A surface treatment process, apparatus and product for artificial leather

Abstract

This invention discloses a surface treatment process, apparatus, and product for artificial leather. The surface treatment process includes the following steps: S1, grooving: anchoring grooves are formed on the top surface of the artificial leather foam layer. Multiple anchoring grooves are evenly spaced along the width direction of the artificial leather, and the direction of the anchoring grooves is consistent with the conveying direction of the artificial leather; S2, coating: a surface slurry is applied to the foam surface of the artificial leather using a coating wheel. The slurry fills the anchoring grooves and the entire surface, and is smoothed using a scraper; S3, drying: the coated artificial leather is continuously dried in an oven, cooled, and then rolled up. This invention increases the adhesion between the coated surface layer and the foam layer, preventing peeling and improving the service life of the artificial leather. This invention also discloses an artificial leather surface treatment apparatus and corresponding artificial leather products.

Description

Technical Field

[0001] This invention relates to the field of artificial leather post-processing technology, and in particular to an artificial leather surface treatment process, apparatus and products. Background Technology

[0002] After foaming, PVC and PU artificial leather often require surface treatment processes such as color changing, printing, varnishing, and matte finishing using a surface treatment machine. Essentially, this involves applying a layer of slurry to the top surface of the foamed layer using a coating roller, followed by drying and winding. This polyvinyl chloride, polyurethane, or polyamide polymer surface layer not only changes color, varnishes, or mattes the surface, but also often adds wear resistance, mildew resistance, and improves the feel, resulting in a very noticeable effect.

[0003] However, because the surface layer is processed and formed on the blank after the foaming process has cooled and solidified, the top surface of the foam layer is a smooth and continuous interface, resulting in poor adhesion between the coated slurry and the foam layer interface. This causes the surface layer of artificial leather products to easily peel off after a period of use, especially the PU artificial leather fabrics on some clothes and chairs. After several washes, the surface layer often peels off in pieces or chunks, which greatly affects the appearance.

[0004] To overcome the above problems, a surface treatment process, apparatus and products for artificial leather are needed. Summary of the Invention

[0005] The purpose of this invention is to provide a surface treatment process, apparatus and product for artificial leather, which can increase the adhesion between the coating layer and the foam layer, prevent peeling and improve the service life of artificial leather.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0007] This invention discloses a surface treatment process for artificial leather, comprising the following steps: S1, grooving: anchoring grooves are formed on the top surface of the foamed layer of artificial leather, and multiple anchoring grooves are evenly spaced along the width direction of the artificial leather, with the direction of the anchoring grooves being consistent with the conveying direction of the artificial leather; S2, coating: a coating wheel is used to coat the foamed surface of the artificial leather with a surface slurry, the slurry filling the anchoring grooves and the entire surface, and then smoothed with a scraper; S3, drying: the coated artificial leather is continuously dried in an oven, cooled, and then rolled up.

[0008] Furthermore, the depth of the anchoring groove is no greater than one-third of the thickness of the foam layer.

[0009] Furthermore, the bottom surface of the anchoring groove is an arc-shaped bottom surface, and the anchoring groove is formed by hot cutting.

[0010] Furthermore, it also includes a cleaning process set between S1 and S2, which involves suction and adsorption cleaning of the anchoring groove and the top surface of the foam layer.

[0011] Furthermore, in the S2 process, the artificial leather is coated with slurry under the support of the convex arc roller surface, and the two side walls of the anchoring groove are slightly open to facilitate the full wetting and filling of the slurry.

[0012] A surface treatment apparatus for artificial leather includes a surface treatment machine frame, a coating support roller, a coating wheel, a slurry scraper, and an oven. It also includes a grooving support roller and a grooving blade assembly. The grooving support roller is rotatably mounted on the surface treatment machine frame and horizontally positioned in front of the coating support roller. The grooving blade assembly is positioned below the grooving support roller. The grooving blade assembly includes a blade holder assembly, a guide drive assembly, a blade shaft, and disc blades. The guide drive assembly is mounted on the surface treatment machine frame and can drive the blade holder assembly to perform forward and backward blade movements. The blade shaft is horizontally mounted on the top of the blade holder assembly. Multiple disc blades are equidistantly and coaxially rotatably mounted on the blade shaft, with the tops of the disc blades capable of contacting and cutting the foam layer of the artificial leather.

