding speed changes, The tension received by the floating roller 522 changes, and the potentiometer receives the signal and outputs it to the controller. The controller controls the motor according to the signal, so that the floating roller 522 makes corresponding position adjustments to achieve constant tension control.
  • the power machine has a good cushioning effect through the lifting of the floating roller 522 and the adjustment of the winding speed, maintaining a constant tension, and avoiding the effect of tension changes on the lock thickness.
  • a foaming material production system includes the thickness setting device described in Example 1 and the winding group 5 described in Example 4.
  • This embodiment provides a more optimized foaming material production system, as shown in FIG. 6, including a thickness setting device, a cooling roller 3, a corona machine 4, and a winding assembly 5 arranged in sequence.
  • the structure of the thickness setting device The same as the embodiment 1, the structure of the winding assembly 5 is the same as that of the embodiment 4.
  • the cooling roller 3 is arranged on one side of the turning roller 22, and the axis of the cooling roller 3 is higher than the turning 22; the corona 4 includes The frame, the rubber rollers arranged in the frame, and the feed rollers 41 arranged on both sides of the rubber rollers. As shown in Fig. 7, the surface of the feed rollers 41 is provided with a number of ring patterns to prevent the foaming material from wrinkling.
  • the ring-shaped pattern is symmetrical about the middle of the feed roller 41, and it is inclined from the inside to the outside, so that the foam material can be fully spread, ensure the corona effect, and enable the subsequent winding to proceed smoothly; an electrode rod is