A slip-resistant glass fiber reinforced plastic pultruded flooring production line

Abstract

A production line for anti-slip fiberglass pultruded flooring, relating to the field of composite flooring technology, includes the following components arranged sequentially along the production process: a yarn rack for holding multiple sets of direct yarns; a yarn threading plate, located downstream of the yarn rack, with threading holes for the direct yarns to pass through, used to organize and gather the direct yarns from the yarn rack; an injection mold, located downstream of the threading plate; an injection machine on one side of the injection mold, which receives the direct yarns gathered by the threading plate, and the injection machine injects adhesive into the injection mold, causing the direct yarns to solidify and form a continuous fiberglass pultruded layer; and a co-extrusion mold, located downstream of the injection mold, with at least one extruder circumferentially positioned on the co-extrusion mold, which receives the fiberglass pultruded layer, and the extruder extrudes the slurry through the co-extrusion mold onto the surface of the fiberglass pultruded layer, forming an anti-slip surface layer covering the outside of the fiberglass pultruded layer within the co-extrusion mold. This invention eliminates traditional secondary processes, achieving integrated continuous production of the fiberglass substrate and the anti-slip surface layer.

Description

Technical Field

[0001] This invention relates to the field of composite flooring technology, and more particularly to a production line for anti-slip fiberglass pultruded flooring. Background Technology

[0002] Composite flooring, as an important outdoor building material, is widely used in various outdoor areas such as park trails, viewing platforms, boardwalks, and outdoor rest areas due to its excellent dimensional stability, outstanding corrosion resistance, superior compressive strength, and outstanding environmental characteristics. The core structure of this type of flooring typically consists of a base material made of high-strength, weather-resistant materials, combined with a surface layer that is wear-resistant, UV-resistant, and has realistic textures. Ideal outdoor flooring not only needs to meet stringent structural strength and long-term durability requirements, but its surface must also possess excellent anti-slip properties and a lasting aesthetic appeal to fully adapt to the complex and ever-changing outdoor environment and effectively ensure pedestrian safety and comfort.

[0003] In the prior art, such as the outdoor flooring disclosed in utility model patent CN202787903U, the flooring profile includes: a flooring profile with recesses on both sides for inserting fastening components to lock the flooring profile onto the joists; and a decorative surface layer extending parallel to the length of the flooring profile and positioned directly above the bottom surface of the flooring profile, the decorative surface layer including a decorative portion covering the top surface of the flooring profile. While this design theoretically provides overall protection, it faces significant bottlenecks in practical production and application. Particularly noteworthy is the difficulty of efficiently and effectively producing decorative surface layers similar to those described in the aforementioned patent.

[0004] The above problems mainly arise because existing production lines generally require secondary processes. After the substrate is formed, it needs to be manually or mechanically transferred to another independent processing area for secondary lamination. The production process is divided into two independent sections, which not only increases equipment investment but also leads to a significant reduction in production capacity due to process interruptions. Since this type of board requires lamination, the semi-finished substrate is prone to positioning deviation due to mechanical vibration, human operation errors, etc. during repeated transfers. When the substrate enters the secondary processing mold, the positional deviation will cause uneven coating of the anti-slip layer. Summary of the Invention

[0005] The present invention aims to solve the technical problem that existing composite flooring production lines cannot efficiently and integrally produce fiberglass flooring that combines high structural strength and high anti-slip performance.

[0006] To achieve the above objectives, according to one aspect of the invention, a production line for anti-slip fiberglass pultruded flooring is provided, comprising: a yarn rack for holding multiple sets of direct yarns; a yarn threading plate disposed downstream of the yarn rack, the yarn threading plate having threading holes for the direct yarns to pass through, for organizing and gathering the direct yarns from the yarn rack; an injection mold disposed downstream of the yarn threading plate; an injection machine disposed on one side of the injection mold, the injection mold receiving the direct yarns gathered by the yarn threading plate, the injection machine injecting adhesive into the injection mold to solidify the direct yarns and form a continuous fiberglass pultruded layer; and a co-extrusion mold disposed downstream of the injection mold, the co-extrusion mold having at least one extruder disposed circumferentially, the co-extrusion mold receiving the fiberglass pultruded layer, the extruder extruding slurry through the co-extrusion mold onto the surface of the fiberglass pultruded layer, forming an anti-slip surface layer covering the outside of the fiberglass pultruded layer in the co-extrusion mold.

