WO2023216422A1 - 一种充气产品高度定型层连续贴合上下布层装置及方法 - Google Patents

一种充气产品高度定型层连续贴合上下布层装置及方法 Download PDF

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WO2023216422A1
WO2023216422A1 PCT/CN2022/107781 CN2022107781W WO2023216422A1 WO 2023216422 A1 WO2023216422 A1 WO 2023216422A1 CN 2022107781 W CN2022107781 W CN 2022107781W WO 2023216422 A1 WO2023216422 A1 WO 2023216422A1
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WIPO (PCT)
Prior art keywords
welding
fabric
conductor
warp knitted
knitted fabric
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PCT/CN2022/107781
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English (en)
French (fr)
Inventor
郑美乾
林贤州
罗群瑞
姚配剑
蔡朋楷
叶永新
李智超
潘为烨
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福建恩迈特新材料有限公司
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Publication of WO2023216422A1 publication Critical patent/WO2023216422A1/zh

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    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
    • B29C65/7861—In-line machines, i.e. feeding, joining and discharging are in one production line
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81463—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
    • B29C66/81465—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint one placed behind the other in a single row in the feed direction

Definitions

  • the invention relates to the field of inflatable products, and in particular to a device and method for continuously fitting the highly shaped layers of the inflatable product to the upper and lower fabric layers.
  • Inflatable products are light in weight, easy to store and easy to carry. They are not only used in outdoor products or toys, but have also become used in household products, such as common inflatable beds, inflatable sofas, etc. If the inflatable product is to be set into a predetermined shape, it must rely on its internal structure.
  • Existing inflatable products are mainly drawstring type inflatable products, such as the previous patent CN202536548U - an inflatable product structure, the interior of which is connected to the inside of the inflatable cavity through multiple sets of drawstring assemblies, in which the wire body in the drawstring assembly is composed of a single It is composed of warp wires, which can only bear force in one direction and has poor stability. Moreover, each set of drawstring components must be produced separately and then welded to the inflatable cavity.
  • the object of the present invention is to provide a device and method for producing highly efficient and high-quality inflatable products with highly shaped layers that continuously adhere to the upper and lower fabric layers.
  • a device for continuously fitting the upper and lower fabric layers with highly shaped layers of inflatable products which includes a top fabric sending mechanism, a warp knitting fabric sending mechanism, a base fabric sending mechanism, a continuous welding mechanism and a finished product winding mechanism;
  • the top cloth sending mechanism, warp knitting cloth sending mechanism, and bottom fabric sending mechanism respectively transport the top cloth, warp knitted fabric, and bottom fabric to the input end of the continuous welding mechanism, and the top cloth, warp knitted fabric, and bottom fabric are continuously welded.
  • the mechanism is welded into one body and then rolled up in the finished winding mechanism;
  • the continuous welding mechanism includes a frame, the upper part of the frame is provided with a plurality of upper welding units, the lower part of the frame is provided with a plurality of lower welding units, and the upper welding units and the lower welding units are arranged alternately and staggered along the direction of the assembly line;
  • each upper welding unit and lower welding unit work synchronously to alternately displace the warp knitted fabric along the direction of the assembly line and weld and fix it with the top fabric and base fabric, so that the warp knitted fabric is welded and fixed with the top fabric and base fabric.
  • the braid forms a zigzag pattern between the top and back fabrics.
  • the upper welding unit includes a lifting platform, an upper bracket, a first welding upper conductor and a first welding lower conductor; the lifting platform is driven up and down by an upper platform lifting cylinder, and the upper bracket is installed on the upper welding unit.
  • the upper bracket On the side of the lifting platform, the upper bracket is provided with an upper bracket with an opening facing the lifting platform.
  • the inner rear wall of the upper bracket is equipped with an upper travel switch.
  • the upper bracket is driven up and down by the upper bracket cylinder. ;
  • An upper telescopic device is fixed on the lifting platform.
  • the output end of the upper telescopic device is fixedly connected to one end of the first welding lower conductor.
  • the upper telescopic device drives the first welding lower conductor in a direction toward or away from the upper bracket. Moving horizontally, the first upper welding conductor is located on the side of the lifting platform, and the first upper welding conductor is driven up and down by the first welding drive cylinder;
  • the lower welding unit includes a lower lifting platform, a lower bracket, a second upper welding conductor and a second lower welding conductor; the lower lifting platform is driven up and down by a lower platform lifting cylinder, and the lower bracket is mounted on the lower lifting platform.
  • the lower bracket is provided with a lower bracket with an opening facing the lower lifting platform, a lower stroke switch is provided on the inner rear wall of the lower bracket, and the lower bracket is lifted and lowered by the lower bracket cylinder;
  • a lower telescopic device is fixed on the lower lifting platform. The output end of the lower telescopic device is fixedly connected to one end of the second welding upper conductor. The lower telescopic device drives the second welding upper conductor to move horizontally in a direction approaching or away from the lower bracket.
  • the second welding lower conductor is located on the side of the lower lifting platform, and the second welding lower conductor is driven up and down by the second welding drive cylinder.
  • the upper part of the frame is provided with an upper needle plate transmission chain for driving the fabric forward.
  • the needles on the upper needle plate transmission chain are arranged downward.
  • the upper needle plate transmission chain is spaced apart along the flow direction.