arranged above the rubber roller , Through the high-voltage discharge of the electrode rod, the surface of the foaming material is reacted with radicals and the polymer is cross-linked, thereby improving the surface roughness and wettability, effectively improving the surface performance of the foaming material, and improving its practical use The level of combination with other boards.
  • Example 6 Using the production equipment described in Example 6 to produce IXPE continuous foaming material specifically includes the following steps:
  • Foaming preheat the IXPE mother film to 90-110°C, and vertically input the foaming cavity 1 with the heating element 13 turned on from the feed port 11, and the foaming cavity 1 is generated through the feed port 11 and the discharge port 12
  • the ventilation effect of the foaming cavity 1 makes the middle part of the foaming cavity 1 reach the second-stage foaming temperature of 230-270°C, and the upper part of the first-stage foaming temperature of 270-290°C;
  • the unfolding roller 14 in 1 is flattened, and then output from the discharge port 12 of the foaming cavity 1;
  • Thickness setting open the cooling water pipe communicating with the pressure roller 21 and the steering roller 22 in advance, the sheet enters the pressing area between the pressure roller 21 and the steering roller 22, the pressure roller 21 and the steering roller 22 run in opposite directions, between the two The roller surface cooling structure 23 and the cooling water in the two rollers realize the thickness lock, and then send the sheet to the cooling roller 3 for further cooling;
  • the sheet material enters the corona machine 4 for surface treatment to roughen the surface;

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Molding Of Porous Articles (AREA)

