Fabric preparation system and method and sofa

Abstract

The application relates to the technical field of furniture manufacturing, in particular to a cloth manufacturing system and method and a sofa. The system comprises a rack, a cloth unwinding mechanism arranged on the rack, a cloth rolling mechanism, a glue film unwinding mechanism, a cotton core unwinding mechanism, a compounding mechanism, a blending and softening mechanism, a cleaning mechanism, a drying mechanism and a discharging mechanism. The cloth unwinding mechanism is used for feeding cloth towards the cloth rolling mechanism, and the cloth rolling mechanism is used for rolling the upper surface of the cloth to form an upper indentation. The glue film unwinding mechanism is used for guiding glue film material towards the compounding mechanism, and the cotton core unwinding mechanism is used for unwinding cotton core material towards the compounding mechanism. The glue film material is located between the cloth and the cotton core material. The cloth and the cotton core are prepared in an integrated manner to serve as the packaging cloth of the sofa, and the problem that the existing sofa is difficult to coat with external cloth and has a large workload is solved. The integrated structure of the cotton core cloth can be directly coated, time cost is saved, and efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of furniture manufacturing technology, and in particular to a fabric manufacturing system and method and a sofa. Background Technology

[0002] Sofa fabrics are the textiles used in the manufacture of sofas, and they come in a wide variety, each with its own characteristics. Common sofa fabrics include pure cotton, linen, polyester, velvet, genuine leather, and synthetic leather. Pure cotton fabric is known for its comfort and skin-friendliness, breathability, and softness, but it wrinkles easily and has average durability. Linen fabric is favored for its coolness, breathability, durability, and antibacterial properties; however, it wrinkles easily and is relatively expensive. Polyester, as a man-made material, is strong, durable, and easy to clean, but its breathability is relatively poor. Blended fabrics, such as cotton-polyester blends, combine the comfort of cotton with the durability of polyester, offering a variety of design options.

[0003] In the current sofa fabric manufacturing process, the fabric is produced separately. When used on a sofa, a cotton core needs to be wrapped around it before the fabric is wrapped around the sofa. This method involves an extra wrapping process for the cotton core, which increases the workload and affects production efficiency. Therefore, new improvements are needed to the existing sofa fabric manufacturing process. Summary of the Invention

[0004] To address the aforementioned problems, this invention integrates the fabric and cotton core into a single unit, serving as the packaging fabric for sofas. This solves the issues of high difficulty and workload associated with existing sofa external coverings. The integrated cotton core and fabric structure allows for direct covering, saving time and costs, and improving efficiency in fabric preparation systems, methods, and sofas.

[0005] The technical solution adopted in this invention is: a fabric preparation system, including a frame, a fabric unwinding mechanism, a fabric rolling mechanism, an adhesive film unwinding mechanism, a cotton core unwinding mechanism, a laminating mechanism, a blending and softening mechanism, a washing mechanism, a drying mechanism, and a feeding mechanism, wherein the fabric unwinding mechanism is used to unwind the fabric toward the fabric rolling mechanism, and the fabric rolling mechanism is used to roll indentations onto the upper surface of the fabric; the adhesive film unwinding mechanism is used to guide the adhesive film material toward the laminating mechanism, and the cotton core unwinding mechanism is used to unwind the cotton core material toward the laminating mechanism, with the adhesive film material located between the fabric and the cotton core material.

[0006] A further improvement to the above scheme is that the composite mechanism includes a hot roller composite assembly, a hot spray assembly, and a composite roller pressing assembly arranged sequentially; the hot roller composite assembly includes two sets of hot press rollers with tangent outer diameters to press the fabric and cotton core material together and heat-melt the adhesive film to bond the fabric and cotton core material; a first composite heating element is provided inside the hot press roller; the hot spray assembly is located on one side of the hot press roller and blows hot air toward the fabric to heat-melt the adhesive film; the composite roller pressing assembly is used to press the heat-melted adhesive film with the fabric and cotton core material so that the adhesive film penetrates and connects the fabric and cotton core material.

[0007] A further improvement to the above solution is that the blending and softening mechanism is used to blend and soften the material by roller pressing, the cleaning mechanism is used to clean one side of the fabric, the drying mechanism is used to dry the cleaned material, and the feeding mechanism is used to roll up the dried material.

[0008] A further improvement to the above solution is that the fabric unwinding mechanism includes a fabric unwinding shaft, an unwinding shaft fixing seat, an unwinding shaft connecting arm, and an unwinding shaft drive module. The unwinding shaft fixing seat is disposed on both sides of the frame. The fabric unwinding shaft is rotatably disposed on the unwinding shaft fixing seat. The unwinding shaft connecting arm is disposed on the fabric unwinding shaft. The unwinding shaft drive module is used to drive the fabric unwinding shaft to rotate, thereby driving the unwinding shaft connecting arm to rotate. An unwinding fixing groove is provided on one side of the unwinding shaft connecting arm, and the unwinding fixing groove is used to fix the fabric roll. A feeding guide roller is disposed on one side of the frame located on the fabric unwinding shaft. A feeding guide panel is disposed on one side of the feeding guide roller. The feeding guide panel is provided with an inclined surface, and the inclined surface is inclined toward the hot roller composite assembly.

[0009] A further improvement to the above scheme is that the fabric rolling mechanism includes a flattening clamping roller group and an indentation roller group. The flattening clamping roller group is provided with two sets of flattening guide rollers to flatten the fabric before feeding it into the indentation roller group. The indentation roller group includes an indentation roller and a support roller. The outer diameter of the indentation roller is tangent to that of the support roller. The outer circumference of the indentation roller is provided with indentation teeth to roll and form indentations on the upper surface of the fabric.