[0007] As a preferred embodiment of the above technical solution, a sandblasting machine is also included, which is disposed between the injection mold and the co-extrusion mold; the sandblasting machine includes a spraying system, which is used to sandblast the surface of the cured fiberglass pultruded layer to form a rough surface structure.

[0008] As a preferred embodiment of the above technical solution, at least two rows of threading holes are provided on the threading plate body along its width direction, and multiple threading holes in any row of threading holes are staggered with multiple threading holes in the adjacent row of threading holes; taking the plane perpendicular to the thickness of the threading plate body as the longitudinal section, the longitudinal section shape of the threading holes is hyperbolic.

[0009] As a preferred embodiment of the above technical solution, the co-extrusion die is provided with a slow-flow inner die, and the slow-flow inner die has a cavity hole for the passage of the fiberglass pultruded layer. The lower end of the slow-flow inner die is provided with an injection hole, which connects the extruder and the runner cavity. The extruder is configured to extrude slurry into the injection hole from bottom to top. The runner cavity is connected to the cavity hole through a number of diversion holes, which are distributed circumferentially along the left, right and top sides of the cavity hole, so that the extruded slurry covers the outer peripheral surface of the fiberglass pultruded layer.

[0010] As a preferred embodiment of the above technical solution, the slow-flow inner mold is a split structure, including an openable front mold and a rear mold; the front mold and the rear mold are closed by a pressurizing device to form a cavity.

[0011] As a preferred embodiment of the above technical solution, the cavity hole is designed as a shrinkage hole in cross-sectional shape along the pultrusion direction.

[0012] As a preferred embodiment of the above technical solution, the diversion holes include at least three sets, and the number of diversion holes on the left and right sides are the same and symmetrically arranged.

[0013] As a preferred embodiment of the above technical solution, the co-extrusion die further includes an overflow stop die, which is located upstream of the slow-flow inner die; the overflow stop die has an overflow stop hole, the cross-sectional size of which is smaller than that of the cavity inlet end and is adapted to the cross-section of the fiberglass pultruded layer.

[0014] As a preferred embodiment of the above technical solution, it further includes a drying tunnel, which is located downstream of the co-extrusion die, and a perforated conveyor belt is provided inside the drying tunnel.

[0015] As a preferred embodiment of the above technical solution, the yarn frame adopts a combined frame structure and is equipped with a multi-layer yarn tube support, wherein the yarn tube support is configured with three or more layers.

[0016] In summary, the present invention has the following advantages: 1. Through a linear process from yarn rack and injection mold to co-extrusion mold, the co-extrusion mold is seamlessly integrated into the downstream station of substrate molding. This allows the anti-slip layer to be directly coated and formed while the substrate is still under continuous traction, eliminating the traditional secondary process and realizing the integrated continuous production of fiberglass substrate and anti-slip surface layer. As a result, the anti-slip layer is directly coated after the substrate has cured, optimizing work efficiency. In addition, a single production line reduces the investment in repetitive equipment, and continuous traction ensures the positioning accuracy of the substrate, reducing waste caused by uneven coating, significantly improving the yield rate, and reducing the cost of machine investment and waste disposal. 2. Furthermore, a rough structure is formed on the surface of the fiberglass substrate by sandblasting, which increases the mechanical interlocking area of ​​the protective layer slurry and helps the two to bond better. 3. Furthermore, the present invention has designed a corresponding mold for co-extrusion, which allows the slurry to be injected from bottom to top in a submerged manner, and to be guided through circumferential diversion holes to wrap the substrate in multiple directions, avoiding bending of the substrate caused by single-sided impact; furthermore, the cross-sectional shrinkage holes further compact the slurry layer.

