Method of continuously processing a wave-shaped roof panel

Abstract

The present application relates to a kind of continuous processing corrugated automobile roof sheet method, mainly solve the existing technology in the market automobile roof sheet because of the internal stress in foaming process cannot be released in time and inevitably form corrugated, existing processing means load pressure or load heating pressure processing effect and efficiency are not good.The present application is by using a new continuous processing corrugated automobile roof sheet method, sequentially includes the following processing steps: (1) the corrugated automobile roof sheet to be processed is placed on the conveying belt, and is continuously conveyed to the heating zone from the conveying area;(2) the corrugated automobile roof sheet is continuously transported to the cooling zone from the heating zone;(3) the corrugated automobile roof sheet is obtained after passing through the cooling zone, and the technical scheme of the treated automobile roof sheet is obtained, which preferably solves the problem, and can be used in the industrial application of automobile roof sheet production.

Description

Technical Field

[0001] This invention relates to a method for continuous processing of corrugated automotive roof sheets. Background Technology

[0002] In the application of polyurethane materials, foam-based materials account for the majority. Based on their strength or hardness, polyurethane foam can be divided into soft, rigid, and semi-rigid types. Among them, semi-rigid polyurethane foam is particularly suitable as a framework material for automotive headliners due to its advantages such as light weight, high strength, good toughness, and good sound absorption. Typically, semi-rigid polyurethane foam is first expanded into large blocks, then cut into thin sheets or panels of a certain thickness before being used in the molding of automotive headliners. Although semi-rigid polyurethane foam has various advantages, due to the special nature of its raw materials and formulation, its rigidity or strength is not as high as rigid foam, and its open-cell capacity is not as high as soft foam. The final sheet will inevitably form a wavy shape because the internal stress during the foaming process cannot be released in time. For continuous wet-process headliner molding in the market, sheets with a maximum wave height of 10-20mm have a smaller impact, but a maximum wave height of 30-50mm or even 50-80mm will seriously affect the headliner molding process, especially causing jamming problems during roll bonding or sheet conveying. Even with strict control over the foaming process of semi-rigid polyurethane foam, corrugated sheets are inevitably produced. Currently, there are some conventional methods for treating these semi-rigid polyurethane foam sheets, such as load-bearing pressure or load-bearing heating pressure, but the treatment effect and efficiency are not ideal.

[0003] Therefore, it is necessary to invent a method for the continuous processing of corrugated semi-rigid polyurethane foam sheets, which can quickly and effectively flatten or reduce the corrugation of the sheets, while reducing the dependence of the semi-rigid polyurethane foam sheets on the control of the foaming process. Summary of the Invention

[0004] The technical problem to be solved by this invention is that existing automotive headliner sheets inevitably form a wavy shape due to the inability to release internal stress during the foaming process. Existing treatment methods such as load pressing or load heating pressurization have poor effects and efficiency. This invention provides a new method for continuous treatment of wavy automotive headliner sheets. This method has the advantages of high processing efficiency, excellent processing effect, and the ability to quickly and effectively flatten or reduce the wavy shape of the sheets.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A method for continuous processing of corrugated automotive roof sheet material, comprising the following processing steps in sequence:

[0006] 1) Place the corrugated car roof sheet with a wave height of 20-80mm and a thickness of 5-10mm on the conveyor belt and continuously transport it from the conveying area to the heating area;

[0007] 2) The corrugated car roof sheet is then continuously transported from the heating zone to the cooling zone; the time for the sheet to pass through the heating zone is 30-60 seconds;

[0008] 3) After the corrugated car roof sheet passes through the cooling zone, the time for the sheet to pass through the cooling zone is 10-60 seconds; thus, the processed car roof sheet is obtained.

[0009] The heating zone consists of three heating zones I, II, and III with different temperatures. Each heating zone includes, from top to bottom, an upper heating device, an upper conveying device, a lower conveying device, and a lower heating device. The cooling zone includes, from top to bottom, a first cooling device, an upper conveying device, a lower conveying device, and a second cooling device. The conveyor belts of the conveying devices in the heating and cooling zones are made of glass fiber cloth coated with Teflon resin.

[0010] In the above technical solution, preferably, the heating method of the heating device in the heating zone is selected from heating tube heating or oil heating; the cooling method of the cooling device in the cooling zone is cooling water cooling.

