Composite nonwoven fabric hot roll film coating device

Abstract

The application is suitable for the field of composite non-woven fabric processing, and provides a composite non-woven fabric hot rolling and film coating device, which comprises a workbench, the workbench is fixedly connected with a hot pressing box, one side of the hot pressing box is provided with a support frame A, the support frame A is connected with two discharging machines for discharging non-woven fabric and film, a corona mechanism is arranged between the discharging machine and the hot pressing box, the corona mechanism is used for corona treatment of the non-woven fabric and the film, and the other side of the hot pressing box is connected with a material collecting machine for winding through a support frame C. The application solves the problem of weak interfacial bonding force caused by uneven temperature distribution in the non-woven fabric film coating process, effectively inhibits the wrinkle defect caused by the shrinkage of the material under the action of heat. Through the synergistic effect of bidirectional gradient heating and stretching, the uniformity of the combination of the film and the non-woven fabric is improved, and the composite strength of the edge region of the wide material is also enhanced.

Description

Technical Field

[0001] This invention belongs to the field of composite nonwoven fabric processing, and particularly relates to a composite nonwoven fabric hot rolling coating device. Background Technology

[0002] Nonwoven fabric lamination technology has become an important development direction in the field of nonwoven material deep processing in recent years. By combining functional films with nonwoven fabric substrates, the waterproofness, breathability, mechanical strength, and aesthetics of the materials can be significantly improved. Hot-roll lamination is one of the mainstream composite processes at present. It uses heated rollers to heat and pressurize the film and nonwoven fabric, so that the film melts and bonds with the nonwoven fibers to form a strong interface.

[0003] However, existing hot-rolling coating equipment and processes still face several technical bottlenecks that urgently need to be addressed. First, traditional heating rollers are typically of a single, integrated structure or have rudimentary partitioning, making precise temperature field control difficult. During the coating process, the ends of the roller lose significant heat, resulting in a lower temperature than the center, causing uneven heating along the width of the nonwoven fabric. This directly leads to inconsistent film melting states, resulting in varying interfacial bonding strength. The product is prone to weak bonding, bubbling, and delamination in low-temperature regions, while overheating can damage the material in high-temperature regions. Second, along the length direction, the nonwoven fabric and film undergo multiple stages, including preheating, lamination, and cooling. If the temperature gradient between these stages is not set appropriately or controlled precisely, it will also affect the diffusion and entanglement of molecular chains, ultimately impacting the composite strength.

[0004] Furthermore, existing tension control systems are mostly designed for the entire width of the material, lacking the ability to fine-tune local tension. When uneven heating of the material causes localized expansion and contraction, defects such as wrinkles and streaks are easily generated. Especially in wide-width, high-speed production conditions, traditional tension control systems have a lag in response and cannot promptly suppress the generation and expansion of defects, leading to a decrease in production efficiency and product yield.

[0005] Therefore, the industry urgently needs a new type of composite nonwoven fabric thermal rolling coating device that can fundamentally solve the problem of synergistic control of heating uniformity and tension. Existing technologies urgently need improvement to address these issues. Summary of the Invention

[0006] The purpose of this invention is to provide a composite nonwoven fabric thermal rolling coating device, which aims to solve the problem of synergistic control of heating uniformity and tension.

[0007] The present invention is implemented as follows: a composite nonwoven fabric hot rolling and laminating device includes a worktable, a hot press box fixedly connected to the worktable, a support frame A on one side of the hot press box, two feeding machines for feeding nonwoven fabric and film connected to the support frame A, a corona treatment mechanism between the feeding machines and the hot press box for corona treatment of nonwoven fabric and film, and a take-up machine for winding connected to the other side of the hot press box via a support frame C.

[0008] The hot press box is provided with multiple heating chambers, and two adjacent heating chambers are interconnected. Each heating chamber is provided with a hot press tensioning mechanism. All hot press tensioning mechanisms work together to perform gradient heating along the length of the nonwoven fabric after lamination. In the width direction of the nonwoven fabric after lamination, each hot press tensioning mechanism can perform gradient heating and stretching from the middle of the nonwoven fabric to both sides.

[0009] The control system can control the hot pressing tensioning mechanism according to the heating and tensioning state of the nonwoven fabric after lamination.

[0010] In a further technical solution, the hot-pressing tensioning mechanism includes a metal guide roller B, a metal rod, a coil unit, and a housing;

[0011] Each heating chamber has two metal guide rollers B rotatably connected to its sidewall. The two metal guide rollers B are arranged vertically, and a drive assembly is set between the two metal guide rollers B to drive them to rotate relative to each other. A metal rod is fixedly connected to each metal guide roller B, and multiple coil units are arranged at equal intervals on the metal rod. Tensioning assemblies are set at both ends of each metal guide roller B. The tensioning assemblies can stretch both ends of the retroperitoneal nonwoven fabric. A shell is set at one end of each metal guide roller B, and a power supply body is set in the shell to supply power to the coil units and the tensioning assembly.

[0012] In a further technical solution, the tensioning assembly includes an electromagnetic block, a magnetic strip, and a metal scraper.

[0013] The metal guide roller B has multiple equally spaced strip grooves at both ends, and each strip groove contains an electromagnetic block. Each electromagnetic block has a magnetic strip on one side, which is slidably connected to the inner wall of the strip groove. A metal scraper is located on the side of the magnetic strip facing away from the electromagnetic block, and the metal scraper is inclined towards the end of the metal guide roller B. When the electromagnetic block is energized, it pushes the magnetic strip to compress the coated nonwoven fabric, increasing the tension of the coated nonwoven fabric in the length direction and preventing wrinkles. Simultaneously, as the magnetic strip rotates with the metal guide roller B, the magnetic strips at both ends of the metal guide roller B drive all the metal scrapers to push the coated nonwoven fabric to both sides, thereby increasing the tension of the coated nonwoven fabric in the width direction and increasing the adhesion between the film and the nonwoven fabric. Furthermore, the increased contact area between the stretched coated nonwoven fabric and the metal guide roller B enhances the heating effect of the coated nonwoven fabric and further increases the interfacial bonding force.