  • the lower part of the frame is provided with a lower needle plate transmission chain for driving the base fabric forward.
  • the needles on the lower needle plate transmission chain are arranged upward.
  • a plurality of lower needle plate transmission chains are spaced along the flow direction.
  • the surface cloth and bottom fabric are The cloth is separated from the upper needle plate transmission chain and the lower needle plate transmission chain respectively, and finally the woven fabric welded together is rolled up on the finished product winding mechanism.
  • the fabric sending mechanism includes a fabric sending roller and a fabric storage rack in sequence along the flow direction;
  • the warp knitting fabric sending mechanism includes a warp knitting fabric sending roller and a warp knitting fabric storage rack in sequence along the flow direction;
  • the base fabric sending mechanism includes a base fabric sending roller and a base fabric storage rack in sequence along the flow direction;
  • the finished product winding mechanism includes a finished product storage frame and a finished product winding roller in sequence along the flow direction.
  • an edge trimming mechanism is provided between the finished product winding mechanism and the finished product winding roller.
  • a connecting plate welding mechanism is provided between the output end of the warp knitting sending mechanism and the input end of the continuous welding mechanism.
  • the connecting plate welding mechanism includes a base and a lifting base, and a plurality of third welding mechanisms are spaced on the base.
  • Three welding lower conductors, the lifting seat is located above the base and is driven up and down by the lifting drive cylinder.
  • a third welding upper conductor is fixed at the bottom of the lifting seat corresponding to each lower fixed welding conductor, and each connecting plate is fed into the corresponding third welding conductor from the side.
  • the third solder is between the lower conductor and the third solder is between the upper conductor.
  • the input and output ends of the connecting plate welding mechanism and the continuous welding mechanism are both equipped with a cloth braking mechanism.
  • the cloth braking mechanism includes a lifting roller and a bottom roller, and the lifting roller is arranged directly above the bottom roller. And driven by the brake cylinder to drive the lifting.
  • a laminating method is adopted in which the highly shaped layer of the inflatable product is continuously bonded to the upper and lower fabric layer devices, which includes the following steps:
  • the warp knitted fabric is fed into the connecting plate welding mechanism through the warp knitted fabric sending mechanism.
  • Connecting plates are fed into each group of third welding lower conductors and third welding upper conductors respectively.
  • the lifting seat descends to drive multiple third weldings.
  • the upper conductor is synchronously pressed down on the corresponding third welding lower conductor, so that multiple connecting plates are alternately and alternately welded and fixed to the top and bottom surfaces of the warp knitted fabric;
  • each connecting plate on the top surface of the warp knitted fabric corresponds to an upper welding unit
  • each connection on the bottom surface of the warp knitted fabric corresponds to an upper welding unit.
  • the plates correspond to the lower welding units respectively; then each upper welding unit and lower welding unit work synchronously.
  • the upper retractor of each upper welding unit extends out the first welding lower conductor, and the upper travel switch stops after being sensed in place.
  • the upper platform lifting cylinder, The first welding drive cylinder and the upper bracket cylinder extend simultaneously, so that the first welding upper conductor and the first welding lower conductor clamp the corresponding connecting plate and surface fabric on the top surface of the warp knitted fabric, and maintain the pressure for a predetermined time, thereby
  • the connecting plate on the top surface of the warp knitted fabric is welded and fixed with the fabric; at the same time, the lower retractor of each lower welding unit stretches out the second welding upper conductor, and stops after the lower stroke switch is sensed in place.
  • the lower platform lifting cylinder and the second welding The driving cylinder and the lower bracket cylinder are extended simultaneously, so that the second welding upper conductor and the second welding lower conductor clamp the corresponding connecting plate and base fabric on the bottom surface of the warp knitted fabric, and keep the pressure for a predetermined time, so that the bottom surface of the warp knitted fabric is pressed
  • the connecting plate and the base fabric are welded and fixed;
  • each upper welding unit and lower welding unit are reset.
  • the welded product is sent out by the continuous welding mechanism and wound on the finished product winding mechanism.
  • the warp knitted fabric is The unwelded parts of the fabric and base fabric then enter the continuous welding mechanism and wait for the next section of welding.
  • the continuous welding mechanism is equipped with multiple upper welding units and lower welding units that are alternately disposed along the direction of the assembly line. During welding, each upper welding unit and lower welding unit move synchronously to realize the alternate dislocation of the braid and the surface fabric in sequence. Welded and fixed with the base fabric, the warp knitted fabric eventually forms a zigzag shape between the surface fabric and the base fabric. After the welding is completed, the welded part is transported forward a predetermined distance, and the unwelded part of the warp knitted fabric is reunited with the surface fabric and the base fabric. Enter the continuous welding mechanism to wait for welding. The above process realizes assembly line production, which greatly improves production efficiency, reduces manual labor, and ensures production quality at the same time;
  • Figure 1 is a front view of the present invention
  • Figure 2 is a schematic diagram of the continuous welding mechanism
  • Figure 3 is a schematic diagram of the connecting plate welding mechanism
  • Figure 4 is a schematic diagram of the upper welding unit
  • Figure 5 is a schematic diagram of the lower welding unit.
