Continuous production equipment for antibacterial composite fabric and composite forming method

Abstract

The invention discloses continuous production equipment for antibacterial composite fabric and a composite forming method, the continuous production equipment comprises a fabric pretreatment unit, an antibacterial composite unit, a shaping and strengthening unit and a rolling unit which are connected in sequence, and each unit realizes continuous fabric conveying through a conveying assembly; the fabric pretreatment unit comprises a pretreatment bin, dust removal modules, a tension adjusting roller set and a base material flattening mechanism are sequentially arranged in the pretreatment bin in the fabric conveying direction, and the dust removal modules are high-pressure airflow spray heads symmetrically distributed on the upper side and the lower side of fabric. The base material flattening mechanism comprises two flattening scrapers capable of moving in the width direction of the fabric, and flexible rubber layers are arranged at the ends of the flattening scrapers. By integrating continuous production equipment and an optimized composite forming process, efficient and stable production of the antibacterial composite fabric is achieved, the product has excellent antibacterial performance, mechanical performance and functional diversity, the production process is environmentally friendly and controllable, and certain application value is achieved.

Description

Technical Field

[0001] This invention relates to the field of textile fabric processing technology, specifically to a continuous production equipment and composite molding method for antibacterial composite fabrics. Background Technology

[0002] Due to its combination of antibacterial and bacteriostatic functions with the physical advantages of its composite structure, antibacterial composite fabrics are increasingly in demand in fields such as clothing, home textiles, medical protective equipment, and industrial decoration. As the consumer market continues to demand higher levels of product functionality, safety, and production efficiency, the industrial production technology of antibacterial composite fabrics has become a key focus of industry research and development.

[0003] Currently, the demand for antibacterial fabrics is increasing in the fields of medical care, home furnishing, and protection. However, existing antibacterial fabric production equipment often suffers from insufficient production continuity and poor coordination between processes, resulting in low production efficiency. At the same time, uneven application of antibacterial coatings and weak adhesion to the substrate can easily lead to peeling, affecting the durability of the antibacterial effect. In addition, insufficient mixing precision of antibacterial agents and functional additives during the production process and inadequate substrate pretreatment result in wrinkle-prone and dimensionally unstable composite fabrics. Furthermore, some equipment lacks effective waste gas treatment and online quality monitoring mechanisms, making it difficult to balance production quality and environmental protection requirements. These problems restrict the large-scale, high-quality production of antibacterial composite fabrics.

[0004] Therefore, a continuous production equipment and composite molding method for antibacterial composite fabrics are proposed to solve the problems mentioned above. Summary of the Invention

[0005] The purpose of this invention is to provide a continuous production equipment and composite molding method for antibacterial composite fabrics, so as to solve the problems mentioned in the background art, such as poor equipment continuity, weak coating adhesion, low mixing accuracy and lack of quality control and environmental protection mechanisms, which seriously restrict the large-scale and high-quality development of antibacterial fabrics.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a continuous production equipment for antibacterial composite fabrics, comprising a fabric pretreatment unit, an antibacterial composite unit, a shaping and strengthening unit, and a winding unit connected in sequence, wherein each unit achieves continuous fabric conveying through a conveying component; The fabric pretreatment unit includes a pretreatment chamber, in which a dust removal module, a tension regulating roller group and a substrate flattening mechanism are arranged sequentially along the fabric conveying direction. The dust removal module consists of high-pressure airflow nozzles symmetrically distributed on the upper and lower sides of the fabric. The substrate flattening mechanism includes two flattening scrapers that can move along the width direction of the fabric, and the ends of the flattening scrapers are provided with flexible rubber layers. The antibacterial composite unit includes a composite chamber, which contains a double-layer coating mechanism, an intermediate substrate conveying assembly, and an online mixing module. The double-layer coating mechanism includes symmetrically arranged coating roller groups, the surface of which is covered with a detachable porous ceramic coating. The online mixing module includes an antibacterial liquid storage tank, a functional additive storage tank, and a dynamic mixer. Both the antibacterial liquid storage tank and the functional additive storage tank are connected to the dynamic mixer via pipes with flow regulating valves. The output end of the dynamic mixer is connected to the two coating roller groups via a diverter pipe. The shaping and strengthening unit includes a shaping chamber, in which a low-temperature pre-condensation module, a microwave curing module, and an anti-wrinkle calibration mechanism are arranged sequentially along the fabric conveying direction. The low-temperature pre-condensation module is a temperature-adjustable cold air spray device. The microwave frequency of the microwave curing module can be adjusted within the range of 2400MHz-2500MHz. The anti-wrinkle calibration mechanism includes two symmetrically arranged elastic pressure rollers, and heating elements are provided inside the elastic pressure rollers. The winding unit includes a winding frame with an axially movable winding roller. A fabric thickness detection module is provided on one side of the winding frame, and the thickness detection module is electrically connected to the drive motor of the winding roller.

[0007] Preferably, the conveying assembly includes several conveying rollers, the surface of which is provided with an anti-slip and wear-resistant coating, and some of the conveying rollers are active rollers. The active rollers are connected to the drive motor through a linkage shaft, and the rotation speed of adjacent active rollers can be independently adjusted. The pretreatment chamber is also provided with a humidity adjustment module, which is a steam generator. The output end of the steam generator is evenly distributed in the pretreatment chamber through a flow equalization plate.

[0008] Preferably, the intermediate substrate conveying assembly includes several guide rollers and a substrate tensioning adjustment mechanism. The substrate tensioning adjustment mechanism includes an adjustable roller body that can move up and down. The two ends of the adjustable roller body are slidably connected to the slide rails on the inner wall of the composite chamber, and the adjustable roller body is driven by a cylinder to achieve lifting and lowering. The dynamic mixer is equipped with a stirring impeller, and the rotation speed of the stirring impeller can be controlled by a variable frequency motor. The antibacterial liquid storage tank and the functional additive storage tank are both equipped with liquid level sensors and temperature control jackets.

