Calender, foam floor production line and one-step molding production process

Abstract

A calender includes a machine base and a calender roller group arranged on the machine base, characterized in that the calender roller group includes a main calender roller group and an embossing roller group for embossing the material to be processed, and the main calender roller group and the embossing roller group are spaced a certain distance apart so that the material can be cooled before entering from one roller group to another roller group. The calender can achieve a better embossing effect. The calender is used in the production of foamed bottom plates to realize the integrated production of foamed bottom plates.

Description

Technical Field

[0001] The invention relates to a processing machine, a foam floor processing production line and a one-step forming production process of the foam floor. Background Art

[0002] Compared with traditional wooden floors, foam floors have the following advantages: (1) soft texture, good moisture and water resistance, good elasticity, good elastic recovery under heavy impact, and not easy to be damaged; (2) green and environmentally friendly, a recyclable product; (3) good flame retardancy and high safety factor; (4) low cost, cheaper than wooden floors; etc. Based on the above, foam floors have great development prospects and application space.

[0003] Foam flooring is usually produced by composite processing of multiple layers of materials. For example, taking WPC foam flooring as an example, it usually includes a middle foam layer and solid layers covering both sides of the middle foam layer. According to processing requirements, an anti-slip layer can be set on the surface of one solid layer, and a color film layer can be set on the surface of another solid layer as a decorative layer. At the same time, a wear-resistant layer is set to enhance the wear resistance of the floor and extend its service life.

[0004] The processing of foam flooring requires the use of a calender, which usually includes more than two rollers, including mirror rollers, embossing rollers, anilox rollers, matte rollers, etc. Each roller has different functions. The calender completes different processing requirements for the materials to be processed by combining different rollers and controlling the temperature of the rollers. Taking the processing of PVC foam flooring as an example, its processing technology includes thickness calendering, anilox calendering on the bottom of the floor, and pattern calendering on the surface of the floor. In the prior art, it is usually embossed directly after mirror calendering with a mirror roller. Since the temperature of the PVC foam floor is relatively high after being discharged from the mirror roller, it is affected by the foaming properties of the floor. At this time, the embossing effect is usually not good, which will cause poor embossing effect on one side, and the pattern will rebound after embossing.

[0005] PVC (stone plastic) foam flooring and WPC (wood plastic) foam flooring are both environmentally friendly composite flooring. Their structure usually includes a middle foam layer and solid layers on both sides of the foam layer. The main difference between the two is the different ratios of PVC and calcium powder in the foam layer and solid layer.

[0006] In general, since the price of calcium powder is relatively lower than that of powdered PVC, in order to reduce costs, PVC (stone plastic) foam flooring usually uses a larger amount of calcium powder. But on the other hand, the density of calcium powder is relatively large, and this ratio will lead to an increase in the quality of the floor.

[0007] For example, according to design requirements, PVC (stone plastic) foam flooring, the foam layer and the solid layer choose to use a larger amount of calcium powder, such as the ratio of powder PVC to calcium powder is 1:2 or 1:3. Calcium powder is low in price and high in density. Therefore, the weight of the PVC floor is heavier, the cost of PVC floor is relatively low, and the price is also relatively low.

[0008] For WPC (wood plastic) foam floor, the proportion of calcium powder is reduced. The ratio of solid layer powder PVC to calcium powder can still be selected as 1:2 or 1:3 (or other ratios), while the foam layer will use less calcium powder, for example, the ratio of powder PVC to calcium powder can be selected as 1:1, which reduces the amount of calcium powder and thus reduces the overall weight of the floor. Although the cost of the floor will increase, it meets people's increasing requirements for quality.

[0009] This change in the raw material ratio will directly lead to a change in the foaming properties of the raw materials, and put forward new requirements for the equipment and process of producing the floor.

[0010] In the prior art, the production process of WPC (wood plastic) foam floor is as follows: extrusion substrate - sanding surface - gluing - laminating - stacking - cold pressing - curing (placed in a constant temperature workshop for a period of time) - slitting - slotting - testing and packaging - palletizing - storage and boxing. On the one hand, the aforementioned foam layer, solid layer, color film layer, wear-resistant film layer and other composite materials are glued together, which is inefficient and not environmentally friendly; on the other hand, each process is carried out in sections, and each process requires a dedicated machine and a dedicated person to operate, which is time-consuming and laborious. There is no production process in the prior art that can achieve the one-time molding production of WPC (wood plastic) foam floor.

[0011] In order to realize streamlined operation, foam floor production lines have appeared in the prior art. For example, Chinese patent CN105459422A discloses a one-time processing PVC floor forming mechanism, including a mixer, an extruder, a feeder, a mold, a calender, etc. Various powders are mixed and extruded, and the blanks processed by the mold directly enter the roller assembly of the calender to complete a series of calendering, film laminating, embossing and other process processes.

[0012] Another example is a four-roller calendering and laminating production device for the surface film of PVC stone plastic floor disclosed in Chinese patent CN205553494U, which provides a calender for stone plastic floor production, including an upper mirror roller, a lower mirror roller, a shading roller and an embossing roller. The blank directly enters the shading roller and the embossing roller after passing through the mirror roller. On the one hand, as mentioned above, this embossing method is difficult to ensure the embossing effect. On the other hand, this production equipment for stone plastic floor cannot be directly copied for the production of wood plastic foam floor, and requires a set of improved structures and improved processing technology.

[0013] The production equipment and production method disclosed in the above patent are not suitable for one-step addition molding production of WPC wood plastic foam floor.

[0014] The above traditional processing technology has the following problems: Due to the change in the ratio of PVC material and calcium powder, the performance of the material will change, which will lead to corresponding changes in the control of the material foaming process and the material coating process. Since the rollers of the calender are all in a high-temperature state, the foaming performance of the blank will be affected during the entire processing process of the mixer, extruder, mold, and calender. After the finished blank is discharged from the high-temperature mold, it directly enters the high-temperature roller. During the entire calendering and embossing process, the blank is always in a high-temperature state, which will further affect the calendering and embossing performance. Similar to the adverse effects described above, there are problems such as embossing failure or pattern rebound after embossing. This problem can be improved by changing the overall structure of the calender, studying a set of effective temperature control strategies, and improving the performance of the blank by controlling the temperature of the rollers and the temperature of the blank. Summary of the invention

[0015] The purpose of the present invention is to provide a calender that can achieve a better embossing effect. At the same time, in view of the problems existing in the existing foam floor production process, especially the WPC wood plastic foam floor production process, a production line for the production of WPC wood plastic foam floor with high production efficiency and good processing quality is provided, and a foam floor production process is provided that improves the processing performance of the WPC wood plastic foam floor and improves the processing quality by controlling the temperature of the material embryo and the calender roller.