[0014] In a further technical solution, the drive assembly includes a transmission wheel and a motor. Each metal guide roller B has a transmission wheel fixedly connected to one end, and adjacent transmission wheels mesh with each other. A metal rod is fixedly connected to one side of the heating chamber, and the output shaft of the metal rod is fixedly connected to one end of a metal guide roller B.

[0015] In a further technical solution, the corona mechanism includes a high-voltage electrode and a metal guide roller A. A support frame B is fixedly connected to the worktable. Two high-voltage electrodes are provided on the support frame B. The rotating seats at both ends of each high-voltage electrode are fitted into the support frame B. A pressure sensor is provided at the connection position between the rotating seat of the high-voltage electrode and the support frame B. Two metal guide rollers A are fixed on a fixed plate on one side of the support frame B, and the two metal guide rollers A face the two high-voltage electrodes respectively.

[0016] A further technical solution is provided, wherein the control system includes:

[0017] Monitoring module: It includes:

[0018] Temperature status assessment unit: At the same time, the surface temperature of the coated nonwoven fabric at the same position in each heating chamber is measured at equal intervals, and the surface temperature difference between the coated nonwoven fabric at the same position in two adjacent heating chambers is calculated. The largest set of surface temperature differences is recorded as the maximum temperature difference value in the length direction. The surface temperature of the coated nonwoven fabric at the middle position and the two ends of each metal guide roller B is measured, and the surface temperature difference between the middle position and the end position of the coated nonwoven fabric is calculated. The largest set of surface temperature differences is recorded as the maximum temperature difference value in the width direction.

[0019] Tension force assessment unit: At the same time, the tension force of the coated nonwoven fabric at the same position in each heating chamber is measured at equal intervals, and the tension force difference between the coated nonwoven fabrics at the same position in two adjacent heating chambers is calculated. The largest set of tension force differences is recorded as the maximum tension force difference in the length direction. The tension force difference of the coated nonwoven fabric at the middle position and the two ends position of each metal guide roller B is measured, and the tension force difference of the coated nonwoven fabric at the middle position and the end position of the metal guide roller B is calculated. The largest set of tension force differences is recorded as the maximum tension force difference in the width direction.

[0020] Heating condition assessment model: It can construct a heating condition assessment model based on the maximum temperature difference in the length direction and the maximum temperature difference in the width direction, and output the heating condition assessment coefficient;

[0021] Tension State Assessment Model: It can construct a tension state assessment model based on the maximum tension force difference in the length direction and the maximum tension force difference in the width direction, and output the tension state assessment coefficient;

[0022] The control module can construct an interface bonding force control model based on the heating state evaluation coefficient and the tensioning state evaluation coefficient, and output the interface bonding force control threshold. The interface bonding force control threshold is compared with the preset threshold. If the interface bonding force control threshold exceeds the preset threshold, the control module controls the hot pressing tensioning mechanism to stretch and tension the coated nonwoven fabric.

[0023] A further technical solution involves substituting the maximum temperature difference values ​​along the length and width directions at the current moment into the maximum value normalization formula for processing, and generating temperature difference indices along the length and width directions respectively; the heating state assessment model is as follows:

[0024] ;

[0025] in This is the length-direction temperature difference weighting coefficient. This is the width-direction temperature difference weighting coefficient, and ,and , All greater than ; The temperature difference index along the length direction. The temperature difference index is in the width direction. This is the evaluation coefficient for the heating state.

[0026] A further technical solution involves substituting the maximum tension difference in the length direction and the maximum tension difference in the width direction at the current moment into the maximum value normalization formula for processing, and generating tension exponents in the length direction and width direction respectively; the tension state evaluation model is as follows:

[0027] ;

[0028] in This is the length-direction tension weighting coefficient. This is the tension force weighting coefficient in the width direction, and , , All greater than ; The tension index is in the length direction. This is the tension index in the width direction. This is the tension state evaluation coefficient.

[0029] A further technical solution, the interface bonding force control model is as follows:

[0030] ;

[0031] in The heating state weighting coefficient is used. The tension state weighting coefficient, ,and , All greater than ; For heating condition evaluation coefficient, This is the tension state evaluation coefficient. The threshold for controlling the interface bonding force.

[0032] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0033] Through the above technical solution, this application solves the problem of weakened interfacial bonding caused by uneven temperature distribution during nonwoven fabric lamination, effectively suppressing wrinkling defects caused by material thermal shrinkage. The synergistic effect of bidirectional gradient heating and stretching improves the uniformity of the bonding between the film and the nonwoven fabric, while simultaneously enhancing the composite strength in the edge areas of wide-width materials. A dynamic control mechanism ensures that process parameters are always optimized during high-speed continuous production, reducing the defect rate.

[0034] When the electromagnetic block is energized, the generated magnetic force pushes the magnetic strip to slide outward along the groove. The magnetic strip directly compresses the coated nonwoven fabric, eliminating the material's slack in the length direction. As the metal guide roller B rotates, the magnetic strip drives the metal scraper to move synchronously. Due to the inclined setting of the metal scraper, it generates a lateral force when in contact with the coated nonwoven fabric, forcing the material to expand to both sides. During this process, the coated nonwoven fabric is uniformly stretched in the width direction, avoiding local stress concentration. At the same time, the contact area between the material and the metal guide roller B increases due to the tension, improving heat conduction efficiency and enhancing interfacial bonding.

