Polyurethane physical foaming carpet bottom covering production line and production process

Abstract

The invention relates to the technical field of carpet manufacturing, and particularly provides a polyurethane physical foaming carpet bottom covering production line and a production process. The production line comprises a polyurethane raw material storage and conveying system, a blank carpet storage machine, a non-woven fabric storage machine, a blank carpet conveying and deviation rectifying machine, a gluing machine, a main plasticizing drying oven, a plate cooling device, a roller cooling machine, a finished carpet storage machine, a finished carpet deviation rectifying machine, a finished carpet punching machine and a finished carpet winding machine. The polyurethane raw material storage and conveying system comprises a polyurethane physical foaming machine, a material conveying pipeline and an inert gas pipeline, and is used for blowing a physical foaming agent for physical foaming; the polyurethane physical foaming carpet with stable quality is produced by mixing and foaming the polyurethane raw material and the physical foaming agent, combining with the blank carpet and the non-woven fabric and carrying out the procedures of curing, cooling, cutting, rolling and the like; the whole structure is reasonable, the production efficiency is high, and the production requirements of different types of carpets can be met.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of carpet manufacturing, in particular to a polyurethane physical foaming carpet backing production line and production process. BACKGROUND

[0002] Carpet backing technology is a key process in carpet production, which aims to form a backing layer on the back of the carpet to enhance its stability, durability and comfort. With the development of the carpet industry, carpet backing technology is constantly innovating and improving. Currently, there are several ways to carpet backing technology, including hot melt adhesive backing, PVC backing and polyurethane backing. Hot melt adhesive film backing process is to stack the tufted carpet, hot melt adhesive film and non-woven fabric, then heat and melt the hot melt adhesive film, and then extrude it through the roller shaft to make the layers adhere to each other. PVC backing technology is to coat PVC glue on the back of the carpet, and then dry and cure it to form a backing layer. Some processes also add foaming agents to the PVC glue to make foamed PVC backing carpet.

[0003] In terms of carpet backing production line, existing technologies have achieved a certain degree of automation and continuous production. For example, CN117656642A discloses an energy-saving production line for carpet anti-staining pre-coating and backing, which includes an anti-staining pre-coating and drying production line, a PE non-woven fabric backing production line and an extruder skin backing production line. Through the design of S-shaped reciprocating walking, the drying efficiency is improved. CN106048924B discloses a joint carpet pre-coating and backing combined machine, which sets the carpet surface pre-coating processing line above the backing processing line, and the pre-coating drying and heating line and the backing plasticizing and heating line are in the same heating oven, realizing the recycling of heating energy. In the preparation of polyolefin backing joint carpet, CN114474932A discloses a preparation method and device, which rolls propylene-based resin glue on the back of the tufted carpet, and then composites with the treated glass fiber cloth, then applies propylene-based resin adhesive material and rolls the backing non-woven fabric layer, and finally cools and shapes to obtain a joint carpet with high dimensional stability. However, the existing polyurethane foaming carpet backing technology still has some technical problems: 1. Traditional polyurethane foaming technology mainly uses chemical foaming method, which is difficult to accurately control the reaction time and process, and is prone to unstable product quality. Chemical foaming agents release harmful gases during the reaction process, which has adverse effects on the environment and the health of operators.

[0004] 2. The existing polyurethane foaming carpet backing process usually needs to use a mold for foaming and molding, which is not suitable for large-scale continuous production, and the production efficiency is low, which is difficult to meet the needs of modern large-scale production.