[0017] Further or other beneficial effects will be discussed in the embodiments. Attached Figure Description

[0018] Figure 1 This is a simplified schematic diagram of the production line for this application; Figure 2 This is a schematic diagram of the yarn threading plate in this application; Figure 3 This is a schematic diagram of the cross-section of the threading hole on the threading plate of this application; Figure 4 This is a schematic diagram of the co-extrusion die structure for this application; Figure 5 This is a full sectional view of the co-extrusion die of this application; Figure 6 This is a schematic diagram of the disassembly of the slow-flow inner mold of this application; Figure 7Cross-sectional view of the anti-slip fiberglass pultruded floor produced in this application; Figure 8 This is a top view of the production line of this application; Among them, 100-yarn frame, 200-yarn threading plate, 201-yarn threading hole, 300-injection mold, 400-co-extrusion mold, 4a-front mold, 4b-rear mold, 410-slow-flow inner mold, 411-injection hole, 412-running channel cavity, 413-diverting hole, 414-cavity hole, 415-arc guide surface, 420-overflow mold, 421-overflow hole, 500-drying tunnel, 600-traction machine, 710-cutting machine, 720-stacking rack, 800-injection machine, 900-extruder, 1000-sandblasting machine, a-fiberglass pultruded layer, b-anti-slip surface layer. Detailed Implementation

[0019] The directional terms such as up, down, left, right, front, back, front, back, top, and bottom mentioned or possibly used in this specification are defined relative to the construction shown in the accompanying drawings. The terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively. These are relative concepts and may therefore vary depending on their location and usage. Therefore, these or other directional terms should not be interpreted as restrictive.

[0020] The present invention will be further explained below with reference to the embodiments: Example

[0021] A production line for anti-slip fiberglass pultruded flooring, used to produce, for example... Figure 7 The composite flooring shown here with an external anti-slip layer is for reference. Figure 1 and Figure 8The production line includes, in sequence along the production direction, a yarn frame 100, a yarn threading plate 200, a glue injection mold 300, a co-extrusion mold 400, a drying tunnel 500, a traction machine 600, a cutting machine 710, and a stacking rack 720. The yarn threading plate 200 has yarn threading holes 201 for direct yarn to pass through, which are used to organize and gather the direct yarn from the yarn frame 100. A glue injection machine 800 is provided on one side of the glue injection mold 300. The glue injection mold 300 receives the direct yarn gathered by the yarn threading plate 200 and injects glue into the glue injection mold 300, so that the direct yarn solidifies to form a continuous fiberglass pultruded layer a. The surface of the glue injection mold 300 is provided with multiple glue injection holes to facilitate the injection by the glue injection machine 800. At least one extruder 900 is circumferentially arranged in the co-extrusion die 400. The co-extrusion die 400 receives the fiberglass pultruded layer a, and the extruder 900 extrudes the slurry through the co-extrusion die 400 onto the surface of the fiberglass pultruded layer a, forming an anti-slip surface layer b covering the outside of the fiberglass pultruded layer a within the co-extrusion die 400. The fiberglass pultruded layer a, now covered with the anti-slip surface layer b, then enters the drying tunnel 500 located downstream of the co-extrusion die 400 for rapid drying. The drying tunnel 500 is equipped with a perforated conveyor belt, designed to prevent incompletely cured slurry from sticking together and to facilitate hot air baking of the underlying anti-slip surface layer b. After complete drying, the anti-slip surface layer b bonds with the fiberglass layer to form the final molded sheet. The traction machine 600, located downstream of the drying tunnel 500, serves as the main conveying device and includes at least two spaced-apart rolling conveyors (preferably a conveyor belt structure). The two conveyors together constitute a clamping and traction structure acting on the sheet, achieving stable movement through a large contact area with the sheet. Downstream of the traction machine 600 is a cutting machine 710, which cuts the continuously manufactured shaped sheet into segments, which are then transported to a stacking rack 720 located downstream for collection.