[0035] Through the above technical solution, this application solves the problem of excessive heating differences in the length and width directions of the coated nonwoven fabric caused by uneven temperature distribution in the heating chamber. By dynamically calculating the heating state evaluation coefficient, abnormal temperature distribution areas can be accurately identified, and the tensioning parameters of the hot-pressing tensioning mechanism can be adjusted accordingly. This solution effectively reduces the phenomenon of insufficient film melting caused by excessively low local temperatures, while avoiding overheating damage to the material in high-temperature areas. Through quantitative evaluation and feedback control, the stability of the interfacial bonding force between the film and the nonwoven fabric is improved, reducing the probability of defects such as weak lamination and blistering. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the structure of the present invention;

[0037] Figure 2 This is a schematic diagram of the internal structure of the autoclave in this invention;

[0038] Figure 3 This is a schematic diagram of the driving component in this invention;

[0039] Figure 4 This is a schematic diagram of the tensioning component in this invention;

[0040] Figure 5 This is a schematic diagram showing the connection between the metal rod and the coil unit in this invention.

[0041] In the attached diagram: 1. Workbench; 2. Hot press box; 3. Feeder; 4. Take-up machine; 5. Corona discharge mechanism; 51. High voltage electrode; 52. Metal guide roller A; 6. Hot press tensioning mechanism; 61. Metal guide roller B; 62. Metal rod; 63. Coil unit; 64. Shell; 7. Drive assembly; 71. Transmission wheel; 72. Motor; 8. Tensioning assembly; 81. Electromagnetic block; 82. Magnetic strip; 83. Metal scraper; 9. Support frame A; 10. Support frame B; 11. Support frame C; 12. Heating chamber. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0043] The specific implementation of the present invention will be described in detail below with reference to specific embodiments.

[0044] like Figures 1-5As shown, a composite nonwoven fabric hot rolling and laminating device according to an embodiment of the present invention includes a worktable 1, a hot press box 2 fixedly connected to the worktable 1, a support frame A9 provided on one side of the hot press box 2, and two feeding machines 3 for feeding nonwoven fabric and film connected to the support frame A9. A corona treatment mechanism 5 is provided between the feeding machines 3 and the hot press box 2, and the corona treatment mechanism 5 is used to corona treat the nonwoven fabric and film. A winding machine 4 for winding is connected to the other side of the hot press box 2 through a support frame C11.

[0045] The hot press box 2 is provided with multiple heating chambers 12, and two adjacent heating chambers 12 are interconnected. Each heating chamber 12 is provided with a hot press tensioning mechanism 6. All hot press tensioning mechanisms 6 perform gradient heating along the length direction of the nonwoven fabric after lamination. In the width direction of the nonwoven fabric after lamination, each hot press tensioning mechanism 6 can perform gradient heating and stretching from the middle of the nonwoven fabric to both sides.

[0046] The control system can control the hot pressing tensioning mechanism 6 according to the heating and tensioning state of the nonwoven fabric after lamination.

[0047] In this embodiment, the autoclave 2 refers to a closed cavity structure that carries multiple heating units. Specifically, it can be formed by splicing together modular heat-insulating components, with heat conduction channels between adjacent modules. This structure allows for independent temperature adjustment of each chamber while maintaining continuous heat transfer. The heating chamber 12 refers to an independently temperature-controlled area within the autoclave 2, which can be configured with an annular heating element and a temperature sensor to achieve regional temperature management. The autoclave tensioning mechanism 6 is a composite component integrating heating and tensioning functions. Specifically, it can be a roller structure with an electromagnetic drive unit, dynamically adjusting the roller surface contact pressure and tension amplitude through electromagnetic force. The control system refers to a control unit with data acquisition and logic operation functions, which can be deployed with an embedded processor and an industrial communication module to achieve multi-parameter collaborative analysis.

[0048] Specifically, the nonwoven fabric and film, after corona treatment, enter the hot press chamber 2, undergoing a composite process of temperature gradient changes in multiple heating chambers 12. The hot press tensioning mechanism 6 within each heating chamber 12 adjusts the roller surface temperature distribution according to the real-time material condition, forming an increasing or decreasing temperature curve along the length direction to match the thermodynamic requirements of the material's melting and solidification stages. In the width direction, differentiated tensile forces are generated in the middle and sides of the roller body to offset the lateral shrinkage differences caused by uneven heat dissipation. The control system continuously collects temperature and tension data, dynamically correcting the power output and tensile parameters of each heating chamber 12 through an algorithm model to ensure that the material maintains uniform heating and stress balance in both directions.

[0049] Through the above technical solution, this application solves the problem of weakened interfacial bonding caused by uneven temperature distribution during nonwoven fabric lamination, effectively suppressing wrinkling defects caused by material thermal shrinkage. The synergistic effect of bidirectional gradient heating and stretching improves the uniformity of the bonding between the film and the nonwoven fabric, while simultaneously enhancing the composite strength in the edge areas of wide-width materials. A dynamic control mechanism ensures that process parameters are always optimized during high-speed continuous production, reducing the defect rate.

[0050] like Figure 4 and Figure 5 As shown, in a preferred embodiment of the present invention, the hot-pressing tensioning mechanism 6 includes a metal guide roller B61, a metal rod 62, a coil unit 63, and a housing 64.

[0051] Each heating chamber 12 has two metal guide rollers B61 rotatably connected to its sidewall. The two metal guide rollers B61 are arranged vertically, and a drive assembly 7 is provided between the two metal guide rollers B61 to drive them to rotate relative to each other. A metal rod 62 is fixedly connected to each metal guide roller B61. Multiple coil units 63 are arranged at equal intervals on the metal rod 62. Tensioning assemblies 8 are provided at both ends of each metal guide roller B61. The tensioning assemblies 8 can stretch the two ends of the retroperitoneal nonwoven fabric. A housing 64 is provided at one end of each metal guide roller B61. A power supply body that can supply power to the coil units 63 and the tensioning assembly 8 is provided in the housing 64.