Abstract

一种连续发泡材料的定厚装置，属于发泡材料生产设备技术领域，包括发泡腔(1)和锁厚部(2)；所述发泡腔(1)的两端分别设置有进料口(11)和出料口(12)，发泡腔(1)的内壁沿着发泡材料输送方向设有若干加热元件(13)；所述锁厚部(2)设于所述出料口(12)的外部，锁厚部(2)包括相对设置的与冷却媒介管路连通的压力辊(21)和转向辊(22)，所述压力辊(21)和转向辊(22)中，至少一个表面设有冷却结构(23)，且至少一个为由动力设备驱转的主动辊；所述发泡材料经过压力辊(21)和转向辊(22)之间的压制区域后以贴合于所述转向辊(22)表面的方式送出。能够实现发泡材料的精确、快速定厚，有效降低成品尺寸偏差，提高成品质量。

Description

一种连续发泡材料的定厚装置 技术领域
本发明属于发泡材料生产设备技术领域，具体涉及一种连续发泡材料的定厚装置。
 背景技术
片材发泡是指将带状的高分子材料在发泡炉中进行加热，发泡剂在高温下分解产生气体，填充于高分子材料内部，产生具有密闭气孔的发泡材料的过程，实际生产中，在发泡完成后需要通过冷却装置使发泡材料冷却定型，再直接收卷或者经一些后处理工序（如切边、压花、裁片等）再收卷得到成品。上述过程中，冷却定型过程尤为重要，直接决定成品质量，现有的发泡材料生产线的定型装置大多是设于发泡炉外的冷却辊组（如CN105599210B、 CN209111359U），存在以下缺陷：一是冷却速度慢，虽然可以通过增加冷却辊组数量或者加大对辊压力改善，但是前者能耗高后者容易将片材挤压过度甚至压断；还有更重要的是目前的冷却定型只是通过冷却辊对片材降温使其固化，很难对片材的厚度做精确控制，而片材又比较薄（通常只有2-3mm），很容易受温度、气流、牵引速度等外界因素影响导致变形，因此成品尺寸难以控制，容易出现大的偏差，而发泡材料通常是需要贴合在其他板材上使用的，一旦不同部位厚度产生较大偏差，直接影响其与板材的结合，进而影响板材的质量和使用性能。
 技术问题
现有的发泡设备无法对发泡材料的尺寸尤其是厚度作精确控制，因此成品容易产生较大的尺寸偏差，影响使用效果。
 技术解决方案
为解决上述问题，本发明提出了一种连续发泡材料的定厚装置，能够实现精确、快速定厚，有效降低成品尺寸偏差，提高成品质量。
为达到上述目的，本发明采用的具体技术方案如下：
一种连续发泡材料的定厚装置，包括发泡腔和锁厚部；所述发泡腔的两端分别设置有进料口和出料口，发泡腔的内壁沿着发泡材料输送方向设有若干加热元件；所述锁厚部设于所述出料口的外部，锁厚部包括相对设置的与冷却媒介管路连通的压力辊和转向辊，所述压力辊和转向辊中，至少一个表面设有冷却结构，且至少一个为由动力设备驱转的主动辊；所述发泡材料经过压力辊和转向辊之间的压制区域后以贴合于所述转向辊表面的方式送出。
本发明通过由发泡腔与锁厚部组成的定厚装置对发泡材料的尺寸进行精确控制，其中锁厚部由相对设置的具有冷却功能的且至少一个表面有冷却结构的压力辊和转向辊组成，冷却结构为能够使片材经过压力辊和转向辊辊压后表面形成凹凸外观的构造。片材在发泡腔发泡后初步成型，然后垂直进入压力辊和转向辊之间，辊压时发泡材料利用余热使冷却结构能够嵌入其表面，同时在冷却媒介的作用下冷却定型；冷却结构在发泡材料表面的多个部位形成凹陷部分，并且由于凹陷部分与平面部分间隔交替，不会对其强度造成影响；冷却结构的设置不仅增加了冷却接触面积，而且使得冷却进程能够快速深入到发泡材料内部，实现对厚度的精确、快速控制，提高片材整体冷却的速度和充分性，与现有技术中增加冷却辊组数量或者加大对辊压力的方式相比在定型效果和效率上具有显著优势；本发明发泡材料在压制完成后还以贴合于转向辊的方式送出，以增加冷却接触时间，对由冷却结构在发泡材料表面形成的纹路起到保护和稳固作用。因此，本发明的锁厚部不仅使发泡材料表面定型，也能在厚度方向上对其进行精确定型，使得成品尺寸偏差小。
优选的，所述冷却结构为压力辊/转向辊表面的若干凸出部，凸出部的形状、尺寸可以多样化。
优选的，所述凸出部高出压力辊/转向辊的表面0.1-0.5mm。
优选的，所述转向辊的辊筒直径至少为所述压力辊的辊筒直径的1.2倍。通过增大转向辊的直径增加发泡材料与其的接触面积，使得发泡材料的冷却定型更加充分，强化锁厚果。