[0009] Preferably, the shaping chamber is further provided with a waste gas recovery module, which includes a waste gas collection hood and a purification device. The waste gas collection hood is located above the microwave curing module, and the purification device is provided with an activated carbon filter layer and a UV photolysis component. The coating roller group is also connected to a scraper adjustment mechanism, which includes a scraper body that can move along the axis of the coating roller group. The distance between the scraper body and the surface of the coating roller group can be adjusted by a fine-tuning screw.

[0010] Preferably, the take-up frame is further provided with a correction module, which includes photoelectric sensors symmetrically arranged on both sides of the take-up roller and a lateral pushing mechanism. The photoelectric sensors are used to detect the edge position of the fabric, and the lateral pushing mechanism is connected to the support seat of the take-up roller and can drive the take-up roller to move axially. The porosity of the porous ceramic coating is 35%-50%, and a hydrophilic modified layer is provided in the pores.

[0011] A method for laminating antibacterial composite fabrics using the continuous production equipment described in any one of claims 1-5, comprising the following steps: S1. Substrate Pretreatment: The outer substrate and the middle substrate are respectively sent into the pretreatment chamber of the fabric pretreatment unit. The high-pressure airflow of the dust removal module removes impurities from the surface of the substrate. The tension of the substrate is adjusted to 20N-35N by the tension adjustment roller group. Then, the substrate flattening scraper of the substrate flattening mechanism flattens it along the width direction of the fabric. At the same time, the humidity in the pretreatment chamber is controlled at 45%-60% by the humidity adjustment module. S2. Preparation and Coating of Antibacterial Composite Liquid: The online mixing module is activated, and the antibacterial liquid from the antibacterial liquid storage tank and the functional additives from the functional additive storage tank are fed into the dynamic mixer at a mass ratio of 8-12:1. The impeller speed is controlled at 600-800 rpm, and the mixture is mixed for 10-15 minutes to form an antibacterial composite liquid. The outer substrate is fed into the double-layer coating mechanism of the composite chamber via the conveying component. The antibacterial composite liquid is uniformly coated onto the inner surface of the outer substrate by the coating roller group, with the coating thickness controlled at 0.15mm-0.3mm. Simultaneously, the intermediate substrate is conveyed between the two coated outer substrates via the intermediate substrate conveying component to form a three-layer composite structure blank. S3. Shaping and Strengthening: The three-layer composite structure blank is fed into the shaping chamber. First, it is pre-cured by spraying cold air at 5℃-10℃ for 3min-5min through the low-temperature pre-curing module. Then, it enters the microwave curing module, where the microwave frequency is adjusted to 2420MHz-2480MHz and the curing time is 8min-12min. Finally, it is calibrated by the elastic pressure roller of the anti-wrinkle calibration mechanism. The temperature of the elastic pressure roller is controlled at 40℃-50℃. S4. Continuous winding: After the antibacterial composite fabric is shaped, the thickness is detected by the thickness detection module. If the thickness deviation exceeds ±0.05mm, the coating thickness is corrected by adjusting the position of the scraper body of the coating roller group. The qualified fabric is wound up by the winding roller of the winding unit. During the winding process, the photoelectric sensor of the correction module detects the edge of the fabric in real time. The lateral push mechanism drives the winding roller to move axially to ensure neat winding and complete the continuous production of antibacterial composite fabric.

[0012] Preferably, in step S2, the antibacterial solution is composed of nano zinc oxide (10wt%-15wt%), chitosan derivative (5wt%-8wt%), plant antibacterial extract (3wt%-5wt%), and deionized water (72wt%-82wt%); the functional additive is a mixture of fragrance microcapsules (1wt%-3wt%) and UV stabilizer (0.5wt%-1.5wt%), and the particle size of the fragrance microcapsules is 1μm-5μm.

[0013] Preferably, in step S1, the outer substrate is a blended fabric of polylactic acid fiber and cotton fiber with a blending ratio of 6:4-7:3; the middle substrate is a bamboo fiber nonwoven fabric with a basis weight of 30g / m²-50g / m².

[0014] Preferably, in step S3, the power of the microwave curing module is 800W-1200W, and the microwave curing module is equipped with a temperature monitoring point to monitor the surface temperature of the fabric in real time. When the temperature exceeds 60℃, the microwave power is automatically reduced. The waste gas collected by the waste gas recovery module is treated by activated carbon filter layer adsorption and UV photolysis component, and the purification rate is not less than 95%.

[0015] Preferably, the antibacterial composite fabric includes an outer substrate, an intermediate substrate, and an antibacterial composite coating. The antibacterial composite coating is located between the outer substrate and the intermediate substrate. The antibacterial rate of the fabric is not less than 99.2%, and the antibacterial rate is still not less than 98% after 50 washes. The tensile strength is not less than 55 MPa, and the color fastness to rubbing is not less than grade 4.5.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: This continuous production equipment and composite molding method for antibacterial composite fabrics, by integrating continuous production equipment and optimized composite molding process, achieves efficient and stable production of antibacterial composite fabrics. The products possess excellent antibacterial properties, mechanical properties, and functional versatility, and the production process is environmentally friendly and controllable, thus having certain application value. The specific details are as follows: First, by sequentially connecting the fabric pretreatment unit, antibacterial composite unit, shaping and strengthening unit and winding unit, and with the help of a transmission component whose rotation speed can be independently adjusted, the present invention realizes the continuous production of antibacterial composite fabric from substrate pretreatment to finished product winding, which greatly shortens the production cycle and improves production efficiency.