[0013] Furthermore, the grooving cutter assembly also includes a heating sleeve, which is coaxially disposed on both sides of the disc cutter and fixedly connected to the cutter shaft.

[0014] Furthermore, the tool holder assembly includes an intermediate support plate, tool holder plate support legs, compression springs, a tool holder plate, and a tool shaft support plate. The tool shaft support plate supports the tool shaft on the tool holder plate. The tool holder plate is connected to the intermediate support plate via multiple sets of tool holder plate support legs and compression springs on its bottom surface. The compression springs are sleeved on the tool holder plate support legs and abut against the tool holder plate and the intermediate support plate at both ends. One end of the tool holder plate support leg connected to the intermediate support plate is configured as a screw section, and an adjusting nut is screwed onto the bottom surface of the intermediate support plate.

[0015] The guide drive assembly includes a support plate frame, a linear drive unit, guide posts, and guide sleeves. The support plate frame is connected to the surface treatment machine frame. The end flange of the linear drive unit is connected to the bottom surface of the support plate frame. The working end of the linear drive unit extends upward and is connected to the bottom surface of the intermediate support plate. The top ends of the multiple guide posts are fixedly connected to the intermediate support plate. The vertically downward bottom ends of the guide posts are slidably connected to the guide sleeves. The guide sleeves are fixedly connected to the top surface of the support plate frame.

[0016] Furthermore, it also includes a limiting cover, which is a U-shaped plate cover with the opening facing downwards. The bottom flange of the limiting cover is connected to the intermediate support plate, and the top plate of the limiting cover is provided with a narrow slit corresponding to the disc cutter to facilitate the exposure of the blade.

[0017] The present invention also discloses an artificial leather product, which is a curved artificial leather comprising a base fabric layer, a foam layer and a surface layer sequentially laminated together from bottom to top. Multiple anchoring grooves are evenly spaced on the top surface of the foam layer, and the surface layer is partially filled into the anchoring grooves. The two side walls of the anchoring grooves are open, and the base fabric layer, foam layer and surface layer all present an outwardly convex curved shape.

[0018] Compared with the prior art, the beneficial technical effects of the present invention are as follows:

[0019] This invention relates to a surface treatment process for artificial leather. By creating anchoring grooves before coating, the surface slurry fills these grooves, increasing the bonding area. Simultaneously, the newly created, relatively rough surface of the anchoring grooves significantly improves adhesion. This surface treatment process increases the adhesion between the coated surface layer and the foamed layer, preventing peeling and extending the lifespan of the artificial leather.

[0020] Furthermore, by appropriately setting the depth of the anchoring groove, a good bonding enhancement effect is achieved while avoiding an overly hard feel caused by foam layer failure. By using a rounded bottom surface and hot-cutting to form the anchoring groove, sharp molding edges and mechanical damage are avoided, preventing hidden cracks. A cleaning process is incorporated to clean the surface of the anchoring groove and the top surface of the foam layer, removing debris and dust, resulting in a clean and tidy bonding surface for the surface slurry, effectively improving adhesion. Applying the slurry under the support of a convex roller surface allows the two sidewalls of the anchoring groove to open slightly, facilitating the smooth flow of the surface slurry into the groove. The newly created groove surface is fully wetted by the surface slurry, promoting bonding between the two components.