优选的，所述发泡材料贴合于所述转向辊表面送出时，送出方向与发泡材料在发泡腔的输送方向呈锐角。通过控制发泡材料的送出方向增加发泡材料与转向辊的接触面积，使得发泡材料的冷却定型更加充分，强化锁厚效果。
优选的，所述压力辊和转向辊上的至少压制区域与所述出料口正对。辊压的同时也在进行冷却，而发泡材料表面需要在冷却结构作用下形成凹凸构造，因此需要避免过早冷却，以克服难以成型而直接影响外观的问题，通过将压力辊和转向辊上的至少压制区域设置在与发泡腔出料口正对的位置，使得压制区域和发泡材料有一定的受热，不会立即冷却。
优选的，所述压力辊位于所述出料口的正对区域，所述转向辊至少70%的部分位于所述出料口的正对区域之外。这样的位置设计，能够有效减缓压冷却结构在与发泡材料贴合辊压时的冷却进程，有利于凹凸结构的成型，辊压后发泡材料贴合于转向辊送出，转向辊受热少，可快速对发泡材料进行锁厚，使得锁厚部可以在确保发泡材料美观性的同时不影响锁厚效果。
优选的，所述出料口为长方形，长边设置方向与压力辊和转向辊的轴向一致，使得发泡材料在宽度方向上不同部位受热均匀，进而避免因受热差异导致的锁厚进程不一致而增加成品尺寸偏差的问题。
优选的，所述压力辊和转向辊的辊轴两端分别设有调节部，所述调节部包括固定架以及套设于辊轴并滑动连接于所述固定架的轴承座。调节部通过轴承座在固定架上的滑动实现压力辊和转向辊的位置调节及拆卸更换，操作简单。
优选的，所述压力辊的调节部还设有一与轴承座相连的气缸，为轴承座在固定架上的移动提供动力，使处于外侧的压力辊的拆装更加方便快速。
优选的，所述加热元件设于所述发泡腔内壁的中部，所述加热元件的设置区域下方设有具有冷却功能的展开辊。发泡腔中片材在加热元件作用下进行发泡，发泡后片材会膨胀，两边也会卷曲，因此在非加温区设置具有冷却功能的展开辊，一方面通过展开辊将片材展平，提高片材的平整性，另一方面，在非加温区域展平的同时通过展开辊的冷却作用使得片材内部完全停止发泡，避免片材展平后厚度再发生变化，为后续片材的锁厚提供良好的结构基础。
发泡材料在定厚装置定型后，需要进行收卷，为减少收卷过程对发泡材料定厚过程的影响，本发明提供一种适用于上述定型装置的收卷组件，包括纠偏机、牵引机和收卷架。片材经定厚装置处理后直接用收卷架收卷，容易产生偏移现象，而一旦片材偏移，会导致正在进行锁厚的片材两侧受力不平衡，直接影响定型效果，增加片材尺寸偏差，因此本发明在收卷组件中设置了纠偏机避免锁厚过程产生偏差；通过张力机的设置为整个传输过程提供良好的缓冲作用，在收卷速度变化时，维持恒定张力，使得锁厚过程能够持续稳定进行，进一步减少收卷对锁厚过程造成的影响。
优选的，所述张力机的数量为两个，所述收卷组件包括依次设置的纠偏机、第一张力机、牵引机、第二张力机以及收卷架。两个张力机的设置可以有效提高生产效率，当收卷架换卷时或者进行后续切割等操作时，两个张力机协同作用，可以提供出一定的调整时间，短时间内对前面的发泡、锁厚工序不会产生影响，因此可以实现连续生产；并且两个张力机的设置可以有效减少发泡材料发生偏移的情况以及发生偏移的程度，减少设置在第一张力机前端的纠偏机工作负荷并降低纠偏难度，即使发生一定偏移也能快速调整，不会对锁厚过程造成影响，进一步提高收卷的稳定性，确保发泡材料尺寸的精确控制。
本发明还提供一种包括上述定型装置和收卷组件的发泡材料的生产系统，为了提高成品的表面性能，除包括定型装置和收卷组件外，还包括设于转向辊一侧用于进一步冷却发泡材料的冷却辊以及设于冷却辊与纠偏机之间的电晕机。通过电晕机的设置对发泡材料进行电晕处理，增加其表面的粗糙度，进而改善其表面的润湿性和附着性，提高后续使用时与胶黏剂的相容性；通过冷却辊的设置确保发泡材料冷却完全，提高其尺寸稳定性，进而获得良好的电晕效果。所述发泡材料的生产系统可以持续稳定地生产各种片状的发泡材料，生产效率高，生产出的发泡材料尺寸偏差小，与其他板材的结合性好。
 有益效果
1、通过由发泡腔与锁厚部组成的定厚装置对发泡材料的尺寸进行精确控制，其中锁厚部由相对设置的具有冷却功能的压力辊和转向辊组成，且至少压力辊和转向辊的一个上具有表面冷却结构；片材在发泡腔发泡后初步成型，在锁厚部通过冷却结构配合辊压完成表面以及厚度方向上的精确定型，与现有技术相比，定型更加快速充分，成品尺寸偏差小（可控制在10%以内）。此外，冷却结构可以在片材表面形成纹路，其样式可根据用户需求设计，无需经过后续处理即可提高美观性，有效降低成本。