  • a device of the present invention for the highly shaped layer of an inflatable product to continuously fit the upper and lower fabric layers which includes a top cloth sending mechanism 1, a warp knitting cloth sending mechanism 2, a base fabric sending mechanism 3, a continuous welding mechanism 4 and Finished product winding mechanism 5;
  • the surface fabric sending mechanism 1, the warp knitting fabric sending mechanism 2, and the base fabric sending mechanism 3 respectively transport the surface fabric, the warp knitting fabric, and the base fabric to the input end of the continuous welding mechanism 4.
  • the surface fabric, the warp knitting fabric, and the base fabric are
  • the continuous welding mechanism 4 is welded into one body and then rolled up in the finished product winding mechanism 5;
  • the surface fabric sending mechanism 1 includes a surface fabric sending roller 11 and a surface fabric storage rack 12 in sequence along the flow direction;
  • the warp knitted fabric sending mechanism 2 includes a warp knitted fabric sending roller 21 and a warp knitting fabric storage rack 22 in sequence along the flow direction;
  • the cloth sending mechanism 3 includes a base cloth sending roller 31 and a base fabric storage rack 32 in sequence along the flow direction;
  • the finished product winding mechanism 5 includes a finished product storage rack 51 and a finished product winding roller 52 in sequence along the flow direction.
  • a first tension adjustment mechanism 23 for adjusting the tension of the warp knitted fabric may be provided at the output end of the warp knitted fabric storage frame 22, or may be provided between the finished product storage frame 51 and the finished product winding roller 52 for adjusting the finished product tension.
  • the continuous welding mechanism 4 includes a frame 41.
  • the upper part of the frame 41 is provided with a plurality of upper welding units 42.
  • the lower part of the frame 41 is provided with a plurality of lower welding units 43.
  • the upper welding units 42 and the lower welding units 43 are arranged along the assembly line direction.
  • the upper and lower welding units 42 and 43 work synchronously to alternately displace the warp knitted fabric and the upper and lower fabrics along the assembly line direction.
  • the base fabric is welded and fixed so that the warp knitted fabric forms a zigzag shape between the top fabric and the base fabric.
  • the upper welding unit 42 includes a lifting platform 421, an upper bracket 422, a first welding upper conductor 423 and a first welding lower conductor 424; the lifting platform 421 is driven up and down by the upper platform lifting cylinder 425, and the upper bracket 422 is provided on the lifting Next to the platform 421, the upper bracket 422 is provided with an upper bracket with an opening facing the lifting platform 421.
  • An upper travel switch 426 is provided on the inner rear wall of the upper bracket.
  • the upper bracket 422 is driven by the upper bracket cylinder 427.
  • Lifting; an upper telescopic device 428 is fixed on the lifting platform 421.
  • the output end of the upper telescopic device 428 is fixedly connected to one end of the first welding lower conductor 424.
  • the upper telescopic device 428 drives the first welding lower conductor 424 to move closer or farther away.
  • the direction of the upper bracket 422 moves horizontally, the first upper welding conductor 423 is located on the side of the lifting platform 421, and the first upper welding conductor 423 is driven up and down by the first welding driving cylinder 429;
  • the lower welding unit 43 includes a lower lifting platform 431, a lower bracket 432, a second upper welding conductor 433 and a second lower welding conductor 434; the lower lifting platform 431 is lifted and lowered by the lower platform lifting cylinder 435, and the lower bracket 432 is located on the lower lifting platform.
  • the lower bracket 432 is provided with a lower bracket with an opening facing the lower lifting platform 431.
  • the inner rear wall of the lower bracket is provided with a down stroke switch 436.
  • the lower bracket 432 is driven by the lower bracket cylinder 437. Lifting; a lower telescopic device 438 is fixed on the lower lifting platform 431.
  • the output end of the lower telescopic device 438 is fixedly connected to one end of the second welding upper conductor 433.
  • the lower telescopic device 438 drives the second welding upper conductor 433 closer or farther away.
  • the direction of the lower bracket 432 moves horizontally
  • the second welding lower conductor 434 is located on the side of the lower lifting platform 431, and the second welding lower conductor 434 is driven up and down by the second welding driving cylinder 439.
  • the upper telescopic device 428 and the lower telescopic device 438 can use other drives such as horizontally placed worm gear screw lifts or cylinders.
  • the upper part of the frame 41 is provided with an upper needle plate transmission chain 44 for driving the fabric forward.
  • the needles on the upper needle plate transmission chain 44 are arranged downward.
  • a plurality of upper needle plate transmission chains 44 are spaced along the flow direction.
  • the pressure roller 441 presses the surface fabric through multiple upper pressure rollers 441, which can ensure the stability of the surface fabric and the warp knitted fabric when welding.
  • the output end of the upper needle plate transmission chain 44 is provided with a transmission chain 44 for connecting the surface fabric and the upper needle plate.
  • the upper detaching needle ejector 442 for detachment;
  • the lower part of the frame 41 is provided with a lower needle plate transmission chain 45 for driving the base fabric forward.
  • the needles on the lower needle plate transmission chain 45 are arranged upward.
  • the lower needle plate transmission chain 45 is provided with a plurality of lower pressures at intervals along the flow direction.
  • the roller 451 presses the base fabric through multiple lower pressure rollers 451, which can ensure the stability of the base fabric and the warp knitted fabric when welding.
  • the output end of the lower needle plate transmission chain 45 is provided with the base fabric and the upper needle plate transmission chain 44.
