WO2024021944A1 - 一种以不同方式涂布且涂布量联动控制的复合方法及设备 - Google Patents

一种以不同方式涂布且涂布量联动控制的复合方法及设备 Download PDF

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Publication number
WO2024021944A1
WO2024021944A1 PCT/CN2023/101883 CN2023101883W WO2024021944A1 WO 2024021944 A1 WO2024021944 A1 WO 2024021944A1 CN 2023101883 W CN2023101883 W CN 2023101883W WO 2024021944 A1 WO2024021944 A1 WO 2024021944A1
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Prior art keywords
coating
unit
roller
coating amount
glue
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PCT/CN2023/101883
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English (en)
French (fr)
Inventor
左光申
左津津
黄顺利
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广州通泽机械有限公司
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Publication of WO2024021944A1 publication Critical patent/WO2024021944A1/zh

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00Processes for applying liquids or other fluent materials
    • B05D1/28Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05CAPPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C1/00Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
    • B05C1/04Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
    • B05C1/08Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
    • B05C1/0808Details thereof, e.g. surface characteristics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05CAPPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C1/00Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
    • B05C1/04Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
    • B05C1/08Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
    • B05C1/0813Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line characterised by means for supplying liquid or other fluent material to the roller
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05CAPPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C1/00Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
    • B05C1/04Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
    • B05C1/08Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
    • B05C1/086Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line a pool of coating material being formed between a roller, e.g. a dosing roller and an element cooperating therewith
    • B05C1/0865Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line a pool of coating material being formed between a roller, e.g. a dosing roller and an element cooperating therewith the cooperating element being a roller, e.g. a coating roller
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05CAPPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C11/00Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
    • B05C11/10Storage, supply or control of liquid or other fluent material; Recovery of excess liquid or other fluent material
    • B05C11/1002Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves
    • B05C11/1007Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves responsive to condition of liquid or other fluent material
    • B05C11/1013Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves responsive to condition of liquid or other fluent material responsive to flow or pressure of liquid or other fluent material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives

Definitions

  • the present invention relates to the field of composites, in particular to a composite method and equipment for coating in different ways and controlling the coating amount in a coordinated manner.
  • the double-coating composite method is required, which is to coat two composite substrates with two-component glue A and B respectively, and then compound the two components.
  • Two substrates but if both substrates use the conventional five-roller transfer coating method, there will be shortcomings such as low coating accuracy or poor product control stability, and the coating amount control will be difficult to meet extremely low requirements.
  • the technical problem to be solved by the present invention is to provide a composite method and equipment for coating in different ways and linkage control of the coating amount.
  • the composite film has the characteristics of short curing time after being removed from the machine, high coating amount accuracy, and extremely low coating amount. It has the advantages of good uniformity, large coating volume and good control operability.
  • one of the technical solutions of the present invention is: a composite method of coating in different ways and controlling the coating amount in a coordinated manner, including the following steps:
  • K B is the transfer rate of B glue to the engraving concave roller
  • ⁇ (g/cm 3 ) is the density of B glue
  • V (mm 3 /m 2 ) is the density specific volume of the engraving mesh
  • is between 0- 20 range.
  • the process control parameter setting process is as follows:
  • the Y value of the transfer steel roller speed of the five-roller transfer coating mechanism can also be obtained by looking up (or interpolating) the transfer steel roller speed/coating amount curve.
  • the engraving concave roller includes a variety of specifications, and the parameter vector of each engraving concave roller is different.
  • the parameter vector is a directly calculated value or a preferred value set by the industry/user; the parameter vector includes the number of mesh lines, the shape of the cavity, the depth and the Cavity volume.
  • the second technical solution of the present invention is: a composite equipment that is coated in different ways and the coating amount is controlled in a linked manner.
  • a connecting beam is provided on the top of the equipment, and a connecting beam is provided below the beam from left to right.
  • the first unwinding and coating unit includes a first unwinding unit and a five-roller transfer coating unit;
  • the compounding and rewinding unit includes a compounding unit and a rewinding unit, and the second unwinding and coating unit includes a second unwinding unit and an engraving gravure roller coating unit; there is a five-roller transfer coating unit connected to the crossbeam.
  • the first belt transfer path guide roller group of the composite unit and the second belt transfer path guide roller group connecting the engraved gravure coating unit and the composite unit; a detection base material is provided at the position of the first belt transfer path on the connecting beam Coating volume instrument.
  • the first unwinding unit is located on the right side of the unit
  • the five-roller transfer coating unit is located on the left side of the unit, and there are two devices on the left and right sides of the upper part of the unit.
  • a first tension control unit and a second tension control unit are located on the first tape transfer path and controls the first tape tension.
  • the second tension control unit is located in the first unwinding unit. and the five-roller transfer coating unit and controls this section Belt tension, the five-roller transfer coating unit is equipped with a two-component glue A glue supply system.
  • the compounding unit is located at the upper part of the unit, the winding unit is located at the lower left part of the unit, and a third tension control is provided on the material belt path between the compounding unit and the winding unit.
  • the unit is used to control the belt tension in this section.