2、通过增大转向辊的直径、控制发泡材料在转向辊的送出方向与其在发泡腔的输送方向呈锐角这两个方面增加发泡材料与转向辊的接触面积，使得发泡材料的冷却定型更加充分，强化锁厚效果。
3、通过将压力辊和转向辊上的至少压制区域设置在与发泡腔出料口正对的位置，使得压制区域和发泡材料有一定的受热，避免发泡材料过早冷却而导致其表面难以在冷却结构作用下形成对应的凹凸构造，进而影响外观和锁厚效果。更加优化的，通过将压力辊设于出料口的正对区域，转向辊至少70%的部分设于出料口的正对区域之外，确保发泡材料凹凸结构顺利成型的同时，实现快速冷却进而获得良好的锁厚效果；通过将出料口设置为长方形，使得发泡材料在宽度方向受热均匀，提高不同部位锁厚效果的一致性。
4、通过在压力辊和转向辊两端设置调节部实现两个辊的位置调节及拆卸更换，调节部包括固定架以及套设于辊轴并滑动连接于固定架的轴承座，操作简单，当辊表面的冷却结构磨损时或者需要不同样式的冷却结构时，可快速完成辊的替换，提高工作效率。
5、通过在加热元件下方的非加温区设置具有冷却功能的展开辊，将膨胀的片材展平，并使片材内部停止发泡进而避免厚度再发生变化，为后续片材的锁厚提供良好的结构基础。
6、通过在收卷组件中设置纠偏机和张力机减少收卷操作对锁厚效果的影响；具体的，通过在收卷组件中设置纠偏机避免片材位置偏差导致的锁厚不准、增加成品尺寸偏差的问题；通过设置张力机为整个传输过程提供良好的缓冲作用，在收卷速度变化时维持恒定的片材张力，使得锁厚过程能够持续稳定进行；更加优化的，通过设置两个张力机避免收卷后续操作对前面的发泡、锁厚工序产生影响，可以实现连续生产，有效提高生产效率；并且能够减少发泡材料的偏移，进一步提高收卷的稳定性，确保发泡材料尺寸的精确控制。
7、锁厚部中冷却结构的设置使得发泡材料表面呈现凹凸结构，有利于其后续使用时与胶黏剂的结合，本发明在此基础上通过设置电晕机对完成定型的发泡材料进行电晕，以增加发泡材料表面的粗糙度，改善表面的润湿性和附着性，进一步提高发泡材料与胶黏剂的相容性。
8、本发明可以进行IXPE、XPE、EVA等发泡材料的连续生产，发泡腔可以是立式也可以是卧式，适用范围广，应用前景好。
 附图说明
图1：实施例1所述定厚装置的结构示意图。
图2：实施例1所述锁厚部的立体结构图。
图3：实施例3所述定厚装置的结构示意图。
图4：实施例4所述收卷组件的结构示意图。
图5：实施例4所述张力机的立体结构图。
图6：实施例6所述连续发泡材料的生产系统的结构示意图。
图7：实施例6所述电晕机的过料辊的结构示意图。
图中：1-发泡腔，2-锁厚部，3-冷却辊，4-电晕机，5-收卷组件；11-进料口，12-出料口，13-加热元件，14-展开辊，21-压力辊，22-转向辊，23-冷却结构，24-第一调节部，25第二调节部，41-过料辊，51-纠偏机，52a-第一张力机，52b-第二张力机，53-牵引机，54-收卷架；241-第一固定架，242-第一轴承座，243-第一滑轨，244-气缸，245-固定板，251-第二固定架，252-第二轴承座，253-第二滑轨，521-导辊，522-浮辊，523-平衡块，524-传动部，525-导向杆，526-弹簧。
 本发明的实施方式
以下结合附图和具体实施例对本发明进行进一步的说明。
实施例1
一种连续发泡材料的定厚装置，如图1所示，包括发泡腔1和锁厚部2；本实施例中，发泡腔1为立式的发泡腔，上下两端分别设置有进料口11和出料口12，发泡腔1的内壁沿着发泡材料输送方向设有若干加热元件13，并且加热元件13设置在发泡炉1的内壁中部，加热元件13的设置区域下方设有展开辊14，所述展开辊14内部中空，并设有冷却水口。