[0010] A further improvement to the above solution is that the film unwinding mechanism includes a film unwinding bracket, a film unwinding assembly, and film unwinding guide rollers. The film unwinding assembly is mounted on the film unwinding bracket, and multiple film unwinding guide rollers are provided to guide the film material toward the laminating mechanism.

[0011] A further improvement to the above scheme is that the cotton core unwinding mechanism includes a cotton core unwinding bracket, a cotton core unwinding assembly, and cotton core unwinding guide rollers. The cotton core unwinding assembly is mounted on the cotton core unwinding bracket. Multiple cotton core unwinding guide rollers are provided and used to guide the cotton core material toward the composite mechanism. A Z-shaped guide line is formed between the multiple cotton core unwinding rollers. The cotton core unwinding bracket is located above the hot roller composite assembly.

[0012] A further improvement to the above scheme is that multiple first composite heating elements are provided, and the multiple first composite heating elements are evenly distributed in a ring around the outer periphery of the hot press roller; the hot spray assembly is a hot air spray gun, which is equipped with a heating element inside to generate hot air to heat melt the adhesive film; the hot spray assembly is provided in two sets and is symmetrically arranged to blow hot air onto both sides of the material respectively; the cotton core is an open-cell foam pad to heat the adhesive film through the opening gap.

[0013] A further improvement to the above scheme is that the composite roller pressing assembly is provided with two sets of composite rollers with tangent outer diameters. A second composite heating element is provided on the outer periphery of the composite roller to heat the composite roller. The two sets of composite rollers are used to press the fabric and cotton core material respectively, so that the adhesive film can penetrate and bond with the fabric and cotton core material after being heated and melted. A cooling nozzle is provided on the rear side of the composite roller pressing assembly. Two sets of cooling nozzles are provided to blow air to cool the fabric and cotton core material respectively, so that the adhesive film material cools and solidifies.

[0014] A further improvement to the above scheme is that the blending and softening mechanism includes at least two sets of blending rollers and at least one set of flattening rollers. The blending roller sets include two sets of blending pressure rollers with tangent outer diameters. Roller strips and roller grooves are spaced apart on the outer circumference of the blending pressure rollers. The two sets of blending rollers cooperate with each other through the roller strips and roller grooves to blend and soften the cured adhesive film material. The flattening roller set is used to flatten the material after it has been blended and pressed.

[0015] A further improvement to the above solution is that the cleaning mechanism includes a wet cleaning component and a dry cleaning component. The wet cleaning component includes a cleaning tank, a wet cleaning brush roller, and a wet cleaning pressure roller. The cleaning tank is filled with cleaning liquid. One side of the wet cleaning brush is immersed in the cleaning liquid. There are two wet cleaning brush rollers. The wet cleaning pressure roller is positioned between the two sets of wet cleaning brush rollers.

[0016] A further improvement to the above solution is that the drying and cleaning assembly includes a drying and cleaning brush and a drying and cleaning roller. The drying and cleaning brush is used to dry and clean the fabric after it has been cleaned with wet water, so as to remove excess moisture from the surface of the fabric.

[0017] A further improvement to the above solution is that the drying mechanism includes a drying nozzle and a drying hood, the drying nozzle and the drying hood are arranged opposite to each other, the drying nozzle is directed toward the cotton core material to blow air toward the cotton core material and blow the moisture of the fabric toward the drying hood.

[0018] A method for preparing fabric, comprising the aforementioned fabric preparation system;

[0019] The fabric preparation method includes the following steps:

[0020] Step S1, Fabric unwinding: The fabric is unwound by the fabric unwinding mechanism and guided toward the fabric rolling mechanism by the guide roller. The fabric is rolled by the fabric rolling mechanism and indentations are rolled onto the upper surface of the fabric.

[0021] Step S2, material unwinding: After the upper surface of the fabric is crimped by the roller, it is conveyed toward the laminating mechanism. At the same time, the adhesive film unwinding mechanism conveys the hot melt adhesive film toward the laminating mechanism, and the cotton core unwinding mechanism conveys the cotton core material toward the laminating mechanism. From bottom to top, the order is fabric, hot melt adhesive film and cotton core.

[0022] Step S3, Thermal Lamination: The fabric and cotton core are first rolled using a thermal roller lamination assembly. During the rolling process, the fabric and cotton core are heated by a first composite heating assembly, and the heat is transferred to the hot melt adhesive film. The hot melt adhesive film is BOPE with a melting point of 125℃~130℃. The temperature of the hot roller is controlled at 200~250℃. The cotton core is a cotton core layer made of cotton, and the fabric layer is cotton-linen or blended fabric. During the rolling process, heat is transferred to the hot melt adhesive film, thereby softening the BOPE. After rolling, the fabric and cotton core are bonded together. After bonding, the adhesive film is further thermally sprayed by a thermal spray assembly to melt the adhesive film. After melting, it is rolled again by the composite roller pressing assembly, so that the melted adhesive film penetrates and connects the fabric and the hot melt adhesive film. Then the hot melt adhesive film is cooled and shaped.

[0023] Step S4, blending and softening: After the hot melt adhesive film is cooled and shaped, the fabric and cotton core are kept in an adhesive state. The material is then rolled and blended by a blending and softening mechanism. After blending, the material is flattened to ensure its softness.

[0024] Step S5: Fabric cleaning. After blending and softening, the material is flattened and transported. During the transport process, one side of the fabric is cleaned with a cleaning brush. After cleaning, the cleaned fabric is dried by blowing air through a drying mechanism. Finally, the dried material is rolled up.