[0022] The yarn rack 100 adopts a modular frame structure and is equipped with a multi-layer yarn bobbin support. The capacity of a single support is typically 30-55 yarn bobbins. A configuration of three or more layers facilitates yarn handling and separation; in this embodiment, five layers are preferred. (Refer to...) Figure 2 At least two rows of threading holes 201 are provided on the threading plate 200 body along its width direction (preferably three rows in this embodiment). Multiple threading holes 201 in any row of threading holes 201 are staggered with multiple threading holes 201 in adjacent rows of threading holes 201. Taking a plane perpendicular to the thickness of the threading plate 200 body as the longitudinal section, the longitudinal section shape of the threading holes 201 is hyperbolic, as shown in the reference... Figure 3 Through the above structural design, the yarn guide holes 201 of adjacent rows form non-overlapping yarn channels, avoiding frictional entanglement caused by the intersection of guide paths when multiple yarns are threaded in parallel. The staggered layout causes the yarns to form staggered paths in the thickness direction, reducing the probability of yarn contact and reducing fuzz generation; the hyperbolic cross section accelerates yarn movement at the entrance of the channel and releases tension at the exit, reducing yarn vibration and suppressing static electricity accumulation.

[0023] In a preferred embodiment, a sandblasting machine 1000 is provided between the injection mold 300 and the supply mold. The sandblasting machine 1000 includes a blasting system for sandblasting the surface of the cured fiberglass pultruded layer a, creating a rough surface structure to enhance the adhesion between the anti-slip surface layer b and the fiberglass pultruded layer a. The rough surface increases the contact area, improves the mechanical bonding force between the cement slurry and the fiberglass layer, and prevents interlayer delamination.

[0024] Reference Figure 4 , Figure 5 and Figure 6 The co-extrusion die 400 is provided with a slow-flow inner die 410. The slow-flow inner die 410 has a cavity hole 414 for the passage of the fiberglass pultruded layer a. The lower end of the slow-flow inner die 410 is provided with an injection hole 411. The injection hole 411 connects the extruder 900 and the runner cavity 412. The extruder 900 is configured to extrude slurry into the injection hole 411 from bottom to top. The runner cavity 412 is connected to the cavity hole 414 through a number of diversion holes 413. The diversion holes 413 are distributed circumferentially along the left, right and top sides of the cavity hole 414, so that the extruded slurry covers the outer circumferential surface of the fiberglass pultruded layer a.

[0025] In this embodiment, three sets of diversion holes 413 are provided. The number of diversion holes 413 on the left, right and top sides is the same, and the left and right sides are symmetrically arranged.

[0026] Specifically, the extruder 900 used in this embodiment is a vacuum extruder 900. Considering cost and the limitations of the overall production line design space, this embodiment preferably uses a single vacuum extruder 900. This extruder 900 is located on one side of the co-extrusion die 400 ( Figure 1 Since this is a simplified planar diagram, the extruder 900 shown in the diagram represents the material feed funnel portion (not indicating that material is added into the co-extrusion die 400 from top to bottom), and is connected to the injection hole 411 located below the slow-flow die. The slurry is extruded into the die from bottom to top through the injection hole 411. Inside the runner cavity 412, above the injection hole 411 (and below the cavity hole 414), there is an arc-shaped guide surface 415 that guides the slurry to the left and right sides of the runner cavity 412. As a preferred embodiment, the injection hole 411 is located in the middle of the lower end of the slow-flow inner die 410 to ensure that the slurry entering the runner cavity 412 can be evenly dispersed to both sides.

[0027] As the slurry disperses within the flow channel cavity 412 and rises along the cavity wall, it gradually submerges the diversion holes 413 located at lower positions on the left and right side walls of the cavity orifice 414, and overflows from these diversion holes 413 into the cavity orifice 414. Slurry that fails to overflow from the lower diversion holes 413 in time will continue to rise with the liquid level (because the slurry overflow rate from the lower diversion holes 413 is limited), and eventually overflow from the diversion holes 413 located at the upper end of the left and right side walls of the cavity orifice 414, or from the diversion holes 413 at the top of the cavity orifice 414.

[0028] In actual operation, the fiberglass pultruded layer a is first pulled through the cavity orifice 414. Then the extruder 900 is started. After the slurry fills the flow channel cavity 412 and completely fills the cavity orifice 414 through the diversion hole 413, the pultrusion process of the entire production line can be started.

