Dip-coating equipment and method for processing impregnated decorative paper

Abstract

The invention discloses dip-coating equipment and a dip-coating method for processing impregnated decorative paper, which are used for realizing uniformity control in the impregnation process of the decorative paper and solving the problem of excessive or insufficient local glue amount in the existing impregnation mode. On one hand, the dip-coating equipment for processing the impregnated decorative paper comprises a glue tank, a paper feeding roller, an impregnating mechanism, a smearing mechanism and a glue scraping mechanism are sequentially arranged on the glue tank from one side to the other side of the glue tank, and the paper feeding roller is arranged above one side of the glue tank and can rotate in the circumferential direction of the paper feeding roller; the dipping mechanism comprises a dipping roller, and the dipping roller is arranged in the glue tank; the coating mechanism is arranged above the glue tank, the coating mechanism comprises two groups of brush rollers, the two groups of brush rollers are symmetrically arranged up and down, and the two groups of brush rollers are driven by a third power device to rotate in the circumferential direction of the brush rollers; the whole glue scraping mechanism is arranged above the glue tank, the glue scraping mechanism comprises two groups of scraping plates, and the two groups of scraping plates are symmetrically arranged up and down.

Description

Technical Field

[0001] This invention relates to the field of product impregnation technology, and in particular to an impregnation coating equipment and method for processing decorative paper. Background Technology

[0002] In the processing and production of decorative paper, impregnation is an indispensable key step. Its purpose is to improve the structural strength of the decorative paper and enhance its mechanical properties such as tear resistance and tensile strength through the impregnation and curing of the adhesive. This ensures that the decorative paper maintains its shape stability during subsequent bonding with building material substrates and long-term use, thus meeting the needs of practical applications.

[0003] Currently, the commonly used method for impregnating decorative paper in the industry involves using a traction device to provide driving force, causing the decorative paper to be continuously conveyed under the guidance of conveyor rollers. During this process, the decorative paper passes through a box containing adhesive, and the impregnation process is completed through contact between the decorative paper and the adhesive. However, the above-mentioned existing impregnation method has the following drawbacks: after impregnation, the decorative paper is prone to localized areas with excessive or insufficient adhesive. This uneven impregnation problem directly affects the quality of the finished decorative paper. Areas with excessive adhesive are prone to wrinkles and poor adhesion, while areas with insufficient adhesive cannot achieve the expected structural strength and protective effect, thus affecting the subsequent bonding quality with building material substrates. Summary of the Invention

[0004] Therefore, in order to overcome the above-mentioned shortcomings, the present invention provides an impregnation and coating equipment and method for processing decorative paper, so as to achieve uniform control of the impregnation process of decorative paper and solve the problem of excessive or insufficient local glue amount in the existing impregnation method.

[0005] On one hand, the present invention provides an impregnation and coating apparatus for processing decorative paper, including an adhesive tank containing a limited amount of impregnation adhesive. The adhesive tank is provided with a paper feed roller, an impregnation mechanism, a coating mechanism and a scraping mechanism in sequence from one side to the other. The paper feed roller is located above one side of the adhesive tank and can rotate around its own circumference. The impregnation mechanism includes an impregnation roller disposed in a glue tank, and the impregnation roller can rotate circumferentially. The coating mechanism is located above the glue tank. The coating mechanism includes two sets of brush rollers, which are arranged symmetrically above and below each other. The two sets of brush rollers are driven to rotate around their own circumference by a third power device. The glue scraping mechanism is located above the glue tank. The glue scraping mechanism includes two sets of scrapers, which are symmetrically arranged vertically.

[0006] Furthermore, the application mechanism also includes: Fourth power unit; The first slider is mounted on a set of brush rollers, which are driven to slide vertically by a fourth power device.

[0007] Furthermore, the adhesive scraping mechanism also includes: Fifth power unit; The second slider is connected to the scraper and is driven to slide vertically by the fifth power device.

[0008] Furthermore, the adhesive scraping mechanism also includes a floating block, on which the adhesive scraper is fixedly mounted, and the floating block is connected to the second slider or the mounting side plate via an elastic element.

[0009] Furthermore, the impregnation mechanism also includes a first power unit, which drives the impregnation roller to move vertically up and down.

[0010] Furthermore, the dip coating equipment also includes: A coating mechanism is provided between the coating mechanism and the dipping mechanism. The coating mechanism includes a coating roller with mesh openings on its circumferential surface. The coating roller is driven to rotate around its own circumference by a fifth power device. Transition rollers are arranged alternately with the coating mechanism.

[0011] Furthermore, the coating mechanism includes: Second power unit; The slide is connected to a second power device, which drives the slide to slide. The glue-spreading roller is installed on the slide.