  • An edge trimming mechanism 54 is provided between the finished product winding mechanism 5 and the finished product winding roller 52 .
  • the edge trimming mechanism 54 is used to cut off the edges of the welded product or cut the welded product into a specific width size.
  • the edge-trimming mechanism 54 includes a rolling cutter with an axially adjustable position.
  • the edge-trimming mechanism 54 belongs to the prior art, and its specific structure and working principle will not be described again.
  • a connecting plate welding mechanism 6 is provided between the output end of the warp knitting cloth sending mechanism 2 and the input end of the continuous welding mechanism 4.
  • the connecting plate welding mechanism 6 includes a base 61 and a lifting base 62.
  • a plurality of thirds are spaced apart on the base 61.
  • Three welding lower conductors 63 (the number of the third welding lower conductor 63 is the same as the total number of the upper welding unit 42 and the lower welding unit 43), the lifting base 62 is located above the base 61 and is driven up and down by the lifting driving cylinder 64.
  • the lifting base A third upper welding conductor 65 is fixed at the bottom of 62 corresponding to each lower fixed welding conductor, and each connecting plate is fed from the side between the corresponding third welding lower conductor 63 and the third upper welding conductor 65 .
  • the input and output ends of the connecting plate welding mechanism 6 and the continuous welding mechanism 4 are equipped with cloth braking mechanisms 7 and 8.
  • the cloth braking mechanisms 7 and 8 include lifting rollers and bottom rollers.
  • the lifting rollers are arranged in front of the bottom rollers.
  • the upper part is driven by the brake cylinder to drive the lifting.
  • an active traction mechanism 9 can be added between the continuous welding mechanism 4 and the finished product winding mechanism 5 to drive the welded warp knitted fabric, top fabric and base fabric to advance together.
  • cylinders involved in the present invention can be replaced by drivers such as electric push rods and servo screw rods.
  • the above-mentioned laminating method in which the highly shaped layer of the inflatable product is continuously bonded to the upper and lower fabric layer devices includes the following steps:
  • the warp knitted fabric is fed into the connecting plate welding mechanism 6 via the warp knitted fabric sending mechanism 2, and connecting plates are fed into each group of the third welding lower conductor 63 and the third welding upper conductor 65 respectively, and the lifting base 62 is lowered to drive A plurality of third welding upper conductors 65 are simultaneously pressed down on the corresponding third welding lower conductors 63, thereby sequentially and alternately dislocating welding and fixing multiple connecting plates to the top and bottom surfaces of the warp knitted fabric;
