A one-piece PVC artificial leather foaming process and equipment

Abstract

The present invention discloses a one-piece PVC artificial leather foaming treatment process and equipment, which belongs to the field of artificial leather manufacturing technology, and aims to solve the problems of large connection loss, large waste of heat energy, high production manpower and equipment maintenance costs, and poor product quality stability in the traditional segmented process. By installing a preheating wheel to preheat the calendered semi-finished product, the cloth pattern originally produced by rolling up in the calendering process disappears before pre-treatment, so as to ensure that the pre-treatment sizing amount is evenly distributed; by installing a pre-treatment sizing wheel after the preheating wheel, the leather with the pre-treatment resin is directly connected to the foaming furnace for heating and foaming, ensuring the leveling and drying stability of the pre-treatment resin film. Compared with the traditional process with independent processes, the present invention adopts a one-piece process to achieve sustainable dynamic linkage production, which increases the production speed by at least 30%, is conducive to improving product quality stability, reducing energy loss and material waste, and saving labor costs and maintenance costs.

Description

Technical Field

[0001] The present invention relates to the technical field of artificial leather processing, and particularly relates to a one-piece PVC artificial leather foaming treatment process and equipment. Background Art

[0002] PVC (polyvinyl chloride) artificial leather is a plastic laminating or coating product with cloth as the base material, which can replace natural leather. There are mainly two production methods for PVC artificial leather: the spread coating method and the calendering method. The production process flow of calendered PVC artificial leather includes making calendered semi-finished products (high-speed stirring and kneading - internal mixing - roller turning and kneading - filtration - calendering), pre-treatment (sizing or printing on the calendered semi-finished products), foaming, post-treatment (sizing or printing), and packaging.

[0003] In the traditional PVC artificial leather production process, the equipment for each process such as the unwinding rack, storage rack, foaming furnace, grain embossing / embossing machine, intermediate cooling roller, edge trimming machine, and winding machine are all completely independent and separated. Therefore, there are the following problems in the whole processing process of artificial leather (especially in the foaming, treatment, and printing processes):

[0004] 1. Each stage of the segmented process generates order head and tail materials and relatively large splicing losses; 2. Due to the long interval between the previous stage and the next stage in the segmented process, the artificial leather needs to be reheated, resulting in a large waste of heat energy; 3. The segmented process requires more production manpower allocation and will increase the maintenance costs of each equipment; 4. Due to the different operating conditions (temperature and speed) of each machine tool equipment in the segmented process, it is easy to cause poor product quality stability; 5. There are high requirements for the synchronization of the operation of each equipment and high requirements for the operating skills of employees. Summary of the Invention

[0005] Aiming at the above technical deficiencies, the purpose of the present invention is to provide a one-piece PVC artificial leather foaming treatment process and equipment.

[0006] To solve the above technical problems, the present invention adopts the following technical solutions:

[0007] The present invention provides a one-piece PVC artificial leather foaming treatment process, including the following steps:

[0008] 1) Preheating: The calendered semi-finished product is preheated by directly installing a simple preheating roller in the feeding section of the foaming furnace, so that the cloth pattern generated by the original calendering process disappears before pre-treatment, so as to ensure uniform sizing amount distribution in pre-treatment;

[0009] 2) Pre-treatment: A treatment sizing roller is installed after preheating and before foaming, and different sizing roller mesh numbers are selected according to different product requirements to apply the pre-treatment resin on the surface of the preheated leather;

[0010] 3) Foaming: The leather with the pre-treatment resin applied is directly fed into the foaming furnace through the needle chain on the production line for heating and foaming, simultaneously ensuring the film-forming leveling property and sufficient drying of the pre-treatment resin.

[0011] 4) Embossing / Graving: After coming out of the foaming furnace, it is directly subjected to embossing / graving forming.

[0012] 5) Primary cooling: The artificial leather with embossing / graving is directly cooled at an appropriate temperature and trimmed by passing through a metal wheel containing cooling water or normal temperature water.