[0017] Secondly, the pretreatment stage effectively avoids the impact of impurities and wrinkles on the substrate surface on subsequent composite processes through high-pressure airflow dust removal, precise tension control (20N-35N), and flexible scraper flattening, ensuring substrate bonding accuracy. The humidity adjustment module (45%-60%) improves the surface activity of the substrate and enhances the adhesion performance of the antibacterial composite liquid. The antibacterial composite unit uses a dynamic mixer (600rpm-800rpm) to achieve uniform dispersion of the antibacterial liquid and functional additives, and uses a porous ceramic coating roller (porosity 35%-50%) to achieve precise coating of 0.15mm-0.3mm. Combined with the tension adjustment mechanism of the intermediate substrate, the stability of the three-layer composite structure is guaranteed. The finishing stage employs a combination of processes: "low-temperature pre-condensation (5℃-10℃) + microwave curing (2420MHz-2480MHz) + elastic pressure roller calibration (40℃-50℃)". This process avoids damage to functional components from high temperatures and ensures the curing strength of the antibacterial coating, resulting in an antibacterial rate of over 99.2% for the fabric. Even after 50 washes, the antibacterial effect remains above 98%.

[0018] Furthermore, this invention allows for flexible adjustment of the ratio of antibacterial liquid to functional additives (8-12:1) via an online mixing module. Combined with a composite antibacterial system of nano-zinc oxide, chitosan derivatives, and plant antibacterial extracts, it imparts long-lasting antibacterial properties to the fabric. Simultaneously, the introduction of fragrance microcapsules and UV stabilizers into the functional additives expands the fabric's aroma and sun protection functions. The equipment is highly adaptable to various substrates such as polylactic acid / cotton blended fabrics and bamboo fiber nonwoven fabrics, meeting the needs of different application scenarios.

[0019] Meanwhile, the thickness detection module (deviation ±0.05mm) of the winding unit and the coating roller scraper adjustment mechanism form a closed-loop control to ensure product thickness uniformity; the correction module ensures winding neatness through photoelectric sensing and lateral adjustment. The waste gas recovery module (activated carbon filtration + UV photolysis) of the setting chamber achieves a purification rate of over 95% for waste gas generated during production, reducing the environmental impact of volatile substances and meeting green production requirements.

[0020] Finally, by optimizing the composite process parameters and the calibration effect of the elastic pressure roller, the tensile strength of the finished fabric reaches more than 55MPa and the color fastness to rubbing is not lower than 4.5, which improves the durability and service life of the fabric and meets the long-term use needs of clothing, home furnishing and other fields. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the process flow structure of the present invention; Figure 2 This is a schematic diagram of the overall structure of the device of the present invention; Figure 3 In this invention Figure 2 Internal structure diagram.