[0011] In the above technical solution, preferably, the upper heating device consists of a first heating device, a third heating device, and a fifth heating device with independent temperature control; the lower heating device consists of a second heating device, a fourth heating device, and a sixth heating device with independent temperature control.

[0012] In the above technical solution, preferably, the temperature of the first heating device and the second heating device is set to 50-140℃, the temperature of the third heating device and the fourth heating device is set to 80-180℃, and the temperature of the fifth heating device and the sixth heating device is set to 110-200℃.

[0013] In the above technical solution, preferably, the temperature of the cooling zone is set to 20-40°C.

[0014] In the above technical solution, preferably, the lengths of heating zone I, heating zone II and heating zone III are 1 to 3 m, and the length of cooling zone is 1 to 10 m; the spacing between the corrugated car roof sheet to be processed during conveying in the conveying zone is controlled at 1 to 3 cm; the distance between the heating device in the heating zone and the conveyor belt is 0 to 20 mm, and the distance between the cooling device in the cooling zone and the conveyor belt is 0 to 20 mm.

[0015] In the above technical solution, preferably, the interval between the conveying zone and the heating zone is 10-30cm, and the interval between the heating zone and the cooling zone is 10-30cm.

[0016] In the above technical solution, preferably, the conveying speed of the heating zone is the same as or slightly faster than the conveying speed of the conveying zone; the conveying speed of the cooling zone is the same as or slightly faster than the conveying speed of the heating zone.

[0017] In the above technical solution, preferably, the distance between the upper and lower conveyor belts of the heating zone is 0.5 to 1.5 mm higher than the thickness of the sheet; and the distance between the upper and lower conveyor devices of the cooling zone is 0.2 to 1.2 mm higher than the thickness of the sheet.

[0018] In the above technical solution, preferably, the conveyor belt material of the conveying area is polyester fiber cloth covered with one of polyurethane adhesive, polyethylene adhesive or polyvinyl chloride adhesive.

[0019] This invention provides a method for continuously processing corrugated car roof sheets. The corrugated roof sheet is first continuously conveyed to a heating zone through a conveying zone. The heating zone has six independent temperature control areas to heat the roof sheet. Then, it is continuously conveyed to a cooling zone for cooling. This method can continuously and efficiently flatten or reduce the corrugation of the curved roof sheet, achieving good technical results. Attached Figure Description

[0020] Appendix Figure 1 This is a schematic diagram of a device for the continuous processing of corrugated car roof sheets.

[0021] Appendix Figure 2 This is a schematic diagram of the heating zone.

[0022] Wherein, 1 is the conveying zone, 2 is the heating zone, 3 is the cooling zone, 4 is the first conveying device, 5-1 is the first heating device, 6-1 is the second conveying device, 7-1 is the third conveying device, 8-1 is the second heating device, 5-2 is the third heating device, 6-2 is the fourth conveying device, 7-2 is the fifth conveying device, 8-2 is the fourth heating device, 5-3 is the fifth heating device, 6-3 is the sixth conveying device, 7-3 is the seventh conveying device, 8-3 is the sixth heating device, 9 is the eighth conveying device, 10 is the first cooling device, 11 is the ninth conveying device, and 12 is the second cooling device. Detailed Implementation

[0023]

Example 1

[0024] A continuous processing device for corrugated automotive roof sheet material includes a conveying zone, a heating zone, and a cooling zone. The heating zone consists of three heating zones at different temperatures: Zone I, Zone II, and Zone III. Each heating zone, from top to bottom, includes an upper heating device, an upper conveyor, a lower conveyor, and a lower heating device. The cooling zone, from top to bottom, includes a first cooling device, an upper conveyor belt, a lower conveyor belt, and a second cooling device. The upper heating device consists of independently temperature-controlled first, third, and fifth heating devices. The lower heating device consists of independently temperature-controlled second, fourth, and sixth heating devices. The conveyor belt in the conveying zone is made of polyester fiber cloth coated with polyethylene rubber. The upper and lower conveyor belts in the heating and cooling zones are made of fiberglass cloth coated with Teflon resin. The heating devices in the heating zone heat the material through heating pipes, directly contacting the corresponding conveyor belts for contact heating. The cooling devices in the cooling zone, with cooling water circulating inside, directly contact the corresponding conveyor belts for contact cooling. The conveying zone and heating zone are spaced 20cm apart, as are the heating and cooling zones.