[0016] To achieve the above objectives, the present invention provides the following contents:

[0017] The calender includes a machine base and a calender roller group arranged on the machine base; the calender roller group includes a main calender roller group and an embossing roller group for embossing the material to be processed; the main calender roller group mentioned here refers to a roller group composed of calender rollers including mirror rollers, and the main calender roller group can be all mirror rollers, or other types of calender rollers can be selected according to needs. The configuration of the embossing roller group depends on the embossing requirements. For example, some materials need to be embossed on both sides, while some only need to be embossed on one side. Different requirements require different configurations. According to processing requirements, the main calender roller group completes one or more of the process flows of flattening, film lamination, matting, and frosting. In order to ensure that the embossing effect is not destroyed, the embossing process is usually completed after the above processes. Therefore, according to the material processing flow, the calender roller group sequentially includes the main calender roller group and the embossing roller group for embossing the material to be processed. The main calendering roller group and the embossing roller group are spaced apart, specifically, the discharge end of the main calendering roller group and the feed end of the embossing roller group are spaced apart, and the two are spaced apart by a certain distance so that the material can be cooled before entering the other roller group from one roller group. For example, according to the common processing flow, the material can be cooled before the discharge end of the mirror roller group and the feed end of the embossing roller group. This distance is not a fixed distance, and depends on the processing requirements. For example, it can be 0.5m, 0.8m, 1m, etc.

[0018] Preferably, a cooling roller group is provided between the main calendering roller group and the embossing roller group, for example, a cooling roller group is provided between the final discharge end of the main calendering roller group and the feed end of the embossing roller group. For a structure without a cooling roller group, the material is cooled naturally, and the auxiliary design of the cooling roller group can speed up the cooling speed of the material, so that the distance between the mirror roller group and the embossing roller group can be reduced accordingly, making the calender structure more compact.

[0019] Preferably, along the material processing flow, the calender includes a cooling and shaping device, a main calendering roller group and an embossing roller group in sequence, wherein the cooling and shaping device is used to shape the material by cooling.

[0020] Preferably, the cooling and shaping device comprises a first cooling component and a second cooling component which are spaced apart, wherein the gap between the first cooling component and the second cooling component can accommodate the passage of the material to be processed and ensure that the material to be processed contacts both the first cooling component and the second cooling component when passing through the material to be processed so as to be cooled and shaped.

[0021] Preferably, the cooling and shaping device comprises a first cooling component and a second cooling component which are spaced apart.

[0022] Preferably, the cooling and shaping device includes a first cooling roller and a second cooling roller arranged in pairs, or a first cooling shaping plate and a second cooling shaping plate arranged in pairs, or a combination of a first cooling roller and a second cooling roller arranged in pairs and a first cooling shaping plate and a second cooling shaping plate arranged in pairs. Specifically, according to the cooling and shaping requirements of different processed materials, the first cooling roller and the second cooling roller arranged in pairs can be selected as the cooling and shaping device, so that the material passes through the gap between the two rollers for cooling and shaping; the first cooling shaping plate and the second cooling shaping plate can also be selected as the cooling and shaping device, so that the material passes through the gap between the two shaping plates for cooling and shaping; or a combination of two groups of cooling devices including the first cooling roller and the second cooling roller and the first cooling shaping plate and the second cooling shaping plate can be selected as the cooling and shaping device, so that the material passes through the two groups of cooling devices in turn. The first cooling roller and the second cooling roller are both provided with cooling channels for passing coolant; the first cooling shaping plate and the second cooling shaping plate are also both provided with cooling channels for passing coolant.

[0023] Preferably, along the material processing flow, the cooling and shaping device sequentially includes a first cooling and shaping plate and a second cooling and shaping plate arranged in pairs and at intervals, and a first cooling roller and a second cooling roller arranged in pairs and at intervals. For materials that require a flat surface, the combination of shaping plates has a better shaping effect than the combination of rollers. After the material is first cooled and flattened by the shaping plate, the shape of the material has been basically formed, and then it is assisted by the combination of cooling rollers for flattening, which can achieve a better flattening effect.

[0024] Preferably, the embossing roller group includes a pattern roller or an anilox roller, or a combination of a pattern roller and an anilox roller, and the pattern roller and the anilox roller are configured to contact different embossed surfaces of the material to be processed. Taking floor processing as an example, the pattern roller is arranged on the side in contact with the top surface of the floor, and the anilox roller is arranged on the side connected with the bottom surface of the floor. According to the embossing requirements, the structure of the embossing roller group can also be improved. For example, when only single-sided embossing is required, only a pattern roller or anilox roller can be configured.

[0025] Preferably, the calender further includes a film unwinding mechanism, and a guiding laminating mechanism for guiding the film unwinding the film unwinding the film unwinding mechanism to the main calender roller group, wherein the guiding laminating mechanism includes a guide wheel and a laminating roller arranged with a gap between the calender rollers in the main calender roller group. The guide wheel can be a single guide wheel or a guide wheel group, and its function is to cooperate with the laminating roller to guide the film unwinding the film unwinding the film unwinding mechanism to the required position. The laminating roller is arranged at a position close to the calender rollers in the main calender roller group, so that the material is laminating the required film before passing through the gap between the calender rollers in the main calender roller group. The main calender roller group may include multiple calender rollers, and the specific calender roller to which the position is directed depends on the processing requirements.

[0026] Preferably, the film-applying and unwinding mechanism includes one of the following: a base film-applying and unwinding mechanism for rolling up a base film, a color film-applying and unwinding mechanism for rolling up a color film, and a wear-resistant film-applying and unwinding mechanism for rolling up a wear-resistant film, or any combination of the three; and if the base film-applying and unwinding mechanism is configured to guide the base film to one side of the material, the color film-applying and unwinding mechanism and the wear-resistant film-applying and unwinding mechanism are configured to guide the color film and the wear-resistant film to the other side of the material. The types of films applied will be different depending on the processing requirements. For example, floor processing may require one of the base film, color film or wear-resistant film, or a combination of two or three. According to the requirements, the corresponding film-applying and unwinding mechanism is configured. Since the base film and the other two films (color film and wear-resistant film) are usually attached to different sides of the floor, the base film is attached to the side close to the ground, and the color film and the wear-resistant film are attached to the side away from the ground, therefore, the positions to which the films are directed are different.

[0027] Preferably, the laminating roller further comprises an auxiliary laminating roller arranged at the rear end of the laminating roller, configured at the same calendering roller as the laminating roller, and arranged with a gap from the calendering roller. The laminating roller first laminates the film, and the auxiliary laminating roller further assists in laminating to ensure that the film is laminated more firmly.