  • the second unwinding unit is located on the left side of the unit
  • the engraving gravure roller coating unit is located on the right side of the unit, and there are two devices on the left and right sides of the upper part of the unit.
  • the fourth and fifth tension control units the fourth tension control unit is located on the web path between the second unwinding unit and the engraving gravure roller coating unit and controls the tension of this section of the web
  • the fifth tension control unit The control unit is on the transfer path of the second material belt and controls the tension of the second material belt.
  • the engraving gravure roller coating unit is equipped with a two-component glue B glue supply system, a glue storage tank and a quick replacement
  • the engraving concave roller and the glue storage tank are equipped with heating and insulation components.
  • Two coating methods five-roller transfer coating and engraved gravure roll, are used to apply two-component glue A and B to the surface and inner layers of the composite substrate respectively.
  • the two methods are used to control the coating amount.
  • Linkage control the coating amount of the two methods so that the coating amount of glue A maintains a certain ratio relative to the coating amount of glue B and the total coating amount meets the requirements of low coating amount and or two-component glue reaction curing, and then the two The coating surfaces of the two base materials are compositely rolled up relative to each other.
  • the composite film produced by this method has the characteristics of short curing time after unloading, high coating amount accuracy, good uniformity at extremely low coating amount, and can achieve large coating amount. Good control operability and other advantages.
  • Figure 1 is a schematic diagram of the equipment of the present invention.
  • FIG. 1 is process flow chart I.
  • FIG. 3 is process flow chart II.
  • a composite equipment that coats in different ways and controls the coating amount in a linked manner is provided with a connecting beam 4 on the top of the equipment, and a first unwinding and coating device are provided below the beam 4 from left to right.
  • Unit 1 compounding and rewinding unit 2 and second unwinding and coating unit 3;
  • the first unwinding and coating unit 1 includes a first unwinding unit 5 and a five-roller transfer coating unit 6;
  • the composite And the rewinding unit 2 includes a composite unit 7 and a rewinding unit 8.
  • the second unwinding and coating unit 3 includes a second unwinding unit 9 and an engraving gravure roller coating unit 10; there are five connecting parts on the crossbeam 4.
  • the first web transfer path guide roller group 11 of the roller transfer coating unit 6 and the composite unit 7 and the second web transfer path guide roller group 12 connecting the engraved gravure coating unit 10 and the composite unit 7 .
  • the first unwinding unit 5 is located on the right side of the unit, and the five-roller transfer coating unit 6 is located on the left side of the unit, at the upper part of the unit.
  • a first tension control unit 14 and a second tension control unit 15 are respectively provided on the left and right sides.
  • the first tension control unit 14 is on the first belt transfer path and controls the first belt tension.
  • the second tension control unit 14 is on the first belt transfer path and controls the first belt tension.
  • the tension control unit 15 is located on the tape path between the first unwinding unit 5 and the five-roller transfer coating unit 6 and controls the tension of this section of the tape.
  • the five-roller transfer coating unit 6 is provided with a two-component glue A.
  • Glue supply system 16 An instrument 13 for detecting the coating amount of the base material is provided at the first strip transfer path position on the connecting beam 4 .
  • the compounding unit 7 is located at the upper part of the unit, the winding unit 8 is located at the lower left part of the unit, and the material belt is between the compounding unit 7 and the winding unit 8.
  • a third tension control unit 17 is provided on the path for controlling the tension of this section of material belt.
  • the second unwinding unit 9 is located on the left side of the unit, and the engraved gravure roller coating unit 10 is located on the right side of the unit, at the upper part of the unit.
  • a fourth tension control unit 18 and a fifth tension control unit 19 are respectively provided on the left and right sides.
  • the fourth tension control unit 18 is located on the material belt path between the second unwinding unit 9 and the engraving gravure roller coating unit 10
  • the fifth tension control unit 19 is on the second belt transfer path and controls the tension of the second belt.
  • the engraving gravure roller coating unit 10 is provided with a two-component Glue B glue supply system 20, glue storage tank 22 and a quickly replaceable engraved concave roller 21.
  • the glue storage tank 22 is equipped with a heating and heat preservation component.
  • the engraved concave roller coating unit 10 is equipped with an engraved concave
  • the roller 21 has a variety of specifications and can be replaced.
  • Each engraving concave roller 21 has different parameter vectors (including the number of mesh lines, cavity shape, depth and cavity volume, etc.). These parameters can be directly calculated values, or they can be industry or Preference set by the user.
  • the present invention is a composite method of double coating in different ways and linkage control of the coating amount:
  • the roll material is quickly cured into a composite film under the set temperature condition, the temperature condition is 35 degrees to 55 degrees, and the curing time is 2 to 8 hours.
  • the present invention utilizes the respective advantages of the two coating systems, and through independent control, linkage control and parameter optimization, the coating amounts of glue A and glue B are both within a reasonable range, and the coating amounts of glue A are compared to The coating amount of glue B is maintained at a certain ratio to meet the requirements of two-component reaction curing; the glued surfaces of the two base materials are pressed together relatively so that the glue films of glue A and glue B can contact and penetrate each other. Start the reaction curing process; roll up the two substrates that have been bonded together while maintaining sufficient tension and pressure; then send the roll into a curing chamber with an appropriate temperature to promote rapid solidification into a film. In this way, the process of fast compounding of two-component glue under high-precision, high-stability, low-coating volume and no-mixing conditions is completed, shortening the production process and speeding up product delivery.