[0022] In the diagram: 10. Pretreatment chamber; 11. Dust removal module; 12. Tension adjusting roller group; 13. Substrate flattening mechanism; 131. Flattening scraper; 14. Humidity adjustment module; 20. Composite chamber; 21. Double-layer coating mechanism; 211. Coating roller group; 212. Porous ceramic coating; 213. Scraper adjusting mechanism; 214. Scraper body; 22. Intermediate substrate conveying assembly; 221. Guide roller; 222. Substrate tension adjusting mechanism; 223. Adjusting roller body; 23. Line mixing module; 231. Antibacterial liquid storage tank; 232. Functional additive storage tank; 233. Dynamic mixer; 30. Shaping chamber; 31. Low-temperature pre-condensation module; 32. Microwave curing module; 33. Anti-wrinkle calibration mechanism; 331. Elastic pressure roller; 34. Waste gas recovery module; 341. Waste gas collection hood; 342. Purification device; 40. Winding rack; 41. Winding roller; 42. Thickness detection module; 43. Correction module; 431. Photoelectric sensor; 432. Lateral pushing mechanism; 50. Conveyor roller. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Please see Figure 1-2 This invention provides a technical solution: a continuous production equipment and composite molding method for antibacterial composite fabrics, aiming to achieve efficient, continuous, and high-quality production of antibacterial composite fabrics. Its overall structure adopts a modular design, with each functional unit connected in sequence and the fabric being stably transported through a conveying component. Specifically, it includes a fabric pretreatment unit, an antibacterial composite unit, a shaping and strengthening unit, and a winding unit. Each unit works collaboratively to form a complete production line, which can effectively ensure the process stability and product consistency throughout the entire process from substrate pretreatment to finished product winding. The conveying assembly is the core conveying mechanism that runs through all units. It includes several evenly distributed conveyor rollers 50, each coated with an anti-slip and wear-resistant coating made of ceramic matrix composite material. This coating not only prevents the fabric from slipping and shifting during conveying but also extends the service life of the conveyor rollers 50. Some of the conveyor rollers 50 are designed as active rollers. These active rollers are connected to a drive motor (a servo motor, model SGM7J-08AFC6S) via a linkage shaft. The rotational speed of adjacent active rollers can be adjusted by an independent frequency converter, with a range of 5-20 m / min. This allows for adaptation to the varying conveying speed requirements of different production stages. For example, the speed can be appropriately reduced in the fabric pretreatment stage to ensure processing effectiveness, while the speed can be adjusted according to the curing efficiency in the setting and strengthening stage to ensure a reasonable production rhythm. (a) Fabric pretreatment unit The core component of the fabric pretreatment unit is the pretreatment chamber 10, which integrates a dust removal module 11, a tension adjustment roller group 12, a substrate flattening mechanism 13 and a humidity adjustment module 14 in sequence along the fabric conveying direction. Each module works together to achieve comprehensive pretreatment of the substrate. Dust Removal Module 11: Employs symmetrically distributed high-pressure airflow nozzles (model SS-1 / 4-M5) on both the upper and lower sides of the fabric. The nozzles spray at a 30° angle to the fabric surface. During operation, a high-pressure airflow of 0.6-0.8 MPa is provided by an air compressor. The airflow, after being sprayed through the nozzles, efficiently removes lint, dust, and other impurities from the substrate surface. Simultaneously, a dust collection drawer is located at the bottom of the pretreatment chamber 10, corresponding to the position of the dust removal module 11. The drawer is lined with filter cotton to collect the removed impurities and prevent secondary pollution. Tension Adjustment Roller Group 12: Consists of five parallel tension rollers. The tension rollers on both sides are fixed rollers, while the middle tension roller is adjustable. Driven by a cylinder, it moves up and down, thereby changing the angle of the fabric around the roller and adjusting the tension of the substrate. The roller assembly is equipped with a tension sensor (model LSZ-A) that can monitor the tension value of the substrate in real time and feed the data back to the control system. The control system automatically adjusts the position of the intermediate tension roller according to the preset tension range (20N-35N) to ensure that the substrate maintains a stable tension state during the conveying process, avoiding fabric stretching and deformation due to excessive tension, or fabric loosening and wrinkling due to insufficient tension. The substrate flattening mechanism 13 includes two flattening scrapers 131 that can move along the width of the fabric. The length of the scrapers is adapted to the width of the pretreatment chamber 10, and a 5mm thick flexible rubber layer (made of nitrile rubber with a Shore A hardness of 50) is attached to their ends. This rubber layer ensures the flattening effect while preventing scratches on the substrate surface. The flattening scrapers 131 are driven by a screw drive mechanism, and the spacing can be adjusted within the range of 0-2000mm according to the width of the fabric. During operation, the two scrapers move slowly from the middle of the fabric to both sides, using the friction between the flexible rubber layer and the fabric surface to flatten the fabric and eliminate wrinkles generated during the conveying process. Humidity control module 14: Employs a steam generator (model LDR0.05-0.7). The saturated steam (temperature 100-110℃) generated by this device is transported to the pretreatment chamber 10 through a pipeline. A flow equalization plate (with 2mm diameter air vents evenly distributed on the flow equalization plate) is connected to the end of the pipeline. After passing through the flow equalization plate, the steam is evenly distributed within the pretreatment chamber 10, thereby stabilizing the humidity within the chamber at 45%-60%. A suitable humidity environment improves the flexibility of the substrate, reduces the risk of fabric breakage during subsequent processing, and also facilitates the adhesion of the antibacterial composite liquid to the substrate surface. (II) Antibacterial Complex Unit The antibacterial composite unit mainly consists of a composite chamber 20, which integrates a double-layer coating mechanism 21, an intermediate substrate conveying assembly 22, and an online mixing module 23. The core function of this unit is to complete the preparation, coating, and composite of the antibacterial composite liquid and the substrate to form a three-layer composite structure blank. Online mixing module 23: As the core of antibacterial compound liquid preparation, it includes an antibacterial liquid storage tank 231, a functional additive storage tank 232, and a dynamic mixer 233. Both the antibacterial liquid storage tank 231 and the functional additive storage tank 232 have a volume of 500L. The inner walls of both tanks are equipped with level sensors (model UQK-61) to monitor the liquid level in real time. When the liquid level falls below the set value (100L), the sensor will issue an alarm signal, reminding the operator to replenish the material in time. Simultaneously, the outer walls of the tanks are equipped with a temperature control jacket, which regulates the temperature of the material inside the tanks through a circulating water system. The temperature control range is 20-30℃, ensuring that the material maintains stable performance at a suitable temperature. The dynamic mixer 233, model SHR-500, is equipped with an internal stirring impeller (300mm diameter, 6 blades). The impeller is driven by a variable frequency motor (model YVP2-100L1-4), with a speed adjustable from 100-1500 rpm. Both the antibacterial liquid storage tank 231 and the functional additive storage tank 232 are connected to the dynamic mixer 233 via pipes equipped with flow regulating valves (model LKV-15). During production, according to process requirements, the antibacterial liquid and functional additives are fed into the dynamic mixer 233 at a precise mass ratio of 8-12:1, controlled by the flow regulating valves. The stirring impeller is then started, and the speed is adjusted to 600-800 rpm to mix the materials for 10-15 minutes, ultimately forming a uniform and stable antibacterial composite liquid. Double-layer coating mechanism 21: includes a coating roller group 211 arranged symmetrically on the upper and lower sides. The coating roller group 211 consists of a coating roller (diameter of 200mm and length of 2200mm) and a scraper. The surface of the coating roller is provided with a detachable porous ceramic coating 212. The porosity of the coating is 35%-50%, and a hydrophilic modification layer (modified by silane coupling agent KH-550) is provided in the pores. The hydrophilic modification layer can improve the wettability of the antibacterial composite liquid on the surface of the coating roller and ensure the uniformity of coating. The coating roller assembly 211 is also connected to a doctor blade adjustment mechanism 213. This mechanism includes a doctor blade body 214 (made of tungsten steel with a thickness of 5 mm) that can move along the axis of the coating roller assembly 211. The distance between the doctor blade and the surface of the coating roller assembly 211 can be adjusted by a fine-tuning screw (adjustment accuracy of 0.01 mm) to control the coating thickness of the antibacterial composite liquid. During production, the antibacterial composite liquid prepared by the dynamic mixer 233 is delivered to the two coating roller assemblies 211 through a diversion pipe (equipped with a flow sensor). The antibacterial composite liquid forms a uniform liquid film on the surface of the coating rollers. Then, through the contact between the coating rollers and the outer substrate, the liquid film is transferred to the inner surface of the outer substrate. At the same time, the doctor blade adjustment mechanism 213 precisely controls the coating thickness to be between 0.15 mm and 0.3 mm. Intermediate substrate conveying assembly 22 includes several guide rollers 221 (80mm in diameter and 2200mm in length) and a substrate tension adjustment mechanism 222. The guide rollers 221 guide the conveying direction of the intermediate substrate, ensuring that the intermediate substrate can accurately enter between the two coated outer substrates. The substrate tension adjustment mechanism 222 includes an adjustable roller body 223 (100mm in diameter and 2200mm in length) that can move up and down. The two ends of the adjustable roller body 223 are slidably connected to the slide rails on the inner wall of the composite chamber 20, and the adjustable roller body 223 is driven by a cylinder (model SC63-500) to achieve lifting and lowering, with a lifting range of 0-300mm. By adjusting the height of the adjustable roller body 223, the length of the intermediate substrate around the roller can be changed, thereby adjusting the tension of the intermediate substrate, ensuring that the intermediate substrate remains flat during the lamination process and is tightly bonded to the outer substrate, avoiding defects such as bubbles and wrinkles. (III) Shaped and reinforced unit The core component of the shaping and strengthening unit is the shaping chamber 30. Inside the chamber, along the fabric conveying direction, there are a low-temperature pre-condensation module 31, a microwave curing module 32, an anti-wrinkle calibration mechanism 33, and a waste gas recovery module 34. This unit is mainly used to shape, cure, and strengthen the performance of the three-layer composite structure blank, while treating the waste gas generated during the production process to achieve green production. Low-temperature pre-condensation module 31: Employs a temperature-adjustable cold air spray device (model DL-100). This device includes several cold air nozzles (100mm spacing), with the cold air supplied by a refrigeration unit and the temperature adjustable within the range of 0-15℃. During operation, the cold air temperature is adjusted to 5℃-10℃ and sprayed evenly in a mist form onto the surface of the three-layer composite structure blank, pre-condensing the antibacterial composite liquid on the blank surface for 3-5 minutes. This pre-condensation treatment allows the antibacterial composite liquid to initially solidify, forming a film with a certain strength, preventing uneven coating due to the flow of the composite liquid during subsequent blank transportation. Microwave curing module 32: Employs a microwave generator (model WM-1200) with an adjustable microwave frequency within the range of 2400MHz-2500MHz. In actual production, the microwave frequency is adjusted to 2420MHz-2480MHz, and the power to 800W-1200W. The microwave curing module 32 is equipped with a temperature monitoring point (using a thermocouple temperature sensor, model K) to monitor the fabric surface temperature in real time. When the temperature exceeds 60℃, the control system automatically reduces the microwave power to prevent damage to the fabric performance due to excessive heat. After low-temperature pre-condensation, the three-layer composite preform enters the microwave curing module 32. Under microwave action, the polymers in the antibacterial composite liquid undergo a cross-linking reaction, achieving complete curing. The curing time is 8-12 minutes, resulting in a strong bond between the cured coating and the substrate. The anti-wrinkle calibration mechanism 33 includes two