[0028] Preferably, the laminating roller and the auxiliary laminating roller are each connected to a gap adjustment device for adjusting the gap between the laminating roller and the calendering roller in the main calendering roller group. This structure can adapt to the different material thicknesses and material thickness processing requirements, adjust the gap between the laminating roller and the auxiliary laminating roller and the calendering roller, and ensure the laminating quality and material thickness processing requirements.

[0029] A foam floor production line comprises the above calender.

[0030] The one-step forming process of the foam floor is realized based on the above foam floor production line, and includes the following steps: after the material is discharged from the main calendering roller group, it is cooled and then enters the embossing roller group for embossing. The temperature of the material after cooling depends on the material characteristics and embossing requirements, and is not a fixed value.

[0031] Preferably, the method further comprises the following steps: the material first passes through a cooling and shaping device for cooling and shaping, and then enters the main calendering roller group. The purpose of cooling and shaping is to avoid the material embryo from wavy bending and ensure the final processing quality.

[0032] Preferably, according to the processing flow, the main calendering roller group includes, in sequence, a first mirror roller, an intermediate mirror roller and a calendering roller at the discharge end, and the temperature of the calendering roller at the discharge end is higher than that of the first mirror roller. The first mirror roller is a calendering roller close to the discharge end of the cooling and shaping device in the processing flow; the calendering roller at the discharge end is a calendering roller close to the embossing roller group in the processing flow; and the intermediate mirror roller is a transitional calendering roller through which the material passes from the first mirror roller to the calendering roller at the discharge end.

[0033] Preferably, according to the processing flow, the main calendering roller group includes, in sequence, a first mirror roller, an intermediate mirror roller group consisting of at least two intermediate mirror rollers and a discharge end calendering roller, the temperature of the first mirror roller and the intermediate mirror roller adjacent thereto is set to 30-90°C, the temperature of the discharge end calendering roller is set to 150-190°C, the temperature of the intermediate mirror roller adjacent to the discharge end calendering roller is set to 90-170°C, the temperature of the pattern roller is set to 150-190°C, and the temperature of the anilox roller is set to 150-190°C.

[0034] Preferably, the production line further comprises a mixer and a feeder. After the materials enter the mixer, they are mixed with cold materials during heating and stirring, and then sent to the feeder after cooling.

[0035] The beneficial effects of the present invention are:

[0036] (1) The present invention provides a one-step forming process for WPC wood plastic foam flooring, which specifically includes: one-step forming - curing - slitting - slotting - testing and packaging - palletizing - warehousing and boxing. Compared with the traditional production process, this process omits the steps of gluing and laminating, saving equipment and space. Since the film is no longer pasted with adhesive, materials can be saved and the environmental performance of the foam floor can be improved; since sanding is not required, dust pollution can be reduced; the production line adopts streamlined operation, which can save labor costs.

[0037] (2) The mirror roller group and embossing roller group of the calender are set separately. When the material moves between the two mirror roller groups, it can be cooled naturally, or a cooling roller can be designed for auxiliary cooling. During the cooling process, the properties of the material will change, which is conducive to ensuring the quality of subsequent processing. For example, during the floor processing, after the material is discharged from the mirror roller group, it will pass a certain distance before entering the embossing roller group. During this process, the temperature of the floor will decrease, which can achieve a better embossing effect.

[0038] (3) Aiming at the processing of WPC wood plastic foam floor, the present invention studies a set of temperature control strategies. By setting the temperature of the main calendering roller group and the embossing roller group, coordinating the cooling device, and the structural design of the cooling section between the main calendering roller group and the embossing roller group, and coordinating the material modification during the high and low temperature process, the foaming performance and embossing effect of the finished product can be greatly improved, and the scrap rate can be reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 A schematic diagram of the structure of a calender in one embodiment;

[0040] Figure 2 A schematic diagram of the structure of the main calendering roller group and the embossing roller group;

[0041] Figure 3It is a schematic diagram of the structure of a calender in another embodiment;

[0042] Figure 4 It is a schematic diagram of the cooling and shaping device mechanism;

[0043] Figure 5 It is a schematic diagram of the structure of a calender in another embodiment;

[0044] Figure 6 It is a schematic diagram of the structure of a calender in another embodiment;

[0045] Figure 7 A simplified structural schematic diagram of a calender in another embodiment;

[0046] Figure 8 This is a structural diagram of a foam base plate production line;

[0047] Fig. 9 This is a schematic diagram of the production line structure from a top view.

[0048] Among them: 1-machine base, 201-first mirror roller, 202-first intermediate mirror roller, 203-second intermediate mirror roller, 204-matt roller, 3-base film winding mechanism, 301-base film laminating roller; 401-pattern roller, 402-anilox roller, 5-cooling roller, 6-wear-resistant film winding mechanism, 601-wear-resistant film, 7-color film winding mechanism, 701-color film, 8-auxiliary laminating roller, 801-gap adjustment cylinder, 901-wear-resistant film guide wheel, 902-wear-resistant film laminating roller, 1001-color film guide wheel, 1002-color film laminating roller, 1003 -gap adjusting cylinder, 1101-first cooling roller, 1102-second cooling roller, 1103-gap adjusting cylinder, 1201-first shaping plate, 1202-second shaping plate, 1203-gap adjusting cylinder, 13-gap adjusting cylinder, 14-mixer, 15-loader, 16-extruder, 1601-first extruder, 1602-second extruder, 17-mold, 18-calender, 19-cooling bracket, 20-traction machine, 21-arch bracket, 22-precision shearing machine, 23-conveyor bracket, 24-automatic plate lifting machine. DETAILED DESCRIPTION

[0049] The specific implementation of the present invention will be described clearly and completely below in conjunction with the accompanying drawings. Obviously, the embodiments described in the specific implementation are only part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0050] It should be noted that in this embodiment, the "bottom surface" refers to the side of the floor that contacts the ground after installation, and the "top surface" refers to the side of the floor that contacts the user after installation, and they should not be understood as limiting the present invention. In addition, the terms "first", "second", and "third" are used for descriptive purposes only and should not be understood as indicating or implying relative importance. The "traveling direction" and "material direction" described in this embodiment are used to assist in indicating the processing flow of materials, "front" and "front end" are used to indicate the process that is completed first in the processing flow, and "rear" and "rear end" are used to indicate the process that is completed later in the processing flow.

[0051] Example 1

[0052] This embodiment provides a calender, which is used for one-step molding production of WPC wood plastic flooring, and can complete one-step molding processing of the process flow such as foaming of the material to be processed, embossing or embossing on both sides of the bottom and top surfaces. This embodiment uses WPC wood plastic foam flooring as the material to be processed. In actual application, the material to be processed is not limited to foam flooring.