  • the coating amount data of the composite film is:
  • K B is the transfer rate of glue B to the engraving concave roller (the ratio of the actual transfer amount of glue on the engraving concave roller to the theoretical maximum coating amount), which is generally 0.65-0.87.
  • the specific value is based on industry standards or determined by Obtained experimentally; ⁇ (g/cm 3 ) is the density of B glue, V (mm 3 /m 2 ) is the density specific volume of the carved mesh, and the value of ⁇ is in the range of 0-20.
  • the process control parameter setting process one is as follows.
  • the process control parameter setting process is as follows:
  • process control parameter setting process 2 when the composite membrane two-component glue mixing ratio R AB and the estimated value of the total coating amount C 0 are known, the composite membrane requires the peel strength index value P E , the process
  • the control parameter setting process is as follows:
  • Y AN C AN *Y E /C E to calculate the transfer steel roller speed of the five-roller transfer coating mechanism; where Y E and C E are the standard transfer steel roller speeds of the five-roller transfer coating mechanism and the corresponding Set the coating amount value (g/m 2 ), and set this value in the input box of the machine control screen; the Y value of the transfer steel roller speed of the five-roller transfer coating mechanism can also be obtained by query (or interpolation calculation) ) Transfer steel roller speed/coating amount curve is obtained.
  • Two coating methods five-roller transfer coating and engraved gravure roll, are used to apply two-component glue A and B to the surface and inner layers of the composite substrate respectively.
  • the two methods are used to control the coating amount.
  • Linkage control the coating amount of the two methods so that the coating amount of glue A maintains a certain ratio relative to the coating amount of glue B and the total coating amount meets the requirements of low coating amount and or two-component glue reaction curing, and then the two The coating surfaces of the two substrates are compounded and rolled up relative to each other.