[0021] This invention discloses a surface treatment device for artificial leather. It employs a grooving support roller and a grooving blade assembly to cut a conveyed artificial leather strip. By controlling the gap between the blades and the grooving support roller, it can cut uniformly deep anchoring grooves on the foamed layer of the artificial leather. Multiple coaxially rotatable disc blades are coaxially mounted at equal intervals on the blade shaft. These rotating disc blades achieve frictionless cutting, avoiding uneven damage to both sides of the anchoring groove. Heating sleeves are installed on both sides of the disc blades to heat them, enabling thermal cutting of the artificial leather foamed layer and preventing hidden cracks caused by harsh mechanical scratches. A screw section with an adjusting nut is installed at one end of the blade support leg connecting to the intermediate support plate. Rotating the adjusting nut adjusts the distance between the disc blade and the intermediate support plate, thus adjusting the height of the disc blade protruding from the top surface of the limiting cover, indirectly determining the depth of the cut anchoring groove. The cooperation of guide posts and guide sleeves stably guides the intermediate support plate to perform the cutting and retraction movements along the cutting direction without deviation. By installing a slag remover on the side wall of the limiting cover, the disc cutter can be cleaned in real time, preventing adhering slag from affecting the opening of the anchoring groove. The dust suction hood and cleaning scraper allow for cleaning of the surface of the artificial leather foam layer after the grooving process, improving the cleanliness of the bonding surface. Supporting the artificial leather strip during coating with a coating support roller with a convex arc surface allows the side walls of all anchoring grooves to be slightly open, facilitating the smooth brushing of the surface slurry into the anchoring groove, and also enabling the formation of artificial leather products with a slightly convex arc surface. When producing this product, it is important to note that subsequent conveyor rollers, guide rollers, and take-up rollers must all use rollers with corresponding convex arc surfaces.

[0022] This invention relates to artificial leather products, specifically curved artificial leather with a slightly convex surface, suitable for manufacturing products such as chair backs, cushions, and sofa surfaces. The surfaces of these products bulge slightly outwards due to the internal filling material, allowing for better shaping, a more aesthetically pleasing appearance, and less bending pre-stress. This also reduces the likelihood of the artificial leather surface tearing or cracking, increasing the product's lifespan. Attached Figure Description

[0023] The present invention will be further described below with reference to the accompanying drawings.

[0024] Figure 1 This is a schematic diagram of the artificial leather surface treatment process of the present invention;

[0025] Figure 2 This is a schematic diagram of the composition and structure of the artificial leather surface treatment device of the present invention;

[0026] Figure 3 This is a schematic diagram of the main structure of the grooving blade assembly of the artificial leather surface treatment device of the present invention;

[0027] Figure 4This is a front view of the cutter shaft portion of the artificial leather surface treatment device of the present invention;

[0028] Figure 5 This is a top view of the coating wheel portion of the artificial leather surface treatment device of the present invention;

[0029] Figure 6 This is a schematic diagram of the cross-sectional structure of the artificial leather product of the present invention.

[0030] Explanation of reference numerals in the attached drawings: 1. Grooving support roller; 2. Coating support roller; 3. Coating wheel; 301. Slurry tank; 4. Slurry scraper; 5. Tensioning roller; 6. Oven guide roller; 7. Oven; 8. Grooving knife assembly; 801. Support plate frame; 802. Linear drive unit; 803. Intermediate support plate; 804. Knife holder plate support leg; 805. Compression spring; 806. Knife shaft bracket plate; 807. Disc knife; 808. Limiting cover; 809. Slag remover; 810. Guide column; 811. Guide sleeve; 812. Heating jacket; 813. Knife shaft; 814. Knife holder plate; 9. Curved artificial leather; 901. Base fabric layer; 902. Foaming layer; 903. Anchoring groove; 904. Surface layer; 10. Dust suction hood; 11. Cleaning scraper. Detailed Implementation

[0031] The core of this invention is to provide a surface treatment process, apparatus and product for artificial leather, which can increase the adhesion between the coating layer and the foaming layer, prevent peeling and improve the service life of artificial leather.