[0053] The calender includes a machine base 1 and a calendering roller group arranged on the machine base 1. According to the material processing flow (foam floor in this embodiment), the calendering roller group sequentially includes a mirror roller group and an embossing roller group for double-sided embossing of the foam floor.

[0054] A schematic diagram of a calender implementation method Figure 1 .

[0055] Among them, the main calendering roller group refers to a roller group composed of calendering rollers including mirror rollers. The main calendering roller group can be all mirror rollers, or other types of calendering rollers can be selected according to needs. According to the processing flow (the order of the material running between the calendering rollers of the main calendering roller group), the main calendering roller group includes the first mirror roller, the intermediate mirror roller group composed of intermediate mirror rollers, and the discharge end calendering roller, which are arranged in sequence in a gap. The material passes through the gap between each adjacent calendering roller. The feeding end between the first mirror roller in contact with the material and the adjacent intermediate mirror roller is the initial feeding end of the main calendering roller group; the feeding end of the material to be processed between the intermediate mirror rollers and between the intermediate mirror roller and the discharge end calendering roller is the inter-roller feeding end, and the discharge end of the discharge end calendering roller and the adjacent intermediate mirror roller is the final discharge end of the main calendering roller group. The discharge end calendering roller can be selected as various forms of calendering rollers, depending on the processing requirements.

[0056] Taking a specific implementation structure as an example, in this embodiment, the main calendering roller group includes a first mirror roller 201, a first intermediate mirror roller 202, a second intermediate mirror roller 203 and a matte roller 204 (the matte roller 204 can also be replaced by other types of calendering rollers such as mirror rollers and frosted rollers) arranged in a gap. The first mirror roller 201 and the first intermediate mirror roller 202 face the incoming material at one end as the initial feeding end of the main calendering roller group. After the material enters from the feeding end, it passes through the gap between the two and then enters the gap between the first intermediate mirror roller 202 and the second intermediate mirror roller 203. The first mirror roller 201 and the first intermediate mirror roller 202 are both connected to a motion drive mechanism, and the rotation directions of the two are opposite (the rotation direction refers to the arrow direction in the figure); the second intermediate mirror roller 203 and the matte roller 204 are also connected to a motion drive mechanism, and the rotation directions of the two are opposite (the rotation direction refers to the arrow direction in the figure). The discharge ends of the second intermediate mirror roller 203 and the matte roller 204 are the final discharge ends of the mirror roller group. The floor enters the embossing roller group through the final discharge end of the main calendering roller group to perform the embossing process.

[0057] In actual application, the number of intermediate mirror rollers and the spacing between the mirror rollers can be configured in combination with the material conditions and the requirements of mirror calendering. For example, three intermediate mirror rollers can be used. Alternatively, a more streamlined structure can be configured without configuring the intermediate mirror rollers and only the first mirror roller 201 and the discharge end calendering roller can be selected.

[0058] The embossing roller group includes a pattern roller 401 and an anilox roller 402 arranged in a gap, and the pattern roller and the anilox roller are configured to contact different embossed surfaces of the material to be processed. Specifically, the anilox roller 402 is placed on the side in contact with the bottom surface of the foam floor, and the pattern roller 401 is placed on the side in contact with the top surface of the foam floor. After the foam floor is discharged from the discharge end of the mirror roller group, it enters the gap between the pattern roller 401 and the anilox roller 402, and the pattern roller 401 and the anilox roller 402 respectively complete the embossing treatment on both sides of the WPC wood-plastic foam floor.

[0059] It should be noted that this embodiment uses the double-sided embossing of WPC wood plastic flooring to illustrate the structure of the calender. In actual application, if the top surface embossing is not required, the pattern roller 401 can be omitted, and a mirror roller can be configured at the end in contact with the top surface of the floor to replace the pattern roller 401; if the ground surface embossing is not required, the anilox roller 402 can be omitted, and a mirror roller can be configured at the end in contact with the ground surface of the floor to replace the anilox roller 402.

[0060] Since the temperature of the calendering rollers in the main calendering roller group and the embossing roller group is usually high, if the material directly enters the embossing roller group from the final discharge end of the calendering roller group, under high temperature, the material has good elasticity and thermal expansion, and most of the embossed patterns will bounce up, resulting in poor embossing effect.

[0061] In order to solve this problem, the final discharge end of the main calendering roller group and the feed end of the embossing roller group are separated by a certain distance, so that the material can be cooled before passing through the discharge end of the main calendering roller group and the feed end of the embossing roller group. Figure 2 . This distance is set according to multiple parameters such as material properties and material thickness, and is not a fixed value. For example, this embodiment takes the processing of foam flooring as an example, and this distance is 100cm (it should be noted that this distance cannot be too far, just leave a certain distance and then emboss the pattern. If the distance is too far or the cooling is too large, the embossed pattern will have no texture). Since the material has been cooled before entering the embossing roller, it has cold shrinkage, and then it is embossed at high temperature, so the pattern quality is high. Taking the processing of foam flooring as an example, after traveling a certain distance, it is cooled to about 110-130℃, depending on the thickness of the wear-resistant film and the thickness of the foam flooring. The embossing effect is good, depending on the material properties and requirements.

[0062] The floor can be cooled by air by setting the main calendering roller group and the embossing roller group at intervals. In order to achieve a better cooling effect and accelerate the cooling speed of the foamed floor, a cooling roller group is set between the discharge end of the mirror roller group and the feed end of the embossing roller group. The cooling roller 5 has the function of cooling and guiding. The foamed floor moves over the cooling roller 5, and enters the feed end of the embossing roller group after being further cooled by the cooling roller 5. After setting the cooling roller 5, the distance between the main calendering roller group and the embossing roller group can be reduced. For example, in this embodiment, this distance can be reduced to 80 cm. This is conducive to reducing the volume of the entire calender.

[0063] As an auxiliary design, in order to ensure that the foam floor can smoothly run from the anilox roller group to the embossing roller group, an embossing guide mechanism is further included to guide the WPC wood plastic foam floor from the discharge end of the mirror roller group to the embossing roller group. For example, the embossing guide mechanism is a guide wheel group composed of a plurality of guide wheels.

[0064] During the production process, there is another problem that will lead to low product quality and affect the embossing quality. The calender usually processes flat materials, usually by putting the hot extruded materials into the calender for processing. However, the hot extruded materials after being processed by the extruder and the mold cannot guarantee good flatness, and are usually wavy and curved.