[0012] Furthermore, the dip coating equipment also includes a control unit, which is communicatively connected to the first power unit. The control unit acquires raw material data, calculates the initial immersion depth based on the raw material data, obtains the initial penetration depth, calculates the immersion depth of the dip roller based on the initial immersion depth, and generates an immersion control signal based on the immersion depth of the dip roller and sends it to the first power unit so that the first power unit drives the dip roller to rise or fall to a preset depth. The raw material data includes paper basis weight and adhesive density.

[0013] Furthermore, the control unit is also communicatively connected to the second power unit, the third power unit, the fourth power unit, the fifth power unit, and the sixth power unit. The control unit acquires the paper type, calculates the contact pressure between the glue-spreading roller and the paper based on the paper type, and generates a glue-spreading lifting control signal based on the contact pressure between the glue-spreading roller and the paper, which is then sent to the second power device to drive the glue-spreading roller to lift and lower, so that the pressure between the glue-spreading roller and the paper reaches a preset value. The paper running linear velocity is obtained, the corresponding angular velocity is matched according to the paper running linear velocity, the rotation speed of the glue-spreading roller is calculated according to the angular velocity corresponding to the paper running linear velocity, and the rotation signal of the glue-spreading roller is generated based on the rotation speed of the glue-spreading roller and sent to the sixth power device so that the sixth power device drives the glue-spreading roller to rotate at a preset speed. The paper adhesive layer uniformity is obtained, and the uniformity error and error change rate are calculated based on the paper adhesive layer uniformity. The brush roller gap is calculated based on the uniformity error and error change rate. The brush roller lifting control signal is generated based on the brush roller gap and sent to the fourth power device so that the fourth power device drives the brush roller to rise or fall to a preset height. The relative speed of the brush roller is calculated based on the paper running line speed, glue density, and glue viscosity. A brush roller rotation signal is generated based on the relative speed of the brush roller and sent to the third power unit so that the third power unit drives the brush roller to rotate at a preset speed. The thickness of the adhesive layer before application is obtained. The squeegee pressure is calculated based on the thickness of the adhesive layer before application and the target adhesive layer thickness. A squeegee lifting control signal is generated based on the squeegee pressure and sent to the fifth power unit, so that the fifth power unit drives the squeegee to lift and lower, thereby making the pressure between the squeegee and the paper surface reach the preset value.

[0014] On the other hand, the present invention also provides a dip coating method for processing impregnated decorative paper, the dip coating method employing the dip coating equipment for processing impregnated decorative paper as described in claim 9, the dip coating method comprising: Acquire raw material data, which includes at least paper basis weight and adhesive density. Calculate the initial immersion depth based on the raw material data to obtain an initial immersion depth value. Generate an immersion control signal based on the initial immersion depth value and send it to a first power unit. The first power unit drives the immersion roller to move vertically up and down according to the immersion control signal, so that its immersion depth in the adhesive reaches a preset value. The paper type and paper running line speed are obtained. The target contact pressure between the glue roller and the paper is calculated based on the paper type. A glue roller lifting control signal is generated based on the target contact pressure and sent to the second power unit. The second power unit drives the glue roller to lift and lower according to the glue roller lifting control signal so that the pressure between the roller and the paper reaches a preset value. The paper running linear velocity is obtained, the corresponding angular velocity is matched according to the paper running linear velocity, the rotation speed of the glue-spreading roller is calculated according to the angular velocity corresponding to the paper running linear velocity, and the rotation signal of the glue-spreading roller is generated based on the rotation speed of the glue-spreading roller and sent to the sixth power device so that the sixth power device drives the glue-spreading roller to rotate at a preset speed. Obtain paper adhesive layer uniformity information, calculate uniformity error and error change rate based on the paper adhesive layer uniformity information; calculate the target gap of the brush roller based on the uniformity error and error change rate; generate a brush roller lifting control signal based on the target gap and send it to the fourth power device; drive at least one set of brush rollers to slide vertically according to the brush roller lifting control signal through the fourth power device to adjust the gap between the two sets of brush rollers to a preset value. The target relative speed of the brush rollers is calculated based on the paper running line speed, adhesive density, and adhesive viscosity; a brush roller rotation signal is generated based on the target relative speed and sent to the third power unit; the third power unit drives the two sets of brush rollers to rotate towards each other at a preset speed according to the brush roller rotation signal. The thickness of the adhesive layer before scraping is obtained, and the target pressure of the scraper is calculated based on the thickness of the adhesive layer before scraping and the preset target adhesive layer thickness. Based on the target pressure, a scraper lifting control signal is generated and sent to the fifth power device. The fifth power device drives the scraper to slide vertically to the reference position according to the scraper lifting control signal. Through the floating block and elastic element, the scraper contacts the surface of the decorative paper with a preset pressure based on the reference position, thereby scraping off excess adhesive and making the final adhesive layer thickness reach the target adhesive layer thickness.