  • the composite film produced by this method has the characteristics of short curing time after unloading, high precision of coating amount, good uniformity at extremely low coating amount, and can achieve large coating amount. Good control operability and other advantages.

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  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Coating Apparatus (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

一种以不同方式涂布且涂布量联动控制的复合方法及设备,使用五辊转移涂布和雕刻凹辊两种涂布方式分别对复合基材的表层和里层涂布双组分胶的A胶和B胶,利用两种方式涂布量控制的不同方式,联动控制两种方式的涂布量,使A胶涂布量相对于B胶涂布量保持一定的比例且总涂布量满足低涂布量及或双组分胶反应固化的要求,然后两种基材涂胶面相对进行复合收卷,按此方法生产的复合膜具有下机后固化时间短、涂布量精度高、极低涂布量时均匀性好、可以实现大涂布量、控制操作性好等优点。

Description

一种以不同方式涂布且涂布量联动控制的复合方法及设备 技术领域
本发明涉及复合领域,尤其是一种以不同方式涂布且涂布量联动控制的复合方法及设备。
背景技术
目前普通无溶剂复合工艺已经得到普遍应用,但在一些特殊应用场所需要用到双涂复合的方法,就是对两个复合基材分别涂布双组分胶的A胶和B胶,然后复合这两个基材,但如果两个基材都用常规的五辊转移涂胶方法,则存在着涂布精度低或者产品控制稳定性差,涂布量控制难以满足极低要求等缺点。
发明内容
本发明所要解决的技术问题是提供一种以不同方式涂布且涂布量联动控制的复合方法及设备,复合膜具有下机后固化时间短、涂布量精度高、极低涂布量时均匀性好、可以实现大涂布量、控制操作性好的优点。
为解决上述技术问题,本发明的技术方案之一是:一种以不同方式涂布且涂布量联动控制的复合方法,包括以下步骤:
(1)在第一基材的涂胶面上采用多辊转移涂布A胶,在第二基材的涂胶面上采用雕刻凹辊涂布B胶,A胶涂布量相对于B胶涂布量保持设定比例且总涂布量满足设定要求;
(2)第一基材的涂胶面与第二基材的涂胶面进行压合复合并收卷;
(3)卷料在设定温度条件下快速固化成复合膜。
作为改进,
A胶涂布量CA=100*CB/RAB=100*KB*QB/RAB g/m2
B胶涂布量CB=KB*QB g/m2
总涂布量CΣ=CA+CB=(1+100/RAB)KB*QB g/m2
B胶理论最大涂布量QB=ρ*V/1000g/m2
双组份胶的实用混配比RAB=R0+△;
其中,KB为B胶对雕刻凹辊的转移率,ρ(g/cm3)为B胶密度,V(mm3/m2)为雕刻网穴的密度比容积,△取值在0-20范围。
作为改进,当已知复合膜总涂布量C0的目标值和双组分胶混配比RAB,工艺控制参数设置流程如下:
1)根据CB0=RAB*C0/(100+RAB)计算B胶需要涂布量CB0值;
2)读取可用雕刻凹辊对B胶的转移率KBN及密度比容积值VN(mm3/m2),所用胶水密度ρ(g/cm3)值,根据CBN=ρ*KBN*VN/1000计算雕刻凹辊的计算涂布量CBN值;
3)根据△C=|CB0-CBN|≤k对雕刻凹辊的计算涂布量与需要涂布量差值绝对值与误差k进行比较,不满足者,排除选用,并返回步骤2)重复读取可用雕刻凹辊参数循环计算,K取0-0.02;满足者进入下一步流程;
4)用CAN=C0-CBN计算雕刻凹辊按总涂布量C0对应的A胶涂布量值;
5)判断上步所计算CAN值是否满足CAN∈[0.8,2.5]的判断条件,不满足者,排除选用,并返回步骤2)重复读取可用雕刻凹辊参数循环计算,满足的列表于“合用雕刻凹辊组”内;循环读取数据计算,直到所有可用雕刻凹辊参数全部读完;所有凹辊参数读完计算后,如没有一个符合要求的凹辊,则需要选择新规格的雕刻凹辊参数;
6)比较雕刻凹辊网线数值,选定“合用雕刻凹辊组”内凹穴网线数最大者为拟用雕刻凹辊;
7)选取拟用雕刻凹辊的CBN赋值于CB,用CA=C0-CB,计算A胶需要 涂布量CA值;
8)用Y=CA*YE/CE计算五辊转移涂布机构的转移钢辊速率,式中YE及CE为五辊转移涂布机构标的准转移钢辊速率及对应的涂布量设定值(g/m2),并将此值设置于机器控制屏输入框;
9)开机运行后,根据检测基材涂布量的检测设备所显示的A胶涂布量TAC值适当调整计量钢辊速率YA值,使五辊转移涂胶量与网纹辊涂胶量匹配。