[0025] A sofa includes a fabric prepared by a fabric preparation method, wherein a cotton core, an adhesive film, and the fabric are sequentially wrapped around the outside of the sofa frame from the inside out.

[0026] The beneficial effects of this invention are:

[0027] Compared to existing fabric preparation methods, this invention integrates the fabric and cotton core into a single unit, serving as the wrapping fabric for sofas. This solves the problems of high difficulty and workload associated with current sofa wrapping methods. The integrated cotton core and fabric structure allows for direct wrapping, saving time and increasing efficiency.

[0028] This invention automates the entire fabric preparation process through the coordinated operation of various mechanisms, significantly improving production efficiency, reducing manual intervention, and lowering production costs. It integrates multiple functions such as fabric unwinding, rolling, film unwinding, wick unwinding, lamination, blending and softening, washing, drying, and unloading, making the entire production process more compact and efficient. The fabric rolling mechanism creates indentations on the fabric surface, increasing its three-dimensionality and aesthetics; the blending and softening mechanism softens the material through rolling, improving its softness and comfort; the washing mechanism cleans one side of the fabric, ensuring cleanliness; and the drying mechanism dries the washed material, ensuring optimal dryness. Precise unwinding of the fabric, film, and wick ensures the continuity and stability of raw material supply. The fabric rolling mechanism accurately creates indentations on the fabric, providing a good bonding foundation for subsequent lamination. The composite structure cleverly combines the fabric, adhesive film, and cotton core, achieving a seamless fusion of multiple layers and enhancing the fabric's warmth, comfort, and durability. The application of a blending and softening mechanism, through roller blending technology, effectively promotes the interpenetration and softening of materials, further improving the overall performance of the composite material. Subsequently, a cleaning mechanism deeply cleans the fabric surface, removing impurities that may have been generated during processing and ensuring product cleanliness. The drying mechanism quickly and evenly removes moisture from the material, avoiding the risk of mold growth while maintaining the material's original properties.

[0029] The composite mechanism, through two sets of tangentially sized hot-press rollers in the hot-roll composite assembly, not only achieves tight rolling of the fabric and cotton core material, but also utilizes a built-in first composite heating element with a highly efficient hot-melt adhesive film to ensure a strong bond between the fabric and the cotton core, enhancing the overall structural strength and durability of the sofa fabric. The ingenious design of the hot-spray assembly further strengthens the hot-melt effect; the hot air blown towards the fabric side precisely acts on the adhesive film, promoting rapid and uniform melting of the film, avoiding localized overheating or incomplete melting, and optimizing the bonding quality. Finally, the pressing action of the composite roller assembly not only tightly presses the hot-melt adhesive film with the fabric and cotton core material, but also promotes the penetration of the adhesive film into the interior of the fabric and cotton core material, achieving a tighter and more durable connection between the three, significantly improving the comfort and lifespan of the sofa fabric. In summary, the application of this composite mechanism in sofa fabric production achieves efficient and high-quality production goals, meeting the high-quality demands of the modern home furnishing market for sofa products.

[0030] This fabric preparation method achieves a strong bond between the fabric and the cotton core through precisely controlled rolling and heating processes. In particular, the use of BOPE hot melt adhesive film, with its suitable melting point range matching the hot roller temperature, ensures bonding strength while avoiding potential damage to the fabric and cotton core from high temperatures. Secondly, the secondary heating of the thermal spraying assembly and the composite rolling further promote the penetration and bonding of the hot melt adhesive film between the fabric and the cotton core, enhancing the overall structural stability and durability. Furthermore, the application of a softening mechanism effectively improves the product's softness and comfort, meeting the high demands of modern textiles for texture. Finally, the introduction of washing and drying steps not only removes impurities that may arise during production but also prevents fabric mildew and deformation through drying, ensuring the cleanliness and smoothness of the final product. In conclusion, this preparation method significantly improves fabric quality and added value while increasing production efficiency, and has broad market application prospects. Attached Figure Description

[0031] Figure 1 This is a three-dimensional schematic diagram of the fabric preparation system of the present invention;

[0032] Figure 2 for Figure 1 A three-dimensional schematic diagram of the fabric preparation system from another perspective;

[0033] Figure 3 for Figure 1 A schematic diagram of part of the fabric preparation system;

[0034] Figure 4 for Figure 1 Schematic diagram of the fabric preparation system;

[0035] Figure 5 for Figure 4 A schematic diagram of the fabric unwinding mechanism in the fabric preparation system;

[0036] Figure 6 for Figure 4 A schematic diagram of the fabric rolling mechanism in the fabric preparation system;

[0037] Figure 7 for Figure 4 A schematic diagram of the film unwinding mechanism of the fabric preparation system;

[0038] Figure 8 for Figure 4 A schematic diagram of the cotton core unwinding mechanism in the fabric preparation system;

[0039] Figure 9 for Figure 4 A schematic diagram of the composite mechanism of the fabric preparation system;

[0040] Figure 10 for Figure 4 A schematic diagram of the blending and softening mechanism in the fabric preparation system;

[0041] Figure 11 for Figure 4 A schematic diagram of the cleaning mechanism in the fabric preparation system;

[0042] Figure 12 for Figure 4 A schematic diagram of the drying mechanism of the fabric preparation system;

[0043] Figure 13 This is a schematic flowchart of the fabric preparation method of the present invention.

[0044] Explanation of reference numerals in the attached drawings: 1. Fabric unwinding mechanism; 11. Fabric unwinding shaft; 111. Unwinding guide roller; 112. Unwinding guide panel; 12. Unwinding shaft fixing seat; 13. Unwinding shaft connecting arm; 131. Unwinding fixing groove; 14. Unwinding shaft drive module.