[0065] In order to make the material have better flatness before entering the calender, according to the material processing flow, it further includes a cooling and shaping device arranged in front of the initial feeding end of the main calender roller group for cooling and shaping the material to be processed.

[0066] Calender structure reference equipped with cooling and shaping device Figure 3 , Figure 4 .

[0067] The structure of the cooling and shaping device in this embodiment is as follows.

[0068] The cooling and shaping device is arranged at the front end of the feeding end of the first mirror roller 201 and the first intermediate mirror roller 202 along the incoming material direction, and includes a cooling roller group, specifically including a first cooling roller 1101 and a second cooling roller 1102 arranged in a gap, and the first cooling roller 1101 and the second cooling roller 1102 are both provided with cooling pipelines for adding coolant, and the first cooling roller 1101 and / or the second cooling roller 1102 are connected to a cooling gap adjustment device. In this embodiment, the first cooling roller 1101 is located above the second cooling roller 1102, and the first cooling roller 1101 is connected to a gap adjustment device, which is a gap adjustment cylinder 1103.

[0069] The cooling shaping device further includes a first shaping plate 1201 and a second shaping plate 1202 which are installed in pairs and at intervals. The first shaping plate 1201 and the second shaping plate 1202 are provided with cooling pipelines for adding coolant, and at least one shaping plate is provided with a shaping gap adjustment device. In this embodiment, the first shaping plate 1201 is located above the second shaping plate 1202, and the first shaping plate 1201 is provided with a gap adjustment device, which is a gap adjustment cylinder 1203.

[0070] Along the incoming direction, the first shaping plate 1201 and the second shaping plate 1202 are located at the front end of the cooling roller group. During the processing, the WPC wood plastic foam floor first passes through the shaping plate to extrude, cool and shape the WPC wood plastic foam floor, and then passes through the cooling roller group for auxiliary extrusion, cooling and shaping, and then enters the mirror roller. In order to ensure that the WPC wood plastic foam floor can pass through the cooling and shaping device smoothly, the gap between the first cooling roller 1101 and the second cooling roller 1102 and the gap between the shaping plates are located at the same level.

[0071] According to the requirements of cooling and shaping, the combination of the first cooling roller 1101 and the second cooling roller 1102 or the combination of the first shaping plate 1201 and the second shaping plate 1202 may also be omitted.

[0072] Hereinafter, another structure of a calender is further provided, which is a calender having the function of laminating and calendering the material to be processed. The foam floor is still used as the material to be processed to illustrate its structure and implementation process.

[0073] The structure of this calender refers to Figure 5 and Figure 6 .

[0074] Different from the above calender structure, it further includes a laminating film unwinding mechanism, which includes one or more of the base film unwinding mechanism 3, the wear-resistant film unwinding mechanism 6 and the color film unwinding mechanism 7. The laminating film unwinding mechanisms described herein all include two unwinding wheels, one of which performs the main work and the other serves as a backup during the film unwinding process.

[0075] Figure 5 Shown is a schematic diagram of the structure of a calender including a wear-resistant film unwinding mechanism 6 and a color film unwinding mechanism 7; Figure 6 What is shown is a schematic diagram of the structure of a calender including a base film unwinding mechanism 3 , a wear-resistant film unwinding mechanism 6 and a color film unwinding mechanism 7 .

[0076] In this embodiment, the laminating film unwinding mechanism includes a base film unwinding mechanism 3 for unwinding the base film, a wear-resistant film unwinding mechanism 6 for unwinding the wear-resistant film 601, and a color film unwinding mechanism 7 for unwinding the color film 701. The calender further includes a base film guiding laminating mechanism for guiding and conveying the base film to the feeding end between the rollers of the main calendering roller group, a wear-resistant film guiding laminating mechanism for guiding and conveying the wear-resistant film 601 to the feeding end between the rollers of the main calendering roller group, and a color film guiding laminating mechanism for guiding and conveying the color film 701 to the feeding end between the rollers of the main calendering roller group.

[0077] Specifically, referring to the structure of the main calendering roller group in the above-mentioned calendering machine, the wear-resistant film 601 and the color film 701 are both guided to the front of the feed end between the second intermediate mirror roller 203 and the matte roller 204; the base film is guided to the front of the feed end between the first intermediate mirror roller 202 and the second intermediate mirror roller 203, so as to achieve the base film and the other two films being bonded to different surfaces of the floor.

[0078] It should be noted that, in actual application, the base film, color film 701 and wear-resistant film 601 are not limited to being guided to the above-mentioned positions, as long as lamination according to the fitting surface can be achieved. For example, the color film 701 and the wear-resistant film 601 can also be guided to the initial feeding end of the main calendering roller group, and the base film can also be guided to the final discharging end of the main calendering roller group.

[0079] The wear-resistant film guide laminating mechanism includes a wear-resistant film guide wheel 901 and a wear-resistant film laminating roller 902, and the color film guide laminating mechanism includes a color film guide wheel 1001 and a color film laminating roller 1002. The wear-resistant film laminating roller and the color film laminating roller are both connected with a gap adjustment device for adjusting the gap between each and the intermediate mirror roller (specifically, the second intermediate mirror roller 203), wherein the wear-resistant film laminating roller 902 is connected with a gap adjustment cylinder 903, and the color film laminating mechanism is connected with a gap adjustment cylinder 1003. Since the color film 701 is firstly pasted during the processing, and the wear-resistant film 601 is pasted on the surface of the color film 701, the wear-resistant film laminating roller 902 is located behind the color film laminating roller 1002 along the conveying direction of the processing material. Similarly, the base film guide laminating mechanism includes a base film laminating roller 301 which is set with a gap with the first intermediate mirror roller 202, and is also connected with a gap adjustment cylinder 13.

[0080] According to the processing flow, it further includes an auxiliary laminating roller which is arranged at the rear end of the laminating roller, configured at the same calendering roller as the laminating roller, and is arranged with a gap between the laminating roller and the calendering roller.

[0081] In this embodiment, the auxiliary laminating roller 8 is arranged at the feeding end between the second intermediate mirror roller 203 and the matte roller 204, and the auxiliary laminating roller 8 is located behind the wear-resistant film laminating roller 902, and its function is to further press and laminate the pasted color film 701 and the wear-resistant film 601. The auxiliary laminating roller 8 is connected to a gap adjustment device for adjusting the gap between the auxiliary laminating roller 8 and the anilox roller, which is a gap adjustment cylinder 801 in this embodiment.

[0082] In addition to the above structure, an auxiliary laminating roller 8 can also be configured for laminating the base film. Correspondingly, it can be configured behind the base film laminating roller 301, at the feeding end of the first intermediate mirror roller 202 and the second intermediate mirror roller 203. The simplified structure of this structure calender is shown in FIG. Figure 7 .