作为改进,当已知复合膜双组分胶混配比RAB和总涂布量的预估值C0,复合膜要求剥离强度指标值PE,工艺控制参数设置流程如下:
1)根据CB0=RAB*C0/(100+RAB)计算B胶需要涂布量CB0值;
2)读取可用雕刻凹辊对B胶的转移率KBN及密度比容积值VN(mm3/m2),所用胶水密度ρ(g/cm3)值,根据CBN=ρ*KBN*VN/1000值计算雕刻凹辊的计算涂布量CBN值;
3)根据△C=CB0-CBN≤k对雕刻凹辊的计算涂布量与需要涂布量差值与误差k进行比较,不满足者,排除选用,并返回步骤2)重复读取可用雕刻凹辊参数循环计算,K取0-0.02,满足者进入下一步流程;
4)用CAN=100CBN/RAB计算雕刻凹辊按预估总涂布量C0对应的A胶涂布量值;
5)判断上步所计算CAN值是否满足CAN∈[0.8,2.5]的判断条件,不满足者,排除选用,并返回步骤2)重复读取可用雕刻凹辊参数循环计算,满足的列表于“初选雕刻凹辊组”内;循环读取数据计算,直到所有可用雕刻凹辊参数全部读完;所有凹辊参数读完计算后,如没有一个符合要求的凹辊,则需要选择新规格的雕刻凹辊参数;
6)用YAN=CAN*YE/CE计算五辊转移涂布机构的转移钢辊速率;式中YE及CE为五辊转移涂布机构的标准转移钢辊速率及对应的涂布量设定值(g/m2),并将此值设置于机器控制屏输入框;
7)开机运行并进行复合膜牢度试验,复合膜实际剥离强度值不 小于剥离强度指标值PE者列入“待用雕刻凹辊组”并进行下一步流程,否则,排除选用,并读取下一个“初选雕刻凹辊组”内参数返回步骤6);
8)用CN=CAN+CBN计算复合膜总涂布量,并读取下一个初选雕刻凹辊参数返回第6步,直到所有“初选雕刻凹辊组”内凹辊参数被读完;
9)读取待用雕刻凹辊组中复合膜总涂布量,并选中最小值者对应的雕刻凹辊,选取对应的转移钢辊速率为五辊转移涂布机构输入值。
作为改进,所述五辊转移涂布机构的转移钢辊速率Y值求取也可用查取(或插值计算)转移钢辊速率/涂布量曲线获得。
作为改进,所述雕刻凹辊包括多种规格,每根雕刻凹辊的参数矢量不同,参数矢量是直接计算值或行业/用户设立的优选值;参数矢量包括网线数、凹穴形状、深度及凹穴容积。
为解决上述技术问题,本发明的技术方案之二是:一种以不同方式涂布且涂布量联动控制的复合设备,在设备顶部设有连接横梁,在横梁下方从左至右依次设有第一放卷及涂布机组、复合及收卷机组和第二放卷及涂布机组;所述第一放卷及涂布机组包括第一放卷单元和五辊转移涂布单元;所述复合及收卷机组包括复合单元和收卷单元,所述第二放卷及涂布机组包括第二放卷单元和雕刻凹辊涂布单元;在横梁上设有连接五辊转移涂布单元与复合单元的第一料带转移路径导辊组和连接雕刻凹辊涂布单元与复合单元的第二料带转移路径导辊组;在连接横梁上第一料带转移路径位置设有检测基材涂布量的仪器。
作为改进,在所述第一放卷及涂布机组中,所述第一放卷单元位于机组右侧,所述五辊转移涂布单元位于机组左侧,在机组上部左右两侧分别设有第一张力控制单元和第二张力控制单元,所述第一张力控制单元在所述第一料带转移路径上并控制第一料带张力,所述第二张力控制单元位于第一放卷单元和五辊转移涂布单元之间料带路径上并控制该段 料带张力,在所述五辊转移涂布单元设有双组分胶A胶供胶系统。
作为改进,在所述复合及收卷机组中,所述复合单元位于机组上部,所述收卷单元位于机组左下部,在复合单元和收卷单元之间料带路径上设有第三张力控制单元用于控制该段料带张力。
作为改进,在所述第二放卷及涂布机组中,所述第二放卷单元位于机组左侧,所述雕刻凹辊涂布单元位于机组右侧,在机组上部左右两侧各设有第四和第五张力控制单元,所述第四张力控制单元位于所述第二放卷单元和雕刻凹辊涂布单元之间料带路径上并控制该段料带张力,所述第五张力控制单元在所述第二料带转移路径上并控制第二料带张力,在所述雕刻凹辊涂布单元设有双组分胶B胶供胶系统、储胶池及一根可快速更换的雕刻凹辊,储胶池设有加热保温组件。
本发明与现有技术相比所带来的有益效果是:
使用五辊转移涂布和雕刻凹辊两种涂布方式分别对复合基材的表层和里层涂布双组分胶的A胶和B胶,利用两种方式涂布量控制的不同方式,联动控制两种方式的涂布量,使A胶涂布量相对于B胶涂布量保持一定的比例且总涂布量满足低涂布量及或双组分胶反应固化的要求,然后两种基材涂胶面相对进行复合收卷,按此方法生产的复合膜具有下机后固化时间短、涂布量精度高、极低涂布量时均匀性好、可以实现大涂布量、控制操作性好等优点。
附图说明
图1为本发明设备示意图。
图2为工艺流程图I。
图3为工艺流程图II。
具体实施方式
下面结合说明书附图对本发明作进一步说明。
如图1所示,一种以不同方式涂布且涂布量联动控制的复合设备,在设备顶部设有连接横梁4,在横梁4下方从左至右依次设有第一放卷及涂布机组1、复合及收卷机组2和第二放卷及涂布机组3;所述第一放卷及涂布机组1包括第一放卷单元5和五辊转移涂布单元6;所述复合及收卷机组2包括复合单元7和收卷单元8,所述第二放卷及涂布机组3包括第二放卷单元9和雕刻凹辊涂布单元10;在横梁4上设有连接五辊转移涂布单元6与复合单元7的第一料带转移路径导辊组11和连接雕刻凹辊涂布单元10与复合单元7的第二料带转移路径导辊组12。