[0013] 6) Post-treatment: The artificially cooled artificial leather is directly connected to the post-treatment wheel rack for secondary sizing, and different sizing wheel meshes are selected according to different product requirements.

[0014] 7) Drying: After secondary sizing, it is dried by a hot air box to facilitate the stability of the film-forming of the treatment resin.

[0015] 8) Secondary cooling: After coming out of the hot air box of the treatment furnace body, it is cooled at an appropriate temperature and wound up by passing through a metal wheel containing cooling water or normal temperature water, which is the final product.

[0016] Preferably, in step 1), the preheating temperature is 50 - 200 °C.

[0017] Preferably, in step 2), the sizing wheel mesh is 40 - 200 meshes.

[0018] Preferably, in step 3), the foaming temperature is 150 - 250 °C, and the foaming time is 30 - 90 s.

[0019] Preferably, in step 6), the sizing wheel mesh varies from 60 to 200 meshes.

[0020] Preferably, in step 7), the drying speed is synchronized with the foaming furnace, and the drying temperature is 60 - 180 °C.

[0021] The present invention also provides a continuous PVC artificial leather foaming treatment device, including a feeding rack, a storage rack, a foaming furnace, a graving / embossing machine, an intermediate cooling wheel, a trimming machine, and a winding machine. It also includes a preheating device, a pre-treatment sizing wheel rack, a post-treatment sizing wheel rack, a hot air box, and a tail-end cooling wheel. The preheating device and the pre-treatment sizing wheel rack are sequentially arranged between the storage rack and the foaming furnace; the post-treatment sizing wheel rack, the hot air box, and the tail-end cooling wheel are sequentially arranged between the trimming machine and the winding machine.

[0022] Preferably, the preheating device is a preheating wheel.

[0023] The beneficial effect of the present invention is that: compared with the traditional process with independent processes for each step, the present invention adopts a continuous process to achieve sustainable dynamic linkage production, which increases the production speed by at least 30%, is beneficial to improving the product quality stability, reducing energy consumption and material waste, and saving labor costs and maintenance costs. Brief Description of the Drawings

[0024] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0025] Figure 1 It is a schematic structural diagram of a combined PVC artificial leather foaming treatment device provided by an embodiment of the present invention.

[0026] Description of the reference numerals: 1, unwinding rack; 2, storage rack; 3, preheating wheel; 4, pre-treatment sizing wheel rack; 5, foaming furnace; 6, embossing / debossing machine; 7, intermediate cooling wheel; 8, trimming machine; 9, post-treatment sizing wheel rack; 10, hot air box; 11, end cooling wheel; 12, winding machine. Detailed Embodiments

[0027] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, rather than all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present invention.

[0028] Embodiment 1

[0029] Refer to Figure 1 , a combined PVC artificial leather foaming treatment device, including a fabric unwinding rack 1, a storage rack 2, a preheating wheel 3, a pre-treatment sizing wheel rack 4, a foaming furnace 5, an embossing / debossing machine 6, an intermediate cooling wheel 7, a trimming machine 8, a post-treatment sizing wheel rack 9, a hot air box 10, an end cooling wheel 11 and a winding machine 12. The preheating wheel 3 and the pre-treatment sizing wheel rack 4 are sequentially arranged between the storage rack 2 and the foaming furnace 5; the post-treatment sizing wheel rack 9, the hot air box 10 and the end cooling wheel 11 are sequentially arranged between the trimming machine 8 and the winding machine 12.