  • each connecting plate on the top surface of the warp knitted fabric corresponds to an upper welding unit 42 respectively
  • the warp knitted fabric on the bottom surface corresponds to an upper welding unit 42.
  • Each connecting plate corresponds to the lower welding unit 43 respectively; then each upper welding unit 42 and the lower welding unit 43 work synchronously, wherein the upper retractor 428 of each upper welding unit 42 extends out the first welding lower conductor 424, and the upper travel switch 426 senses After it is in place, it stops.
  • the upper platform lifting cylinder 425, the first welding drive cylinder 429 and the upper bracket cylinder 427 are extended simultaneously, so that the first welding upper conductor 423 and the first welding lower conductor 424 clamp the corresponding top surface of the warp knitted fabric.
  • the connecting plate and the base fabric corresponding to the bottom surface of the cloth are kept pressed for a predetermined time, thereby welding and fixing the connecting plate and the base fabric on the bottom side of the warp knit
  • each upper welding unit 42 and lower welding unit 43 are reset.
  • the welded product is sent out by the continuous welding mechanism 4 and wound on the finished product winding mechanism 5.
  • the unwelded parts of the braided fabric, top fabric and base fabric then enter the continuous welding mechanism 4 and wait for the next section of welding.

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  • Manufacturing & Machinery (AREA)
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Abstract

本发明公开一种充气产品高度定型层连续贴合上下布层装置及方法，其包括面布发送机构、经编布发送机构、底布发送机构、连续焊接机构和成品收卷机构；所述连续焊接机构包括机架，机架的上部设有多个上焊接单元，机架的下部设有多个下焊接单元，且上焊接单元和下焊接单元沿流水线方向依序交替错位设置；所述面布、经编布和底布进入连续焊接机构后，各上焊接单元和下焊接单元同步工作从而将经编布沿流水线方向依序交替错位与面布和底布焊接固定，使得经编布在面布和底布之间形成锯齿形。本发明实现流水线式生产，大大提高了生产效率，降低人工劳动力，同时能保证生产质量。

Description

一种充气产品高度定型层连续贴合上下布层装置及方法 技术领域
本发明涉及充气产品领域，尤其涉及一种充气产品高度定型层连续贴合上下布层装置及方法。
背景技术
充气产品具有重量轻、易收藏与易携带的特点，不仅在户外用品或玩具中有所应用，现已成为应用为家居产品，如常见的充气床、充气沙发等。而充气产品如要设置为预定的形状，必须依靠其内部的结构而实现。现有的充气产品主要为拉带式充气产品，如在先专利CN202536548U-一种充气产品结构，其内部通过多组拉带组件连接于充气腔内部，其中拉带组件中的线体由单一的经线组成，这样只能单向受力，稳定性差，而且每组拉带组件要单独生产后再与充气腔焊接，加工工艺复杂，耗费时间长，人工劳动力也耗费多。为了解决上述缺点，本领域的技术人员已经在研究设计一种采用经编布替代拉带组件的充气产品，但是如何将经编布与面布、底布贴合高效高质量的连接在一起又是一个棘手的问题。
发明内容
为克服现有技术中的不足，本发明的目的在于提供一种生产高效、高质量的充气产品高度定型层连续贴合上下布层装置及方法。
为实现上述目的，本发明采用以下技术方案：