[0029] The reason for adopting the aforementioned slow-flow inner mold 410 structure design in this embodiment is that when the extruder 900 extrudes slurry into the co-extrusion die 400, regardless of whether the slurry enters the die from above, below, left, or right, the part that first contacts the fiberglass pultruded layer a will inevitably be directly impacted by the extrusion force. This impact may cause the fiberglass pultruded layer a, which has just completed its initial molding, to bend and deform in the direction of the force. In addition, since the slurry first contacts and coats a specific side, it is easy to cause the slurry layer thickness on that contact surface to be too large, while the slurry layer thickness on the last side to be coated is too thin, resulting in uneven coating thickness in the final product and a decrease in overall molding quality.

[0030] The slow-flow inner mold 410 design used in this embodiment, through the setting of the flow channel cavity 412 and the circumferentially distributed diversion holes 413, realizes the flow mode of the slurry gradually rising and "submerging" into the cavity hole 414. This design has the following advantages: it can avoid unilateral force, because the slurry enters the cavity hole 414 simultaneously through the circumferentially distributed diversion holes 413, forming a relatively uniform circumferential wrapping force on the fiberglass pultruded layer a, effectively avoiding the bending deformation problem caused by unilateral concentrated force; and it improves the uniformity of coating, because the "submerged" pouring method allows the slurry to contact and wrap the pultruded layer more evenly from multiple directions and multiple positions simultaneously or sequentially, significantly improving the uniformity of slurry distribution on the outer circumference of the pultruded layer, thereby obtaining a coating layer with more consistent thickness and density, and improving the molding quality of the final product.

[0031] Reference Figure 5The co-extrusion die 400 also includes an overflow stop die 420, which is located upstream of the slow-flow inner die 410. The overflow stop die 420 has an overflow stop hole 421, the cross-sectional size of which is smaller than the cross-sectional size of the inlet end of the cavity hole 414. The cross-sectional size of the overflow stop hole 421 is adapted to the cross-sectional size of the fiberglass pultruded layer a. The cross-sectional size of this hole is designed to be smaller than the inlet end of the cavity hole 414, but strictly matches the outer contour size of the fiberglass pultruded layer a, forming a physical barrier to prevent overflow.

[0032] Additionally, refer to Figure 5 The cavity 414 is designed as a shrinkage cavity in the cross-sectional shape along the pultrusion direction, so that the slurry on the surface of the fiberglass pultruded layer a can be gradually compacted during the pultrusion process.

[0033] The slurry involved in this embodiment is prone to coagulation into lumps when left to stand at room temperature for an extended period, which may cause blockage of the inner mold. For ease of cleaning, refer to... Figure 6 The co-extrusion die 400 features a split-type inner die 410, consisting of an openable front die 4a and a rear die 4b. When closed by a pressure device, they form the complete cavity 414, runner 412, injection hole 411, and diversion hole 413. Furthermore, the outer die (not shown in the figure) is equipped with guide posts (not shown in the figure) and positioning holes (not shown in the figure), ensuring precise alignment during closure. If the outer die is omitted, guide posts and positioning holes can be directly installed on the mating surface of the front die 4a and the rear die 4b, similarly ensuring positioning accuracy during closure. The split-type design also facilitates thorough cleaning of the die after opening.

[0034] If the co-extrusion die and extruder are separate pieces of equipment, the substrate will shift during transfer, and even with a positioning device, it is difficult to eliminate the accumulated error. However, in this embodiment, the co-extrusion die 400 is directly integrated downstream of the 300 injection die. The substrate is in a continuous traction state from curing to encapsulation. More importantly, when using this co-extrusion die 400, the substrate needs to move continuously on the production line rather than be processed intermittently in segments. This is because the co-extrusion die 400 adopts a bottom-up submerged injection method, where the slurry gradually rises through the flow channel 412 and circumferentially fills the cavity 414. If the substrate feeding is interrupted, the slurry continuously supplied in the co-extrusion die 400 will overflow due to lack of filling space. If the substrate is fed intermittently, the slurry supply rhythm cannot be matched in real time, which can easily form local stagnation areas in the cavity 414 and the diversion hole 413, leading to blockage. Continuous and uniform substrate traction can maintain the stability of the slurry flow.