symmetrically arranged elastic pressure rollers 331 (150mm in diameter and 2200mm in length). The outer layer of the elastic pressure rollers 331 is made of rubber (Shore A hardness 60), and the inside is equipped with a heating element (using an electric heating tube with a power of 500W). The heating element can control the temperature of the elastic pressure rollers 331 at 40℃-50℃. During operation, the two elastic pressure rollers 331 press the microwave-cured fabric with a certain pressure (the pressure can be adjusted by a cylinder, ranging from 0.2-0.5MPa). On the one hand, this can perform anti-wrinkle calibration on the fabric, eliminating wrinkles generated during the curing process; on the other hand, the appropriate temperature and pressure can further promote the bonding between the coating and the substrate, improving the overall performance of the fabric. The waste gas recovery module 34 includes a waste gas collection hood 341 and a purification device 342. The waste gas collection hood 341 has an inverted conical structure and is positioned above the microwave curing module 32. Its opening size is adapted to the size of the microwave curing module 32, effectively collecting volatile organic waste gas generated during the microwave curing process. The waste gas is transported to the purification device 342 through a pipeline. The purification device 342 contains an activated carbon filter layer (activated carbon particles with a diameter of 2-3 mm and a filling amount of 50 kg) and a UV photolysis component (UV lamp power of 150W and wavelength of 185-254 nm). The waste gas first passes through the activated carbon filter layer to remove particulate matter and some organic pollutants; then it enters the UV photolysis component, where, under the action of ultraviolet light, the organic pollutants undergo a decomposition reaction, converting into harmless CO2 and H2O. Testing shows that the waste gas recovery module 34 achieves a purification rate of no less than 95%, meeting relevant national emission standards. (iv) Rewinding Unit The winding unit includes a winding frame 40, on which is mounted an axially movable winding roller 41 (300mm in diameter and 2200mm in length). The winding roller 41 is driven by a drive motor (model Y90S-4), and its rotation speed can be synchronously adjusted according to the fabric conveying speed. A fabric thickness detection module 42 (using a laser thickness gauge, model ZTMS08, with a measurement accuracy of ±0.001mm) is located on one side of the winding frame 40. The thickness detection module 42 is electrically connected to the drive motor of the winding roller 41 and the scraper adjustment mechanism 213 of the coating roller group 211. During production, the thickness detection module 42 monitors the thickness of the antibacterial composite fabric in real time after shaping. When a thickness deviation exceeding ±0.05mm is detected, a signal is fed back to the control system. Based on the direction and magnitude of the deviation, the control system adjusts the position of the scraper body 214 of the coating roller group 211 to correct the coating thickness of the antibacterial composite liquid. Simultaneously, it appropriately adjusts the rotation speed of the take-up roller 41 to ensure stable winding tension. Meanwhile, the take-up frame 40 is also equipped with a correction module 43, which includes photoelectric sensors 431 (model E3Z-T61) symmetrically arranged on both sides of the take-up roller 41 and a transverse pushing mechanism 432 (using a screw slide, model KK8610P-750A1-F0). The photoelectric sensor 431 is used to detect the position of the fabric edge. When the fabric is offset, the photoelectric sensor 431 will generate a signal difference and send the difference signal to the control system. The control system drives the lateral pushing mechanism 432 to move the take-up roller 41 along the axial direction to correct the offset fabric, ensure neat take-up, and avoid fabric waste caused by uneven take-up. Specific implementation process of antibacterial composite fabric composite molding method Based on the aforementioned continuous production equipment, this embodiment also provides a method for composite molding of antibacterial composite fabrics, specifically including the following steps: Substrate pretreatment (S1) The outer and middle substrates are selected as follows: The outer substrate is a blended fabric of polylactic acid fiber and cotton fiber, wherein the blending ratio of polylactic acid fiber and cotton fiber is 6:4-7:3 (in this embodiment, a blending ratio of 7:3 is selected). This fabric has good breathability and biodegradability. The middle substrate is a bamboo fiber nonwoven fabric with a basis weight of 30g / m²-50g / m² (in this embodiment, a nonwoven fabric with a basis weight of 40g / m² is selected). Bamboo fiber nonwoven fabric has natural antibacterial properties and can work synergistically with the antibacterial composite liquid to further improve the antibacterial effect of the fabric. Substrate conveying and pretreatment: The outer substrate and the middle substrate are fed into the pretreatment chamber 10 of the fabric pretreatment unit through the unwinding mechanism. First, they pass through the dust removal module 11, and the air compressor is started to spray a high-pressure airflow of 0.7MPa from the high-pressure airflow nozzle to remove impurities from the surface of the substrate for 20 seconds. Then, the substrate enters the tension regulating roller group 12. The tension of the substrate is monitored in real time by the tension sensor, and the control system automatically adjusts the tension to 28N to ensure stable substrate conveying. Next, the substrate passes through the substrate flattening mechanism 13. According to the fabric width (1500mm in this embodiment), the distance between the two flattening scrapers 131 is adjusted so that the scrapers move from the middle of the fabric to both sides to flatten the fabric. At the same time, the steam generator of the humidity regulating module 14 is started to control the humidity in the pretreatment chamber 10 at 52%, completing the pretreatment of the substrate. Preparation and coating of antibacterial composite solution (S2) Preparation of antibacterial compound solution: The online mixing module 23 is activated. First, antibacterial solution is added to the antibacterial solution storage tank 231. This antibacterial solution consists of nano-zinc oxide (12wt%), chitosan derivative (6wt%), plant antibacterial extract (4wt%), and deionized water (78wt%) (the nano-zinc oxide has a particle size of 20nm, the chitosan derivative is carboxymethyl chitosan, and the plant antibacterial extract is honeysuckle extract). Functional additives are added to the functional additive storage tank 232. These functional additives are a mixture of fragrance microcapsules (2wt%) and UV stabilizer (1wt%) (the fragrance microcapsules have a particle size of 3μm, and the UV stabilizer is UV-531). The flow rate of the antibacterial solution and functional additives is controlled by a flow regulating valve to maintain a mass ratio of 10:1. The materials are then fed into the dynamic mixer 233. Start the variable frequency motor and adjust the impeller speed to 700 rpm to mix the materials. The mixing time is controlled at 12 minutes. During this period, the mixing status of the materials is observed in real time through the observation window of the dynamic mixer 233 to ensure the formation of a uniform and sediment-free antibacterial composite liquid. Outer substrate coating and substrate lamination: The pretreated outer substrate is fed into the double-layer coating mechanism 21 of the lamination chamber 20 through the conveying component. The speed of the active roller of the conveying component is adjusted to stabilize the outer substrate conveying speed at 10 m / min. Start the coating roller group 211, and the antibacterial composite liquid in the dynamic mixer 233 is conveyed to the upper and lower coating rollers through the diversion pipe. The antibacterial composite liquid forms a uniform liquid film under the action of the porous ceramic coating 212 on the surface of the coating roller. According to the process requirements, the distance between the scraper body 214 and the surface of the coating roller is adjusted to 0.2 mm by the fine-tuning screw of the scraper adjustment mechanism 213 to ensure that the coating thickness of the antibacterial composite liquid on the inner surface of the outer substrate is 0.2 mm. Simultaneously, the intermediate substrate is guided by the guide roller 221 of the intermediate substrate conveying assembly 22 and fed into the composite chamber 20. The cylinder of the substrate tension adjustment mechanism 222 is activated, driving the adjusting roller body 223 to descend 200mm, so that the tension of the intermediate substrate is maintained in a suitable state. When the intermediate substrate is conveyed between the two coated outer substrates, the three-layer structure is initially pressed by the pressure roller (150mm in diameter, pressure adjusted to 0.3MPa) in the composite chamber 20 to form a three-layer composite structure blank. After pressing, the blank is conveyed to the shaping and strengthening unit by the conveying assembly. Shaping and strengthening (S3) Low-temperature pre-condensation: The three-layer composite structure billet is fed into the low-temperature pre-condensation module 31 of the shaping chamber 30 via a conveying assembly. The refrigeration unit is adjusted to stabilize the cold air temperature of the cold air spraying device at 8°C. The nozzles are then activated to spray the billet surface in a mist form for 4 minutes. During this period, the surface temperature of the billet is monitored in real time by a temperature sensor inside the shaping chamber 30 to ensure that the temperature is maintained at 8-10°C, allowing the antibacterial composite liquid to initially solidify and form a film with a certain strength, thus preventing problems such as coating dripping and unevenness during subsequent transportation. Microwave Curing: The pre-cured material continues to enter the microwave curing module 32 via the conveyor assembly. The microwave generator is adjusted, setting the microwave frequency to 2450MHz and the power to 1000W, and the microwave curing program is started. The curing time is controlled to be 10 minutes. Thermocouple temperature sensors within the microwave curing module 32 monitor the fabric surface temperature in real time. When the temperature approaches 60℃, the control system automatically reduces the microwave power to 800W to prevent problems such as yellowing and reduced strength caused by excessive temperature. During the microwave curing process, the exhaust gas collection hood 341 of the exhaust gas recovery module 34 is activated, drawing the generated volatile organic waste gas into the purification device 342. The waste gas first passes through an activated carbon filter layer to remove particulate matter and some organic pollutants, and then enters the UV photolysis component, where it is decomposed into harmless substances under ultraviolet light. The purified gas is discharged through the exhaust pipe. Wrinkle-resistant calibration: The microwave-cured fabric enters the wrinkle-resistant calibration mechanism 33. The heating element inside the elastic pressure roller 331 is activated to heat the roller to 45°C. The cylinder is adjusted to apply a pressure of 0.4 MPa to the two elastic pressure rollers 331 in opposite directions, calibrating the fabric by rolling. The rolling speed is consistent with the fabric conveying speed (10 m / min). Through the rolling of the elastic pressure rollers 331, not only are the wrinkles generated during the curing process eliminated, but the adhesion between the antibacterial composite coating and the substrate is further enhanced, improving the overall smoothness and structural stability of the fabric. Continuous winding (S4) Thickness Detection and Correction: After shaping, the antibacterial composite fabric is conveyed to the winding unit via a conveyor assembly. The thickness detection module 42 on one side of the winding frame 40 is activated, and a laser thickness gauge detects the fabric thickness at a frequency of 10 times per second. The detection data is transmitted to the control system in real time. When the detected fabric thickness is 0.26mm (the standard thickness is set at 0.25mm, and the deviation exceeds ±0.05mm), the control system immediately sends a signal. On the one hand, it adjusts the scraper adjustment mechanism 213 of the coating roller group 211, reducing the distance between the scraper body 214 and the surface of the coating roller by 0.01mm through the fine-tuning screw to correct the coating thickness. On the other hand, it reduces the rotation speed of the winding roller 41 from 10m / min to 9.5m / min to ensure stable winding tension and avoid uneven winding due to thickness deviation. Correction and winding: During the winding process, the photoelectric sensor 431 of the correction module 43 is activated to detect the edge position of the fabric in real time. When the fabric shifts 5mm to the left, the signal received by the left photoelectric sensor 431 weakens, while the signal on the right strengthens. The signal difference is transmitted to the control system, which drives the screw slide of the transverse pushing mechanism 432, causing the winding roller 41 to move 5mm to the left to correct the fabric shift. The winding roller 41 continues to rotate under the drive motor, neatly winding up the qualified antibacterial composite fabric. When the winding diameter reaches 1000mm, the machine stops and the winding roller 41 is replaced, completing the production of one batch of antibacterial composite fabric.

