阅读说明：本技术 一种连续发泡材料的生产系统 (Production system of continuous foaming material ) 是由 万立祥 杨庆锋 张镤 于 2020-06-22 设计创作，主要内容包括：本发明属于发泡材料生产设备技术领域,具体公开了一种连续发泡材料的生产系统,包括依次设置的定厚装置、冷却辊、电晕机和收卷组件；所述定厚装置包括发泡腔和设于发泡腔外的锁厚部；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至冷却辊；所述收卷组件包括依次设置的纠偏机、第一张力机、牵引机、第二张力机和收卷架。本发明能够实现精确、快速定厚,且整体生产效率高,生产的成品发泡材料尺寸偏差小,表面性能好。(The invention belongs to the technical field of foaming material production equipment, and particularly discloses a continuous foaming material production system which comprises a thickness fixing device, a cooling roller, a corona machine and a winding component which are sequentially arranged; the thickness fixing device comprises a foaming cavity and a thickness locking part arranged outside the foaming cavity; the thickness locking part comprises a pressure roller and a steering roller which are oppositely arranged and communicated with the cooling medium pipeline, at least one surface of the pressure roller and the steering roller is provided with a cooling structure, and at least one driving roller is driven to rotate by power equipment; the foaming material passes through a pressing area between a pressure roller and a turning roller and then is sent to a cooling roller in a mode of being attached to the surface of the turning roller; the winding assembly comprises a deviation rectifying machine, a first tension machine, a traction machine, a second tension machine and a winding frame which are sequentially arranged. The invention can realize accurate and rapid thickness setting, has high integral production efficiency, and produces finished foaming materials with small size deviation and good surface performance.)

1. A production system for a continuous foamed material, characterized in that: comprises a thickness fixing device, a cooling roller (3), a corona machine (4) and a winding component (5) which are arranged in sequence; the thickness fixing device comprises a foaming cavity (1) and a thickness locking part (2), a feeding hole (11) and a discharging hole (12) are respectively formed in two ends of the foaming cavity (1), and a plurality of heating elements (13) are arranged on the inner wall of the foaming cavity (1) along the conveying direction of a foaming material; the thickness locking part (2) is arranged outside the discharge hole (12), the thickness locking part (2) comprises a pressure roller (21) and a steering roller (22) which are oppositely arranged and communicated with a cooling medium pipeline, at least one surface of the pressure roller (21) and the steering roller (22) is provided with a cooling structure (23), and at least one surface of the pressure roller and the steering roller is a driving roller driven by power equipment to rotate; the foaming material passes through a pressing area between a pressure roller (21) and a turning roller (22) and then is sent to a cooling roller (3) in a mode of being attached to the surface of the turning roller (22); the winding assembly (5) comprises a deviation rectifying machine (51), a first tension machine (52 a), a traction machine (53), a second tension machine (52 b) and a winding frame (54) which are arranged in sequence.

2. The production system of continuous foamed material according to claim 1, characterized in that: the cooling structure (23) is a plurality of bulges on the surface of the pressure roller (21)/the steering roller (22).

3. The production system of continuous foamed material according to claim 1, characterized in that: the roller diameter of the deflecting roller (22) is at least 1.2 times of the roller diameter of the pressure roller (21); when the foaming material is attached to the surface of the turning roller (22) and sent out, the sending-out direction and the conveying direction of the foaming material in the foaming cavity (1) form an acute angle.

4. The production system of continuous foamed material according to claim 1, characterized in that: at least the pressing areas of the pressure roller (21) and the deflecting roller (22) are opposite to the discharge opening (12).

5. The production system of continuous foamed material according to claim 4, characterized in that: the pressure roller (21) is located in the area directly opposite to the discharge opening (12), and at least 70% of the deflecting roller (22) is located outside the area directly opposite to the discharge opening (12); the discharge hole (12) is rectangular.

6. The production system of continuous foamed material according to claim 1, characterized in that: two ends of a roll shaft of the pressure roll (21) and two ends of a roll shaft of the steering roll (22) are respectively provided with an adjusting part, and each adjusting part comprises a fixing frame and a bearing seat which is sleeved on the roll shaft and is connected to the fixing frame in a sliding manner; the adjusting part of the pressure roller (21) is also provided with an air cylinder connected with the bearing seat.