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0033] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0034] Refer to the attached diagram. Figure 1 This is a schematic diagram of the artificial leather surface treatment process of the present invention; Figure 2 This is a schematic diagram of the composition and structure of the artificial leather surface treatment device of the present invention; Figure 3 This is a schematic diagram of the main structure of the grooving blade assembly of the artificial leather surface treatment device of the present invention; Figure 4 This is a front view of the cutter shaft portion of the artificial leather surface treatment device of the present invention; Figure 5 This is a top view of the coating wheel portion of the artificial leather surface treatment device of the present invention; Figure 6 This is a schematic diagram of the cross-sectional structure of the artificial leather product of the present invention.

[0035] Example 1

[0036] like Figure 1 As shown, the artificial leather surface treatment process of the present invention includes the following steps: S1, grooving: anchoring grooves are formed on the top surface of the artificial leather foam layer. Multiple anchoring grooves are evenly spaced along the width direction of the artificial leather, and the direction of the anchoring grooves is consistent with the conveying direction of the artificial leather. S2, coating: a coating wheel is used to apply a surface slurry to the foamed surface of the artificial leather. The slurry fills the anchoring grooves and the entire surface, and is smoothed using a scraper. S3, drying: the coated artificial leather is continuously dried in an oven, cooled, and then rolled up.

[0037] In actual production, a second surface treatment is often required after the first surface treatment, which is achieved through a series of surface coating devices. The artificial leather surface treatment process of this invention is applied in the first surface treatment.

[0038] Unlike existing surface coating processes, the anchoring groove is created before coating. The surface slurry fills the anchoring groove, increasing the bonding area. Simultaneously, the surface of the anchoring groove is newly created and relatively rough, significantly improving adhesion. This artificial leather surface treatment process increases the adhesion between the coated surface layer and the foamed layer, preventing peeling and extending the service life of the artificial leather.

[0039] In one specific implementation of this embodiment, such as Figure 6 As shown, the depth of the anchoring groove is no more than one-third of the thickness of the foam layer. Generally speaking, the thickness of the foam layer of PU artificial leather is about 1 mm, so the depth of the anchoring groove is often set at around 0.3 mm, and the width of the anchoring groove ranges from 2 to 6 mm.

[0040] Specifically, such as Figure 6 As shown, the bottom surface of the anchoring groove is an arc-shaped bottom surface, that is, there are no sharp forming edges. The anchoring groove is formed by hot cutting. The use of hot cutting can reduce hidden cracks caused by mechanical scratches.

[0041] By reasonably setting the depth of the anchoring groove, a better bonding enhancement effect is achieved while avoiding an overly hard feel caused by foam layer failure; by making the bottom surface of the anchoring groove rounded and forming it by hot cutting, sharp forming edges and mechanical damage are avoided, and hidden cracks will not be generated.

[0042] In one specific implementation of this embodiment, such as Figure 1 As shown, it also includes a cleaning process set between S1 and S2, which performs suction and adsorption cleaning on the anchoring groove and the top surface of the foam layer.

[0043] By setting up a cleaning process, the surface of the anchoring groove and the top surface of the foam layer can be cleaned to remove debris and dust, making the bonding surface of the surface slurry clean and tidy, which can effectively improve the adhesion.

[0044] In one specific implementation of this embodiment, such as Figure 5 As shown, in process S2, the artificial leather is coated with slurry under the support of the convex arc roller surface, and the two side walls of the anchoring groove are slightly open to facilitate the full wetting and filling of the slurry.

[0045] By applying the slurry under the support of the convex arc roller surface, the two sidewalls of the anchoring groove are slightly opened, which facilitates the smooth flow of the surface slurry into the anchoring groove. The newly created groove surface of the anchoring groove can be fully wetted by the surface slurry, which is beneficial to the adhesion between the two.