[0025] As can be seen from the above specific embodiments, the continuous production equipment and composite molding method for antibacterial composite fabrics of the present invention can realize continuous and automated production of antibacterial composite fabrics with high production efficiency. Furthermore, through precise control of each unit, the stability and consistency of product quality can be effectively guaranteed. The produced antibacterial composite fabrics have excellent antibacterial properties, mechanical properties, and performance characteristics, and can be widely used in medical protection, home textiles, clothing, and other fields.

[0026] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A continuous production equipment for antibacterial composite fabrics, characterized in that: It includes a fabric pretreatment unit, an antibacterial composite unit, a shaping and strengthening unit, and a winding unit connected in sequence. Each unit achieves continuous fabric conveying through a conveying component. The fabric pretreatment unit includes a pretreatment chamber (10). The pretreatment chamber (10) is provided with a dust removal module (11), a tension adjustment roller group (12) and a substrate flattening mechanism (13) in sequence along the fabric conveying direction. The dust removal module (11) is a high-pressure airflow nozzle symmetrically distributed on the upper and lower sides of the fabric. The substrate flattening mechanism (13) includes two flattening scrapers (131) that can move along the width direction of the fabric. The flattening scrapers (131) are provided with a flexible rubber layer at their ends. The antibacterial composite unit includes a composite chamber (20), which is equipped with a double-layer coating mechanism (21), an intermediate substrate conveying assembly (22), and an online mixing module (23). The double-layer coating mechanism (21) includes a coating roller group (211) arranged symmetrically on the upper and lower sides. The surface of the coating roller group (211) is provided with a detachable porous ceramic coating (212). The online mixing module (23) includes an antibacterial liquid storage tank (231), a functional additive storage tank (232), and a dynamic mixer (233). The antibacterial liquid storage tank (231) and the functional additive storage tank (232) are both connected to the dynamic mixer (233) through a pipe with a flow regulating valve. The output end of the dynamic mixer (233) is connected to the two coating roller groups (211) through a diversion pipe. The shaping and strengthening unit includes a shaping chamber (30). The shaping chamber (30) is provided with a low-temperature pre-condensation module (31), a microwave curing module (32) and an anti-wrinkle calibration mechanism (33) in sequence along the fabric conveying direction. The low-temperature pre-condensation module (31) is a temperature-adjustable cold air spray device. The microwave frequency of the microwave curing module (32) can be adjusted in the range of 2400MHz-2500MHz. The anti-wrinkle calibration mechanism (33) includes two symmetrically arranged elastic pressure rollers (331). The elastic pressure rollers (331) are provided with heating elements inside. The winding unit includes a winding frame (40), on which a winding roller (41) that can move axially is provided. A fabric thickness detection module (42) is provided on one side of the winding frame (40), and the thickness detection module (42) is electrically connected to the drive motor of the winding roller (41).