[0005] 3. In traditional processes, the preparation, transportation, and mixing of raw materials largely rely on manual operation, which is not only labor-intensive but also energy-intensive, resulting in high production costs. Inaccurate raw material measurement directly affects product quality, and manual operation makes it difficult to guarantee high-precision measurement requirements. Summary of the Invention

[0006] In view of the shortcomings of the prior art described above, the purpose of this invention is to provide a polyurethane physical foaming carpet backing production line and production process. The production line design of this invention enables large-scale continuous production without the need for molds, overcoming the shortcomings of traditional polyurethane foaming technology, which requires molds and is not suitable for large-scale continuous production. Through an automated raw material storage and conveying system, the need for manual operation is greatly reduced, energy consumption is reduced, and the problem of high energy consumption for raw materials and manual labor is solved. This invention uses physical foaming technology, with no chemical foaming agent residue, which meets environmental protection regulations. At the same time, the cell structure is uniform and delicate, achieving high performance under low density conditions. It is used to solve the problems of existing polyurethane foaming technology, such as uncontrollable reaction time and process, the need for molds which is not suitable for large-scale continuous production, high energy consumption for raw materials and manual labor, and high price of finished products.

[0007] To achieve the above and other related objectives, the present invention provides a polyurethane physical foaming carpet backing production line, the production line comprising: A polyurethane raw material storage and conveying system, used to manufacture polyurethane coatings and convey the polyurethane coatings for application; Blanket storage machine, used for unwinding, correcting and storing blank blankets; Nonwoven fabric storage machine, used for unwinding and storing nonwoven fabric; Blanket conveying and straightening machine is used to convey blanks and straighten them during the conveying process; A gluing machine is used to simultaneously input raw carpet, polyurethane coating, and nonwoven fabric to produce carpets; The main plasticizing oven is used to plasticize the physical foaming materials in polyurethane coatings and form a stable structure by using a high temperature of 80-120°C. Plate cooling device, used for initial cooling of plasticized carpet; Roller coolers are used to further cool carpets to form finished carpets; Finished blanket storage machine, used for storing finished blankets; Finished blanket correction machine is used to correct the deviation of finished blankets during the conveying process; Finished blanket punching machine is used to cut polyurethane block finished blankets into shapes; Finished blanket rewinding machine is used to rewind polyurethane roll finished blankets.

[0008] In an embodiment of the present application, the polyurethane raw material storage and conveying system comprises a polyurethane physical foaming machine, a material conveying pipeline is arranged on the polyurethane physical foaming machine, and the polyurethane raw material after mixing is conveyed into the polyurethane physical foaming machine through the material conveying pipeline; an inert gas pipeline is connected to the material conveying pipeline, and the physical foaming agent is blown into the polyurethane physical foaming machine to cooperate with the polyurethane raw material for physical foaming.

[0009] In an embodiment of the present application, the polyurethane raw material storage and conveying system further comprises an A material storage tank, a B material storage tank, an A material batching tank, a B material batching tank, an A material feeding pump and a B material feeding pump; the A material batching tank is connected to the A material storage tank through a pipeline, and the A material feeding pump is arranged on the pipeline between the A material batching tank and the A material storage tank; the B material batching tank is connected to the B material storage tank through a pipeline, and the B material feeding pump is arranged on the pipeline between the B material batching tank and the B material storage tank. The output ends of the A material storage tank and the B material storage tank are connected to the material conveying pipeline through pipelines.

[0010] In an embodiment of the present application, the output ends of the A material storage tank and the B material storage tank are respectively provided with a blue-flange type filter, a rotor pump and a flow meter; and a backflow pipeline is arranged between the input end and the output end of the A material storage tank and between the input end and the output end of the B material storage tank.

[0011] In an embodiment of the present application, the polyurethane raw material storage and conveying system further comprises a refrigerator, and a cooler is further arranged on the output end of the B material storage tank; the output end of the refrigerator is connected to the cooler and the polyurethane physical foaming machine respectively.

[0012] In an embodiment of the present application, a thermometer is arranged on the output end of the polyurethane physical foaming machine.

[0013] In an embodiment of the present application, a flushing pump is further connected to the material conveying pipeline, and the flushing pump is arranged between the inert gas pipeline and the input end of the polyurethane physical foaming machine; a pressure sensor is arranged on the pipeline of the material conveying pipeline close to the input end of the polyurethane physical foaming machine.