[0025] (1) Place the corrugated car roof sheet with a maximum wave height of 20mm, a thickness of 5mm, and a length of 2.5m on the conveyor belt in the conveying area, with a spacing of 1cm between each sheet, and set the speed of the conveyor belt in the conveying area to 5m / min;

[0026] (2) The sheet material is conveyed from the conveying area to the heating area; the temperature of the first heating device and the second heating device is set to 50℃, the temperature of the third heating device and the fourth heating device is set to 105℃, and the temperature of the fifth heating device and the sixth heating device is set to 165℃; the length of each heating device is 1m; the distance between each heating area is 10cm; the distance between the upper and lower conveyor belts in the heating area is set to 5.5mm; the conveying speed of the upper and lower conveyor belts is 5m / min.

[0027] (3) The heated sheet is continuously conveyed to the cooling zone. The cooling water temperature of the upper and lower cooling devices in the cooling zone is set to 20℃. The distance between the upper and lower conveyor belts in the heating zone is set to 5.2mm. The conveying speed of the upper and lower conveyor belts is 5m / min. The length of the cooling zone is 5m.

[0028] After the above treatment, the maximum wave height of the sheet was reduced from 20mm to 12mm; the wave shape reduction rate reached 40%.

[0029]

Example 2

[0030] The apparatus for continuous processing of corrugated car roof sheets is the same as that used in Example 1.

[0031] (1) Place the corrugated car roof sheet with a maximum wave height of 50mm, a thickness of 7mm and a length of 2.5m on the conveyor belt in the conveying area, with a spacing of 2cm between each sheet, and set the speed of the conveyor belt in the conveying area to 5m / min;

[0032] (2) The sheet material is conveyed from the conveying area to the heating area; the temperature of the first and second heating devices is set to 80℃, the temperature of the third and fourth heating devices is set to 110℃, and the temperature of the fifth and sixth heating devices is set to 140℃; the length of each heating device is 1m; the distance between each heating area is 10cm; the distance between the upper and lower conveyor belts of the heating area is set to 8.0mm; the conveying speed of the upper and lower conveyor belts is 6m / min;

[0033] (3) The heated sheet is continuously conveyed to the cooling zone. The cooling water temperature of the upper and lower cooling devices in the cooling zone is set to 30℃. The distance between the upper and lower conveyor belts in the heating zone is set to 8.0mm. The conveying speed of the upper and lower conveyor belts is 7m / min. The length of the cooling zone is 6m.

[0034] After the above treatment, the maximum wave height of the sheet was reduced from 50mm to 23mm; the wave shape reduction rate reached 54%.

[0035]

Example 3

[0036] The apparatus for continuous processing of corrugated car roof sheets is the same as that used in Example 1.

[0037] (1) Place the corrugated car roof sheet with a maximum wave height of 80mm, a thickness of 10mm and a length of 2.5m on the conveyor belt in the conveying area, with a spacing of 3cm between each sheet, and set the speed of the conveyor belt in the conveying area to 8m / min;

[0038] (2) The sheet material is conveyed from the conveying area to the heating area; the temperature of the first and second heating devices is set to 100℃, the temperature of the third and fourth heating devices is set to 150℃, and the temperature of the fifth and sixth heating devices is set to 160℃; the length of each heating device is 2m; the distance between each heating area is 10cm; the distance between the upper and lower conveyor belts of the heating area is set to 11.5mm; the conveying speed of the upper and lower conveyor belts is 10m / min;

[0039] (3) The heated sheet is continuously conveyed to the cooling zone. The cooling water temperature of the upper and lower cooling devices in the cooling zone is set to 40℃. The distance between the upper and lower conveyor belts in the heating zone is set to 11.2mm. The conveying speed of the upper and lower conveyor belts is 10m / min. The length of the cooling zone is 5m.

[0040] After the above treatment, the maximum wave height of the sheet was reduced from 80mm to 30mm; the wave reduction rate reached 62.5%.