7. The production system of continuous foamed material according to claim 1, characterized in that: the heating element (13) is arranged in the middle of the inner wall of the foaming cavity (1), and an unfolding roller (14) with a cooling function is arranged below the arrangement area of the heating element (13).

8. The production system of continuous foamed material according to claim 1, characterized in that: the corona machine (4) comprises a frame, rubber rollers arranged in the frame and material passing rollers (41) arranged on two sides of the rubber rollers, wherein a plurality of annular grains used for preventing foaming materials from wrinkling are arranged on the surfaces of the material passing rollers (41).

9. The production system of continuous foamed material according to claim 1, characterized in that: the first tension machine (52 a) and/or the second tension machine (52 b) comprise a floating roller (522) and guide rollers (521) which are arranged on two sides of the floating roller (522) and are positioned above the floating roller (522).

10. A method for producing a foamed material using the production system as claimed in any one of claims 1 to 9, characterized in that: the method comprises the following steps:

s1, foaming: inputting the preheated master slice into a foaming cavity, foaming under the action of a heating element in the foaming cavity, flattening by an unfolding roller, and outputting from a discharge port of the foaming cavity;

s2, thickness fixing: the sheet enters a pressing area between the pressure roller and the turning roller, the pressure roller and the turning roller run reversely, the thickness locking is realized under the action of the surface cooling structures of the two rollers and the cooling media in the two rollers, and then the sheet is sent to the cooling roller for further cooling;

s3, corona treatment, namely, enabling the sheet to enter a corona machine for surface treatment to roughen the surface;

s4, rolling, namely, sequentially passing the sheet through a deviation corrector, a first tension machine, a tractor, a second tension machine and a rolling frame to finish the procedures of deviation correction, tension control, traction and rolling to obtain the finished product of the foaming material.

Technical Field

The invention belongs to the technical field of foaming material production equipment, and particularly relates to a production system of a continuous foaming material.

Background

The foaming of the sheet material refers to a process of heating a belt-shaped polymer material in a foaming furnace, decomposing a foaming agent at high temperature to generate gas, filling the gas into the polymer material to generate a foamed material with closed pores, and in actual production, after foaming is completed, the foamed material needs to be cooled and shaped by a cooling device, and then the foamed material is directly rolled or is rolled through some post-treatment processes (such as edge cutting, embossing, cutting pieces and the like) to obtain a finished product. Among the above processes, the cooling and setting process is particularly important, and directly determines the quality of the finished product, and most of the setting devices of the existing foaming material production line are cooling roller sets (such as CN105599210B and CN 209111359U) arranged outside the foaming furnace, and have the following defects: firstly, the cooling speed is slow, although the improvement can be realized by increasing the number of cooling roller sets or increasing the pressure of the roller pairs, the energy consumption of the former is high, and the latter is easy to excessively extrude the sheet and even break the sheet; more importantly, the prior cooling and shaping only cools and solidifies the sheet by a cooling roller, so that the thickness of the sheet is difficult to control accurately, the sheet is relatively thin (usually only 2-3 mm) and is easy to deform under the influence of external factors such as temperature, airflow, traction speed and the like, so that the size of a finished product is difficult to control and large deviation is easy to occur, and the foaming material is usually required to be attached to other sheets for use, so that once the thickness of different parts generates large deviation, the combination of the foaming material and the sheets is directly influenced, and the quality and the use performance of the sheets are further influenced.

Disclosure of Invention

One of the purposes of the invention is to provide a production system of continuous foaming materials, which can realize accurate and rapid thickness setting, has high overall production efficiency, and produces finished foaming materials with small size deviation and good surface performance.

In order to achieve the purpose, the invention adopts the following specific technical scheme:

a production system of continuous foaming materials comprises a thickness fixing device, a cooling roller, a corona machine and a winding component which are sequentially arranged; the thickness fixing device comprises a foaming cavity and a thickness locking part, a feeding hole and a discharging hole are respectively formed in two ends of the foaming cavity, and a plurality of heating elements are arranged on the inner wall of the foaming cavity along the conveying direction of the foaming material; the thickness locking part is arranged outside the discharge port and comprises a pressure roller and a steering roller which are oppositely arranged and communicated with a cooling medium pipeline, at least one surface of the pressure roller and the steering roller is provided with a cooling structure, and at least one surface of the pressure roller and the steering roller is a driving roller driven by power equipment to rotate; the foaming material passes through a pressing area between a pressure roller and a turning roller and then is sent to a cooling roller in a mode of being attached to the surface of the turning roller; the winding assembly comprises a deviation rectifying machine, a first tension machine, a traction machine, a second tension machine and a winding frame which are sequentially arranged.