[0014] In an embodiment of the present application, a closed cycle Teflon belt is arranged in the glue spreading machine, the main plasticizing oven and the plate cooling device; the blank and the non-woven fabric are adhered to the outer side of the Teflon belt after being input into the glue spreading machine; a scraper is arranged in the glue spreading machine, and the scraper is arranged on the outer side of the Teflon belt and used for scraping the Teflon adhered between the blank and the non-woven fabric.

[0015] The present application further provides a polyurethane physical foaming carpet underlay production process, which adopts the polyurethane physical foaming carpet underlay production line. S1, raw material preparation: according to the formula proportion, the amount of each component is automatically measured by PLC control coriolis mass flowmeter, and is transported to the mixing head; S2, mixing and foaming: the polyurethane raw material is mixed with the inert gas which is automatically measured by the air flowmeter according to a certain proportion, and the mixed material is stirred violently to make the inert gas fully mix with the material to form the polyurethane coating; S3, forming: the foamed polyurethane coating is sent into the glue coating machine together with the blank and non-woven and other cloth, and the polyurethane coating forms the required bottom shape and thickness on the back of the carpet; S4, curing: the carpet after covering the bottom is sent into the main plasticizing oven, and the physical foaming material in the polyurethane coating is plasticized and forms a stable structure through 80-120° high temperature; S5, cooling: the plasticized carpet is sent into the plate cooling device and the roller cooling machine in sequence for preliminary cooling and secondary cooling, so that the carpet is shaped to form the finished carpet; S6, cutting and winding: the shaped carpet after covering the bottom is sent into the finished carpet storage machine, the finished carpet deviation correcting machine, the finished carpet punching machine and the finished carpet winding machine in sequence, is cut according to the required size, and the cut carpet after covering the bottom is wound into a roll; S7, quality inspection and packaging: the produced carpet after covering the bottom is subjected to quality inspection, including thickness, density, hardness, elasticity, wear resistance and flame retardance index detection; the qualified products are packaged and prepared for shipment.

[0016] In an embodiment of the present application, in the step S2, the physical foaming agent includes inert gas, and the inert gas includes CO2 and nitrogen.

[0017] As described above, the polyurethane physical foaming carpet backing production line and production process of the present application has the following beneficial effects: The technical scheme of the present application is that polyhydric alcohol and isocyanate and calcium powder enter a mixing head according to the required proportion through a CRIOLI mass flow meter and an automatic air flow meter respectively, the reaction time and process are accurately controlled, and the problem that the reaction time and process cannot be controlled in the prior art is solved; the production line design of the present application realizes large-scale continuous production, a mold is not needed, and the defect that the traditional polyurethane foaming technology must use a mold and is not suitable for large-scale continuous production is overcome; through an automatic raw material storage and conveying system, the labor operation demand is greatly reduced, energy consumption is reduced, and the problem of high labor and energy consumption of raw materials is solved; the present application adopts a physical foaming technology, there is no chemical foaming agent residue, environmental protection regulations are met, the cell structure is uniform and delicate, high performance is realized under low density conditions; the process of the present application has high flexibility as a whole, product performance can be quickly adjusted by adjusting parameters such as the proportion of each component and the amount of foaming agent, and the production of products with different shapes and requirements is adapted; through an optimized material formula and production process, the polyurethane foaming material produced by the present application has low thermal conductivity and good aging resistance; the present application significantly improves the economy of products by reducing raw material costs and reducing post-processing procedures, and solves the problem of expensive finished products. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 The overall structure schematic diagram of the polyurethane physical foaming carpet underlay production line disclosed by the present application is shown.

[0019] Figure 2 The enlarged structure schematic diagram of the polyurethane raw material storage and conveying system of the polyurethane physical foaming carpet underlay production line disclosed by the present application is shown.

[0020] Figure 3 The enlarged structure schematic diagram of the polyurethane physical foaming machine part is shown. Figure 2

[0021] Figure 4 The enlarged structure schematic diagram of the cooperation of the carpet storage machine, the non-woven fabric storage machine, the carpet conveying and deviation correction machine and the glue coating machine of the polyurethane physical foaming carpet underlay production line disclosed by the present application is shown.