[0041]

Example 4

[0042] The apparatus for continuous processing of corrugated car roof sheets is basically the same as that in Example 1, except that the conveyor belt in the conveying area is made of polyester fiber cloth plus polyvinyl chloride adhesive.

[0043] (1) Place the corrugated car roof sheet with a maximum wave height of 80mm, a thickness of 5mm, and a length of 2.5m on the conveyor belt in the conveying area, with a spacing of 1cm between each sheet, and set the speed of the conveyor belt in the conveying area to 8m / min.

[0044] (2) The sheet material is conveyed from the conveying area to the heating area; the temperature of the first and second heating devices is set to 70℃, the temperature of the third and fourth heating devices is set to 100℃, and the temperature of the fifth and sixth heating devices is set to 130℃; the length of each heating device is 2m; the distance between each heating area is 10cm; the distance between the upper and lower conveyor belts of the heating area is set to 6.0mm; the conveying speed of the upper and lower conveyor belts is 8m / min;

[0045] (3) The heated sheet is continuously conveyed to the cooling zone. The cooling water temperature of the upper and lower cooling devices in the cooling zone is set to 20℃. The distance between the upper and lower conveyor belts in the heating zone is set to 6.0mm. The conveying speed of the upper and lower conveyor belts is 8m / min. The length of the cooling zone is 3m.

[0046] After the above treatment, the maximum wave height of the sheet was reduced from 80mm to 29mm; the wave reduction rate reached 63.8%.

[0047]

Example 5

[0048] The apparatus for continuous processing of corrugated car roof sheets is basically the same as that in Example 1, except that the conveyor belt in the conveying area is made of polyester fiber cloth plus polyvinyl chloride adhesive.

[0049] (1) Place the corrugated car roof sheet with a maximum wave height of 55mm, a thickness of 7mm, and a length of 2.5m on the conveyor belt in the conveying area, with a spacing of 2cm between each sheet, and set the speed of the conveyor belt in the conveying area to 9m / min;

[0050] (2) The sheet material is conveyed from the conveying area to the heating area; the temperature of the first and second heating devices is set to 90℃, the temperature of the third and fourth heating devices is set to 130℃, and the temperature of the fifth and sixth heating devices is set to 160℃; the length of each heating device is 2m; the distance between each heating area is 10cm; the distance between the upper and lower conveyor belts of the heating area is set to 7.5mm; the conveying speed of the upper and lower conveyor belts is 10m / min;

[0051] (3) The heated sheet is continuously conveyed to the cooling zone. The cooling water temperature of the upper and lower cooling devices in the cooling zone is set to 30℃. The distance between the upper and lower conveyor belts in the heating zone is set to 7.2mm. The conveying speed of the upper and lower conveyor belts is 11m / min. The length of the cooling zone is 3m.

[0052] After the above treatment, the maximum wave height of the sheet was reduced from 55mm to 22mm; the wave reduction rate reached 60.0%.

[0053]

Example 6

[0054] The apparatus for continuous processing of corrugated car roof sheets is basically the same as that in Example 1, except that the conveyor belt in the conveying area is made of polyester fiber cloth plus polyvinyl chloride adhesive.

[0055] (1) Place the corrugated car roof sheet with a maximum wave height of 45mm, a thickness of 10mm and a length of 2.5m on the conveyor belt in the conveying area, with a spacing of 3cm between each sheet, and set the speed of the conveyor belt in the conveying area to 10m / min.

[0056] (2) The sheet material is conveyed from the conveying area to the heating area; the temperature of the first and second heating devices is set to 120℃, the temperature of the third and fourth heating devices is set to 170℃, and the temperature of the fifth and sixth heating devices is set to 180℃; the length of each heating device is 2m; the distance between each heating area is 10cm; the distance between the upper and lower conveyor belts of the heating area is set to 11.0mm; the conveying speed of the upper and lower conveyor belts is 11m / min;

[0057] (3) The heated sheet is continuously conveyed to the cooling zone. The cooling water temperature of the upper and lower cooling devices in the cooling zone is set to 40℃. The distance between the upper and lower conveyor belts in the heating zone is set to 11.0mm. The conveying speed of the upper and lower conveyor belts is 12m / min. The length of the cooling zone is 3m.