[0030] Embodiment 2

[0031] A combined PVC artificial leather foaming treatment process includes the following steps:

[0032] 1) Preheating: Directly install a preheating wheel 3 at the feeding section of the foaming furnace to preheat the calendered semi-finished product. The preheating temperature ranges from 50 to 200 °C, so that the cloth pattern generated by rolling up in the original calendering process disappears before foaming, ensuring uniform distribution of the pre-treatment sizing amount;

[0033] 2) Pretreatment: After preheating and before foaming, install a pretreatment sizing wheel 4. Select different sizing wheel meshes according to different product requirements (the sizing wheel mesh is 40 - 200 meshes) and apply the pretreatment resin on the preheated leather surface;

[0034] 3) Foaming: The leather with the applied pretreatment resin is directly fed into the foaming furnace 5 online for heating and foaming. The foaming temperature is 150 - 250 °C, and the foaming time is 30 - 90 s, synchronously ensuring the adequacy of the pretreatment resin film formation, leveling, and drying;

[0035] 4) Embossing / Graining: After coming out of the foaming furnace, it directly enters the graining / embossing machine 6 for embossing / graining forming;

[0036] 5) Primary Cooling: The artificial leather with embossing / graining directly passes through the intermediate cooling wheel 7 containing cooling water or normal temperature water for temperature-appropriate cooling and edge trimming;

[0037] 6) Post-treatment: The temperature-appropriately cooled artificial leather is directly connected to the post-treatment sizing wheel rack 9 for secondary sizing. Select different sizing wheel meshes according to different product requirements, and the sizing wheel mesh is 60 - 200 meshes;

[0038] 7) Drying: After secondary sizing, it is dried by the hot air box 10 to facilitate the stability of the treatment resin film formation. Depending on the product, the drying speed is synchronized with the foaming furnace, and the drying temperature is 60 - 180 °C;

[0039] 8) Secondary Cooling: After coming out of the hot air box of the treatment furnace body, it passes through the end cooling wheel 11 containing cooling water or normal temperature water for temperature-appropriate cooling, and is wound by the winding machine 12 to obtain the final product.

[0040] Obviously, those skilled in the art can make various modifications and variations to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and its equivalent technologies, the present invention is also intended to include these modifications and variations.

Claims

1. A one-piece PVC artificial leather foaming process, characterized in that: The following steps are involved: 1) Preheating: A simple preheating wheel is directly installed in the discharge section of the foaming furnace to preheat the calendered semi-finished product. The preheating temperature is 50-200°C, so that the cloth pattern originally produced by rolling up in the calendering process disappears before pretreatment, so as to ensure that the sizing amount of the pretreatment is evenly distributed; 2) Pretreatment: After preheating and before foaming, a sizing wheel is installed. The mesh number of the sizing wheel is 40-200 mesh. Different mesh numbers of the sizing wheel are selected according to different product requirements to apply the pretreatment resin wheel to the preheated leather; 3) Foaming: The leather with pre-treatment resin is directly connected to the foaming furnace needle chain into the foaming furnace body for heating and foaming. The foaming temperature is 150-250℃ and the foaming time is 30-90s, which simultaneously ensures the adequacy of the pre-treatment resin film leveling and drying; 4) Embossing / absorption: Embossing / absorption molding is carried out directly after coming out of the foaming furnace; 5) Primary cooling: The artificial leather with embossed / absorbed patterns is directly cooled by a metal wheel containing cooling water or normal temperature water and then trimmed; 6) Post-processing: The artificial leather cooled to appropriate temperature is directly connected to the post-processing wheel frame for secondary sizing. Different sizing wheel meshes are selected according to different product requirements, which directly avoids the secondary fabric indentation caused by the traditional segmented foaming and rolling for post-processing; 7) Drying: After the secondary sizing, it is dried in a hot air oven to facilitate the processing of resin film formation and stability; 8) Secondary cooling: After leaving the hot air box, it passes through a metal wheel containing cooling water or normal temperature water for appropriate temperature cooling and winding to obtain the final product.

2. The one-piece PVC artificial leather foaming process according to claim 1, characterized in that: In step 6), the sizing wheel has a mesh size of 60-200.

3. The foaming process of one-piece PVC artificial leather according to claim 1, characterized in that: In step 7), the drying speed is synchronized with the foaming furnace and the drying temperature is 60-180°C.

Images