一种充气产品高度定型层连续贴合上下布层装置，其包括面布发送机构、经编布发送机构、底布发送机构、连续焊接机构和成品收卷机构；
所述面布发送机构、经编布发送机构、底布发送机构分别将面布、经编布和底布分别输送至连续焊接机构的输入端，面布、经编布和底布在连续焊接机构内焊接成一体后收卷于成品收卷机构；
所述连续焊接机构包括机架，机架的上部设有多个上焊接单元，机架的下部设有多个下焊接单元，且上焊接单元和下焊接单元沿流水线方向依序交替错位设置；
所述面布、经编布和底布进入连续焊接机构后，各上焊接单元和下焊接单元同步工作从而将经编布沿流水线方向依序交替错位与面布和底布焊接固定，使得经编布在面布和底布之间形成锯齿形。
进一步的，所述上焊接单元包括上升降平台、上托架、第一焊接上导体和第一焊接下导体；所述上升降平台由上平台升降气缸带动升降，所述上托架设于上升降平台的旁侧，所述上托架上设有开口朝向上升降平台设置的上托槽，上托槽的内侧后壁设有上行程开关，所述上托架由上托架气缸带动升降；所述上升降平台上固定有上伸缩器，该上伸缩器的输出端与第一焊接下导体的一端固定连接，上伸缩器带动第一焊接下导体沿朝靠近或远离上托架的方向水平移动，所述第一焊接上导体位于上升降平台的旁侧，第一焊接上导体由第一焊接驱动气缸带动升降；
所述下焊接单元包括下升降平台、下托架、第二焊接上导体和第二焊接下导体；所述下升降平台由下平台升降气缸带动升降，所述下托架设于下升降平台的旁侧，所述下托架上设有开口朝向下升降平台设置的下托槽，下托槽的内侧后壁设有下行程开关，所述下托架由下托架气缸带动升降；所述下升降平台上固定有下伸缩器，该下伸缩器的输出端与第二焊接上导体的一端固定连接，下伸缩器带动第二焊接上导体沿朝靠近或远离下托架的方向水平移动，所述第二焊接下导体位于下升降平台的旁侧，第二焊接下导体由第二焊接驱动气缸带动升降。
进一步的，所述机架的上部设有用于带动面布前进的上针板传动链，所述上针板传动链上的针头朝下设置，所述上针板传动链上沿流水方向间隔设有多个上压辊，所述上针板传动链的输出端设有将面布与上针板传动链进行脱离的上脱针顶刀；
所述机架的下部设有用于带动底布前进的下针板传动链，所述下针板传动链上的针头朝上设置，所述下针板传动链上沿流水方向间隔设有多个下压辊，所述下针板传动链的输出端设有将底布与上针板传动链进行脱离的下脱针顶刀。待焊接完成后，上针板传动链和下针板传动链分别带动面布和底布向前移动预定的距离，在上脱针顶刀和下脱针顶刀的作用下，面布和底布分别与上针板传动链和下针板传动链脱离，最终与焊接成一体的编织布收卷于成品收卷机构上。
进一步的，所述面布发送机构沿流水方向依序包括面布发送辊和面布收纳架；所述经编布发送机构沿流水方向依序包括经编布发送辊和经编布收纳架；所述底布发送机构沿流水方向依序包括底布发送辊和底布收纳架；所述成品收卷机构沿流水方向依序包括成品收纳架和成品收卷辊。
进一步的，所述成品收卷机构和成品收卷辊之间设有切边机构。
进一步的，所述经编布发送机构的输出端和连续焊接机构的输入端之间设有连接 板焊接机构，该连接板焊接机构包括底座和升降座，所述底座上间隔设有多个第三焊接下导体，所述升降座位于底座上方并由升降驱动气缸带动升降，升降座底部对应各下固定焊接导体分别固定有第三焊接上导体，各连接板分别从侧方送入对应的第三焊接下导体和第三焊接上导体之间。
进一步的，所述连接板焊接机构和连续焊接机构的输入端和输出端均设有用于布匹制动机构，所述布匹制动机构包括升降辊和底辊，升降辊设置在底辊的正上方并由制动气缸驱动带动升降。
采用一种充气产品高度定型层连续贴合上下布层装置的贴合方法，其包括以下步骤：
1)经编布经由经编布发送机构送入连接板焊接机构中，在每组第三焊接下导体和第三焊接上导体之间分别送入连接板，升降座下降带动多个第三焊接上导体同步下压于对应的第三焊接下导体上，从而将多个连接板依序交替错位焊接固定在经编布的顶面和底面；
2)焊接完连接板的经编布与面布和底布一同送入连续焊接机构中，且经编布顶面上的各连接板分别对应一上焊接单元，经编布底面上的各连接板分别对应一下焊接单元；然后各上焊接单元和下焊接单元同步工作，其中，各上焊接单元的上伸缩器伸出第一焊接下导体，上行程开关感应到位后停止，上平台升降气缸、第一焊接驱动气缸和上托架气缸同步伸出，使得第一焊接上导体和第一焊接下导体夹住经编布顶面对应的连接板与面布，并保压预定时间，从而将经编布顶面的连接板与面布焊接固定；于此同时，各下焊接单元的下伸缩器伸出第二焊接上导体，下行程开关感应到位后停止，下平台升降气缸、第二焊接驱动气缸和下托架气缸同步伸出，使得第二焊接上导体和第二焊接下导体夹住经编布底面对应的连接板与底布，并保压预定时间，从而将经编布底面的连接板与底布焊接固定；
3)经编布与面布和底布焊接形成焊接成品后，各上焊接单元和下焊接单元复位，焊接成品由连续焊接机构送出而收卷于成品收卷机构上，同时经编布与面布和底布未焊接部分再进入连续焊接机构中，等待下一段焊接。
本发明采用以上技术方案，具有以下有益技术效果：
1、连续焊接机构上设置多个沿流水线方向依序交替错位设置的上焊接单元和下焊接单元，焊接时，各上焊接单元和下焊接单元同步动作，实现将编布依序交替错位 与面布和底布焊接固定，最终使得经编布在面布和底布之间形成锯齿形，焊接完成后，焊接完成部分往前输送预定距离，未焊接部分的经编布与面布和底布再进入连续焊接机构中等待焊接，上述过程实现流水线式生产，大大提高了生产效率，降低人工劳动力，同时能保证生产质量；
2、在经编布的顶面和底面先分别间隔焊接固定连接板，再通过上下交错设置的连接板与对应的面布和底布焊接固定，有效提高了经编布与面布和底布的连接强度。
附图说明
以下结合附图和具体实施方式对本发明做进一步详细说明；
图1为本发明的正视图；
图2为连续焊接机构的示意图；
图3为连接板焊接机构的示意图；
图4为上焊接单元的示意图；
图5为下焊接单元的示意图。
具体实施方式
请参照图1-5，本发明一种充气产品高度定型层连续贴合上下布层装置，其包括面布发送机构1、经编布发送机构2、底布发送机构3、连续焊接机构4和成品收卷机构5；
面布发送机构1、经编布发送机构2、底布发送机构3分别将面布、经编布和底布分别输送至连续焊接机构4的输入端，面布、经编布和底布在连续焊接机构4内焊接成一体后收卷于成品收卷机构5；