如图1所示,在所述第一放卷及涂布机组1中,所述第一放卷单元5位于机组右侧,所述五辊转移涂布单元6位于机组左侧,在机组上部左右两侧分别设有第一张力控制单元14和第二张力控制单元15,所述第一张力控制单元14在所述第一料带转移路径上并控制第一料带张力,所述第二张力控制单元15位于第一放卷单元5和五辊转移涂布单元6之间料带路径上并控制该段料带张力,在所述五辊转移涂布单元6设有双组分胶A胶供胶系统16。在连接横梁4上第一料带转移路径位置设有检测基材涂布量的仪器13。
如图1所示,在所述复合及收卷机组2中,所述复合单元7位于机组上部,所述收卷单元8位于机组左下部,在复合单元7和收卷单元8之间料带路径上设有第三张力控制单元17用于控制该段料带张力。
如图1所示,在所述第二放卷及涂布机组3中,所述第二放卷单元9位于机组左侧,所述雕刻凹辊涂布单元10位于机组右侧,在机组上部左右两侧各设有第四张力控制单元18和第五张力控制单元19,所述第四张力控制单元18位于所述第二放卷单元9和雕刻凹辊涂布单元10之间料带路径上并控制该段料带张力,所述第五张力控制单元19在所述第二料带转移路径上并控制第二料带张力,在所述雕刻凹辊涂布单元10设有双组分胶B胶供胶系统20、储胶池22及一根可快速更换的雕刻凹辊21,储胶池22设有加热保温组件。所述雕刻凹辊涂布单元10配备的雕刻凹 辊21有多种规格可更换,每根雕刻凹辊21的参数矢量(包括网线数、凹穴形状、深度及凹穴容积等)不同,这些参数是可以是直接计算值,也可以是行业或用户设立的优选值。
本发明以不同方式双涂且涂布量联动控制的复合方法:
(1)在第一基材的涂胶面上采用多辊转移涂布A胶,在第二基材的涂胶面上采用雕刻凹辊涂布B胶,A胶涂布量相对于B胶涂布量保持设定比例且总涂布量满足设定要求;
(2)第一基材的涂胶面与第二基材的涂胶面进行压合复合并收卷;
(3)卷料在设定温度条件下快速固化成复合膜,温度条件为35度至55度,固化时间为2至8小时。
本发明根据胶黏剂特性,利用两个涂布系统各自的优点,通过单独控制和联动控制及参数优化,使A胶和B胶的涂布量均在合理范围内,并使A胶相对于B胶的涂布量保持一定的比例,以满足双组分反应固化的要求;将两基材的涂胶面相对地压合在一起使A胶和B胶的胶膜可以相互接触和渗透,开始反应固化过程;将两个已贴合在一起的基材在保持足够的张力与压力条件下进行卷取;再将料卷送入适当温度的固化室促成其快速固化成膜。如此完成对双组分胶在高精度高稳定性的低涂布量和免混胶条件下快捷复合的工艺实现,缩短生产流程,加快产品交付。
复合膜的涂布量数据为:
A胶涂布量CA=100*CB/RAB=100*KB*QB/RAB g/m2
B胶涂布量CB=KB*QB g/m2
总涂布量CΣ=CA+CB=(1+100/RAB)KB*QB g/m2
B胶理论最大涂布量QB=ρ*V/1000g/m2
双组份胶的实用混配比RAB=R0+△;
其中,KB为B胶对雕刻凹辊的转移率,(雕刻凹辊的实际转移胶量与理论最大涂布量之比),一般为0.65-0.87,具体数值采用行业规范或由 实验获得;ρ(g/cm3)为B胶密度,V(mm3/m2)为雕刻网穴的密度比容积,△取值在0-20范围。
如图2所示,工艺控制参数设置流程一,当已知复合膜总涂布量C0的目标值和双组分胶混配比RAB,工艺控制参数设置流程如下:
1)根据CB0=RAB*C0/(100+RAB)计算B胶需要涂布量CB0值;
2)读取可用雕刻凹辊对B胶的转移率KBN及密度比容积值VN(mm3/m2),所用胶水密度ρ(g/cm3)值,根据CBN=ρ*KBN*VN/1000计算雕刻凹辊的计算涂布量CBN值;
3)根据△C=|CB0-CBN|≤k对雕刻凹辊的计算涂布量与需要涂布量差值绝对值与误差k进行比较,不满足者,排除选用,并返回步骤2)重复读取可用雕刻凹辊参数循环计算,K取0-0.02;满足者进入下一步流程;
4)用CAN=C0-CBN计算雕刻凹辊按总涂布量C0对应的A胶涂布量值;
5)判断上步所计算CAN值是否满足CAN∈[0.8,2.5]的判断条件,不满足者,排除选用,并返回步骤2)重复读取可用雕刻凹辊参数循环计算,满足的列表于“合用雕刻凹辊组”内;循环读取数据计算,直到所有可用雕刻凹辊参数全部读完;所有凹辊参数读完计算后,如没有一个符合要求的凹辊,则需要选择新规格的雕刻凹辊参数;
6)比较雕刻凹辊网线数值,选定“合用雕刻凹辊组”内凹穴网线数最大者为拟用雕刻凹辊;
7)选取拟用雕刻凹辊的CBN赋值于CB,用CA=C0-CB,计算A胶需要涂布量CA值;
8)用Y=CA*YE/CE计算五辊转移涂布机构的转移钢辊速率,式中YE及CE为五辊转移涂布机构的标准转移钢辊速率及对应的涂布量设定值(g/m2),并将此值设置于机器控制屏输入框;所述五辊转移涂布机构的转移钢辊速率Y值求取也可用查取(或插值计算)转移钢辊速率/涂布量曲线获得;
9)开机运行后,根据检测基材涂布量的检测设备所显示的A胶涂布量TAC值适当调整计量钢辊速率YA值,使五辊转移涂胶量与网纹辊涂胶量匹配。