[0046] Example 2

[0047] like Figures 2-5 As shown, this invention discloses a surface treatment device for artificial leather. Similar to existing surface treatment machines, it includes a machine frame, a coating support roller 2, a coating wheel 3, a slurry scraper 4, and an oven 7. The artificial leather strip is continuously conveyed by multiple guide rollers, sequentially passing through the coating support roller 2, tension roller 5, oven guide roller 6, and oven 7 before being output to the next surface treatment device. At the coating support roller 2, the coating wheel 3 dips into the slurry tank and rotates to coat the artificial leather strip. Then, the slurry scraper 4 smooths the surface slurry on the artificial leather strip. A key difference between this invention and existing surface treatment machines is that this artificial leather surface treatment device also includes a grooving support roller 1 and a grooving blade assembly 8. The grooving support roller 1 is rotatably mounted on the machine frame via bearing seats at both ends. The grooving support roller 1 is horizontally positioned in front of the coating support roller 2, and the grooving blade assembly 8 is positioned below the grooving support roller 1. The grooving cutter assembly 8 includes a cutter holder assembly, a guide drive assembly, a cutter shaft 813, and disc cutters 807. The guide drive assembly is mounted on the surface treatment machine frame and can drive the cutter holder assembly to perform cutting advance and retraction movements. The cutter shaft 813 is horizontally mounted on the top of the cutter holder assembly, and multiple disc cutters 807 are equidistantly and coaxially rotatably mounted on the cutter shaft 813. The tops of the disc cutters 807 can contact and cut the artificial leather foam layer.

[0048] The artificial leather material belt is cut by using a grooving support roller 1 and a grooving knife set 8. By controlling the gap between the knife and the grooving support roller 1, a uniform anchoring groove can be cut on the foam layer of the artificial leather. By installing multiple disc cutters 807 rotatably and coaxially at equal intervals on the cutter shaft 813, the rotating disc cutters 807 can achieve non-slip friction cutting, avoiding uneven damage to both sides of the anchoring groove.

[0049] In one specific implementation of this embodiment, such as Figure 4 As shown, the grooving cutter assembly 8 also includes heating sleeves 812, which are coaxially arranged on both sides of the disc cutter 807. The heating sleeves 812 are fixedly connected to the cutter shaft 813. The power lines of all heating sleeves 812 are connected in parallel and then connected to the equipment control box via a bus. An infrared temperature sensor is correspondingly installed on the cutter holder to measure the operating temperature of the disc cutter 807. In a specific embodiment, for cutting PU foam layers, the operating temperature of the disc cutter 807 is controlled at 120 degrees Celsius, which can drive better thermal cutting to form anchor grooves. The infrared temperature sensor is electrically connected to the equipment control box.

[0050] By setting heating sleeves 812 on both sides of the disc cutter 807, the disc cutter 807 can be heated to perform thermal cutting on the artificial leather foam layer, avoiding hidden cracks caused by harsh mechanical scratches.

[0051] In one specific implementation of this embodiment, such as Figure 3 and Figure 4 As shown, the tool holder assembly includes a central support plate 803, tool holder plate support legs 804, compression springs 805, a tool holder plate 814, and a tool shaft support plate 806. The tool shaft support plate 806 supports the tool shaft 813 on the tool holder plate 814. The tool shaft 813 does not rotate on the tool shaft support plate 806 because the tool shaft 813 is relatively long, typically 1.4 meters. Multiple tool shaft support plates 806 can be installed along the length of the tool shaft 813 to prevent deformation. The tool holder plate 814 is connected to the central support plate 803 via multiple sets of tool holder plate support legs 804 and compression springs 805 on its bottom surface. The tool holder plate support legs 804 and compression springs 805 are used in groups, with at least four groups installed at the four corners. A compression spring 805 is sleeved on the tool holder plate support leg 804, with both ends abutting between the tool holder plate 814 and the intermediate support plate 803. One end of the tool holder plate support leg 804 connecting to the intermediate support plate 803 is configured as a screw section, and an adjusting nut is screwed onto the bottom surface of the intermediate support plate 803. By rotating the adjusting nut, the distance between the disc cutter 807 and the intermediate support plate 803 can be adjusted. To lock and prevent loosening, two adjusting nuts can be used to tighten and lock the adjustment position on a section of the screw section.