面布发送机构1沿流水方向依序包括面布发送辊11和面布收纳架12；经编布发送机构2沿流水方向依序包括经编布发送辊21和经编布收纳架22；底布发送机构3沿流水方向依序包括底布发送辊31和底布收纳架32；成品收卷机构5沿流水方向依序包括成品收纳架51和成品收卷辊52。此外，可以在经编布收纳架22的输出端设置用于调节经编布张力的第一张力调节机构23，也可以在成品收纳架51和成品收卷辊52之间设置用于调节成品张力的第二张力调节机构53。第一张力调节机构23和第二张力调节机构53均采用可摆动的气缸调节张力，这部分内容属于现有技术，具体的结构和工作原理不再赘述。
连续焊接机构4包括机架41，机架41的上部设有多个上焊接单元42，机架41 的下部设有多个下焊接单元43，且上焊接单元42和下焊接单元43沿流水线方向依序交替错位设置；面布、经编布和底布进入连续焊接机构4后，各上焊接单元42和下焊接单元43同步工作从而将经编布沿流水线方向依序交替错位与面布和底布焊接固定，使得经编布在面布和底布之间形成锯齿形。
上焊接单元42包括上升降平台421、上托架422、第一焊接上导体423和第一焊接下导体424；上升降平台421由上平台升降气缸425带动升降，上托架422设于上升降平台421的旁侧，上托架422上设有开口朝向上升降平台421设置的上托槽，上托槽的内侧后壁设有上行程开关426，上托架422由上托架气缸427带动升降；上升降平台421上固定有上伸缩器428，该上伸缩器428的输出端与第一焊接下导体424的一端固定连接，上伸缩器428带动第一焊接下导体424沿朝靠近或远离上托架422的方向水平移动，第一焊接上导体423位于上升降平台421的旁侧，第一焊接上导体423由第一焊接驱动气缸429带动升降；
下焊接单元43包括下升降平台431、下托架432、第二焊接上导体433和第二焊接下导体434；下升降平台431由下平台升降气缸435带动升降，下托架432设于下升降平台431的旁侧，下托架432上设有开口朝向下升降平台431设置的下托槽，下托槽的内侧后壁设有下行程开关436，下托架432由下托架气缸437带动升降；下升降平台431上固定有下伸缩器438，该下伸缩器438的输出端与第二焊接上导体433的一端固定连接，下伸缩器438带动第二焊接上导体433沿朝靠近或远离下托架432的方向水平移动，第二焊接下导体434位于下升降平台431的旁侧，第二焊接下导体434由第二焊接驱动气缸439带动升降。其中，上伸缩器428和下伸缩器438可以采用水平放置的蜗轮丝杆升降机或气缸等其他驱动器。
机架41的上部设有用于带动面布前进的上针板传动链44，上针板传动链44上的针头朝下设置，上针板传动链44上上沿流水方向间隔设有多个上压辊441，通过多个上压辊441压面布，能够保证面布与经编布焊接时的稳定性，上针板传动链44的输出端设有将面布与上针板传动链44进行脱离的上脱针顶刀442；
机架41的下部设有用于带动底布前进的下针板传动链45，下针板传动链45上的针头朝上设置，下针板传动链45上沿流水方向间隔设有多个下压辊451，通过多个下压辊451压底布，能够保证底布与经编布焊接时的稳定性，下针板传动链45的输出端设有将底布与上针板传动链44进行脱离的下脱针顶刀452。待焊接完成后，上针板 传动链44和下针板传动链45分别带动面布和底布向前移动预定的距离，在上脱针顶刀442和下脱针顶刀452的作用下，面布和底布分别与上针板传动链44和下针板传动链45脱离，最终与焊接成一体的编织布收卷于成品收卷机构5上。
成品收卷机构5和成品收卷辊52之间设有切边机构54。切边机构54用于将焊接成品的边缘切除，或者将焊接成品裁切成特定的宽度尺寸。切边机构54包括具有能够轴向调节位置的滚切刀，切边机构54属于现有技术，具体的结构和工作原理不再赘述。
经编布发送机构2的输出端和连续焊接机构4的输入端之间设有连接板焊接机构6，该连接板焊接机构6包括底座61和升降座62，底座61上间隔设有多个第三焊接下导体63(第三焊接下导体63的个数与上焊接单元42和下焊接单元43相加的总数相同)，升降座62位于底座61上方并由升降驱动气缸64带动升降，升降座62底部对应各下固定焊接导体分别固定有第三焊接上导体65，各连接板分别从侧方送入对应的第三焊接下导体63和第三焊接上导体65之间。
连接板焊接机构6和连续焊接机构4的输入端和输出端均设有用于布匹制动机构7、8，布匹制动机构7、8包括升降辊和底辊，升降辊设置在底辊的正上方并由制动气缸驱动带动升降。通过设计布匹制动机构7、8，可以提高焊接过程中的稳定性，从而提高成品质量。
此外，在连续焊接机构4和成品收卷机构5之间可以增加主动牵引机构9，以带动焊接后的经编布、面布和底布共同前进。
要强调的是，本发明中涉及到的气缸均可以替换为电动推杆、伺服丝杆等驱动器。
采用上述一种充气产品高度定型层连续贴合上下布层装置的贴合方法，其包括以下步骤：
1)经编布经由经编布发送机构2送入连接板焊接机构6中，在每组第三焊接下导体63和第三焊接上导体65之间分别送入连接板，升降座62下降带动多个第三焊接上导体65同步下压于对应的第三焊接下导体63上，从而将多个连接板依序交替错位焊接固定在经编布的顶面和底面；
2)焊接完连接板的经编布与面布和底布一同送入连续焊接机构4中，且经编布顶面上的各连接板分别对应一上焊接单元42，经编布底面上的各连接板分别对应一下焊接单元43；然后各上焊接单元42和下焊接单元43同步工作，其中，各上焊接单元 42的上伸缩器428伸出第一焊接下导体424，上行程开关426感应到位后停止，上平台升降气缸425、第一焊接驱动气缸429和上托架气缸427同步伸出，使得第一焊接上导体423和第一焊接下导体424夹住经编布顶面对应的连接板与面布，并保压预定时间，从而将经编布顶面的连接板与面布焊接固定；于此同时，各下焊接单元43的下伸缩器438伸出第二焊接上导体433，下行程开关436感应到位后停止，下平台升降气缸435、第二焊接驱动气缸439和下托架气缸437同步伸出，使得第二焊接上导体433和第二焊接下导体434夹住经编布底面对应的连接板与底布，并保压预定时间，从而将经编布底面的连接板与底布焊接固定，其中经编布的宽度小于面布和底布的宽度；