所述锁厚部2设于所述出料口12的外部，如图1-2所示，包括相对设置的与冷却水管路连通的表面均设有冷却结构23的压力辊21和转向辊22；所述转向辊22为由电机驱转的主动辊；所述冷却结构23为设置在压力辊21和转向辊22表面的若干凸出部，所述凸出部高出压力辊21/转向辊22的表面0.1-0.5mm（设置在压力辊21和转向辊22表面的凸出部形状、尺寸、样式可以相同，也可以不同）；所述转向辊22的辊筒直径至少为所述压力辊21的辊筒直径的1.2倍；所述发泡材料经过压力辊21和转向辊22之间的压制区域后以贴合于所述转向辊22表面的方式送出，送出方向与发泡材料在发泡腔1的输送方向呈锐角；压力辊21位于所述出料口12的正对区域，转向辊22上的压制区域与出料口12正对，且转向辊22至少70%位于所述出料口12的正对区域之外；压力辊21和转向辊22的压制区域与出料口12的距离在0.2-0.35m；出料口12为长方形，且长边的设置方向与压力辊21和转向辊22的轴向相同。
所述压力辊21的辊轴两端分别设有第一调节部24，所述转向辊22的辊轴两端分别设有第二调节部25，所述有第二调节部25位于第一调节部24外侧，第一调节部24包括第一固定架241、两侧通过第一滑轨243滑动连接于所述第一固定架241的第一轴承座242以及套接于所述第一轴承座242底部的气缸244，所述气缸244还通过一固定板245与所述第一固定架241螺纹连接；所述第二调节部25包括第二固定架251以及两侧通过第二滑轨253滑动连接于所述第二固定架251的第二轴承座252，所述第二固定架251的一侧敞开设置；需要更换压力辊21时，松掉气缸244，再取下固定板245与第一固定架241连接的螺丝，即可通过第一轴承座242在第一滑轨243的滑动将其取出，当需要更换所述转向辊22时，需要再将第一固定架241取下，通过第二轴承座252在第二滑轨253上沿敞开侧滑动即可取出。
实施例2
一种连续发泡材料的生产设备，基本构造同时实施例1，区别在于：本实施例仅在压力辊21表面设有冷却结构23。
实施例3
一种连续发泡材料的生产设备，基本构造同时实施例1，区别在于：本实施例发泡腔1为卧式发泡腔，如图3所示，发泡腔1左右两端分别设置有进料口11和出料口12，压花辊 21和转向辊22上下相对设置，其余构造同实施例1。
实施例4
为减少直接收卷对定厚效果的影响，本实施例提供一种优化的适用于本发明定厚装置的收卷组件，如图4所示，包括依次设置的纠偏机51、第一张力机52a、牵引机53、第二张力机52b以及收卷架54；收卷组件5中两个张力机的设置在维持恒定张力的基础上，还能避免收卷后续工序对锁厚过程造成影响，实现连续化生产，提高生产效率。
所述纠偏机51包括机架以及固定于所述机架的四个辊，纠偏机51通过红外探测器检验位置正确性，通过自动控制器调整机架方向实现对发泡材料输送方向的纠偏，进而避免发泡材料的偏移对锁厚效果造成影响。
所述第一张力机52a和第二张力机52b的构造一样，如图5所示，包括中间的浮辊522以及设于所述浮辊522两侧的并处于浮辊522上方的两个导辊521，所述导辊521与浮522相互平行；浮辊522的两端设置有传动部524，本实施例中传动部524为链轮链条机构，所述链轮链条机构包括竖向设置的链条以及供所述链条绕设的链轮，所述链轮由电机驱转，所述链条一端固接有用于降低浮辊522升降阻力的平衡块523、另一端与所述浮辊522固接；浮辊522的两端还套设于一竖向设置的导向杆525，所述导向杆525能够有效避免浮辊522的升降发生偏移，进而避免发泡材料在张力控制过程发生偏移；通过链轮的正反转使链条带动浮辊522在固定杆525上下移动；所述导向杆525上还套设有两个弹簧526，其中一个弹簧526位于所述浮辊522上方，另一弹簧526位于所述浮辊522下方，所述弹簧526可以减少浮辊522触底时产生的冲击力，提高调节稳定性；浮辊522还与电位器电性连接，当收卷速度发生变化时，浮辊522收到的张力发生变化，电位器接受到该信号，并将其输出至控制器，控制器根据该信号控制电机，进而使浮辊522作出相应位置调整，实现恒张力控制。动力机通过浮辊522的升降配合收卷速度的调整，起到良好的缓冲作用，维持恒定的张力，避免了张力变化对锁厚效果造成影响。
实施例5
一种发泡材料的生产系统，包括实施例1所述的定厚装置和实施例4所述的收卷组5。
实施例6