[0022] Figure 5 The enlarged structure schematic diagram of the cooperation of the glue coating machine, the main plasticizing oven and the plate cooling device of the polyurethane physical foaming carpet underlay production line disclosed by the present application is shown.

[0023] Figure 6 The enlarged structure schematic diagram of the cooperation of the finished product carpet storage machine, the finished product carpet deviation correction machine, the finished product carpet punching machine, the finished product carpet winding machine of the polyurethane physical foaming carpet underlay production line disclosed by the present application is shown.

[0024] Figure 7 ​The schematic diagram of the layer structure of the backside carpet manufactured by the polyurethane physical foaming carpet backing production line disclosed in the present application.

[0025] Figure 8 The schematic diagram of the layer structure of the backside carpet manufactured by the polyurethane physical foaming carpet backing production line disclosed in the present application.

[0026] Element number explanation Polyurethane raw material storage and conveying system 1; carpet blank storage machine 2; non-woven fabric storage machine 3; carpet blank conveying and deviation correction machine 4; glue coating machine 5; doctor blade 51; main plasticizing oven 6; plate cooling device 7; roller cooling machine 8; finished carpet storage machine 9; finished carpet deviation correction machine 10; finished carpet punching machine 11; finished carpet winding machine 12; polyurethane physical foaming machine 13; material conveying pipeline 14; inert gas pipeline 15; A material storage tank 16; B material storage tank 17; A material batching tank 18; B material batching tank 19; A material feeding pump 20; B material feeding pump 21; blue's flange type filter 22; rotor pump 23; flow meter 24; cooler 25; flushing pump 26; pressure sensor 27; thermometer 28; refrigerator 29; carpet surface layer 30; base cloth layer 31; polyurethane glue coating layer 32; glass mesh fiber layer 33; Teflon belt 34. DETAILED DESCRIPTION

[0027] The following specific embodiments illustrate the implementation of the present application, and those skilled in the art can easily understand other advantages and effects of the present application from the content disclosed in the specification.

[0028] Please refer to Figures 1 to 8 It should be understood that the structures, proportions, sizes, etc. shown in the drawings attached to the specification are only used to cooperate with the content disclosed in the specification for understanding and reading by those skilled in the art, and do not have technical significance to limit the implementation conditions of the present application, so any modification of the structure, change of the proportional relationship or adjustment of the size, without affecting the effects and purposes that can be achieved by the present application, should be within the scope of the technical content disclosed by the present application. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" in the specification are only for the convenience of clear description, and are not used to limit the implementation range of the present application, and the change or adjustment of the relative relationship, without substantially changing the technical content, is also considered as the implementation scope of the present application.

[0029] Example 1, please refer to Figure 1 , Figures 4-6The application provides a polyurethane physical foaming carpet underlay production line, which comprises a polyurethane raw material storage and conveying system 1, a blank carpet storage machine 2, a non-woven fabric storage machine 3, a blank carpet conveying and deviation rectifying machine 4, a gluing machine 5, a main plasticizing oven 6, a plate cooling device 7, a roller cooling machine 8, a finished carpet storage machine 9, a finished carpet deviation rectifying machine 10, a finished carpet punching and cutting machine 11 and a finished carpet winding machine 12, the polyurethane raw material storage and conveying system 1 can manufacture polyurethane coating and convey the polyurethane coating for gluing, the blank carpet storage machine 2 is used for unwinding, deviation rectifying and storing the blank carpet, the blank carpet conveying and deviation rectifying machine 4 is used for conveying the blank carpet and rectifying the deviation during conveying, so that the blank carpet can be stably conveyed to the subsequent process and the deviation during conveying is rectified, so that the blank carpet can keep correct position and tension during conveying, the non-woven fabric storage machine 3 is used for unwinding and storing the non-woven fabric and provides stable non-woven fabric supply for the production line, the gluing machine 5 is used for simultaneously inputting the blank carpet, the polyurethane coating and the non-woven fabric to manufacture the carpet, the main plasticizing oven 6 is used for plasticizing the physical foaming material in the polyurethane coating by high temperature of 80-120 DEG and forming a stable structure, in the main plasticizing oven 6, the polyurethane coating is chemically reacted under the action of high temperature and pressure to form a stable polyurethane structure, so that the strength and durability of the carpet are enhanced, the plate cooling device 7 is used for preliminarily cooling the plasticized carpet, the roller cooling machine 8 is used for further cooling the carpet to form the finished carpet, the two-stage cooling system ensures that the carpet can be fully cooled and shaped, and the product quality and production efficiency are improved, the finished carpet storage machine 9 is used for storing the finished carpet and provides a buffer for the subsequent process, the finished carpet deviation rectifying machine 10 is used for rectifying the deviation of the finished carpet during conveying, so that the finished carpet can keep correct position during the subsequent process, the finished carpet punching and cutting machine 11 is used for cutting the polyurethane square finished carpet into a shape and size according to preset dimensions, and the finished carpet winding machine 12 is used for winding the polyurethane roll finished carpet, so that the finished carpet can be conveniently stored and transported.