The invention reduces the size deviation of the finished product of the foaming material by the arrangement of the fixed-thickness device and the composition design of the winding component.

Firstly, precisely controlling the size of the foaming material by a thickness fixing device consisting of a foaming cavity and a thickness locking part, wherein the thickness locking part consists of a pressure roller and a turning roller which are oppositely arranged and have a cooling function and at least one surface of which is provided with a cooling structure, and the cooling structure is a structure which can enable the surface of a sheet to form a concave-convex appearance after the sheet is rolled by the pressure roller and the turning roller; the sheet is preliminarily molded after foaming in the foaming cavity, then vertically enters between the pressure roller and the steering roller, and the foaming material utilizes the waste heat to enable the cooling structure to be embedded into the surface of the sheet during rolling and is cooled and shaped under the action of a cooling medium; the cooling structure forms concave parts at a plurality of positions on the surface of the foaming material, and the strength of the foaming material is not influenced because the concave parts and the plane parts are alternately arranged at intervals; the arrangement of the cooling structure not only increases the cooling contact area, but also enables the cooling process to quickly go deep into the foaming material, realizes the accurate and quick control of the thickness, improves the speed and the sufficiency of the integral cooling of the sheet, and has obvious advantages in the shaping effect and the efficiency compared with the mode of increasing the number of cooling roller sets or increasing the pressure of the roller pair in the prior art; the foaming material is delivered in a mode of being attached to a steering roller after being pressed, so that the cooling contact time is prolonged, and the lines formed on the surface of the foaming material by a cooling structure are protected and stabilized.

Then, the winding assembly that includes rectifying machine, first tension machine, tractor, second tension machine and rolling frame through the setting in proper order reduces the influence of pulling the operation to the thick process of fixed thick device lock: the sheet is directly wound by the winding frame after being processed by the thickness fixing device, so that the deviation phenomenon is easy to generate, once the sheet deviates, the stress on two sides of the sheet which is subjected to thickness locking is unbalanced, the setting effect is directly influenced, and the size deviation of the sheet is increased, so that the deviation generated in the thickness locking process is avoided by arranging the deviation rectifying machine in the winding assembly; the tensioner is arranged to provide a good buffering effect for the whole transmission process, and constant tension is maintained when the winding speed is changed, so that the locking thickness process can be continuously and stably carried out, and the influence of winding on the locking thickness process is further reduced; the number of the tension machines is two, so that the production efficiency can be effectively improved, when the winding frame is used for changing rolls or subsequent cutting and other operations are carried out, the two tension machines have a synergistic effect, a certain adjusting time can be provided, the former foaming and thickness locking processes cannot be influenced in a short time, and therefore continuous production can be realized; the setting of two tensioners can also effectively reduce the condition that the expanded material takes place the skew and the degree that takes place the skew, reduces the deviation correcting machine work load that sets up at first tensioner front end and reduces the degree of difficulty of rectifying, even take place certain skew also can quick adjustment, can not lead to the fact the influence to the thick process of lock, further improves the stability of rolling, ensures the accurate control of expanded material size.

Preferably, the cooling structure is a plurality of bulges on the surface of the pressure roller/turning roller, and the shapes and the sizes of the bulges can be diversified.

Preferably, the roll diameter of the turning roll is at least 1.2 times the roll diameter of the pressure roll; when the foaming material is attached to the surface of the steering roller and is sent out, the sending-out direction and the conveying direction of the foaming material in the foaming cavity form an acute angle. The diameter of the steering roller is increased, the diameter of the foaming material in the sending direction is controlled, the contact area of the foaming material and the steering roller is increased, the foaming material is cooled and shaped more fully, and the locking thickness effect is enhanced.

Preferably, at least the pressing area of the pressure roller and the turning roller is opposite to the discharge port. Also cooling when the roll-in, and the foaming material surface need form unsmooth structure under the cooling structure effect, consequently need avoid cooling early to overcome and be difficult to the shaping and the problem of direct influence outward appearance, through set up the regional setting in the position just right with foaming chamber discharge gate with the at least suppression on pressure roller and the turn to roller, make suppression region and foaming material have certain being heated, can not cool off immediately.