[0052] Specifically, such as Figure 3As shown, the guide drive assembly includes a support plate frame 801, a linear drive unit 802, guide posts 810, and guide sleeves 811. The support plate frame 801 is connected to the frame of the surface treatment machine. The end flange of the linear drive unit 802 is connected to the bottom surface of the support plate frame 801, and the working end of the linear drive unit 802 extends upward and is connected to the bottom surface of the intermediate support plate 803. The top ends of multiple guide posts 810 are fixedly connected to the intermediate support plate 803, and the vertically downward bottom ends of the guide posts 810 are slidably connected to the guide sleeves 811. The guide sleeves 811 are fixedly connected to the top surface of the support plate frame 801. Four guide posts 810 and guide sleeves 811 are arranged at the four corners, and the linear drive unit 802 is located in the middle position. The linear drive unit 802 can be an electric push rod or a cylinder.

[0053] Specifically, such as Figure 3 As shown, the grooving cutter assembly 8 also includes a limiting cover 808, which is a U-shaped plate cover with its opening facing downwards. The bottom flange of the limiting cover 808 is connected to the intermediate support plate 803. The top plate of the limiting cover 808 has a narrow slit corresponding to the disc cutter 807 to facilitate the exposure of the cutting edge. The two sides of the top surface of the limiting cover 808 are rounded.

[0054] A screw section is provided at one end of the tool holder plate support leg 804 connecting to the intermediate support plate 803, and an adjusting nut is fitted therein. By rotating the adjusting nut, the distance between the disc cutter 807 and the intermediate support plate 803 can be adjusted, which means the height at which the cutting edge of the disc cutter 807 protrudes from the top surface of the limiting cover 808 can be adjusted, thus indirectly determining the depth of the cutting anchoring groove. Through the cooperation of the guide post 810 and the guide sleeve 811, the intermediate support plate 803 can be stably guided to make cutting and retraction movements along the cutting direction without deviation.

[0055] In one specific implementation of this embodiment, such as Figure 3 As shown, the grooving cutter assembly 8 also includes a slag remover 809. A passage window is provided on the side wall of the limiting cover 808, and the number of passage windows is the same as that of the disc cutter 807, with each window corresponding to the previous one. The slag remover 809 is mounted on the passage window via a flange. The protruding end of the slag remover 809 is in the shape of a clamp, which is engaged with the disc cutter 807. The clamp can scrape off the resin residue adhering to the disc cutter 807.

[0056] By installing a slag remover 809 on the side wall of the limit cover 808, the disc cutter 807 can be cleaned in real time, avoiding the impact of the adhering slag on the opening of the anchoring groove.

[0057] In one specific implementation of this embodiment, such as Figure 1As shown, the artificial leather surface treatment device of the present invention also includes a dust suction hood 10 and a cleaning scraper 11. The dust suction hood 10 and the cleaning scraper 11 are installed in parallel behind the grooving knife assembly 8, and a cleaning support roller is also provided on the opposite side of the cleaning scraper 11. The top of the cleaning scraper 11 scrapes and cleans the surface of the artificial leather strip, and the dust suction hood 10 is set on the feed side of the cleaning scraper 11 to exhaust and clean the scraped residue and large amount of dust.

[0058] By using the dust hood 10 and the cleaning scraper 11, the surface of the artificial leather foam layer can be cleaned after the grooving process, improving the cleanliness of the bonding surface.

[0059] In one specific implementation of this embodiment, such as Figure 1 As shown, the coating support roller 2 and coating wheel 3 of the artificial leather surface treatment device of the present invention are both arc-shaped rollers, wherein the coating support roller 2 is an outwardly convex arc-shaped roller and the corresponding coating wheel 3 is an inwardly concave arc-shaped roller.

[0060] When coating the artificial leather strip using a coating support roller 2 with a convex arc surface, the side walls of all anchoring grooves are slightly opened, facilitating the smooth application of the surface slurry into the anchoring grooves. This also allows for the formation of artificial leather products with a slightly convex arc surface. When producing this type of product, it is important to note that subsequent conveyor rollers, guide rollers, and take-up rollers must all use rollers with corresponding convex arc surfaces.