[0030] Please refer to Figures 1-3The polyurethane raw material storage and conveying system 1 includes a polyurethane physical foaming machine 13, which is equipped with a material conveying pipeline 14. After mixing, the polyurethane raw materials enter the polyurethane physical foaming machine 13 through the material conveying pipeline 14. An inert gas pipeline 15 is connected to the material conveying pipeline 14. The polyurethane raw material storage and conveying system 1 also includes an A material storage tank 16, a B material storage tank 17, an A material batching tank 18, a B material batching tank 19, an A material feeding pump 20, and a B material feeding pump 21. The A material batching tank 18 is connected to the A material storage tank 16 through a pipeline, and the A material feeding pump 20 is installed on the pipeline between the A material batching tank 18 and the A material storage tank 16. The B material batching tank 19 is connected to the B material storage tank 17 via a pipeline, and the B material feeding pump 21 is installed on the pipeline between the B material batching tank 19 and the B material storage tank 17. The output ends of both the A material storage tank 16 and the B material storage tank 17 are connected to the material conveying pipeline 14 via pipelines. Both the A material storage tank 16 and the B material storage tank 17 are equipped with a Lancôme flange-type filter 22, a rotor pump 23, and a flow meter 24. Return pipelines are provided between the input and output ends of the A material storage tank 16 and between the input and output ends of the B material storage tank 17. The design of the return pipelines ensures the purity of the raw materials and precise control of the flow rate, improving the stability of the production line and product quality. The polyurethane raw material storage and conveying system 1 also includes a chiller 29. A cooler 25 is also provided at the output end of the B material storage tank 17. The output end of the chiller 29 is connected to both the cooler 25 and the polyurethane physical foaming machine 13. The chiller 29 is a mechanical device that achieves low-temperature cooling through a compression refrigeration cycle, used for temperature control and cooling needs in industrial production. In this invention, the chiller 29 can control the raw material temperature, ensuring the stability and quality of the foaming process. A thermometer 28 is provided at the output end of the polyurethane physical foaming machine 13 to monitor temperature changes during the foaming process and ensure foaming quality.

[0031] A flushing pump 26 is also connected to the material conveying pipeline 14. The flushing pump 26 is located between the inert gas pipeline 15 and the input end of the polyurethane physical foaming machine 13. A pressure sensor 27 is installed on the pipeline of the material conveying pipeline 14 near the input end of the polyurethane physical foaming machine 13. The flushing pump 26 and the pressure sensor 27 can ensure the cleanliness of the pipeline and the stability of the system pressure, thereby improving the operating efficiency of the production line and the product quality.