[0015] The present invention has the following advantages: This invention feeds paper through a paper feed roller, and an impregnation roller presses the paper down into the glue tank for immersion. A brush roller coating mechanism arranged symmetrically above and below evenly coats both sides of the decorative paper with glue. The glue layer thickness is then controlled by a symmetrical scraper glue scraping mechanism, thereby improving the consistency of the overall glue impregnation of the decorative paper. This, in turn, enhances the structural strength, tear resistance, and tensile strength of the decorative paper, and reduces quality problems such as wrinkles and poor adhesion. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the dip coating equipment; Figure 2 yes Figure 1 A schematic diagram of the coating mechanism in the dip coating equipment shown; Figure 3 yes Figure 1 A schematic diagram of the impregnation mechanism in the dip coating equipment shown; Figure 4 yes Figure 1 A schematic diagram of the coating mechanism in the dip coating equipment shown; Figure 5 yes Figure 1 A schematic diagram of the adhesive scraping mechanism in the dip coating equipment shown; Figure 6 yes Figure 1 The diagram shows the working operation of the dip coating equipment. In the picture: 100. Rack; 200. Feed roller; 300. Impregnation mechanism; 310. First power unit; 320. Mounting frame; 330. Impregnation roller; 400. Spreading mechanism; 410. Second power unit; 420. Gear and rack mechanism; 430. Fixed frame; 440. Spreading roller; 450. Slide carriage; 500. Transition roller; 600. Coating mechanism; 610. Brush roller; 620. First slider; 630. Third power unit; 640. Tensioning mechanism; 700. Glue scraping mechanism; 710. Scraper; 720. Mounting side plate; 730. Second slider; 740. Floating block; 750. Spring; 800, glue tank; 900. Paper. Detailed Implementation

[0017] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0018] In this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, without necessarily requiring or implying any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0019] As described in the background section, the commonly used method for impregnating decorative paper in the industry involves using a traction device to provide driving force, causing the decorative paper to be continuously conveyed under the guidance of conveyor rollers. During this process, the decorative paper passes through a box containing adhesive, and the impregnation operation is completed through contact between the decorative paper and the adhesive. However, the above-mentioned existing impregnation method has the following drawbacks: after impregnation, the decorative paper is prone to localized areas with excessive or insufficient adhesive. This uneven impregnation directly affects the quality of the finished decorative paper. Areas with excessive adhesive are prone to wrinkles and poor adhesion, while areas with insufficient adhesive cannot achieve the expected structural strength and protective effect, thus affecting the subsequent bonding quality with building material substrates.

[0020] Example 1: Therefore, in order to solve the above-mentioned technical problems existing in the prior art, this embodiment provides an impregnation and coating equipment for processing impregnated decorative paper, such as... Figure 1 As shown, the dipping equipment includes an adhesive tank 800, which contains a limited amount of dipping adhesive. The adhesive tank is provided with a paper feed roller 200, an dipping mechanism 300, a coating mechanism 600 and a scraping mechanism 700 in sequence from one side to the other. The paper feed roller is located above one side of the adhesive tank and can rotate around its own circumference. like Figure 3 As shown, the impregnation mechanism includes an impregnation roller disposed in a glue tank, and the impregnation roller can rotate around its own circumference; The application mechanism is located above the glue tank, such as Figure 4 As shown, the coating mechanism includes a brush roller 610, which is provided in two sets. The two sets of brush rollers are arranged symmetrically above and below each other. The two sets of brush rollers are driven to rotate around their own circumference by a third power device 630. The glue scraping mechanism is located entirely above the glue tank, such as... Figure 5 As shown, the adhesive scraping mechanism includes scrapers 710, which are arranged in two sets, with the two sets of scrapers arranged symmetrically above and below each other.