[0061] The working principle of the artificial leather surface treatment device of this invention is as follows: The artificial leather strip requiring surface treatment is continuously conveyed by multiple guide rollers, passing sequentially through grooving support roller 1, cleaning support roller, coating support roller 2, tensioning roller 5, oven guide roller 6, and oven 7 before being output to the next surface treatment device. When passing through grooving support roller 1, the grooving blade assembly 8 cooperates below grooving support roller 1 to cut the foam layer surface of the artificial leather strip. Multiple disc blades 807 cut anchoring grooves in parallel and synchronously. The anchoring grooves formed by the heated disc blades 807 have a smooth, rounded surface without hidden cracks. During cutting, the limiting cover 808 contacts the foam layer surface and slightly compresses the passing artificial leather strip. The depth of the anchoring groove is determined by adjusting the height of the disc blades 807 protruding from the top surface of the limiting cover 808. When passing the cleaning support roller, the cleaning scraper 11 scrapes and cleans the surface of the artificial leather strip. The dust suction hood 10, located on the feed side of the cleaning scraper 11, uses negative pressure to remove the scraped residue and large amounts of dust. When passing the coating support roller 2, the coating wheel 3 dips into the surface slurry in the slurry tank and rotates to coat the artificial leather strip. The surface slurry is smoothly brushed into the anchoring groove, and then the slurry scraper 4 smooths the surface slurry on the artificial leather strip. For some specific products, the coating support roller 2 can be set as an outwardly convex arc roller, and the corresponding coating wheel 3 can be set as an inwardly concave arc roller, which can produce artificial leather products with a slightly convex arc surface suitable for specific applications.

[0062] Example 3

[0063] like Figure 6 As shown, this invention also discloses an artificial leather product. The artificial leather product of this invention is a curved artificial leather 9 comprising a base fabric layer 901, a foam layer 902, and a surface layer 904 sequentially laminated together from bottom to top. Multiple anchoring grooves 903 are evenly spaced on the top surface of the foam layer 902, and the surface layer 904 partially fills the anchoring grooves 903. This increases the bonding area between the foam layer 902 and the surface layer 904, and the newly created anchoring grooves 903 can bond well with the surface layer 904. The two side walls of the anchoring grooves 903 are open, and the base fabric layer 901, foam layer 902, and surface layer 904 all exhibit an outwardly convex curved shape.

[0064] It should be noted that if a pattern is made on the foam layer 902 of the curved artificial leather 9 with anchor groove 903, it is necessary to consider whether the anchor groove 903 will have a significant impact on the visual appearance of the leather pattern. If it has a significant impact, it is not recommended to make it as curved artificial leather 9.

[0065] Curved artificial leather 9 has a slightly convex surface, making it suitable for manufacturing products such as chair backs, cushions, and sofa surfaces. The surface of these products convexes slightly outwards due to the internal filling material, allowing for better shaping, a more aesthetically pleasing appearance, and less bending pre-stress. This also reduces the likelihood of the artificial leather surface tearing or cracking, increasing the product's lifespan.

[0066] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0067] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A surface treatment apparatus for artificial leather, comprising a surface treatment machine frame, a coating support roller (2), a coating wheel (3), a slurry scraper (4), and an oven (7), characterized in that, It also includes a grooving support roller (1) and a grooving knife assembly (8). The grooving support roller (1) is rotatably mounted on the frame of the surface treatment machine. The grooving support roller (1) is horizontally mounted in front of the coating support roller (2). The grooving knife assembly (8) is fitted and mounted below the grooving support roller (1). The grooving knife assembly (8) includes a knife holder assembly, a guide drive assembly, a knife shaft (813), and a disc knife (807). The guide drive assembly is mounted on the frame of the surface treatment machine and can drive the knife holder assembly to perform knife advance and retraction actions. The knife shaft (813) is horizontally mounted on the top of the knife holder assembly. Multiple disc knives (807) are equidistantly and coaxially rotatably mounted on the knife shaft (813). The top of the disc knife (807) can contact and cut the artificial leather foam layer. The grooving cutter assembly (8) also includes a heating sleeve (812), which is coaxially arranged on both sides of the disc cutter (807) and is fixedly connected to the cutter shaft (813). The tool holder assembly includes an intermediate support plate (803), a tool holder plate support leg (804), a compression spring (805), a tool holder plate (814), and a tool shaft bracket plate (806). The tool shaft bracket plate (806) supports the tool shaft (813) on the tool holder plate (814). The tool holder plate (814) is connected to the intermediate support plate (803) through multiple sets of tool holder plate support legs (804) and compression springs (805) on its bottom surface. The compression springs (805) are sleeved on the tool holder plate support legs (804) and their two ends abut against the tool holder plate (814) and the intermediate support plate (803). One end of the tool holder plate support leg (804) connected to the intermediate support plate (803) is set as a screw section. An adjusting nut is screwed onto the bottom surface of the intermediate support plate (803) of the screw section.