2. The continuous production equipment for antibacterial composite fabrics according to claim 1, characterized in that: The conveying assembly includes several conveying rollers (50), the surface of which is provided with an anti-slip and wear-resistant coating, and some of the conveying rollers (50) are active rollers. The active rollers are connected to the drive motor through a linkage shaft, and the rotation speed of adjacent active rollers can be independently adjusted. The pretreatment chamber (10) is also provided with a humidity adjustment module (14), which is a steam generator. The output end of the steam generator is evenly distributed in the pretreatment chamber (10) through a flow equalization plate.

3. The continuous production equipment for antibacterial composite fabrics according to claim 1, characterized in that: The intermediate substrate conveying assembly (22) includes several guide rollers (221) and a substrate tension adjustment mechanism (222). The substrate tension adjustment mechanism (222) includes an adjustment roller body (223) that can move up and down. The two ends of the adjustment roller body (223) are slidably connected to the slide rails on the inner wall of the composite chamber (20), and the adjustment roller body (223) is driven by a cylinder to achieve lifting and lowering. The dynamic mixer (233) is equipped with a stirring impeller. The rotation speed of the stirring impeller can be controlled by a variable frequency motor. The antibacterial liquid storage tank (231) and the functional additive storage tank (232) are both equipped with a liquid level sensor and a temperature control interlayer.