[0052] In this embodiment, the metal guide roller B61 refers to a cylindrical metal roller with thermally conductive surface, specifically made of copper alloy, with a hollow internal structure to accommodate the metal rod 62 and the coil unit 63. The metal rod 62 is a support member extending axially along the guide roller, specifically made of stainless steel, with grooves on its surface for fixing the coil unit 63. The coil unit 63 is a spiral heating element wound with conductive material, specifically made of nickel-chromium alloy wire, which generates Joule heat through energization and conducts it to the surface of the guide roller. The housing 64 is a sealed power transmission device, specifically made by encasing a copper brush structure in an insulating engineering plastic shell, supplying power to the moving guide roller through a rotational contact method.

[0053] Specifically, the two metal guide rollers B61 rotate in opposite directions under the action of the drive assembly 7, allowing the coated nonwoven fabric to move stably under the clamping and traction of the double rollers. The coil units 63, evenly distributed on the metal rod 62, are controlled by independent circuits, allowing for differentiated current input to different sections of the guide rollers to compensate for heat loss in the width direction. When a temperature difference is detected between the center and edge of the guide roller, the control system can increase the current intensity of the coil units 63 in the edge area, creating a uniform temperature field on the guide roller surface. The tensioning assemblies 8 at both ends of the metal guide rollers B61 generate mechanical force after being energized, applying lateral stretching to the edges of the nonwoven fabric and eliminating wrinkles caused by thermal expansion differences. The power supply unit built into the housing 64 continuously supplies power to the rotating guide rollers through a sliding contact method, ensuring stable operation of the coil units 63 and the tensioning assembly 8 under dynamic conditions.

[0054] Compared to existing technologies, traditional devices using an integral heating roller result in excessive heat dissipation in the edge areas. This solution utilizes a split dual-guide roller structure in conjunction with a discrete coil unit 63 to achieve dynamic compensation of the temperature field in the width direction. Existing technologies relying on a single drive roller are prone to stress concentration; this solution reduces internal material stress through the coordinated traction of two rollers. Traditional tensioning devices can only adjust the overall tension; this solution uses independent tensioning components 8 at both ends of the guide rollers to achieve localized tension control in the edge areas, effectively suppressing wrinkle formation.

[0055] like Figure 4 As shown, in a preferred embodiment of the present invention, the tensioning assembly 8 includes an electromagnetic block 81, a magnetic strip 82, and a metal scraper 83;

[0056] The metal guide roller B61 has multiple equally spaced strip grooves at both ends, and each strip groove contains an electromagnetic block 81. Each electromagnetic block 81 has a magnetic strip 82 on one side, which is slidably connected to the inner wall of the strip groove. A metal scraper 83 is located on the side of the magnetic strip 82 facing away from the electromagnetic block 81, and the metal scraper 83 is inclined towards the end of the metal guide roller B61. When the electromagnetic block 81 is energized, it pushes the magnetic strip 82 to compress the coated nonwoven fabric, thus increasing the fabric's elasticity over time. The tension in the width direction is increased to avoid wrinkles. At the same time, as the magnetic strip 82 rotates with the metal guide roller B61, the magnetic strips 82 at both ends of the metal guide roller B61 drive all the metal scrapers 83 to push the coated nonwoven fabric to both sides to tighten it, thereby increasing the tension of the coated nonwoven fabric in the width direction and increasing the adhesion between the film and the nonwoven fabric. At the same time, the contact area between the coated nonwoven fabric and the metal guide roller B61 increases after the coated nonwoven fabric is tightened, thereby increasing the heating effect of the coated nonwoven fabric and further increasing the interfacial bonding force of the coated nonwoven fabric.

[0057] In this embodiment, the electromagnetic block 81 refers to a device that generates a magnetic field through an electric current. Specifically, it can be implemented by combining an energized coil or a permanent magnet with an electromagnet, used to generate magnetic force to move the magnetic strip 82 when energized. The magnetic strip 82 refers to a metal strip with magnetic permeability, specifically made of ferromagnetic material, which can be attracted or repelled in the magnetic field generated by the electromagnetic block 81, thereby sliding along the strip groove. The metal scraper 83 refers to a metal sheet with a specific tilt angle, specifically made of stainless steel or alloy material, with the tilt angle set to an acute angle, for example, between 30 and 60 degrees, used to convert the longitudinal movement of the magnetic strip 82 into a lateral tensile force on the coated nonwoven fabric. The strip groove refers to a groove structure formed at the end of the metal guide roller B61, specifically formed by machining or casting process, used to accommodate the electromagnetic block 81 and the magnetic strip 82, and to restrict the movement trajectory of the magnetic strip 82.

[0058] Specifically, when the electromagnetic block 81 is energized, the generated magnetic force pushes the magnetic strip 82 to slide outward along the strip groove. The magnetic strip 82 directly compresses the coated nonwoven fabric, eliminating the material's slack in the length direction. As the metal guide roller B61 rotates, the magnetic strip 82 drives the metal scraper 83 to move synchronously. Due to the inclined setting of the metal scraper 83, it generates a lateral force when it contacts the coated nonwoven fabric, forcing the material to expand to both sides. During this process, the coated nonwoven fabric is uniformly stretched in the width direction, avoiding local stress concentration. At the same time, the contact area between the material and the metal guide roller B61 increases due to the tension, improving heat conduction efficiency and enhancing interfacial bonding.

[0059] Through the above technical solution, this application solves the problems of poor adhesion and weak interfacial bonding caused by insufficient bidirectional tension of the coated nonwoven fabric, avoids wrinkle defects caused by relaxation of the material during hot pressing, and improves heating uniformity by increasing the contact area, ensuring that the film and nonwoven fabric form a stable and firm composite interface.

[0060] like Figure 3 As shown, in a preferred embodiment of the present invention, the drive assembly 7 includes a transmission wheel 71 and a motor 72. One end of each metal guide roller B61 is fixedly connected to the transmission wheel 71, and adjacent transmission wheels 71 mesh with each other. One side of the heating chamber 12 is fixedly connected to a metal rod 62, and the output shaft of the metal rod 62 is fixedly connected to one end of a metal guide roller B61.