[0045] Fabric roller pressing mechanism 2, flattening clamping roller group 21, flattening guide roller 211, indentation roller group 22, indentation roller 221, support roller 222;

[0046] 3. Film unwinding mechanism; 31. Film unwinding bracket; 32. Film unwinding assembly; 33. Film unwinding guide roller;

[0047] 4. Cotton core unwinding mechanism; 41. Cotton core unwinding bracket; 42. Cotton core unwinding assembly; 43. Cotton core unwinding guide roller;

[0048] Composite mechanism 5, hot roller composite assembly 51, hot press roller 511, first composite heating element 512, hot spray assembly 52, composite roller pressing assembly 53, composite press roller 531, second composite heating element 532, cooling nozzle 533;

[0049] The blending and softening mechanism 6, the blending roller group 61, the blending pressure roller 611, the roller pressing strip 612, the roller pressing groove 613, and the flattening roller group 62;

[0050] Cleaning mechanism 7, wet cleaning component 71, cleaning box 711, wet cleaning brush roller 712, wet cleaning pressure roller 713, dry cleaning component 72, dry cleaning brush 721, dry cleaning pressure roller 722;

[0051] Drying mechanism 8, drying nozzle 81, drying hood 82, drying buffer roller 83, feeding mechanism 9. Detailed Implementation

[0052] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention.

[0053] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component.

[0054] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Figures 1-13 As shown, in one embodiment of the present invention, a fabric preparation system is disclosed, including a frame, a fabric unwinding mechanism 1, a fabric rolling mechanism 2, a film unwinding mechanism 3, a wick unwinding mechanism 4, a composite mechanism 5, a blending and softening mechanism 6, a washing mechanism 7, a drying mechanism 8, and a feeding mechanism 9, all mounted on the frame. The fabric unwinding mechanism 1 unwinds the fabric towards the fabric rolling mechanism 2, which indents the upper surface of the fabric. The film unwinding mechanism 3 guides the film material towards the composite mechanism 5, and the wick unwinding mechanism 4 unwinds the wick material towards the composite mechanism 5, with the film material positioned between the fabric and the wick material. The blending and softening mechanism 6 performs rolling, blending, and softening of the material. The washing mechanism 7 cleans one side of the fabric. The drying mechanism 8 dries the cleaned material, and the feeding mechanism 9 rewinds the dried material. This invention integrates fabric and cotton core into a single unit, serving as the wrapping material for sofas. This solves the problems of high difficulty and workload associated with existing sofa wrapping materials. The integrated cotton core and fabric structure allows for direct wrapping, saving time and increasing efficiency.

[0055] This embodiment achieves full automation of fabric preparation through the coordinated operation of various mechanisms, greatly improving production efficiency, reducing manual intervention, and lowering production costs. It integrates multiple functions such as fabric unwinding, rolling, film unwinding, wick unwinding, lamination, blending and softening, washing, drying, and unloading, making the entire production process more compact and efficient. The fabric rolling mechanism 2 can roll indentations on the upper surface of the fabric, increasing its three-dimensionality and aesthetics; the blending and softening mechanism 6 can roll and blend the material, improving its softness and comfort; the washing mechanism 7 can clean one side of the fabric, ensuring its cleanliness; and the drying mechanism 8 can dry the washed material, ensuring its dryness. From the precise unwinding of the fabric, film, and wick, the continuity and stability of raw material supply are ensured. The fabric rolling mechanism 2 precisely forms indentations on the fabric, providing a good bonding foundation for subsequent lamination. The composite mechanism 5 cleverly combines the fabric, adhesive film, and cotton core, achieving a seamless fusion of multiple layers and enhancing the fabric's warmth, comfort, and durability. The blending and softening mechanism 6, through roller blending technology, effectively promotes the interpenetration and softening of materials, further improving the overall performance of the composite material. Subsequently, the cleaning mechanism 7 deeply cleans the fabric surface, removing impurities that may have been generated during processing and ensuring product cleanliness. The drying mechanism 8 quickly and evenly removes moisture from the material, avoiding the risk of mold growth while maintaining the material's original properties.

[0056] See Figure 5As shown, the fabric unwinding mechanism 1 includes a fabric unwinding shaft 11, an unwinding shaft fixing seat 12, an unwinding shaft connecting arm 13, and an unwinding shaft drive module 14. The unwinding shaft fixing seat 12 is disposed on both sides of the frame. The fabric unwinding shaft 11 is rotatably disposed on the unwinding shaft fixing seat 12. The unwinding shaft connecting arm 13 is disposed on the fabric unwinding shaft 11. The unwinding shaft drive module 14 is used to drive the fabric unwinding shaft 11 to rotate, thereby driving the unwinding shaft connecting arm 13 to rotate. An unwinding fixing groove 131 is provided on one side of the unwinding shaft connecting arm 13, which is used to fix the fabric roll. A feeding guide roller 111 is disposed on one side of the frame located on the fabric unwinding shaft 11. A feeding guide panel 112 is disposed on one side of the feeding guide roller 111. The feeding guide panel 112 is provided with an inclined surface, which is inclined toward the hot roller composite assembly 51. In this embodiment, the precisely designed unwinding shaft and fixing seat structure ensures the stable placement and rotation of the fabric roll, effectively reducing tension fluctuations during the unwinding process and guaranteeing the flatness of the fabric. The design of the unwinding shaft connecting arm 13 and its fixing groove enhances the stability of the fabric fixation, preventing deviation and loosening during the unwinding process. Furthermore, the inclined design of the unwinding guide roller 111 and the guide panel enables a smooth transition and precise guidance of the fabric to the hot roller composite assembly 51, improving production efficiency and optimizing the uniformity and quality of the fabric composite.