[0083] The complete working process is as follows: the board blank enters the mirror roller group from the gap between the first mirror roller 201 and the first intermediate mirror roller 202, and then moves in an "S"-shaped curve with the calendering roller. Before the board blank is discharged from the first mirror roller 201 and the first intermediate mirror roller 202 and enters the gap between the first intermediate mirror roller 202 and the second intermediate mirror roller 203, it is affixed with a base film (it is optional to set an auxiliary laminating roller 8 to assist in laminating); before it moves to the roller feeding end between the second intermediate mirror roller 203 and the matte roller 204, it is firstly laminated with the color film 701 rolled up by the color film unwinding mechanism 7, during which the color film laminating roller 1002 assists in laminating; then, it is laminated with the wear-resistant film 601 rolled up by the wear-resistant film unwinding mechanism 6, during which the wear-resistant film laminating roller 902 assists in laminating; then, the auxiliary laminating roller 8 presses the wear-resistant film 601, the color film 701 and the floor board blank; after laminating, it enters between the third mirror roller and the fourth calendering roller for calendering. After being discharged from the discharge end of the second intermediate mirror roller 203 and the matte roller 204, the material enters the embossing roller group to complete the embossing and embossing process. At this point, a complete process of film lamination, bottom embossing and top embossing can be completed.

[0084] The calender provided in this embodiment can complete the whole process of material processing including cooling and shaping, calendering and shaping, double-side embossing and embossing.

[0085] Example 2

[0086] This embodiment provides a foam floor production line using the calender in Embodiment 1 for producing foam floor.

[0087] Specific reference Figure 8 According to the product production process, it includes a mixer 14 (the figure shows a mixer silo to simplify the mixer), a feeder 15, an extruder 16, a mold 17 and a calender 18. The structure of the calender 18 in the calender embodiment 1 will not be described in detail here.

[0088] The mixer 14 is used for mixing powders. Various materials for producing the foaming substrate layer are introduced into the mixer 14 for high-speed stirring and mixing. The stirred mixed materials are put into the silo of the spring feeder 15, and then the spring feeder 15 rotates and feeds the materials to the hopper of the extruder.

[0089] It should be noted that since the floor is made of multi-layer composite materials, a covering layer is provided on each side of the foam substrate layer. Before entering the mold for extrusion, the foam substrate layer and the two covering layers must be discharged. Therefore, the extruder includes two extruders, and each extruder corresponds to its own mixer and feeder. The two extruders are arranged at an angle. In this embodiment, the angle between the two extruders is 60°. Fig. 9Specifically, it includes a first extruder 1601 (corresponding to the first mixer 1401 and the first feeder 1501) for extruding the foam flooring middle layer material, and a second extruder 1602 (corresponding to the second mixer 1402 and the second feeder 1502) equipped with a distributor. The second extruder 1602 is used to extrude the covering layer material covering the two sides of the middle layer. Since the second extruder 1602 is equipped with a distributor, the extruded material is two layers of covering material covering the two sides of the foaming substrate layer respectively, and after preliminary bonding, it enters the mold.

[0090] The mold is used to process the blank, specifically, the blank is a three-layer blank in this embodiment. According to the production process, the calender is located at the rear end of the mold. Due to the high temperature of the mold, the blank will be wavy after being discharged from the mold. To solve this problem, a front-end cooling device is used to cool and shape the blank.

[0091] The cooling and shaping process is as follows: after the three-layer blank is discharged from the mold, it first enters the front-end cooling device for cooling and shaping. Specifically, after the blank is discharged from the mold, it first enters the gap between the first shaping plate 1201 and the second shaping plate 1202. The shaping plate is flat and coolant is passed into the interior to exchange heat with the blank for cooling and shaping. After cooling on the shaping plate, the three-layer blank is basically flat and then enters the gap between the first cooling roller 1101 and the second cooling roller 1102 for auxiliary cooling and shaping. During the cooling and shaping process, the gaps between the first shaping plate 1201 and the shaping plate 1202, and the gaps between the first cooling roller 1101 and the second cooling roller 1102 can be adjusted according to the demand for the blank shaping thickness. If the two gaps are large, the blank thickness after discharge is large, and if the gaps are small, the blank thickness after discharge is small.

[0092] After being discharged from the first cooling roller 1101 and the second cooling roller 1102, the blank will enter the initial feeding end of the main calendering roller group, and after going through the work process of film lamination, bottom embossing and top embossing described in Example 1, it will enter the subsequent processing steps.

[0093] Subsequent processing steps are completed by the equipment installed after the calender 18. According to the product production process and processing requirements, a cooling bracket 19, a traction machine 20, an arch bracket 21, a precision shearing machine 22, a conveying bracket 23, an automatic plate lifting machine 24, etc. are also installed after the calender to complete the cooling, shaping, cutting and other processes of the foam floor.

[0094] Example 3

[0095] This embodiment provides a one-step forming production process for foam flooring. The process specifically includes: one-step forming - curing - slitting - slotting - testing and packaging - palletizing - storage and boxing. Compared with the traditional production process, this process omits the steps of gluing and laminating, saving equipment and floor space.

[0096] The specific process includes the following steps:

[0097] Before the production line is started, the mixer 14, feeder 15, extruder 16, mold 17 and other equipment that work with temperature are preheated and kept warm in advance. The preheating time depends on the demand. In this embodiment, the preheating time is 2 hours. The purpose of heating is to allow the material to change from the previous powder to a melt before starting mixing, extrusion and other operations. The preheating stability is between 150-180°C. In this embodiment, 150°C, 160°C and 180°C are used for preheating respectively, and the working performance is not much different. If the machine is turned on and work is performed before the temperature is reached, it is easy to cause damage to the screw of the feeder 15 and the reducer of the mixer 14 and feeder 15, affecting the service life of the equipment.

[0098] First, pour the powder and auxiliary materials into the mixer 14 for hot mixing and high-speed stirring. When the stirring temperature reaches 115 degrees, add cold materials for cooling and stirring again. After the stirring temperature drops to about 30 degrees, put the stirred powder into the silo of the spring feeder 15, and then the spring feeder 15 rotates to feed the material to the hopper of the first extruder 1601. The powder described in this step includes powder for making the middle foam layer of the foam floor and powder for making the solid layer covering the two sides of the foam layer. The mixer 14 and the feeder 15 are also configured with two sets, one set for mixing and feeding the foam layer, and the other set for mixing and feeding the solid layer.