[0061] In this embodiment, the motor 72 transmits power to the drive wheel 71 at one end of the metal guide roller B61 via the metal rod 62, driving the metal guide roller B61 to rotate around its axis. The drive wheels 71 of the two metal guide rollers B61 are linked together through meshing.

[0062] like Figure 1As shown, in a preferred embodiment of the present invention, the corona mechanism 5 includes a high-voltage electrode 51 and a metal guide roller A52. The worktable 1 is fixedly connected to a support frame B10. Two high-voltage electrodes 51 are provided on the support frame B10. The rotating seats at both ends of each high-voltage electrode 51 are fitted into the support frame B10. A pressure sensor is provided at the connection position between the rotating seat of the high-voltage electrode 51 and the support frame B10. Two metal guide rollers A52 are fixed on a fixed plate on one side of the support frame B10. The two metal guide rollers A52 face the two high-voltage electrodes 51 respectively.

[0063] In this embodiment, the high-voltage electrode 51 refers to a device that performs corona treatment on the material surface through high-voltage discharge. Specifically, it can be implemented using a tungsten alloy electrode rod in conjunction with a high-frequency power supply, which generates polar groups on the material surface by ionizing air. The metal guide roller A52 refers to a conductive metal roller, which can be implemented using a chrome-plated steel roller or an aluminum alloy roller, used to guide the material through the corona treatment area and form a stable electric field distribution. The pressure sensor refers to a sensor that detects the contact pressure between the electrode and the material. Specifically, it can be implemented using a piezoelectric thin-film sensor or a strain gauge sensor, which monitors the contact pressure in real time and feeds it back to the control system.

[0064] Specifically, the support frame B10 rigidly connects and fixes the relative positions of the high-voltage electrode 51 and the metal guide roller A52 to prevent electrode displacement caused by equipment vibration or material traction. The rotating seats at both ends of the high-voltage electrode 51 are fitted into the positioning grooves of the support frame B10. Pressure sensors are embedded in the contact surface between the rotating seats and the support frame B10 to collect real-time contact pressure data between the electrode and the material. The metal guide roller A52 is arranged parallel to the high-voltage electrode 51, forming a uniform electric field region during material transport, allowing the nonwoven fabric and film surfaces to simultaneously receive corona treatment of equal intensity.

[0065] In a preferred embodiment of the present invention, the control system includes:

[0066] Monitoring module: It includes:

[0067] Temperature status assessment unit: At the same time, the surface temperature of the coated nonwoven fabric at the same position in each heating chamber 12 is measured at equal intervals, and the surface temperature difference between the coated nonwoven fabric at the same position in two adjacent heating chambers 12 is calculated. The largest set of surface temperature differences is recorded as the maximum temperature difference value in the length direction. The surface temperature of the coated nonwoven fabric at the middle position and the two end positions of each metal guide roller B61 is measured, and the surface temperature difference between the middle position and the end position of the coated nonwoven fabric is calculated. The largest set of surface temperature differences is recorded as the maximum temperature difference value in the width direction.

[0068] Tension force assessment unit: At the same time, the tension force of the coated nonwoven fabric at the same position in each heating chamber 12 is measured at equal intervals, and the tension force difference between the coated nonwoven fabrics at the same position in two adjacent heating chambers 12 is calculated. The largest set of tension force differences is recorded as the maximum tension force difference in the length direction. The tension force difference of the coated nonwoven fabric at the middle position and the two ends position of each metal guide roller B61 is measured, and the tension force difference of the coated nonwoven fabric at the middle position and the end position of the metal guide roller B61 is calculated. The largest set of tension force differences is recorded as the maximum tension force difference in the width direction.

[0069] Heating condition assessment model: It can construct a heating condition assessment model based on the maximum temperature difference in the length direction and the maximum temperature difference in the width direction, and output the heating condition assessment coefficient;

[0070] Tension State Assessment Model: It can construct a tension state assessment model based on the maximum tension force difference in the length direction and the maximum tension force difference in the width direction, and output the tension state assessment coefficient;

[0071] The control module can construct an interface bonding force control model based on the heating state evaluation coefficient and the tensioning state evaluation coefficient, and output the interface bonding force control threshold. The interface bonding force control threshold is compared with the preset threshold. If the interface bonding force control threshold exceeds the preset threshold, the control module controls the hot pressing tensioning mechanism 6 to stretch and tension the coated nonwoven fabric.

[0072] In this embodiment, the temperature state assessment unit refers to a device that simultaneously measures the surface temperature difference between the 12 heating chambers and the middle and end of the guide rollers. Specifically, it can be implemented using an infrared temperature measurement array combined with a temperature sensor matrix to capture the uneven distribution characteristics of material heating. The tension state assessment unit refers to a device that simultaneously measures the tension difference between the 12 heating chambers and the middle and end of the guide rollers. Specifically, it can be implemented using a distributed fiber optic sensor combined with a strain gauge array to identify stress concentration areas. The heating state assessment model is a mathematical model that integrates the temperature differences in the length and width directions. Specifically, it can be implemented using a normalized weighted algorithm to quantify the degree of temperature field anomalies. The tension state assessment model is a mathematical model that integrates the tension differences in the length and width directions. Specifically, it can be implemented using a normalized weighted algorithm to quantify the degree of stress field imbalance. The interface bonding force control model is a geometric synthesis model that integrates thermodynamic parameters. Specifically, it can be implemented using a square weighted root algorithm to establish a nonlinear control threshold.