4. The continuous production equipment for antibacterial composite fabrics according to claim 1, characterized in that: The shaping chamber (30) is also provided with a waste gas recovery module (34), which includes a waste gas collection hood (341) and a purification device (342). The waste gas collection hood (341) is located above the microwave curing module (32), and the purification device (342) is provided with an activated carbon filter layer and a UV photolysis component. The coating roller group (211) is also connected to a scraper adjustment mechanism (213), which includes a scraper body (214) that can move along the axis of the coating roller group (211). The distance between the scraper body (214) and the surface of the coating roller group (211) can be adjusted by a fine-tuning screw.

5. A continuous production equipment for antibacterial composite fabrics according to claim 1, characterized in that: The take-up frame (40) is also provided with a correction module (43). The correction module (43) includes photoelectric sensors (431) and a transverse pushing mechanism (432) symmetrically arranged on both sides of the take-up roller (41). The photoelectric sensors (431) are used to detect the edge position of the fabric. The transverse pushing mechanism (432) is connected to the support seat of the take-up roller (41) and can drive the take-up roller (41) to move axially. The porous ceramic coating (212) has a porosity of 35%-50% and a hydrophilic modified layer is provided in the pores.

6. A method for composite molding of antibacterial composite fabric using the continuous production equipment described in any one of claims 1-5, characterized in that: Includes the following steps: S1. Substrate pretreatment: The outer substrate and the middle substrate are respectively sent into the pretreatment chamber (10) of the fabric pretreatment unit. The high-pressure airflow of the dust removal module (11) removes impurities from the surface of the substrate. The tension of the substrate is adjusted to 20N-35N by the tension adjustment roller group (12). Then, the substrate is flattened along the width direction by the flattening scraper (131) of the substrate flattening mechanism (13). At the same time, the humidity in the pretreatment chamber (10) is controlled at 45%-60% by the humidity adjustment module (14). S2, Preparation and Coating of Antibacterial Composite Liquid: Start the online mixing module (23), and feed the antibacterial liquid in the antibacterial liquid storage tank (231) and the functional additives in the functional additive storage tank (232) into the dynamic mixer (233) at a mass ratio of 8-12:

1. Control the speed of the stirring impeller to 600rpm-800rpm and mix for 10min-15min to form an antibacterial composite liquid. The outer substrate is fed into the double-layer coating mechanism (21) of the composite chamber (20) through the conveying component. The antibacterial composite liquid is uniformly coated on the inner surface of the outer substrate through the coating roller group (211). The coating thickness is controlled to be 0.15mm-0.3mm. At the same time, the intermediate substrate is conveyed to the space between the two coated outer substrates through the intermediate substrate conveying component (22) to form a three-layer composite structure blank. S3, Shaping and Strengthening: The three-layer composite structure blank is fed into the shaping chamber (30), and first pre-cured by the low temperature pre-curing module (31) with cold air spray at 5℃-10℃ for 3min-5min. Then it enters the microwave curing module (32), and the microwave frequency is adjusted to 2420MHz-2480MHz. The curing time is 8min-12min. Finally, it is calibrated by the elastic pressure roller (331) of the anti-wrinkle calibration mechanism (33). The temperature of the elastic pressure roller (331) is controlled at 40℃-50℃. S4. Continuous winding: The thickness of the antibacterial composite fabric after shaping is detected by the thickness detection module (42). If the thickness deviation exceeds ±0.05mm, the coating thickness is corrected by adjusting the position of the scraper body (214) of the coating roller group (211). The qualified fabric is wound up by the winding roller (41) of the winding unit. During the winding process, the edge of the fabric is detected in real time by the photoelectric sensor (431) of the correction module (43). The winding roller (41) is driven to move axially by the transverse pushing mechanism (432) to ensure neat winding and complete the continuous production of antibacterial composite fabric.

7. The method for composite molding of antibacterial composite fabric according to claim 6, characterized in that: In step S2, the antibacterial solution is composed of nano zinc oxide (10wt%-15wt%), chitosan derivative (5wt%-8wt%), plant antibacterial extract (3wt%-5wt%), and deionized water (72wt%-82wt%); the functional additive is a mixture of fragrance microcapsules (1wt%-3wt%) and UV stabilizer (0.5wt%-1.5wt%), and the particle size of the fragrance microcapsules is 1μm-5μm.

8. The method for composite molding of antibacterial composite fabric according to claim 6, characterized in that: In step S1, the outer substrate is a blended fabric of polylactic acid fiber and cotton fiber with a blending ratio of 6:4-7:3; the middle substrate is a bamboo fiber nonwoven fabric with a basis weight of 30g / m²-50g / m².

9. The method for composite molding of antibacterial composite fabric according to claim 6, characterized in that: In step S3, the power of the microwave curing module (32) is 800W-1200W, and the microwave curing module (32) is equipped with a temperature monitoring point to monitor the surface temperature of the fabric in real time. When the temperature exceeds 60°C, the microwave power is automatically reduced. The waste gas collected by the waste gas recovery module (34) is treated by activated carbon filter layer adsorption and UV photolysis component, and the purification rate is not less than 95%.

10. The method for composite molding of antibacterial composite fabric according to claim 6, characterized in that: The antibacterial composite fabric includes an outer substrate, an intermediate substrate, and an antibacterial composite coating. The antibacterial composite coating is located between the outer substrate and the intermediate substrate. The antibacterial rate of the fabric is not less than 99.2%, and the antibacterial rate is still not less than 98% after 50 washes. The tensile strength is not less than 55 MPa, and the color fastness to rubbing is not less than grade 4.5.

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