[0032] Please see Figures 7-8In the glue spreader 5, main plasticizing oven 6, plate cooling device 7, a closed cycle Teflon belt 34 is simultaneously provided, the blank blanket and non-woven fabric input glue spreader 5 are all attached to the outer side end of the Teflon belt 34; The glue spreader 5 is provided with a scraper 51, which is matched with the outer side end of the Teflon belt 34, which is used to scrape the Teflon attached between the blank blanket and the non-woven fabric; The present application includes two process lines, process 1 includes: the physical foaming polyurethane coating is coated on the Teflon belt 34, the required Teflon thickness is scraped out by the scraper 51, then the blank blanket is input from the blank blanket conveying and correcting machine 4, and is combined with the polyurethane coating, and then enters the main plasticizing oven 6 for curing, enters the plate cooling device 7 and the roller cooling machine 8 for cooling, and directly enters the finished product blanket winding machine 12 for winding after correction by the finished product blanket correcting machine 10; Please refer to Figure 7 The process formed product is a light bottom covered bottom back carpet, and the light bottom covered bottom back carpet comprises a blanket surface layer 30, a base cloth layer 31 and a polyurethane coating layer 32 which are sequentially superimposed. Figure 8 The process formed product is a non-woven fabric covered bottom back carpet, and the non-woven fabric covered bottom back carpet comprises a blanket surface layer 30, a glass mesh fiber layer 33, a base cloth layer 31 and a polyurethane coating layer 32 which are sequentially superimposed. The double-line design increases the flexibility of the production line, and different types of carpet products can be produced as needed.

[0033] The technical scheme that the polymeric polyols, isocyanate and calcium powder are respectively introduced into the mixing head through the Kriolite mass flow meter according to the required proportion is adopted, the reaction time and process are accurately controlled, and the problem that the reaction time and process cannot be controlled in the prior art is solved; The production line design of the present application realizes large-scale continuous production, and a mold is not needed, so that the defect that the traditional polyurethane foaming technology must use a mold and is not suitable for large-scale continuous production is overcome; Through the automatic raw material storage and conveying system 1, the labor operation demand is greatly reduced, the energy consumption is reduced, and the problem of large energy consumption of raw materials by labor is solved; The physical foaming technology is adopted, there is no chemical foaming agent residue, the environmental protection regulation requirements are met, the bubble hole structure is uniform and delicate, and high performance is realized under the condition of low density.

[0034] In the embodiment 2, the embodiment also provides a polyurethane physical foaming carpet covering production process, and the polyurethane physical foaming carpet covering production line in the embodiment 1 is adopted; Including the following steps: S1. Raw material preparation: Weigh the amount of each component according to the formula ratio and transfer it to the mixing head; S2. Mixing and foaming: Polyurethane raw materials and physical foaming agents are mixed in a certain proportion, and the mixed materials are vigorously stirred to make them physically foamed to form a polyurethane coating; the physical foaming agent includes an inert gas and a low-boiling-point liquid, the inert gas includes CO2 and nitrogen, and the low-boiling-point liquid includes cyclopentane. S3. Molding: The foamed polyurethane coating, along with the raw carpet and non-woven fabric, is fed into the coating machine 5. The polyurethane coating forms the required backing shape and thickness on the back of the carpet. S4. Curing: The carpet after being covered is sent into the main plasticizing oven 6, where the physical foaming material in the polyurethane coating is plasticized and forms a stable structure by using a high temperature of 80-120°C. S5. Cooling: The plasticized carpet is sequentially fed into the plate cooling device 7 and the roller cooler 8 for preliminary cooling and secondary cooling, so that the carpet is shaped into a finished carpet. S6. Cutting and winding: The formed backing carpet is fed into the finished carpet storage machine 9, the finished carpet straightening machine 10, the finished carpet punching machine 11, and the finished carpet winding machine 12 in sequence. It is cut according to the required size and the cut carpet backing is wound into a roll. S7. Quality Inspection and Packaging: Conduct quality inspection on the carpet backing produced, including testing for thickness, density, hardness, elasticity, abrasion resistance, and flame retardancy; package qualified products for shipment.

[0035] This polyurethane physical foam carpet backing production line, through reasonable equipment configuration and process flow, has achieved efficient and stable production of carpet backing, improved product quality and production efficiency, and met the production needs of different types of carpets.