[0035] Furthermore, ensuring that the slurry level rises uniformly within the flow channel cavity 412 and synchronously wrapping the substrate through the circumferentially distributed diversion holes 413 is the basis for the synergistic effect of the overflow mold 420 and the split-type slow-flow inner mold 410.

[0036] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0037] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A non-slip glass fiber reinforced plastic pultruded flooring production line characterized by, Including those set up sequentially along the production process: Yarn rack, used to hold multiple sets of direct yarn; A yarn threading plate is located downstream of the yarn frame. The yarn threading plate has threading holes for direct yarn to pass through, and is used to organize and gather the direct yarn from the yarn frame. The glue injection mold is located downstream of the yarn threading plate; a glue injection machine is provided on one side of the glue injection mold. The glue injection mold receives the direct yarn gathered by the yarn threading plate, and the glue injection machine injects glue into the glue injection mold to solidify the direct yarn and form a continuous fiberglass pultruded layer. A co-extrusion die is located downstream of the injection die. The co-extrusion die has at least one extruder in its circumferential direction. The co-extrusion die receives the fiberglass pultruded layer. The extruder extrudes the slurry through the co-extrusion die onto the surface of the fiberglass pultruded layer, forming an anti-slip surface layer covering the outside of the fiberglass pultruded layer in the co-extrusion die. The co-extrusion die is provided with a slow-flow inner die, and the slow-flow inner die has a cavity hole for the fiberglass pultruded layer to pass through. The lower end of the slow-flow inner die is provided with an injection hole, which connects the extruder and the runner cavity. The extruder is configured to extrude slurry into the injection hole from bottom to top. The runner cavity is connected to the cavity hole through a number of diversion holes, which are distributed circumferentially along the left, right and top sides of the cavity hole, so that the extruded slurry covers the outer peripheral surface of the fiberglass pultruded layer. The cavity orifice is designed as a shrinkage orifice along the pultrusion direction; the co-extrusion die also includes an overflow stop die, which is located upstream of the slow-flow inner die; the overflow stop die has an overflow stop hole, the cross-sectional size of which is smaller than that of the cavity orifice inlet end and is adapted to the cross-section of the fiberglass pultruded layer.

2. A non-slip glass fiber reinforced plastic pultruded flooring production line according to claim 1, characterized in that, It also includes a sandblasting machine, which is disposed between the injection mold and the co-extrusion mold; the sandblasting machine includes a blasting system, which is used to sandblast the surface of the cured fiberglass pultruded layer to form a rough surface structure.

3. The anti-slip fiberglass pultruded flooring production line according to claim 1, characterized in that, At least two rows of threading holes are provided on the threading plate body along its width direction, and multiple threading holes in any row of threading holes are staggered with multiple threading holes in the adjacent row of threading holes; with a plane perpendicular to the thickness of the threading plate body as the longitudinal section, the longitudinal section shape of the threading holes is hyperbolic.

4. The anti-slip fiberglass pultruded flooring production line according to claim 1, characterized in that, The slow-flow inner mold is a split structure, including an openable front mold and a rear mold; the front mold and the rear mold are closed by a pressure device to form a cavity.

5. The anti-slip fiberglass pultruded flooring production line according to claim 1, characterized in that, The diversion holes include at least three sets, and the number of diversion holes on the left and right sides are the same and they are arranged symmetrically.

6. The anti-slip fiberglass pultruded flooring production line according to claim 1, characterized in that, It also includes a drying tunnel, which is located downstream of the co-extrusion die, and a perforated conveyor belt is provided inside the drying tunnel.

7. The anti-slip fiberglass pultruded flooring production line according to claim 1, characterized in that, The yarn frame adopts a combined frame structure and is equipped with a multi-layer yarn tube support, and the yarn tube support is configured with three or more layers.

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