本实施例提供一种更加优化的发泡材料的生产系统，如图6所示，包括依次设置的定厚装置、冷却辊3、电晕机4和收卷组件5，所述定厚装置的构造同实施例1，所述收卷组件5的构造同实施例4，所述冷却辊3设于转向辊22的一侧，且冷却辊3的轴心高于转向22；所述电晕机4包括机架、设于机架内的胶辊以及设于胶辊两侧的过料辊41，所述过料辊41如图7所示，表面设有防止发泡材料褶皱的若干环状纹路，环状纹路的设置关于过料辊41中部对称，由内向外倾斜，使得发泡材料可以充分铺展开，确保电晕效果，并使后续收卷能够顺利进行；所述胶辊上方设有电极棒，通过电极棒的高压放电，使发泡材料表面产生游离基反应而使聚合物发生交联，从而提高表面的粗糙度和润湿性，有效改善发泡材料的表面性能，提高其在实际使用时与其他板材的结合水平。
利用实施例6所述生产设备生产IXPE连续发泡材料，具体包括以下步骤：
S1.发泡：将IXPE母片预热至90-110℃，由进料口11垂直输入已开启加热元件13的发泡腔1，发泡腔1通过进料口11和出料口12产生的抽风效应，使得发泡腔1内中部达到二段发泡温度230-270℃，上部达到一段发泡温度270-290℃；片材依次进行一段发泡和二段发泡后通过发泡腔1内的展开辊14展平，然后从发泡腔1的出料口12输出；
S2.定厚：提前打开与压力辊21和转向辊22连通的冷却水管道，片材进入压力辊21和转向辊22之间的压制区域，压力辊21和转向辊22反向运转，在两辊表面冷却结构23以及两辊内冷却水的作用下实现锁厚，再将片材送至冷却辊3进一步冷却；
S3.电晕: 片材进入电晕机4进行表面处理，使表面粗糙化；
S4.收卷: 片材依次经过纠偏机51、第一张力机52a、牵引机53、第二张力机52b以及收卷架54，完成纠偏、张力控制、牵引和收卷工序，得到IXPE成品发泡材料。
本具体实施方式仅仅是对本发明的解释，并不是对本发明的限制，本领域技术人员在阅读了本发明的说明书之后所做的任何改变，只要在本发明权利要求书的范围内，都将受到专利法的保护。

Claims (11)

  1. 一种连续发泡材料的定厚装置，其特征在于：包括发泡腔（1）和锁厚部（2）；所述发泡腔（1）的两端分别设置有进料口（11）和出料口（12），发泡腔（1）的内壁沿着发泡材料输送方向设有若干加热元件（13）；所述锁厚部（2）设于所述出料口（12）的外部，锁厚部（2）包括相对设置的与冷却媒介管路连通的压力辊（21）和转向辊（22），所述压力辊（21）和转向辊（22）中，至少一个表面设有冷却结构（23），且至少一个为由动力设备驱转的主动辊；所述发泡材料经过压力辊（21）和转向辊（22）之间的压制区域后以贴合于所述转向辊（22）表面的方式送出。
  2. 根据权利要求1所述的连续发泡材料的定厚装置，其特征在于：所述冷却结构（23）为压力辊（21）/转向辊（22）表面的若干凸出部。
  3. 根据权利要求2所述的连续发泡材料的定厚装置，其特征在于：所述凸出部高出压力辊（21）/转向辊（22）的表面0.1-0.5mm。
  4. 根据权利要求1所述的连续发泡材料的定厚装置，其特征在于：所述转向辊（22）的辊筒直径至少为所述压力辊（21）的辊筒直径的1.2倍。
  5. 根据权利要求1所述的连续发泡材料的定厚装置，其特征在于：所述发泡材料贴合于所述转向辊（22）表面送出时，送出方向与发泡材料在发泡腔（1）的输送方向呈锐角。
  6. 根据权利要求1所述的连续发泡材料的定厚装置，其特征在于：所述压力辊（21）和转向辊（22）上的至少压制区域与所述出料口（12）正对。
  7. 根据权利要求6所述的连续发泡材料的定厚装置，其特征在于：所述压力辊（21）位于所述出料口（12）的正对区域，所述转向辊（22）至少70%的部分位于所述出料口（12）的正对区域之外。
  8. 根据权利要求6所述的连续发泡材料的定厚装置，其特征在于：所述出料口（12）为长方形。
  9. 根据权利要求1所述的连续发泡材料的定厚装置，其特征在于：所述压力辊（21）和转向辊（22）的辊轴两端分别设有调节部，所述调节部包括固定架以及套设于辊轴并滑动连接于所述固定架的轴承座。
  10. 根据权利要求9所述的连续发泡材料的定厚装置，其特征在于：所述压力辊（21）的调节部还设有一与轴承座相连的气缸。
  11. 根据权利要求1所述的连续发泡材料的定厚装置，其特征在于：所述加热元件（13）设于所述发泡腔（1）内壁的中部，所述加热元件（13）的设置区域下方设有具有冷却功能的展开辊（14）。
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