[0058] After the above treatment, the maximum wave height of the sheet was reduced from 45mm to 29mm; the wave reduction rate reached 35.6%.

[0059]

Example 7

[0060] The apparatus for continuous processing of corrugated car roof sheets is basically the same as that in Example 1, except that the conveyor belt in the conveying area is made of polyester fiber cloth plus polyvinyl chloride adhesive.

[0061] (1) Place the corrugated car roof sheet with a maximum wave height of 20mm, a thickness of 5mm, and a length of 2.5m on the conveyor belt in the conveying area, with a spacing of 1cm between each sheet, and set the speed of the conveyor belt in the conveying area to 10m / min.

[0062] (2) The sheet material is conveyed from the conveying area to the heating area; the temperature of the first and second heating devices is set to 90℃, the temperature of the third and fourth heating devices is set to 120℃, and the temperature of the fifth and sixth heating devices is set to 150℃; the length of each heating device is 3m; the distance between each heating area is 10cm; the distance between the upper and lower conveyor belts of the heating area is set to 6.2mm; the conveying speed of the upper and lower conveyor belts is 10m / min;

[0063] (3) The heated sheet is continuously conveyed to the cooling zone. The cooling water temperature of the upper and lower cooling devices in the cooling zone is set to 20℃. The distance between the upper and lower conveyor belts in the heating zone is set to 6.0mm. The conveying speed of the upper and lower conveyor belts is 10m / min. The length of the cooling zone is 3m.

[0064] After the above treatment, the maximum wave height of the sheet was reduced from 20mm to 11mm; the wave reduction rate reached 45%.

[0065]

Example 8

[0066] The apparatus for continuous processing of corrugated car roof sheets is basically the same as that in Example 1, except that the conveyor belt in the conveying area is made of polyester fiber cloth plus polyvinyl chloride adhesive.

[0067] (1) Place the corrugated car roof sheet with a maximum wave height of 50mm, a thickness of 7mm, and a length of 2.5m on the conveyor belt in the conveying area, with a spacing of 2cm between each sheet, and set the speed of the conveyor belt in the conveying area to 11m / min.

[0068] (2) The sheet material is conveyed from the conveying area to the heating area; the temperature of the first and second heating devices is set to 110℃, the temperature of the third and fourth heating devices is set to 150℃, and the temperature of the fifth and sixth heating devices is set to 180℃; the length of each heating device is 3m; the distance between each heating area is 10cm; the distance between the upper and lower conveyor belts in the heating area is set to 8.8mm; the conveying speed of the upper and lower conveyor belts is 12m / min;

[0069] (3) The heated sheet is continuously conveyed to the cooling zone. The cooling water temperature of the upper and lower cooling devices in the cooling zone is set to 30℃. The distance between the upper and lower conveyor belts in the heating zone is set to 7.8mm. The conveying speed of the upper and lower conveyor belts is 13m / min. The length of the cooling zone is 3m.

[0070] After the above treatment, the maximum wave height of the sheet was reduced from 50mm to 22mm; the wave reduction rate reached 56%.

[0071]

Example 9

[0072] The apparatus for continuous processing of corrugated car roof sheets is basically the same as that in Example 1, except that the conveyor belt in the conveying area is made of polyester fiber cloth plus polyvinyl chloride adhesive.

[0073] (1) Place the corrugated car roof sheet with a maximum wave height of 79mm, a thickness of 10mm and a length of 2.5m on the conveyor belt in the conveying area, with a spacing of 3cm between each sheet, and set the speed of the conveyor belt in the conveying area to 12m / min.

[0074] (2) The sheet material is conveyed from the conveying area to the heating area; the temperature of the first and second heating devices is set to 140℃, the temperature of the third and fourth heating devices is set to 180℃, and the temperature of the fifth and sixth heating devices is set to 200℃; the length of each heating device is 3m; the distance between each heating area is 10cm; the distance between the upper and lower conveyor belts of the heating area is set to 11.0mm; the conveying speed of the upper and lower conveyor belts is 15m / min;

[0075] (3) The heated sheet is continuously conveyed to the cooling zone. The cooling water temperature of the upper and lower cooling devices in the cooling zone is set to 40℃. The distance between the upper and lower conveyor belts in the heating zone is set to 11.0mm. The conveying speed of the upper and lower conveyor belts is 15m / min. The length of the cooling zone is 3m.