3)经编布与面布和底布焊接形成焊接成品后，各上焊接单元42和下焊接单元43复位，焊接成品由连续焊接机构4送出而收卷于成品收卷机构5上，同时经编布与面布和底布未焊接部分再进入连续焊接机构4中，等待下一段焊接。
上面结合附图对本发明的实施加以描述，但是本发明不局限于上述的具体实施方式，上述的具体实施方式是示意性而不是加以局限本发明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的范围，其均应涵盖在本发明的权利要求和说明书的范围当中。

Claims (8)

  1. 一种充气产品高度定型层连续贴合上下布层装置，其特征在于：其包括面布发送机构、经编布发送机构、底布发送机构、连续焊接机构和成品收卷机构；
    所述面布发送机构、经编布发送机构、底布发送机构分别将面布、经编布和底布分别输送至连续焊接机构的输入端，面布、经编布和底布在连续焊接机构内焊接成一体后收卷于成品收卷机构；
    所述连续焊接机构包括机架，机架的上部设有多个上焊接单元，机架的下部设有多个下焊接单元，且上焊接单元和下焊接单元沿流水线方向依序交替错位设置；
    所述面布、经编布和底布进入连续焊接机构后，各上焊接单元和下焊接单元同步工作从而将经编布沿流水线方向依序交替错位与面布和底布焊接固定，使得经编布在面布和底布之间形成锯齿形。
  2. 根据权利要求1所述的一种充气产品高度定型层连续贴合上下布层装置，其特征在于：所述上焊接单元包括上升降平台、上托架、第一焊接上导体和第一焊接下导体；所述上升降平台由上平台升降气缸带动升降，所述上托架设于上升降平台的旁侧，所述上托架上设有开口朝向上升降平台设置的上托槽，上托槽的内侧后壁设有上行程开关，所述上托架由上托架气缸带动升降；所述上升降平台上固定有上伸缩器，该上伸缩器的输出端与第一焊接下导体的一端固定连接，上伸缩器带动第一焊接下导体沿朝靠近或远离上托架的方向水平移动，所述第一焊接上导体位于上升降平台的旁侧，第一焊接上导体由第一焊接驱动气缸带动升降；
    所述下焊接单元包括下升降平台、下托架、第二焊接上导体和第二焊接下导体；所述下升降平台由下平台升降气缸带动升降，所述下托架设于下升降平台的旁侧，所述下托架上设有开口朝向下升降平台设置的下托槽，下托槽的内侧后壁设有下行程开关，所述下托架由下托架气缸带动升降；所述下升降平台上固定有下伸缩器，该下伸缩器的输出端与第二焊接上导体的一端固定连接，下伸缩器带动第二焊接上导体沿朝靠近或远离下托架的方向水平移动，所述第二焊接下导体位于下升降平台的旁侧，第二焊接下导体由第二焊接驱动气缸带动升降。
  3. 根据权利要求2所述的一种充气产品高度定型层连续贴合上下布层装置，其特征在于：所述机架的上部设有用于带动面布前进的上针板传动链，所述上针板传动链上的针头朝下设置，所述上针板传动链上沿流水方向间隔设有多个上压辊，所述上 针板传动链的输出端设有将面布与上针板传动链进行脱离的上脱针顶刀；
    所述机架的下部设有用于带动底布前进的下针板传动链，所述下针板传动链上的针头朝上设置，所述下针板传动链上沿流水方向间隔设有多个下压辊，所述下针板传动链的输出端设有将底布与上针板传动链进行脱离的下脱针顶刀。
  4. 根据权利要求1所述的一种充气产品高度定型层连续贴合上下布层装置，其特征在于：所述面布发送机构沿流水方向依序包括面布发送辊和面布收纳架；所述经编布发送机构沿流水方向依序包括经编布发送辊和经编布收纳架；所述底布发送机构沿流水方向依序包括底布发送辊和底布收纳架；所述成品收卷机构沿流水方向依序包括成品收纳架和成品收卷辊。
  5. 根据权利要求4所述的一种充气产品高度定型层连续贴合上下布层装置，其特征在于：所述成品收卷机构和成品收卷辊之间设有切边机构。
  6. 根据权利要求2所述的一种充气产品高度定型层连续贴合上下布层装置，其特征在于：所述经编布发送机构的输出端和连续焊接机构的输入端之间设有连接板焊接机构，该连接板焊接机构包括底座和升降座，所述底座上间隔设有多个第三焊接下导体，所述升降座位于底座上方并由升降驱动气缸带动升降，升降座底部对应各下固定焊接导体分别固定有第三焊接上导体，各连接板分别从侧方送入对应的第三焊接下导体和第三焊接上导体之间。
  7. 根据权利要求6所述的一种充气产品高度定型层连续贴合上下布层装置，其特征在于：所述连接板焊接机构和连续焊接机构的输入端和输出端均设有用于布匹制动机构，所述布匹制动机构包括升降辊和底辊，升降辊设置在底辊的正上方并由制动气缸驱动带动升降。
  8. 采用权利要求6所述的一种充气产品高度定型层连续贴合上下布层装置的贴合方法，其特征在于：其包括以下步骤：
    1)经编布经由经编布发送机构送入连接板焊接机构中，在每组第三焊接下导体和第三焊接上导体之间分别送入连接板，升降座下降带动多个第三焊接上导体同步下压于对应的第三焊接下导体上，从而将多个连接板依序交替错位焊接固定在经编布的顶面和底面；
    2)焊接完连接板的经编布与面布和底布一同送入连续焊接机构中，且经编布顶面上的各连接板分别对应一上焊接单元，经编布底面上的各连接板分别对应一下焊接 单元；然后各上焊接单元和下焊接单元同步工作，其中，各上焊接单元的上伸缩器伸出第一焊接下导体，上行程开关感应到位后停止，上平台升降气缸、第一焊接驱动气缸和上托架气缸同步伸出，使得第一焊接上导体和第一焊接下导体夹住经编布顶面对应的连接板与面布，并保压预定时间，从而将经编布顶面的连接板与面布焊接固定；于此同时，各下焊接单元的下伸缩器伸出第二焊接上导体，下行程开关感应到位后停止，下平台升降气缸、第二焊接驱动气缸和下托架气缸同步伸出，使得第二焊接上导体和第二焊接下导体夹住经编布底面对应的连接板与底布，并保压预定时间，从而将经编布底面的连接板与底布焊接固定；
    3)经编布与面布和底布焊接形成焊接成品后，各上焊接单元和下焊接单元复位，焊接成品由连续焊接机构送出而收卷于成品收卷机构上，同时经编布与面布和底布未焊接部分再进入连续焊接机构中，等待下一段焊接。
PCT/CN2022/107781 2022-05-11 2022-07-26 一种充气产品高度定型层连续贴合上下布层装置及方法 WO2023216422A1 (zh)

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