如图3所示,工艺控制参数设置流程二,当已知复合膜双组分胶混配比RAB和总涂布量的预估值C0,复合膜要求剥离强度指标值PE,工艺控制参数设置流程如下:
1)根据CB0=RAB*C0/(100+RAB)计算B胶需要涂布量CB0值;
2)读取可用雕刻凹辊对B胶的转移率KBN及密度比容积值VN(mm3/m2),所用胶水密度ρ(g/cm3)值,根据CBN=ρ*KBN*VN/1000值计算雕刻凹辊的计算涂布量CBN值;
3)根据△C=CB0-CBN≤k对雕刻凹辊的计算涂布量与需要涂布量差值与误差k进行比较,不满足者,排除选用,并返回步骤2)重复读取可用雕刻凹辊参数循环计算,K取0-0.02,满足者进入下一步流程;
4)用CAN=100CBN/RAB计算雕刻凹辊按预估总涂布量C0对应的A胶涂布量值;
5)判断上步所计算CAN值是否满足CAN∈[0.8,2.5]的判断条件,不满足者,排除选用,并返回步骤2)重复读取可用雕刻凹辊参数循环计算,满足的列表于“初选雕刻凹辊组”内;循环读取数据计算,直到所有可用雕刻凹辊参数全部读完;所有凹辊参数读完计算后,如没有一个符合要求的凹辊,则需要选择新规格的雕刻凹辊参数;
6)用YAN=CAN*YE/CE计算五辊转移涂布机构的转移钢辊速率;式中YE及CE为五辊转移涂布机构的标准转移钢辊速率及对应的设定涂布量值(g/m2),并将此值设置于机器控制屏输入框;所述五辊转移涂布机构的转移钢辊速率Y值求取也可用查取(或插值计算)转移钢辊速率/涂布量曲线获得。
7)开机运行并进行复合膜牢度试验,复合膜实际剥离强度值不小于剥离强度指标值PE者列入“待用雕刻凹辊组”并进行下一步流程,否则, 排除选用,并读取下一个“初选雕刻凹辊组”内参数返回步骤6);
8)用CN=CAN+CBN计算复合膜总涂布量,并读取下一个初选雕刻凹辊参数返回第6步,直到所有“初选雕刻凹辊组”内凹辊参数被读完;
9)读取待用雕刻凹辊组中复合膜总涂布量,并选中最小值者对应的雕刻凹辊,选取对应的转移钢辊速率为五辊转移涂布机构输入值。
使用五辊转移涂布和雕刻凹辊两种涂布方式分别对复合基材的表层和里层涂布双组分胶的A胶和B胶,利用两种方式涂布量控制的不同方式,联动控制两种方式的涂布量,使A胶涂布量相对于B胶涂布量保持一定的比例且总涂布量满足低涂布量及或双组分胶反应固化的要求,然后两种基材涂胶面相对进行复合收卷,按此方法生产的复合膜具有下机后固化时间短、涂布量精度高、极低涂布量时均匀性好、可以实现大涂布量、控制操作性好等优点。

Claims (10)

  1. 一种以不同方式涂布且涂布量联动控制的复合方法,其特征在于,包括以下步骤:
    (1)在第一基材的涂胶面上采用多辊转移涂布A胶,在第二基材的涂胶面上采用雕刻凹辊涂布B胶,A胶涂布量相对于B胶涂布量保持设定比例且总涂布量满足设定要求;
    (2)第一基材的涂胶面与第二基材的涂胶面进行压合复合并收卷;
    (3)卷料在设定温度条件下快速固化成复合膜。
  2. 根据权利要求1所述的一种以不同方式涂布且涂布量联动控制的复合方法,其特征在于:
    A胶涂布量CA=100*CB/RAB=100*KB*QB/RAB  g/m2
    B胶涂布量CB=KB*QB  g/m2
    总涂布量CΣ=CA+CB=(1+100/RAB)KB*QB  g/m2
    B胶理论最大涂布量QB=ρ*V/1000  g/m2
    双组份胶的实用混配比RAB=R0+△;
    其中,KB为B胶对雕刻凹辊的转移率,ρ(g/cm3)为B胶密度,V(mm3/m2)为雕刻网穴的密度比容积,△取值在0-20范围。
  3. 根据权利要求1所述的一种以不同方式涂布且涂布量联动控制的复合方法,其特征在于:当已知复合膜总涂布量C0的目标值和双组分胶混配比RAB,工艺控制参数设置流程如下:
    1)根据CB0=RAB*C0/(100+RAB)计算B胶需要涂布量CB0值;
    2)读取可用雕刻凹辊对B胶的转移率KBN及密度比容积值VN(mm3/m2),所用胶水密度ρ(g/cm3)值,根据CBN=ρ*KBN*VN/1000计算雕刻凹辊的计算涂布量CBN值;
    3)根据△C=|CB0-CBN|≤k对雕刻凹辊的计算涂布量与需要涂布量差值绝对值与误差k进行比较,不满足者,排除选用,并返回步骤2) 重复读取可用雕刻凹辊参数循环计算,K取0-0.02;满足者进入下一步流程;
    4)用CAN=C0-CBN计算雕刻凹辊按总涂布量C0对应的A胶涂布量值;
    5)判断上步所计算CAN值是否满足CAN∈[0.8,2.5]的判断条件,不满足者,排除选用,并返回步骤2)重复读取可用雕刻凹辊参数循环计算,满足的列表于“合用雕刻凹辊组”内;循环读取数据计算,直到所有可用雕刻凹辊参数全部读完;所有凹辊参数读完计算后,如没有一个符合要求的凹辊,则需要选择新规格的雕刻凹辊参数;
    6)比较雕刻凹辊网线数值,选定“合用雕刻凹辊组”内凹穴网线数最大者为拟用雕刻凹辊;
    7)选取拟用雕刻凹辊的CBN赋值于CB,用CA=C0-CB,计算A胶需要涂布量CA值;