[0036] In summary, the present application adopts the technical scheme that poly-multiple polyols and isocyanate and calcium powder enter the mixing head according to the required proportion through the Kriolite mass flow meter respectively, realizes the accurate control of the reaction time and process, solves the problem that the reaction time and process cannot be controlled in the prior art, the production line design of the present application realizes large-scale continuous production, and no mold is needed, which overcomes the defect that the traditional polyurethane foaming technology must use a mold and is not suitable for large-scale continuous production, through the automatic raw material storage and conveying system 1, the manual operation demand is greatly reduced, the energy consumption is reduced, and the problem of high energy consumption of raw materials by manual operation is solved, the present application adopts the physical foaming technology, there is no chemical foaming agent residue, meets the environmental protection regulation requirements, the bubble hole structure is uniform and delicate at the same time, high performance is realized under the condition of low density, the process of the present application has high flexibility as a whole, the product performance can be quickly adjusted by adjusting the component proportion, the foaming agent amount and other parameters, and the production of products with different shapes and requirements is adapted, through the optimized material formula and production process, the polyurethane foaming material produced by the present application has low thermal conductivity and good aging resistance, the present application significantly improves the economy of the product by reducing the raw material cost and reducing the post-processing process, and solves the problem of high price of the finished product, therefore, the present application effectively overcomes the various defects in the prior art and has high industrial utilization value.

[0037] The above embodiments only exemplarily illustrate the principles and effects of the present application, and are not used to limit the present application. Any person skilled in the art can modify or change the above embodiments without departing from the spirit and scope of the present application. Therefore, all equivalent modifications or changes completed by those skilled in the art without departing from the spirit and technical thought disclosed by the present application should be covered by the claims of the present application.

Claims

1. A polyurethane physically foamed carpet underlay production line characterised in that, The production line comprises: a polyurethane raw material storage and conveying system (1) for manufacturing polyurethane coating and conveying the polyurethane coating for use in gluing; a blank storage machine (2) for blank unwinding, deviation rectification and storage; a non-woven fabric storage machine (3) for non-woven fabric unwinding and storage; a blank conveying and deviation rectification machine (4) for conveying the blank and rectifying the deviation during conveying; a gluing machine (5) for simultaneously inputting the blank, polyurethane coating and non-woven fabric to make a carpet; a main plasticizing oven (6) for plasticizing the physical foaming material in the polyurethane coating by high temperature of 80-120° and forming a stable structure; a plate cooling device (7) for primary cooling of the plasticized carpet; a roller cooling machine (8) for further cooling the carpet to form a finished carpet; a finished carpet storage machine (9) for finished carpet storage; a finished carpet deviation rectification machine (10) for deviation rectification during conveying of the finished carpet; a finished carpet cutting machine (11) for cutting the polyurethane square block finished carpet into shape; a finished carpet winding machine (12) for winding the polyurethane roll finished carpet.

2. The polyurethane physically foamed carpet underlay production line according to claim 1, characterized in that: The polyurethane raw material storage and conveying system (1) comprises a polyurethane physical foaming machine (13) provided with a material conveying pipeline (14) through which the polyurethane raw material mixture enters the polyurethane physical foaming machine (13); the material conveying pipeline (14) is connected with an inert gas pipeline (15) for blowing the physical foaming agent into the polyurethane physical foaming machine (13) to cooperate with the polyurethane raw material mixture for physical foaming.

3. The polyurethane physically foamed carpet underlay production line according to claim 2, characterized in that: The polyurethane raw material storage and conveying system (1) further comprises an A material storage tank (16), a B material storage tank (17), an A material batching tank (18), a B material batching tank (19), an A material feeding pump (20) and a B material feeding pump (21); the A material batching tank (18) is connected with the A material storage tank (16) through a pipeline, and the A material feeding pump (20) is arranged on the pipeline between the A material batching tank (18) and the A material storage tank (16); the B material batching tank (19) is connected with the B material storage tank (17) through a pipeline, and the B material feeding pump (21) is arranged on the pipeline between the B material batching tank (19) and the B material storage tank (17). The output ends of the A material storage tank (16) and the B material storage tank (17) are connected with the material conveying pipeline (14) through pipelines.