Preferably, the pressure roller is positioned in the opposite area of the discharge port, and at least 70% of the turning roller is positioned outside the opposite area of the discharge port; the discharge hole is rectangular. The design of the position of the pressure roller and the steering roller can effectively slow down the cooling process of the pressure cooling structure when being laminated and rolled with the foaming material, is favorable for the forming of the concave-convex structure, the rolling foamed material is laminated and sent out in the steering roller, the steering roller is heated less, and the thickness of the foaming material can be quickly locked, so that the thickness locking part can ensure the attractiveness of the foaming material without influencing the thickness locking effect. The discharge gate is the rectangle, and the long limit sets up the axial unanimity of direction and pressure roller and steering roll for the expanded material is heated evenly at different positions on the width direction, and then avoids increasing the problem of finished product size deviation because of the thick process inconsistency of lock that the difference of being heated leads to.

Preferably, two ends of a roll shaft of the pressure roll and two ends of a roll shaft of the steering roll are respectively provided with an adjusting part, and each adjusting part comprises a fixing frame and a bearing seat which is sleeved on the roll shaft and is connected to the fixing frame in a sliding manner; the adjusting part of the pressure roller is also provided with an air cylinder connected with the bearing seat. 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 fixing frame, and the operation is simple.

Preferably, the heating element is arranged in the middle of the inner wall of the foaming cavity, and an unfolding roller with a cooling function is arranged below the arrangement area of the heating element. Foaming is carried out to sheet in the foaming chamber under heating element effect, and the foaming back sheet can expand, and both sides also can curl, consequently set up the expansion roller that has cooling function in non-warm area, on the one hand through the expansion roller with the sheet exhibition flat, improve the planarization of sheet, on the other hand, make the inside foaming that stops completely of sheet through the cooling effect of expansion roller when non-warm area is flat, avoid the flattening back thickness of sheet to change again, provide good structural basis for the lock of follow-up sheet is thick.

Preferably, the corona machine comprises a frame, a rubber roller arranged in the frame and a material passing roller arranged on two sides of the rubber roller, wherein the surface of the material passing roller is provided with a plurality of annular grains for preventing the foaming material from wrinkling. This line leans out for foamed material can both fully be opened by comfortable around the corona, ensures the corona effect, and makes follow-up rolling go on smoothly.

Preferably, the first tension machine and/or the second tension machine comprise a floating roller and guide rollers arranged on two sides of the floating roller and positioned above the floating roller, and the constant tension control is realized through the lifting of the floating roller.

Another object of the present invention is to provide a method for producing a foamed material using the continuous foamed material production system, comprising the steps of:

s1, foaming: inputting the preheated master slice into a foaming cavity, foaming under the action of a heating element in the foaming cavity, flattening by an unfolding roller, and outputting from a discharge port of the foaming cavity;

s2, thickness fixing: the sheet enters a pressing area between the pressure roller and the turning roller, the pressure roller and the turning roller run reversely, the thickness locking is realized under the action of the surface cooling structures of the two rollers and the cooling media in the two rollers, and then the sheet is sent to the cooling roller for further cooling;

s3, corona treatment, namely, enabling the sheet to enter a corona machine for surface treatment to roughen the surface;

s4, rolling, namely, sequentially passing the sheet through a deviation corrector, a first tension machine, a tractor, a second tension machine and a rolling frame to finish the procedures of deviation correction, tension control, traction and rolling to obtain the finished product of the foaming material.

The invention has the following beneficial effects:

1. can carry out the accurate thick device of deciding of confirming and can reduce the rolling subassembly that pulls the influence to deciding thick effect and reduce the dimensional deviation of foaming material finished product through setting up to foaming material. Specifically, the size of the foaming material is accurately controlled through a thickness fixing device consisting of a foaming cavity and a thickness locking part, the sheet is preliminarily molded after foaming of the foaming cavity, and the thickness locking part is pressed through a cooling structure matched with a pressure roller and a steering roller with a cooling function to finish surface and accurate shaping in the thickness direction, so that compared with the prior art, the shaping is quicker and more sufficient, and the size deviation of a finished product is small (can be controlled within 10%); in addition, the cooling structure can form lines on the surface of the sheet, the pattern of the cooling structure can be designed according to the requirements of users, the attractiveness can be improved without subsequent treatment, and the cost is effectively reduced. The winding component is internally provided with the deviation correcting machine and the tension machine to reduce the influence of the winding operation on the thickness locking effect, wherein the deviation correcting machine can avoid the problems of inaccurate thickness locking and increased size deviation of finished products caused by the deviation of the position of the sheet; the arrangement of the two tensioners not only can play a role of buffering, but also can maintain constant sheet tension; the subsequent winding operation can be prevented from influencing the previous foaming and thickness locking procedures, continuous production can be realized, and the production efficiency is effectively improved; meanwhile, the deviation of the foaming material can be reduced, the rolling stability is further improved, and the accurate control of the size of the foaming material is ensured.