[0057] See Figure 6 As shown, the fabric rolling mechanism 2 includes a flattening clamping roller group 21 and an indentation roller group 22. The flattening clamping roller group 21 is equipped with two sets of flattening guide rollers 211 to flatten the fabric before feeding it into the indentation roller group 22. The indentation roller group 22 includes an indentation roller 221 and a support roller 222. The outer diameter of the indentation roller 221 is tangent to that of the support roller 222, and the outer circumference of the indentation roller 221 is provided with indentation teeth to roll and form indentations on the upper surface of the fabric. In this embodiment, through the precise cooperation of the flattening clamping roller group 21, the two sets of flattening guide rollers 211 effectively ensure that the sofa fabric reaches a high degree of flatness before entering the next process, eliminating wrinkles and unevenness, and laying a solid foundation for subsequent processing. The introduction of the indentation roller group 221 further enhances the texture and aesthetics of the sofa fabric. The ingenious design of the indentation roller 221 and the support roller 222 enables the indentation teeth to accurately roll out a uniform texture on the fabric surface, which facilitates a more uniform and stable bonding process and higher connection strength in the subsequent thermal bonding process.

[0058] See Figures 7-8As shown, the film unwinding mechanism 3 includes a film unwinding bracket 31, a film unwinding assembly 32, and film unwinding guide rollers 33. The film unwinding assembly 32 is mounted on the film unwinding bracket 31, and multiple film unwinding guide rollers 33 are provided to guide the film material toward the laminating mechanism 5. Specifically, the wick unwinding mechanism 4 includes a wick unwinding bracket 41, a wick unwinding assembly 42, and wick unwinding guide rollers 43. The wick unwinding assembly 42 is mounted on the wick unwinding bracket 41, and multiple wick unwinding guide rollers 43 are provided to guide the wick material toward the laminating mechanism 5. A Z-shaped guide line is formed between the multiple wick unwinding rollers. The wick unwinding bracket 41 is located above the hot roller laminating assembly 51. In this embodiment, the film unwinding mechanism 3, through a precisely controlled guide roller system, ensures that the film material is smoothly and continuously guided to the laminating mechanism 5, effectively avoiding wrinkles and deviations, and providing a stable foundation for subsequent lamination. The cotton core unwinding mechanism 4, with its Z-shaped guide line design, not only optimizes the material flow path but also promotes the uniform distribution and tension balance of the cotton core, further enhancing the bonding force between the composite layers. Furthermore, the precise positioning of the cotton core unwinding bracket 41 above the hot roller composite assembly 51 ensures accurate alignment and efficient hot pressing during the composite process, thereby producing sofa fabrics with stable structure and excellent texture, meeting the market's demand for high-quality home furnishings.

[0059] See Figure 9As shown, the composite mechanism 5 includes a hot roller composite assembly 51, a hot spray assembly 52, and a composite roller pressing assembly 53 arranged sequentially. The hot roller composite assembly 51 includes two sets of hot rollers 511 with tangent outer diameters to roll the fabric and cotton core material together and heat-melt the adhesive film, thus bonding the fabric and cotton core material. A first composite heating element 512 is provided inside the hot roller 511. The hot spray assembly 52 is located on one side of the hot roller 511 and blows hot air toward the fabric to heat-melt the adhesive film. The composite roller pressing assembly 53 is used to press the heat-melted adhesive film with the fabric and cotton core material, so that the adhesive film penetrates and connects the fabric and cotton core material. In this embodiment, the two sets of hot rollers 511 with tangent outer diameters in the hot roller composite assembly 51 not only achieve tight rolling of the fabric and cotton core material, but also utilize the built-in first composite heating element 512 to efficiently heat-melt the adhesive film, ensuring a strong bond between the fabric and the cotton core, and enhancing the overall structural strength and durability of the sofa fabric. The ingenious design of the thermal spray component 52 further enhances the heat-melting effect. The hot air blown onto the fabric side precisely targets the adhesive film, promoting rapid and uniform melting and preventing localized overheating or incomplete melting, thus optimizing the bonding quality. Finally, the pressing action of the composite roller pressing component 53 not only tightly presses the heat-melted adhesive film against the fabric and cotton core material but also promotes the penetration of the adhesive film into the fabric and cotton core material, achieving a tighter and more durable bond among the three, significantly improving the comfort and lifespan of the sofa fabric. In conclusion, the application of this composite mechanism 5 in sofa fabric preparation achieves efficient and high-quality production goals, meeting the high-quality demands of the modern home furnishing market for sofa products.

[0060] Multiple first composite heating elements 512 are arranged in a circumferential pattern around the outer periphery of the hot press roller 511. The thermal spray assembly 52 is a hot air gun with a heating element inside to generate hot air for melting the adhesive film. Two sets of thermal spray assemblies 52 are arranged symmetrically to blow hot air onto both sides of the material. The cotton core is an open-cell foam pad that heats the adhesive film through the openings. In this embodiment, firstly, the multiple circumferentially arranged first composite heating elements 512 effectively improve the heating uniformity of the hot press roller 511, ensuring the consistency of the adhesive film melting process, avoiding local overheating or underheating, and improving product quality. Secondly, the two symmetrically arranged hot air guns, as thermal spray assemblies 52, can directly and efficiently heat both sides of the material with hot air, accelerating the softening and fusion of the adhesive film and enhancing the adhesion and stability between the fabric layers. Finally, the perforated foam pad, designed as a cotton core, not only achieves good heat insulation, but also effectively transfers heat through its perforations, further promoting uniform heating and rapid melting of the adhesive film, thus optimizing the overall preparation efficiency and quality of the sofa fabric.