[0076] After the above treatment, the maximum wave height of the sheet was reduced from 79mm to 28mm; the wave reduction rate reached 64.6%.

[0077]

Comparative Example 1

[0078] By stacking heavy objects on top of 100 corrugated car roof panels at a time and placing them at room temperature for 48 hours, the maximum corrugation height was measured as follows:

[0079]

[0080] [Comparative Example 2]

[0081] By stacking heavy objects on top of 100 corrugated car roof panels per roll and placing them in a 100-degree oven for 24 hours, the maximum corrugation height was measured as follows:

[0082]

[0083] As can be seen from the comparison, the existing processing methods are not as effective as the continuous processing method of the present invention in improving the wavy shape, and they are also time-consuming (the present invention processes 100 wavy semi-rigid polyurethane foam sheets in a single batch in no more than 1 hour).

[0084] The above description is merely a typical embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications, alterations, or equivalent changes made to the above embodiments based on the method of the present invention shall fall within the protection scope of the present invention.

Claims

1. A method for continuous processing of corrugated automotive roof sheet material, comprising the following processing steps in sequence: a) Place the corrugated car roof sheet with a wave height of 20-80mm and a thickness of 5-10mm on the conveyor belt and continuously transport it from the conveying area to the heating area; b) The corrugated car roof sheet is then continuously transported from the heating zone to the cooling zone; the time for the sheet to pass through the heating zone is 30-60 seconds; c) After the corrugated car roof sheet passes through the cooling zone, the time for the sheet to pass through the cooling zone is 10-60 seconds; thus, the processed car roof sheet is obtained. in, The heating zone consists of three heating zones at different temperatures: Zone I, Zone II, and Zone III. Each heating zone, from top to bottom, includes an upper heating device, an upper conveying device, a lower conveying device, and a lower heating device. The cooling zone, from top to bottom, includes a first cooling device, an upper conveying device, a lower conveying device, and a second cooling device. The conveyor belts of the heating and cooling zones are made of fiberglass cloth coated with Teflon resin. The upper heating device consists of a first, third, and fifth heating device with independent temperature control. The lower heating device consists of a second, fourth, and sixth heating device with independent temperature control. The temperatures of the first and second heating devices are set to 50–140°C, the third and fourth heating devices to 80–180°C, and the fifth and sixth heating devices to 110–200°C. The temperature of the cooling zone is set to 20–40°C.

2. The method for continuous processing of corrugated automotive roof sheet according to claim 1, characterized in that, The heating method of the heating device in the heating zone is selected from heating tube heating or oil heating; the cooling method of the cooling device in the cooling zone is cooling water cooling.

3. The method for continuous processing of corrugated automotive roof sheet according to claim 1, characterized in that, The lengths of heating zone I, heating zone II, and heating zone III are 1–3 m, and the length of cooling zone is 1–10 m. The spacing between the corrugated car roof sheet to be processed during conveying in the conveying zone is controlled at 1–3 cm. The distance between the heating device in the heating zone and the conveyor belt is 0–20 mm, and the distance between the cooling device in the cooling zone and the conveyor belt is 0–20 mm.

4. The method for continuous processing of corrugated automotive roof sheet according to claim 1, characterized in that, The interval between the conveying zone and the heating zone is 10-30cm, and the interval between the heating zone and the cooling zone is 10-30cm.

5. The method for continuous processing of corrugated automotive roof sheet according to claim 1, characterized in that, The conveying speed of the heating zone is the same as or slightly faster than that of the conveying zone; the conveying speed of the cooling zone is the same as or slightly faster than that of the heating zone.

6. The method for continuous processing of corrugated automotive roof sheet according to claim 1, characterized in that, The spacing between the upper and lower conveyor belts in the heating zone is 0.5 to 1.5 mm higher than the sheet thickness; the spacing between the upper and lower conveyor devices in the cooling zone is 0.2 to 1.2 mm higher than the sheet thickness.

7. The method for continuous processing of corrugated automotive roof sheet according to claim 1, characterized in that, The conveyor belt in the conveying area is made of polyester fiber cloth covered with one of polyurethane adhesive, polyethylene adhesive or polyvinyl chloride adhesive.

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