4. The polyurethane physically foamed carpet underlay production line according to claim 3, characterized in that: The output ends of the A material storage tank (16) and the B material storage tank (17) are respectively provided with a blue's flange type filter (22), a rotor pump (23) and a flow meter (24), and a backflow pipeline is arranged between the input end and the output end of the A material storage tank (16) and between the input end and the output end of the B material storage tank (17).

5. The polyurethane physically foamed carpet underlay production line according to claim 4, characterized in that: The polyurethane raw material storage and conveying system (1) further comprises a refrigerator (29), and the output end of the B material storage tank (17) is further provided with a cooler (25), and the output end of the refrigerator (29) is connected with the cooler (25) and the polyurethane physical foaming machine (13).

6. The polyurethane physically foamed carpet underlay production line according to claim 5, characterized in that: A thermometer (28) is arranged on the output end of the polyurethane physical foaming machine (13).

7. The polyurethane physically foamed carpet underlay production line according to claim 2, characterized in that: The material conveying pipeline (14) is further connected with a flushing pump (26), the flushing pump (26) is arranged between the inert gas pipeline (15) and the input end of the polyurethane physical foaming machine (13); a pressure sensor (27) is arranged on the pipeline of the material conveying pipeline (14) close to the input end of the polyurethane physical foaming machine (13).

8. The polyurethane physically foamed carpet underlayment production line of claim 1, wherein: A closed loop Teflon belt (34) is arranged in the glue spreading machine (5), the main plasticizing oven (6) and the plate cooling device (7), the base mat and the non-woven fabric are adhered to the outer side end of the Teflon belt (34) after being input into the glue spreading machine (5); a scraper (51) is arranged in the glue spreading machine (5) and cooperates with the outer side end of the Teflon belt (34) and is used for scraping the Teflon adhered between the base mat and the non-woven fabric.

9. A process for producing a polyurethane physically foamed carpet underlay using the polyurethane physically foamed carpet underlay production line according to any one of claims 1 to 8, characterized in that, The method comprises the following steps: S1, raw material preparation: according to the formula proportion, the amount of each component is automatically measured by PLC control Coriolis mass flowmeter, and is conveyed to the mixing head; S2, mixing and foaming: the polyurethane raw material is mixed with the inert gas which is automatically measured by the air flowmeter according to a certain proportion, and the mixed material is stirred intensively, so that the inert gas is fully mixed with the material to form the polyurethane coating; S3, forming: the foamed polyurethane coating, the base mat, the non-woven fabric and other fabrics are sent into the glue spreading machine (5) together, and the polyurethane coating forms the required bottom shape and thickness on the back of the carpet; S4, curing: the carpet with the bottom is sent into the main plasticizing oven (6), and the physical foaming material in the polyurethane coating is plasticized and forms a stable structure through 80-120° high temperature; S5, cooling: the plasticized carpet is sent into the plate cooling device (7) and the roll cooling machine (8) in sequence for preliminary cooling and secondary cooling, so that the carpet is shaped to form a finished carpet; S6, cutting and winding: the formed carpet with the bottom is sent into the finished carpet storage machine (9), the finished carpet correcting machine (10), the finished carpet cutting machine (11) and the finished carpet winding machine (12) in sequence, is cut according to the required size, and the cut carpet with the bottom is wound into a roll; S7, quality inspection and packaging: the produced carpet with the bottom is subjected to quality inspection, including thickness, density, hardness, elasticity, wear resistance and flame resistance detection; The qualified products are packaged and prepared for shipment.

10. The polyurethane physically foamed carpet underlay production process according to claim 9, characterized in that: In the step S2, the physical foaming agent comprises inert gas, and the inert gas comprises CO2 and nitrogen.

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