[0099] The material is pushed forward by the rotation of the screw of the extruder 16. It should be noted that the two extruders 16 work simultaneously, the first extruder 1601 extrudes the foaming layer, and the second extruder 1602 extrudes two solid layers covering the two end surfaces of the foaming layer.

[0100] The extruded material enters the wall of the die 17 and is extruded to form a floor material embryo.

[0101] Since the temperature of the mold 17 is relatively high, the floor blank coming out of the mold 17 is wavy, and is cooled and shaped by the cooling and shaping device, and then enters the initial feeding end of the main calendering roller group. Tests show that although the blank will also be shaped by the calendering roller during the process of passing through the main calendering roller group, if the front-end cooling and shaping step is omitted, the blank shaping effect is not good and the embossing effect is also affected.

[0102] According to the processing flow, the main calendering roller group includes, in sequence, the first mirror roller, the middle mirror roller and the calendering roller at the discharge end, and the temperature of the calendering roller at the discharge end is higher than that of the first mirror roller. The first mirror roller is the calendering roller close to the discharge end of the cooling and shaping device in the processing flow; the calendering roller at the discharge end is the calendering roller close to the embossing roller group in the processing flow; the middle mirror roller is the transition calendering roller through which the material passes from the first mirror roller to the calendering roller at the discharge end. The middle calendering roller is used to assist in the film laminating work, and the number of middle mirror rollers depends on the demand, which is not a fixed value and can be one, two or three. In this way, the board blank of the foam floor is gradually heated up after cooling and shaping, and the blank is gradually modified to ensure that the blank is sufficiently softened before the embossing process is performed, and good flatness is guaranteed.

[0103] The purpose of the present invention is to realize one-time processing and forming of WPC wood plastic foam floor. The proportion of solid layer PVC powder and calcium powder in WPC wood plastic foam floor is about 1:1. Since the proportion of powder changes, the control of powder and material foaming must change. Since it is necessary to complete the glue-free coating at the same time, it is necessary to ensure that the material has a certain viscosity during the calendering and foaming process. Based on the above needs, it is necessary to improve the processing technology of foam floor.

[0104] The improved processing technology is as follows.

[0105] The main calendering roller group includes, in sequence, the first mirror roller, the intermediate mirror roller group consisting of at least two intermediate mirror rollers, and the discharge end calendering roller. The temperature design of each calendering roller must follow strict standards to ensure the quality of foaming and embossing. Among them, the temperature of the first mirror roller and the intermediate mirror roller adjacent to it is set to 30-90℃, the temperature of the discharge end calendering roller is set to 150-190℃, the temperature of the intermediate mirror roller adjacent to the discharge end calendering roller is set to 90-170℃, the temperature of the pattern roller is set to 160-190℃, and the temperature of the anilox roller is set to 160-190℃. The structure of the calendering rollers in Example 1 is used to illustrate the temperatures of the various calendering rollers: wherein the temperatures of the first mirror roller 201 and the first intermediate mirror roller 202 are set to 30-90°C; the temperature of the second intermediate mirror roller 203 is set to 90-170°C; the temperature of the matte roller 204 is set to 150-190°C; the temperature of the patterned roller 401 is set to 160-190°C, and the temperature of the anilox roller 402 is set to 160-190°C.

[0106] The temperature of each calendering roller is related to factors such as the thickness of the floor and the thickness of the wear-resistant layer.

[0107] The following are several sets of specific production process data:

[0108] Production process 1: The thickness of the foamed floor is 5 mm, and the thickness of the wear-resistant layer is 0.15 mm; the mold temperature is 170°C, the temperature of the first mirror roller 201 is 30°C, the temperature of the first intermediate mirror roller 202 is 30°C, the temperature of the second intermediate mirror roller 203 is set to 130°C, the temperature of the matte roller 204 is set to 165°C, the temperature of the patterned roller 401 is set to 165°C, and the temperature of the anilox roller 402 is set to 165°C; after the foamed floor is discharged by the second intermediate mirror roller 203 and the matte roller 204, it is cooled to 110°C and then enters the embossing roller group.

[0109] Production process two: The thickness of the foamed floor is 7 mm, and the thickness of the wear-resistant layer is 0.3 mm; the mold temperature is 175°C, the temperature of the first mirror roller 201 is 60°C, the temperature of the first intermediate mirror roller 202 is 50°C, the temperature of the second intermediate mirror roller 203 is set to 90°C, the temperature of the matte roller 204 is set to 150°C, the temperature of the patterned roller 401 is set to 160°C, and the temperature of the anilox roller 402 is set to 160°C; after the foamed floor is discharged by the second intermediate mirror roller 203 and the matte roller 204, it is cooled to 120°C and then enters the embossing roller group.

[0110] Production process three: The thickness of the foamed floor is 8 mm, and the thickness of the wear-resistant layer is 0.2 mm; the mold temperature is 180°C, the temperature of the first mirror roller 201 is 70°C, the temperature of the first intermediate mirror roller 202 is 80°C, the temperature of the second intermediate mirror roller 203 is set to 160°C, the temperature of the matte roller 204 is set to 185°C, the temperature of the patterned roller 401 is set to 170°C, and the temperature of the anilox roller 402 is set to 170°C; after the foamed floor is discharged by the second intermediate mirror roller 203 and the matte roller 204, it is cooled to 125°C and then enters the embossing roller group.

[0111] Production process four: The thickness of the foamed floor is 11 mm, and the thickness of the wear-resistant layer is 0.5 mm; the mold temperature is 175°C, the temperature of the first mirror roller 201 is 90°C, the temperature of the first intermediate mirror roller 202 is 90°C, the temperature of the second intermediate mirror roller 203 is set to 170°C, the temperature of the matte roller 204 is set to 190°C, the temperature of the patterned roller 401 is set to 190°C, and the temperature of the anilox roller 402 is set to 190°C; after the foamed floor is discharged by the second intermediate mirror roller 203 and the matte roller 204, it is cooled to 130°C and then enters the embossing roller group.

[0112] The test results show that the foaming, embossing and graining effects of the above production processes are all good.

[0113] It should be noted that the temperature of the pattern roller 401 and the anilox roller 402 is mainly related to the thickness of the wear-resistant layer. Since the second intermediate mirror roller 203 and the matte roller 204 in contact with the wear-resistant layer mainly plasticize the wear-resistant layer and press the pattern on the basis of plasticization, if the temperature of the pattern roller 401 and the anilox roller 402 is too low, the embossing and graining effects are not good.