[0073] Specifically, the monitoring module collects temperature and tension data in real time during material operation. The temperature status assessment unit simultaneously calculates the maximum temperature difference between longitudinally adjacent heating chambers 12 and the maximum temperature difference between the middle and both ends of the transverse guide rollers using equally spaced temperature measuring points, identifying abnormal temperature gradients. The tension status assessment unit simultaneously calculates the maximum tension difference between longitudinally adjacent areas and the maximum tension difference at different transverse positions using distributed tension sensors, capturing uneven stress distribution. The heating status assessment model normalizes and weights the two-dimensional temperature difference data to generate an assessment coefficient reflecting the overall heating uniformity. The tension status assessment model normalizes and weights the two-dimensional tension difference to generate an assessment coefficient reflecting the tension balance state. The control module constructs a comprehensive control threshold using a geometric synthesis algorithm based on the two assessment coefficients. When this threshold exceeds a preset range, it triggers the guide roller tensioning component 8 to perform local fine-tuning, achieving dynamic balance of thermal parameters.

[0074] Through the above technical solution, this application effectively eliminates local composite defects caused by uneven heating, avoiding material wrinkles and interface separation. Real-time dynamic adjustment ensures optimal contact between the film and nonwoven fabric during hot pressing, improving the stability of interfacial adhesion. This solution can adapt to different production conditions of varying widths and speeds, significantly improving product yield and production efficiency.

[0075] In a preferred embodiment of the present invention, the maximum temperature difference value in the length direction and the maximum temperature difference value in the width direction at the current moment are substituted into the maximum value normalization formula for processing, and the temperature difference index in the length direction and the temperature difference index in the width direction are generated respectively; the heating state evaluation model is as follows:

[0076] ;

[0077] in This is the length-direction temperature difference weighting coefficient. This is the width-direction temperature difference weighting coefficient, and ,and , All greater than ; The temperature difference index along the length direction. The temperature difference index is in the width direction. This is the evaluation coefficient for the heating state.

[0078] In this embodiment, the maximum value normalization formula refers to standardizing the original data by dividing it by the maximum value in the dataset, thus eliminating the influence of different dimensions on the evaluation results. Specifically, the maximum temperature difference value in the length direction and the maximum temperature difference value in the width direction can be divided by the maximum historical temperature difference value in the corresponding direction, generating an index between 0 and 1. Through normalization, the temperature difference data in different directions can be converted into comparable dimensionless values, facilitating subsequent weighted calculations. The length direction temperature difference weighting coefficient α and the width direction temperature difference weighting coefficient β are proportional parameters set according to process requirements, used to adjust the degree of influence of the temperature difference in the length and width directions on the overall heating state evaluation. Specifically, preset empirical values ​​or dynamic adjustments can be made through machine learning algorithms. By setting the weighting coefficients, the system can flexibly adapt to the differentiated requirements for temperature uniformity in different materials and different process stages.

[0079] Specifically, during the continuous hot pressing of the coated nonwoven fabric, temperature sensors collect real-time surface temperature data of the nonwoven fabric at the same location in each heating chamber 12. The maximum temperature difference along the length is obtained by comparing the temperature differences at corresponding locations in adjacent heating chambers 12, and the maximum temperature difference along the width is obtained by comparing the temperature differences between the middle and both ends of the same heating chamber 12. After maximum value normalization, these temperature difference values ​​are converted into length-direction temperature difference indices and width-direction temperature difference indices, respectively. The heating state evaluation model integrates the two-direction temperature difference indices into a single evaluation coefficient through a weighted summation method. The values ​​of the weighting coefficients α and β determine the system's priority in focusing on temperature uniformity along the length or width. For example, when producing wide-width materials, the value of β can be increased to improve the sensitivity to temperature differences along the width. The real-time output of the evaluation coefficient H provides a quantitative indicator for the control system. When H exceeds a preset threshold, the hot pressing tensioning mechanism 6 is triggered to locally stretch the nonwoven fabric, thereby increasing the heated contact area and promoting temperature uniformity.

[0080] Compared to existing technologies, traditional hot-rolling coating equipment often uses single-point temperature monitoring or simple arithmetic averaging to assess the heating state, failing to effectively identify temperature gradient differences in the length and width directions of the material. This solution, however, constructs a multi-dimensional temperature difference data fusion model, enabling not only dynamic assessment of the overall heating uniformity of the material but also adjusting the control strategy for temperature sensitivity in different directions through weighting coefficients. Existing technologies lack the application of a normalized temperature difference index, resulting in poor comparability of temperature difference data across different production batches or material specifications. This solution, through maximum value normalization, significantly improves the generalization ability of the assessment model.

[0081] In a preferred embodiment of the present invention, the maximum tension difference in the length direction and the maximum tension difference in the width direction at the current moment are substituted into the maximum value normalization formula for processing, and the tension force index in the length direction and the tension force index in the width direction are generated respectively; the tension state evaluation model is as follows:

[0082] ;

[0083] in This is the length-direction tension weighting coefficient. This is the tension force weighting coefficient in the width direction, and , , All greater than ; The tension index is in the length direction. This is the tension index in the width direction. This is the tension state evaluation coefficient.

[0084] In this embodiment, the maximum value normalization formula refers to scaling the original data proportionally to the maximum value to eliminate the influence of different dimensions on the evaluation results. Specifically, this can be achieved by calculating the ratio of the tension force difference in each direction to the system's preset maximum allowable difference, thereby generating a dimensionless index. The length direction tension force index reflects the degree of tension force fluctuation in each heating section along the material's travel direction, while the width direction tension force index reflects the difference in tension force between the material's edge and center within the same heating section. γ and δ are used to adjust the influence of the length and width direction tension states on the comprehensive evaluation results. Specifically, this can be achieved by matching the optimal weight combination corresponding to different material types through the process parameter database, ensuring that the evaluation model adapts to different production conditions.