[0061] The composite roller pressing assembly 53 is equipped with two sets of composite rollers 531 with tangent outer diameters. A second composite heating element 532 is provided on the outer periphery of each composite roller 531 to heat it. The two sets of composite rollers 531 are used to press the fabric and the cotton core material respectively, allowing the adhesive film to penetrate and bond with them after hot melting. A cooling nozzle 533 is provided on the rear side of the composite roller pressing assembly 53. Two sets of cooling nozzles 533 are provided to blow air onto the fabric and the cotton core material respectively, allowing the adhesive film to cool and solidify. In this embodiment, the composite roller pressing assembly 53, combined with two sets of composite rollers 531 with tangent outer diameters and equipped with the second composite heating element 532, effectively achieves precise pressing of the fabric and the cotton core material and efficient penetration and bonding of the hot melt adhesive film. This design ensures that the adhesive film is evenly distributed between the fabric and the cotton core, significantly improving the structural strength and durability of the sofa fabric. Subsequently, the dual cooling nozzles 533 are used to selectively cool the fabric and cotton core materials with air, promoting rapid cooling and solidification of the hot melt adhesive film, further strengthening the bonding effect, and optimizing production efficiency. Overall, this technical solution not only improves the processing quality of sofa fabrics but also shortens the production cycle, representing a significant technological innovation in the sofa manufacturing industry.

[0062] See Figure 10 As shown, the blending and softening mechanism 6 includes at least two sets of blending roller groups 61 and at least one set of flattening roller groups 62. Each blending roller group 61 includes two sets of blending pressure rollers 611 with tangential outer diameters. Roller strips 612 and roller grooves 613 are spaced apart on the outer circumference of each blending pressure roller 611. The two sets of blending roller groups 61 cooperate with each other through the roller strips 612 and roller grooves 613 to blend and soften the cured adhesive film material. The flattening roller group 62 is used to flatten the material after blending and pressing. In this embodiment, the introduction of the blending and softening mechanism 6 significantly improves material processing efficiency and quality. This mechanism, through the synergistic action of at least two sets of blending rollers 61, utilizes tangentially shaped blending pressure rollers 611 and their meticulously designed roller pressing strips 612 and roller pressing grooves 613 to achieve effective roller pressing and blending of the cured adhesive film material. This effectively softens the material, promotes tight bonding and uniform distribution between fibers, and enhances the fabric's flexibility and durability. Subsequently, at least one set of flattening rollers 62 further refines and flattens the material, ensuring a smooth and wrinkle-free surface for the sofa fabric, improving the final product's aesthetics and comfort, and meeting the stringent quality and feel requirements of high-end sofa fabrics.

[0063] See Figures 11-12As shown, the cleaning mechanism 7 includes a wet cleaning component 71 and a dry cleaning component 72. The wet cleaning component 71 includes a cleaning tank 711, a wet cleaning brush roller 712, and a wet cleaning pressure roller 713. The cleaning tank 711 contains cleaning liquid, and one side of the wet cleaning brush is immersed in the cleaning liquid. There are two wet cleaning brush rollers 712, and the wet cleaning pressure roller 713 is positioned between the two sets of wet cleaning brush rollers 712. Specifically, the dry cleaning component 72 includes a dry cleaning brush 721 and a dry cleaning pressure roller 722. The dry cleaning brush 721 is used to dry the fabric after wet cleaning to remove excess moisture from the fabric surface. The drying mechanism 8 includes a drying nozzle 81 and a drying hood 82. The drying nozzle 81 is positioned opposite the drying hood 82, and the drying nozzle 81 is directed towards the cotton core material to blow air towards the cotton core material and blow the moisture from the fabric towards the drying hood 82. In this embodiment, two major modules, wet cleaning and drying, are integrated to ensure efficient and thorough fabric processing. The wet cleaning component 71 is cleverly designed, containing a cleaning tank 711 to store cleaning solution, a dual-roller configuration of wet brush rollers, and an intermediate pressure roller to effectively penetrate and remove deep-seated dirt from the fabric. Subsequently, the drying cleaning component 72 takes over, using a combination of drying brushes and pressure rollers to quickly absorb and remove residual moisture from the fabric surface, achieving initial drying. Finally, the drying mechanism 8, with its precise layout, integrates drying nozzles 81 and a drying hood 82. Directional airflow accelerates the evaporation of moisture from the fabric, guiding the humid airflow towards the drying hood 82 to ensure rapid and complete drying of the fabric, improving overall processing efficiency and quality. The drying mechanism 8 also includes multiple drying buffer rollers 83, which extend the material transport path, thereby prolonging the drying effect.

[0064] A method for preparing fabric, comprising the aforementioned fabric preparation system;

[0065] The fabric preparation method includes the following steps:

[0066] Step S1, Fabric unwinding: The fabric is unwound by the fabric unwinding mechanism 1 and guided toward the fabric rolling mechanism 2 by the guide roller. The fabric is rolled by the fabric rolling mechanism 2 and indentations are rolled onto the upper surface of the fabric.

[0067] Step S2, material unwinding: After the upper surface of the fabric is pressed by the creasing roller 221, it is conveyed toward the laminating mechanism 5. At the same time, the adhesive film unwinding mechanism 3 conveys the hot melt adhesive film toward the laminating mechanism 5, and the cotton core unwinding mechanism 4 conveys the cotton core material toward the laminating mechanism 5. From bottom to top, the order is fabric, hot melt adhesive film and cotton core.