2. The thickness fixing device is optimized in the following aspects, and the thickness fixing effect is further improved:

the method comprises the following steps of increasing the contact area between the foaming material and a steering roller by increasing the diameter of the steering roller and controlling the acute angle between the delivery direction of the foaming material in the steering roller and the delivery direction of the foaming material in a foaming cavity, so that the foaming material is cooled and shaped more fully, and the locking thickness effect is enhanced;

at least the pressing area on the pressure roller and the steering roller is arranged at the position right opposite to the discharge port of the foaming cavity, so that the pressing area and the foaming material are heated to a certain extent, and the phenomenon that the foaming material is cooled too early to cause that the surface of the foaming material is difficult to form a corresponding concave-convex structure under the action of a cooling structure, and further the appearance and the thickness locking effect are influenced is avoided. More optimally, the pressure roller is arranged in the opposite area of the discharge hole, and at least 70% of the steering roller is arranged outside the opposite area of the discharge hole, so that the concave-convex structure of the foaming material is smoothly formed, and meanwhile, the rapid cooling is realized, and the good locking thickness effect is obtained; the discharge hole is rectangular, so that the foaming material is uniformly heated in the width direction, and the consistency of thickness locking effects at different parts is improved;

and arranging an expansion roller with a cooling function in a non-heating area below the heating element in the foaming cavity, flattening the expanded sheet, and stopping foaming inside the sheet so as to avoid the thickness change, thereby providing a good structural foundation for the thickness locking of the subsequent sheet.

3. Through the pressure roller at the thickness locking portion and the change of dismantling that the position regulation of two rollers was realized to the steering roll both ends set up regulating part, the regulating part includes that roller and sliding connection in the bearing frame of mount are located to mount and cover, easy operation, when the cooling structure on roller surface weared and torn or need the cooling structure of different patterns, can accomplish the replacement of roller fast, improvement work efficiency.

4. The arrangement of the cooling structure in the locking thickness part enables the surface of the foaming material to be in a concave-convex structure, and is beneficial to combination with the adhesive in subsequent use.

5. The invention can be used for continuous production of IXPE, XPE, EVA and other foaming materials, and the foaming cavity can be vertical or horizontal, so that the invention has wide application range and good application prospect.

Drawings

FIG. 1: the schematic structure of the continuous foamed material production system described in example 1.

FIG. 2: a three-dimensional structure of a thickness locking part of the thickness fixing device described in embodiment 1.

FIG. 3: the structure of the tension machine in example 1 is a three-dimensional structure.

FIG. 4: the structure of the feed roller of the corona machine in the embodiment 1 is schematically shown.

FIG. 5: the structure of the thickness fixing device in the embodiment 3 is schematically shown.

In the figure: 1-foaming cavity, 2-thickness locking part, 3-cooling roller, 4-corona machine and 5-winding component; 11-a feeding port, 12-a discharging port, 13-a heating element, 14-an unwinding roller, 21-a pressure roller, 22-a steering roller, 23-a cooling structure, 24-a first adjusting part, 25-a second adjusting part, 41-a material passing roller, 51-a deviation correcting machine, 52 a-a first tension machine, 52 b-a second tension machine, 53-a traction machine and 54-a winding frame; 241-a first fixing frame, 242-a first bearing seat, 243-a first sliding rail, 244-an air cylinder, 245-a fixing plate, 251-a second fixing frame, 252-a second bearing seat, 253-a second sliding rail, 521-a guide roller, 522-a floating roller, 523-a balance block, 524-a transmission part, 525-a guide rod and 526-a spring.

Detailed Description

The invention is further described below with reference to the accompanying drawings and specific embodiments.