[0085] Specifically, when the material continuously passes through multiple heating chambers 12, the tension force difference at the same measurement point in adjacent heating chambers 12 along the length direction, as well as the tension force difference between the middle and sides of the same heating chamber 12, are collected in real time and normalized to generate exponential parameters. The normalized exponential parameters are input into a weighted evaluation model. By adjusting the numerical ratio of γ and δ, the evaluation focus can be dynamically optimized based on the material characteristics. For example, for materials with a low elastic modulus, the width direction weight coefficient δ can be increased to enhance sensitivity to lateral tension unevenness. The tension state evaluation coefficient F output by the evaluation model is used to determine whether the material is within the allowable tension deviation range. When the coefficient exceeds a preset threshold, the control system is triggered to compensate and adjust the tensioning component 8 in a specific area.

[0086] Compared to existing technologies, traditional tension control methods rely solely on single-dimensional tension sensor data for threshold judgment, failing to quantify the coupling effect of tension forces in the length and width directions. This solution establishes a multi-dimensional normalized evaluation model, transforming the differences in physical quantities across different directions into comparable exponential parameters. Combined with adjustable weighting coefficients, dynamic optimization is achieved, resolving the difficulty in accurately identifying localized tension imbalances during wide-width material production.

[0087] As a preferred embodiment of the present invention, the interface bonding force control model is as follows:

[0088] ;

[0089] in The heating state weighting coefficient is used. The tension state weighting coefficient, ,and , All greater than ; For heating condition evaluation coefficient, This is the tension state evaluation coefficient. The threshold for controlling the interface bonding force.

[0090] In this embodiment, the heating state evaluation coefficient refers to a comprehensive evaluation value obtained by measuring the maximum temperature difference along the length direction and the maximum temperature difference along the width direction, and then weighting the result after normalization. Specifically, this can be achieved by using a temperature sensor array to collect temperature data from different areas of the heating cavity 12 in real time, and then performing normalization calculations through a data processing unit. This coefficient is used to quantify the influence of heating uniformity on interfacial bonding force. The tension state evaluation coefficient refers to a comprehensive evaluation value obtained by measuring the maximum tension force difference along the length direction and the maximum tension force difference along the width direction, and then weighting the result after normalization. Specifically, this can be achieved by using a tension sensor group to monitor the tensile stress in each area of ​​the material in real time, and then performing normalization calculations through a data processor. This coefficient is used to quantify the influence of tension distribution on interfacial bonding force. , This refers to the proportional parameter of the contribution of the heating state and the tension state to the interfacial bonding force. Specifically, the optimal weight combination can be obtained by training with historical data from the process database, or it can be achieved by manually inputting preset values ​​through the operation interface. This is used to dynamically adjust the control priority of the two state parameters. The weighted square root operation refers to a mathematical processing method that squares the evaluation coefficients of the heating state and the tension state respectively, sums them with weights, and then takes the square root. This can be implemented using an embedded processor executing floating-point arithmetic instructions, used to amplify abnormal fluctuation signals while maintaining dimensional consistency.

[0091] Specifically, this technical solution calculates the heating state evaluation coefficient H by real-time acquisition of temperature distribution data in the length and width directions of the heating chamber 12; and simultaneously acquires tension distribution data in the length and width directions of the material to calculate the tension state evaluation coefficient F. and Assign weight coefficients respectively , Then, a square operation is performed to enhance the sensitivity to abnormal temperature gradients or tension deviations, and a square root operation is used to eliminate the dimensional distortion caused by the square operation. The final generated interface bonding force control threshold C is compared with the preset threshold. When the value of C exceeds the preset range, a control command is triggered to adjust the operating parameters of the hot-pressing tensioning mechanism 6. This processing method provides a mathematical basis for the coordinated control of the temperature field and the tension field, which can suppress misjudgments caused by abrupt changes in a single state parameter, and can adapt to different process requirements through weight allocation.

[0092] This solution achieves synergistic optimization of heating uniformity and tension distribution by constructing a mathematical model of multidimensional state parameters, thus resolving the problem of interfacial bonding force fluctuations caused by the temperature-tension coupling effect. Compared to conventional PID control algorithms, this model exhibits higher recognition accuracy and response speed to abnormal fluctuations in composite process parameters.

[0093] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A composite nonwoven fabric thermal rolling coating device, comprising a workbench (1), characterized in that, The workbench (1) is fixedly connected to a hot press box (2). A support frame A (9) is provided on one side of the hot press box (2). The support frame A (9) is connected to two feeding machines (3) for feeding non-woven fabric and film. A corona mechanism (5) is provided between the feeding machine (3) and the hot press box (2). The corona mechanism (5) is used to corona treat non-woven fabric and film. A winding machine (4) for winding is connected to the other side of the hot press box (2) through a support frame C (11). The hot press box (2) is provided with multiple heating chambers (12), and two adjacent heating chambers (12) are interconnected. Each heating chamber (12) is provided with a hot press tensioning mechanism (6). All hot press tensioning mechanisms (6) work together to perform gradient heating along the length of the nonwoven fabric after coating. In the width direction of the nonwoven fabric after coating, each hot press tensioning mechanism (6) can perform gradient heating and stretching from the middle of the nonwoven fabric to both sides. The control system can control the hot pressing tensioning mechanism (6) according to the heating and tensioning state of the nonwoven fabric after coating; The hot-pressing tensioning mechanism (6) includes a metal guide roller B (61), a metal rod (62), a coil unit (63), and a housing (64); two metal guide rollers B (61) are rotatably connected to the side wall of each heating chamber (12). The two metal guide rollers B (61) are arranged vertically, and a drive assembly (7) is provided between the two metal guide rollers B (61) to drive them to rotate relative to each other. A metal rod (62) is fixedly connected in each metal guide roller B (61). Multiple coil units (63) are arranged at equal intervals on the metal rod (62). Tensioning assemblies (8) are provided at both ends of each metal guide roller B (61). The tensioning assemblies (8) can stretch the two ends of the retroperitoneal nonwoven fabric. A housing (64) is provided at one end of each metal guide roller B (61). A power supply body that can supply power to the coil unit (63) and the tensioning assembly (8) is provided in the housing (64). The tensioning assembly (8) includes an electromagnetic block (81), a magnetic strip (82), and a metal scraper (83); the metal guide roller B (61) has multiple strip grooves evenly spaced at both ends, and each strip groove contains an electromagnetic block (81). Each electromagnetic block (81) has a magnetic strip (82) on one side, which is slidably connected to the inner wall of the strip groove. A metal scraper (83) is located on the side of the magnetic strip (82) facing away from the electromagnetic block (81), and the metal scraper (83) is inclined towards the end of the metal guide roller B (61). When the electromagnetic block (81) is energized, it pushes the magnetic strip (82) to move. 82) Squeeze the coated nonwoven fabric. This increases the tension of the coated nonwoven fabric in the length direction, preventing wrinkles. At the same time, as the magnetic strip (82) rotates with the metal guide roller B (61), the magnetic strips (82) at both ends of the metal guide roller B (61) drive all the metal scrapers (83) to push the coated nonwoven fabric to both sides to tighten, thereby increasing the tension of the coated nonwoven fabric in the width direction and increasing the adhesion between the film and the nonwoven fabric. At the same time, the contact area between the coated nonwoven fabric and the metal guide roller B (61) increases after the coated nonwoven fabric is tightened, thereby increasing the heating effect of the coated nonwoven fabric and further increasing the interfacial bonding force of the coated nonwoven fabric.