[0114] After embossing, the material is discharged from the embossing roller group, passes through the cooling bracket 19, and enters the tractor 20 (the main function of the tractor is to pull the material forward evenly). After passing through the tractor 20, it enters the arch bracket 21 (the length is about 2000mm, and the precision shearing machine 22 is used for longitudinal trimming to cut it to the desired ideal size. After cutting, it enters the conveying bracket. At the same time, the scraps are also cut. There are devices for connecting the scraps on both sides of the conveying bracket. It is transported to the position where the robot grabs it through the conveying rack. After being grabbed by the robot, it is sent to the pallet. When it reaches a certain height, the robot alarms, and then it is forked away by a forklift and put into a new pallet.

[0115] The calender and WPC wood plastic foam floor production process provided by the present invention are different from the traditional calender and production process for producing PVC stone plastic foam floor, so that the material embryo is cooled at the front end before entering the calender, and the material embryo is also cooled when entering the embossing roller group from the main calender roller group. Combined with the temperature control of the calender roller group, this process can ensure the foaming type of the material and improve the embossing effect, thereby realizing the one-time molding production of the WPC wood plastic floor.

Claims

1. A foam floor production line, used for foam floor processing, characterized by: According to the production process, the production line includes: a mixer, a feeder, an extruder, a mold and a calender in sequence. The extruder includes a first extruder and a second extruder. Each extruder corresponds to a mixer and a feeder. The two extruders are arranged at an angle. The calender includes a machine base and a calendering roller group arranged on the machine base. The calendering roller group includes a main calendering roller group and an embossing roller group for embossing the material to be processed. The embossing roller group includes a pattern roller and an anilox roller; The ratio of PVC powder to calcium powder in the solid layer is 1:1; the first extruder is used to extrude the foaming layer, and the second extruder is provided with a distributor for extruding the solid layer covering both sides of the foaming layer; the foaming layer and the solid layers on both sides enter the mold after preliminary bonding; The main calendering roller group includes, in sequence, a first mirror roller, an intermediate mirror roller group consisting of at least two intermediate mirror rollers, and a discharge end calendering roller; the temperature of the first mirror roller and the intermediate mirror rollers adjacent thereto is set to 30-90°C, the temperature of the discharge end calendering roller is set to 150-190°C, the temperature of the intermediate mirror roller adjacent to the discharge end calendering roller is set to 90-170°C, the temperature of the pattern roller is set to 160-190°C, and the temperature of the anilox roller is set to 160-190°C; The main calendering roller group and the embossing roller group are spaced a certain distance apart so that the material is cooled by air before it passes from one roller group to the other roller group; The calender further comprises a film rolling mechanism, and a guide laminating mechanism for guiding the film rolled by the film rolling mechanism to the main calender roller group, wherein the guide laminating mechanism comprises a guide wheel and a laminating roller arranged with a gap between the calender rollers in the main calender roller group; The material to be processed is cooled to 110-130° C. before entering the embossing roller group.

2. The foam floor production line according to claim 1, characterized in that: A cooling roller group is arranged between the main calendering roller group and the embossing roller group.

3. The foam floor production line according to claim 1, characterized in that: According to the processing flow, the calendering machine sequentially comprises a cooling and shaping device, a main calendering roller group and an embossing roller group.

4. The foam floor production line according to claim 3, characterized in that: The cooling and shaping device comprises a first cooling component and a second cooling component which are arranged at an interval.

5. The foam floor production line according to claim 3, characterized in that: The cooling and shaping device includes a first cooling roller and a second cooling roller arranged in pairs with an interval, or a first cooling and shaping plate and a second cooling and shaping plate arranged in pairs with an interval, or a combination of a first cooling roller and a second cooling roller arranged in pairs with an interval and a first cooling and shaping plate and a second cooling and shaping plate arranged in pairs with an interval.

6. The foam floor production line according to claim 5, characterized in that: According to the processing flow, the cooling and shaping device sequentially includes a first cooling and shaping plate and a second cooling and shaping plate which are spaced apart in pairs, and a first cooling roller and a second cooling roller which are spaced apart in pairs.

7. The foam floor production line according to claim 1, characterized in that: The film unwinding mechanism includes one of the base film unwinding mechanism for unwinding the base film, the color film unwinding mechanism for unwinding the color film, and the wear-resistant film unwinding mechanism for unwinding the wear-resistant film, or any combination of the three; and if the base film unwinding mechanism is configured to guide the base film to one side of the material, the color film unwinding mechanism and the wear-resistant film unwinding mechanism are configured to guide the color film and the wear-resistant film to the other side of the material.

8. The foam floor production line according to claim 1, characterized in that: According to the processing flow, it further includes an auxiliary laminating roller which is arranged at the rear end of the laminating roller, configured at the same calendering roller as the laminating roller, and is arranged with a gap between the laminating roller and the calendering roller.

9. The foam floor production line according to claim 1 or 8, characterized in that: The laminating roller and the auxiliary laminating roller are each connected to a gap adjusting device for adjusting the gap between the laminating roller and the calendering roller in the main calendering roller group.

10. One-step forming process of foam floor, characterized by: The foam floor production line according to any one of claims 1 to 9 is implemented, comprising the following steps: The first extruder is used to extrude the foaming layer, and the second extruder is provided with a distributor for extruding the solid layer covering both sides of the foaming layer; the foaming layer and the solid layers on both sides enter the mold after preliminary lamination; The material passes through the die and enters the calender; The material is laminated with wear-resistant film and printed film in the main calender roller group; After the material is discharged from the main calendering roller group, it passes through the air for cooling and then enters the embossing roller group for embossing; The material to be processed is cooled to 110-130° C. before entering the embossing roller group.

11. The one-step forming process for foam flooring according to claim 10, characterized in that: Further comprising the steps of: The material first passes through the cooling and shaping device for cooling and shaping, and then enters the main calendering roller group.

12. The one-step forming process of the foam floor as claimed in claim 10, characterized in that: According to the processing flow, the main calendering roller group includes, in sequence, a first mirror roller, an intermediate mirror roller and a discharge end calendering roller, and the temperature of the discharge end calendering roller is higher than that of the first mirror roller.

13. The one-step forming process of the foam floor as claimed in claim 12, characterized in that: According to the processing flow, the main calendering roller group includes, in sequence, a first mirror roller, an intermediate mirror roller group consisting of at least two intermediate mirror rollers, and a discharge end calendering roller. The temperature of the first mirror roller and the intermediate mirror roller adjacent thereto is set to 30-90°C, the temperature of the discharge end calendering roller is set to 150-190°C, and the temperature of the intermediate mirror roller adjacent to the discharge end calendering roller is set to 90-170°C.

14. The one-step forming process for foamed flooring according to claim 12, characterized in that: The temperature of the pattern roller is set at 160-190°C, and the temperature of the anilox roller is set at 160-190°C.

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