    8)用Y=CA*YE/CE计算五辊转移涂布机构的转移钢辊速率,式中YE及CE为五辊转移涂布机构的标准转移钢辊速率及对应的涂布量设定值(g/m2),并将此值设置于机器控制屏输入框;
    9)开机运行后,根据检测基材涂布量的检测设备所显示的A胶涂布量TAC值适当调整计量钢辊速率YA值,使五辊转移涂胶量与网纹辊涂胶量匹配。
  4. 根据权利要求1所述的一种以不同方式涂布且涂布量联动控制的复合方法,其特征在于:当已知复合膜双组分胶混配比RAB和总涂布量的预估值C0,复合膜要求剥离强度指标值PE,工艺控制参数设置流程如下:
    1)根据CB0=RAB*C0/(100+RAB)计算B胶需要涂布量CB0值;
    2)读取可用雕刻凹辊对B胶的转移率KBN及密度比容积值VN(mm3/m2),所用胶水密度ρ(g/cm3)值,根据CBN=ρ*KBN*VN/1000值计算雕刻凹辊的计算涂布量CBN值;
    3)根据△C=CB0-CBN≤k对雕刻凹辊的计算涂布量与需要涂布量差值与 误差k进行比较,不满足者,排除选用,并返回步骤2)重复读取可用雕刻凹辊参数循环计算,K取0-0.02,满足者进入下一步流程;
    4)用CAN=100CBN/RAB计算雕刻凹辊按预估总涂布量C0对应的A胶涂布量值;
    5)判断上步所计算CAN值是否满足CAN∈[0.8,2.5]的判断条件,不满足者,排除选用,并返回步骤2)重复读取可用雕刻凹辊参数循环计算,满足的列表于“初选雕刻凹辊组”内;循环读取数据计算,直到所有可用雕刻凹辊参数全部读完;所有凹辊参数读完计算后,如没有一个符合要求的凹辊,则需要选择新规格的雕刻凹辊参数;
    6)用YAN=CAN*YE/CE计算五辊转移涂布机构的转移钢辊速率;式中YE及CE为五辊转移涂布机构的标准转移钢辊速率及对应的涂布量设定值(g/m2),并将此值设置于机器控制屏输入框;
    7)开机运行并进行复合膜牢度试验,复合膜实际剥离强度值不小于剥离强度指标值PE者列入“待用雕刻凹辊组”并进行下一步流程,否则,排除选用,并读取下一个“初选雕刻凹辊组”内参数返回步骤6);
    8)用CN=CAN+CBN计算复合膜总涂布量,并读取下一个初选雕刻凹辊参数返回第6步,直到所有“初选雕刻凹辊组”内凹辊参数被读完;
    9)读取待用雕刻凹辊组中复合膜总涂布量,并选中最小值者对应的雕刻凹辊,选取对应的转移钢辊速率为五辊转移涂布机构输入值。
  5. 据权利要求3或4所述的一种以不同方式双涂且涂布量联动控制的复合方法,其特征在于:所述五辊转移涂布机构的转移钢辊速率Y值求取用查取或插值计算转移钢辊速率/涂布量曲线获得。
  6. 据权利要求3或4所述的一种以不同方式双涂且涂布量联动控制的复合方法,其特征在于:雕刻凹辊包括多种规格,每根雕刻凹辊的参数矢量不同,参数矢量是直接计算值或行业/用户设立的优选值;参数矢量包括网线数、凹穴形状、深度及凹穴容积。
  7. 一种以不同方式涂布且涂布量联动控制的复合设备,其特征在于:在 设备顶部设有连接横梁,在横梁下方从左至右依次设有第一放卷及涂布机组、复合及收卷机组和第二放卷及涂布机组;所述第一放卷及涂布机组包括第一放卷单元和五辊转移涂布单元;所述复合及收卷机组包括复合单元和收卷单元,所述第二放卷及涂布机组包括第二放卷单元和雕刻凹辊涂布单元;在横梁上设有连接五辊转移涂布单元与复合单元的第一料带转移路径导辊组和连接雕刻凹辊涂布单元与复合单元的第二料带转移路径导辊组;在连接横梁上第一料带转移路径位置设有检测基材涂布量的仪器。
  8. 根据权利要求7所述的一种以不同方式涂布且涂布量联动控制的复合设备,其特征在于:在所述第一放卷及涂布机组中,所述第一放卷单元位于机组右侧,所述五辊转移涂布单元位于机组左侧,在机组上部左右两侧分别设有第一张力控制单元和第二张力控制单元,所述第一张力控制单元在所述第一料带转移路径上并控制第一料带张力,所述第二张力控制单元位于第一放卷单元和五辊转移涂布单元之间料带路径上并控制该段料带张力,在所述五辊转移涂布单元设有双组分胶A胶供胶系统。
  9. 根据权利要求7所述的一种以不同方式涂布且涂布量联动控制的复合设备,其特征在于:在所述复合及收卷机组中,所述复合单元位于机组上部,所述收卷单元位于机组左下部,在复合单元和收卷单元之间料带路径上设有第三张力控制单元用于控制该段料带张力。
  10. 根据权利要求7所述的一种以不同方式涂布且涂布量联动控制的复合设备,其特征在于:在所述第二放卷及涂布机组中,所述第二放卷单元位于机组左侧,所述雕刻凹辊涂布单元位于机组右侧,在机组上部左右两侧各设有第四和第五张力控制单元,所述第四张力控制单元位于所述第二放卷单元和雕刻凹辊涂布单元之间料带路径上并控制该段料带张力,所述第五张力控制单元在所述第二料带转移路径上并控制第二料带张力,在所述雕刻凹辊涂布单元设有双组分胶B胶供 胶系统、储胶池及一根可快速更换的雕刻凹辊,储胶池设有加热保温组件。
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