2. The composite nonwoven fabric thermal lamination apparatus according to claim 1, characterized in that, The drive assembly (7) includes a drive wheel (71) and a motor (72). Each metal guide roller B (61) is fixedly connected to one end of a drive wheel (71). Adjacent drive wheels (71) mesh with each other. A metal rod (62) is fixedly connected to one side of the heating chamber (12). The output shaft of the metal rod (62) is fixedly connected to one end of a metal guide roller B (61).

3. The composite nonwoven fabric thermal rolling coating device according to claim 1, characterized in that, The corona mechanism (5) includes a high voltage electrode (51) and a metal guide roller A (52). The workbench (1) is fixedly connected to a support frame B (10). Two high voltage electrodes (51) are provided on the support frame B (10). The rotating seats at both ends of each high voltage electrode (51) are fitted into the support frame B (10). A pressure sensor is provided at the connection position between the rotating seat of the high voltage electrode (51) and the support frame B (10). Two metal guide rollers A (52) are fixed on a fixed plate on one side of the support frame B (10). The two metal guide rollers A (52) face the two high voltage electrodes (51) respectively.

4. The composite nonwoven fabric thermal lamination apparatus according to claim 1, characterized in that, The control system includes: Monitoring module: It includes: Temperature status assessment unit: At the same time, the surface temperature of the nonwoven fabric at the same position in each heating chamber (12) is measured at equal intervals, and the surface temperature difference between the nonwoven fabrics at the same position in two adjacent heating chambers (12) is calculated. The largest set of surface temperature differences is recorded as the maximum temperature difference value in the length direction. The surface temperature of the nonwoven fabric at the middle position of each metal guide roller B (61) and the end positions on both sides of the metal guide roller B (61) is measured, and the surface temperature difference between the middle position and the end positions of the nonwoven fabrics is calculated. The largest set of surface temperature differences is recorded as the maximum temperature difference value in the width direction. Tension force assessment unit: At the same time, the tension force of the film-coated nonwoven fabric at the same position in each heating chamber (12) is measured at equal intervals, and the tension force difference between the film-coated nonwoven fabrics at the same position in two adjacent heating chambers (12) is calculated. The largest set of tension force differences is recorded as the maximum tension force difference in the length direction. The tension force difference of the film-coated nonwoven fabric at the middle position of each metal guide roller B (61) and the two ends of the metal guide roller B (61) is measured, and the tension force difference of the film-coated nonwoven fabric at the middle position and the end position of the metal guide roller B (61) is calculated. The largest set of tension force differences is recorded as the maximum tension force difference in the width direction. Heating condition assessment model: It can construct a heating condition assessment model based on the maximum temperature difference in the length direction and the maximum temperature difference in the width direction, and output the heating condition assessment coefficient; Tension State Assessment Model: It can construct a tension state assessment model based on the maximum tension force difference in the length direction and the maximum tension force difference in the width direction, and output the tension state assessment coefficient; The control module can construct an interface bonding force control model based on the heating state evaluation coefficient and the tensioning state evaluation coefficient, and output the interface bonding force control threshold. The interface bonding force control threshold is compared with the preset threshold. If the interface bonding force control threshold exceeds the preset threshold, the control module controls the hot pressing tensioning mechanism (6) to stretch and tension the coated nonwoven fabric.

5. The composite nonwoven fabric thermal lamination apparatus according to claim 4, characterized in that, The maximum temperature difference along the length and width at the current moment are substituted into the maximum value normalization formula for processing, and the temperature difference index along the length and width is generated respectively; the heating state assessment model is as follows: ； in This is the length-direction temperature difference weighting coefficient. This is the width-direction temperature difference weighting coefficient, and ,and , All greater than ; The temperature difference index along the length direction. The temperature difference index is in the width direction. This is the heating condition evaluation coefficient.

6. The composite nonwoven fabric thermal lamination apparatus according to claim 4, characterized in that, The maximum tension force difference along the length and width at the current moment are substituted into the maximum value normalization formula for processing, and tension force indices along the length and width are generated respectively; the tension state evaluation model is as follows: ； in This is the length-direction tension weighting coefficient. This is the tension force weighting coefficient in the width direction, and , , All greater than ; The tension index is in the length direction. This is the tension index in the width direction. This is the tension state evaluation coefficient.

7. The composite nonwoven fabric thermal lamination apparatus according to claim 4, characterized in that, The interface bonding force control model is as follows: ； in The heating state weighting coefficient is used. The tension state weighting coefficient, ,and , All greater than ; For heating condition evaluation coefficient, This is the tension state evaluation coefficient. The threshold for controlling the interface bonding force.

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