[0068] Step S3, thermal lamination: The fabric and cotton core are first rolled by the hot roller lamination component 51. During the rolling process, the fabric and cotton core are heated by the first composite heating component, and the heat is transferred to the hot melt adhesive film. The hot melt adhesive film is BOPE with a melting point of 125℃~130℃. The temperature of the hot press roller 511 is controlled at 200~250℃. The cotton core is a cotton core layer made of cotton, and the fabric layer is cotton-linen fabric or blended fabric. During the rolling process, the heat is transferred to the hot melt adhesive film, thereby softening the BOPE by heat melting. After rolling, the fabric and cotton core are bonded together. After bonding, the adhesive film is further heat-sprayed by the hot spray component 52 to heat melt it. After heat melting, it is rolled again by the composite roller pressing component 53, so that the heat-melted adhesive film penetrates and connects on the fabric and the hot melt adhesive film. Then the hot melt adhesive film is cooled and shaped.

[0069] Step S4, blending and softening: After the hot melt adhesive film is cooled and shaped, the fabric and cotton core are kept in an adhesive state. The blending and softening mechanism 6 is used to roll and blend the material. After blending, the material is flattened to ensure its softness.

[0070] Step S5 involves fabric cleaning. After blending and softening, the material is transported flat. During transport, one side of the fabric is cleaned with a cleaning brush. After cleaning, the fabric is dried by air blowing through the drying mechanism 8. Finally, the dried material is rolled up. In this embodiment, a strong bond between the fabric and the cotton core is achieved through precisely controlled roller pressing and heating processes. In particular, the use of BOPE hot melt adhesive film, whose suitable melting point range matches the temperature of the hot roller, ensures the bonding strength while avoiding potential damage to the fabric and cotton core from high temperatures. Secondly, the secondary heating and composite roller pressing of the hot spray assembly 52 further promote the penetration and connection of the hot melt adhesive film between the fabric and the cotton core, enhancing the stability and durability of the overall structure. Furthermore, the application of the blending and softening mechanism 6 effectively improves the softness and comfort of the product, meeting the high requirements of modern textiles for texture. Finally, the introduction of the cleaning and drying steps not only removes impurities that may be generated during the production process but also prevents the fabric from becoming moldy and deformed through drying, ensuring the cleanliness and flatness of the final product. In summary, this preparation method not only improves production efficiency but also significantly enhances the quality and added value of the fabric, and has broad market application prospects.

[0071] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this patent should be determined by the appended claims.

Claims

1. A fabric preparation system, characterized in that: The system includes a frame, a fabric unwinding mechanism, a fabric rolling mechanism, an adhesive film unwinding mechanism, a cotton wick unwinding mechanism, a laminating mechanism, a blending and softening mechanism, a washing mechanism, a drying mechanism, and a feeding mechanism, all mounted on the frame. The fabric unwinding mechanism unwinds the fabric towards the fabric rolling mechanism, which in turn rolls indentations onto the upper surface of the fabric. The adhesive film unwinding mechanism guides the adhesive film material towards the laminating mechanism, and the cotton wick unwinding mechanism unwinds the cotton wick material towards the laminating mechanism. The adhesive film material is located between the fabric and the cotton wick material. The composite mechanism includes a hot roller composite assembly, a hot spray assembly, and a composite roller pressing assembly arranged sequentially. The hot roller composite assembly includes two sets of hot rollers with tangent outer diameters to press the fabric and cotton core material together and to heat-melt the adhesive film, thereby bonding the fabric and cotton core material. A first composite heating element is provided inside the hot roller. The hot spray assembly is located on one side of the hot roller and blows hot air toward the fabric to heat-melt the adhesive film. The composite roller pressing assembly is used to press the heat-melted adhesive film together with the fabric and cotton core material, so that the adhesive film penetrates and connects the fabric and cotton core material. The cotton core is an open-cell foam pad or a cotton core made of cotton. The blending and softening mechanism is used to roll and blend the material, the cleaning mechanism is used to clean one side of the fabric, the drying mechanism is used to dry the cleaned material, and the feeding mechanism is used to roll up the dried material. The blending and softening mechanism includes at least two sets of blending rollers and at least one set of flattening rollers. The blending roller sets include two sets of blending pressure rollers with tangent outer diameters. Roller pressure strips and roller pressure grooves are spaced apart on the outer circumference of the blending pressure rollers. The two sets of blending rollers cooperate with each other through the roller pressure strips and roller pressure grooves to blend and soften the cured adhesive film material. The flattening roller set is used to flatten the material after it has been blended and pressed.

2. The fabric preparation system according to claim 1, characterized in that: The fabric unwinding mechanism includes a fabric unwinding shaft, an unwinding shaft fixing seat, an unwinding shaft connecting arm, and an unwinding shaft drive module. The unwinding shaft fixing seat is located on both sides of the frame. The fabric unwinding shaft is rotatably mounted on the unwinding shaft fixing seat. The unwinding shaft connecting arm is mounted on the fabric unwinding shaft. The unwinding shaft drive module is used to drive the fabric unwinding shaft to rotate, thereby driving the unwinding shaft connecting arm to rotate. An unwinding fixing groove is provided on one side of the unwinding shaft connecting arm, which is used to fix the fabric roll. A feeding guide roller is provided on one side of the frame located on the fabric unwinding shaft. A feeding guide panel is provided on one side of the feeding guide roller. The feeding guide panel is provided with an inclined surface, which is inclined towards the hot roller composite assembly.