2. The artificial leather surface treatment apparatus according to claim 1, characterized in that: The guide drive assembly includes a support plate frame (801), a linear drive unit (802), guide posts (810), and a guide sleeve (811). The support plate frame (801) is connected to the surface treatment machine frame. The end flange of the linear drive unit (802) is connected to the bottom surface of the support plate frame (801). The working end of the linear drive unit (802) extends upward and is connected to the bottom surface of the intermediate support plate (803). The top ends of the multiple guide posts (810) are fixedly connected to the intermediate support plate (803). The vertically downward bottom ends of the guide posts (810) are slidably connected to the guide sleeve (811). The guide sleeve (811) is fixedly connected to the top surface of the support plate frame (801).

3. The artificial leather surface treatment apparatus according to claim 1, characterized in that: It also includes a limiting cover (808), which is a U-shaped plate cover with the opening facing downward. The bottom flange of the limiting cover (808) is connected to the intermediate support plate (803). The top plate of the limiting cover (808) is provided with a narrow slit at the disc cutter (807) to facilitate the exposure of the blade.

4. A surface treatment process for artificial leather, characterized in that, Processing with the artificial leather surface treatment apparatus according to any one of claims 1 to 3 includes the following steps: S1, grooving: anchoring grooves are opened on the top surface of the artificial leather foam layer, and a plurality of anchoring grooves are equally spaced along the width direction of the artificial leather, the opening direction of the anchoring grooves being consistent with the conveying direction of the artificial leather; S2, coating: a coating wheel is used to apply a surface slurry to the foam surface of the artificial leather, the slurry filling the anchoring grooves and the entire large surface, and a scraper is used to smooth it; S3, drying: the coated artificial leather is continuously dried in an oven, cooled, and then rolled up.

5. The artificial leather surface treatment process according to claim 4, characterized in that: The depth of the anchoring groove is no more than one-third of the thickness of the foam layer.

6. The artificial leather surface treatment process according to claim 5, characterized in that: The bottom surface of the anchoring groove is an arc-shaped bottom surface, and the anchoring groove is formed by hot cutting.

7. The artificial leather surface treatment process according to claim 4, characterized in that: It also includes a cleaning process set between S1 and S2, which involves exhausting and adsorbing the anchoring groove and the top surface of the foam layer for cleaning.

8. The artificial leather surface treatment process according to claim 4, characterized in that: In the S2 process, the artificial leather is coated with slurry under the support of the convex arc roller surface, and the two side walls of the anchoring groove are open to facilitate the full wetting and filling of the slurry.

9. A synthetic leather product, characterized in that: The artificial leather surface treatment device described in any one of claims 1 to 3 is used for processing to form an arc-shaped artificial leather (9), which includes a base fabric layer (901), a foam layer (902), and a surface layer (904) sequentially bonded together from bottom to top. A plurality of anchoring grooves (903) are evenly spaced on the top surface of the foam layer (902), and the surface layer (904) is partially filled into the anchoring grooves (903). The two side walls of the anchoring grooves (903) are open, and the base fabric layer (901), the foam layer (902), and the surface layer (904) all present an outwardly convex arc shape.

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