3. The fabric preparation system according to claim 1, characterized in that: The fabric rolling mechanism includes a flattening clamping roller group and an indentation roller group. The flattening clamping roller group is provided with two sets of flattening guide rollers to flatten the fabric before feeding it into the indentation roller group. The indentation roller group includes an indentation roller and a support roller. The outer diameter of the indentation roller is tangent to that of the support roller. The outer circumference of the indentation roller is provided with indentation teeth to roll and form indentations on the upper surface of the fabric.

4. The fabric preparation system according to claim 1, characterized in that: The film unwinding mechanism includes a film unwinding bracket, a film unwinding assembly, and film unwinding guide rollers. The film unwinding assembly is mounted on the film unwinding bracket, and multiple film unwinding guide rollers are provided to guide the film material toward the laminating mechanism. The cotton core unwinding mechanism includes a cotton core unwinding bracket, a cotton core unwinding assembly, and cotton core unwinding guide rollers. The cotton core unwinding assembly is mounted on the cotton core unwinding bracket. Multiple cotton core unwinding guide rollers are provided and used to guide the cotton core material toward the composite mechanism. A Z-shaped guide line is formed between the multiple cotton core unwinding rollers. The cotton core unwinding bracket is located above the hot roller composite assembly.

5. The fabric preparation system according to claim 1, characterized in that: The first composite heating element is provided in multiple ways, and the multiple first composite heating elements are evenly distributed in a ring around the outer periphery of the hot press roller; the hot spray assembly is a hot air spray gun, which is provided with a heating element inside to generate hot air to melt the adhesive film; the hot spray assembly is provided in two sets and is arranged symmetrically to blow hot air out to both sides of the material; the cotton core is an open-cell foam pad to heat the adhesive film through the opening gap.

6. The fabric preparation system according to claim 5, characterized in that: The composite roller pressing assembly is equipped with two sets of composite rollers with tangent outer diameters. A second composite heating element is provided on the outer periphery of the composite rollers to heat the composite rollers. The two sets of composite rollers are used to press the fabric and cotton core materials respectively, so that the adhesive film can penetrate and bond with the fabric and cotton core materials after being heated and melted. A cooling nozzle is provided on the rear side of the composite roller pressing assembly. Two sets of cooling nozzles are provided to blow air to cool the fabric and cotton core materials respectively, so that the adhesive film materials can be cooled and solidified.

7. The fabric preparation system according to claim 1, characterized in that: The cleaning mechanism includes a wet cleaning component and a dry cleaning component. The wet cleaning component includes a cleaning tank, a wet cleaning brush roller, and a wet cleaning pressure roller. The cleaning tank is filled with cleaning liquid. One side of the wet cleaning brush is immersed in the cleaning liquid. There are two wet cleaning brush rollers. The wet cleaning pressure roller is positioned between the two sets of wet cleaning brush rollers. The drying and cleaning assembly includes a drying and cleaning brush and a drying and cleaning roller. The drying and cleaning brush is used to dry and clean the fabric after it has been cleaned with wet water, so as to remove excess moisture from the surface of the fabric. The drying mechanism includes a drying nozzle and a drying hood. The drying nozzle and the drying hood are arranged opposite each other. The drying nozzle is directed toward the cotton core material to blow air toward the cotton core material and blow the moisture of the fabric toward the drying hood.

8. A method for preparing fabric, characterized in that: Includes the fabric preparation system according to any one of claims 1 to 4; The fabric preparation method includes the following steps: Step S1, Fabric unwinding: The fabric is unwound by the fabric unwinding mechanism and guided toward the fabric rolling mechanism by the guide roller. The fabric is rolled by the fabric rolling mechanism and indentations are rolled onto the upper surface of the fabric. Step S2, material unwinding: After the upper surface of the fabric is crimped by the roller, it is conveyed toward the laminating mechanism. At the same time, the adhesive film unwinding mechanism conveys the hot melt adhesive film toward the laminating mechanism, and the cotton core unwinding mechanism conveys the cotton core material toward the laminating mechanism. From bottom to top, the order is fabric, hot melt adhesive film and cotton core. Step S3, Thermal Lamination: The fabric and cotton core are first rolled using a hot roller lamination assembly. During the rolling process, the fabric and cotton core are heated by a first composite heating assembly, and the heat is transferred to the hot melt adhesive film. The hot melt adhesive film is BOPE with a melting point of 125℃~130℃. The temperature of the hot roller is controlled at 200~250℃. The cotton core is a cotton core layer made of cotton, and the fabric is cotton-linen fabric. During the rolling process, heat is transferred to the hot melt adhesive film, thereby softening the BOPE. After rolling, the fabric and cotton core are bonded together. After bonding, the adhesive film is further hot-sprayed by a thermal spray assembly to melt the adhesive film. After melting, it is rolled again by the composite roller pressing assembly, so that the melted adhesive film penetrates and connects the fabric and the hot melt adhesive film. Then the hot melt adhesive film is cooled and shaped. Step S4, blending and softening: After the hot melt adhesive film is cooled and shaped, the fabric and cotton core are kept in an adhesive state. The material is then rolled and blended by a blending and softening mechanism. After blending, the material is flattened to ensure its softness. Step S5: Fabric cleaning. After blending and softening, the material is flattened and transported. During the transport process, one side of the fabric is cleaned with a cleaning brush. After cleaning, the cleaned fabric is dried by blowing air through a drying mechanism. Finally, the dried material is rolled up.

9. A sofa, characterized in that: The fabric prepared by the fabric preparation method of claim 8 includes a cotton core, a film, and the fabric that are sequentially wrapped around the outside of the sofa frame from the inside out.

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