[0021] Specifically, such as Figure 6As shown, in this embodiment, the decorative paper to be impregnated is continuously moved forward by an external traction device. The paper 900 sequentially passes through the feed roller, impregnation roller, brush roller, and scraper, and enters the glue tank under the traction of the impregnation roller, making full contact with the glue in the glue tank to complete the initial glue impregnation operation. The impregnated decorative paper is lifted out of the glue tank and conveyed to the coating mechanism located above the glue tank. The decorative paper passes between two sets of brush rollers symmetrically arranged above and below. A third power device drives the two sets of brush rollers to rotate actively in their circumference. The two sets of brush rollers contact the upper and lower surfaces of the decorative paper respectively. Through the rotation of the brush rollers, the glue on the surface of the decorative paper is evenly coated, improving the initial unevenness problem of excessive or insufficient glue in some areas after impregnation, so that the glue is initially evenly distributed on the upper and lower surfaces of the decorative paper. The decorative paper, after being homogenized by the coating mechanism, continues to move to the scraping mechanism. The decorative paper passes between two sets of symmetrically arranged scrapers. These scrapers wipe away excess adhesive from the upper and lower surfaces of the paper, improving the uniformity of the adhesive layer thickness and further addressing the problem of uneven adhesive application. This equipment effectively improves the defects of existing adhesive application methods, such as excessive or insufficient adhesive in certain areas, enhancing the uniformity of adhesive application and improving the quality of the finished decorative paper. In this embodiment, the dipping equipment may further include a frame 100, on which the paper feed roller, dipping mechanism, coating mechanism, glue scraping mechanism, and glue tank are all mounted. In this embodiment, the third power unit may be a servo motor or a speed-regulating motor. The third power unit is connected to a set of brush rollers. The two sets of brush rollers can be connected through a synchronous belt drive mechanism, a sprocket drive mechanism, or other transmission mechanisms. In addition, the coating mechanism may also include a tensioner 640, which adjusts the tension of the chain or belt. The tensioner may adopt a structure commonly used in the prior art, such as a sliding or swingable tension wheel bracket, in conjunction with adjusting elements such as springs, screws, or eccentric wheels, to apply and maintain appropriate tension on the transmission belt or chain, ensuring stable and reliable power transmission.

[0022] In this embodiment, as Figure 4 As shown, the application mechanism further includes: Fourth power unit; The first slider 620 is on which a set of brush rollers are mounted and driven to slide vertically by the fourth power device.

[0023] Specifically, the fourth power unit can be a pneumatic cylinder, a hydraulic cylinder, or a servo electric cylinder. The fourth power unit drives the first slider and the brush roller mounted on it to slide vertically, achieving automatic and dynamic adjustment of the gap between the two sets of brush rollers to adapt to different process requirements.

[0024] In this embodiment, as Figure 5As shown, the adhesive scraping mechanism further includes: Fifth power unit; The second slider 730 is connected to the scraper and is driven to slide vertically by the fifth power device.

[0025] Specifically, the fifth power unit can be a pneumatic cylinder, a hydraulic cylinder, or a servo electric cylinder. The fifth power unit drives the second slider and the scraper connected to it to slide vertically, achieving automatic and dynamic adjustment of the gap between the two sets of scrapers to adapt to different process requirements.

[0026] In this embodiment, the adhesive scraping mechanism further includes a floating block 740, on which the adhesive scraper is fixedly mounted. The floating block is connected to the second slider or the mounting side plate 720 via an elastic element.

[0027] Specifically, the scraping mechanism may further include a mounting side plate 720. The second slider and the floating block are slidably engaged with the mounting side plate. The scraper is flexibly mounted through the floating block and the elastic element, enabling it to adapt to the slight undulations and tension fluctuations on the surface of the decorative paper. During operation, the scraper can float under the action of the elastic element, thereby dynamically maintaining a basically constant contact pressure between its blade and the paper surface. This allows for a more stable amount of excess glue removed, improving the uniformity of the final glue layer thickness. In this embodiment, the elastic element may be a spring, a rubber elastomer, or an air bladder, or other components with elastic restoring force.

[0028] In this embodiment, as Figure 3 As shown, the impregnation mechanism also includes a first power unit 310, which drives the impregnation roller to move vertically up and down.

[0029] Specifically, the first power unit is fixedly installed on the frame, and the impregnation mechanism may also include a mounting frame. The impregnation roller is installed on the mounting frame, which is slidably engaged with the frame and connected to the first power unit. The first power unit may be a cylinder, a hydraulic cylinder, or a servo electric cylinder. The first power unit drives the impregnation roller to move vertically up and down, thereby adjusting the depth of the impregnation roller immersed in the adhesive.

[0030] In this embodiment, as Figure 1 As shown, the dip coating equipment further includes: A coating mechanism 400 is provided, which is located between the coating mechanism and the dipping mechanism, such as... Figure 2 As shown, the glue-spreading mechanism includes a glue-spreading roller 440, with mesh openings on the circumferential surface of the glue-spreading roller. The glue-spreading roller is driven to rotate around its own circumference by a fifth power device. Transition roller 500, which is arranged alternately with the coating mechanism.

[0031] Specifically, both the plating mechanism and the transition roller are mounted on the frame, and the fifth power unit can be a servo motor or a stepper motor. After initial plating by the impregnation mechanism, the decorative paper continues to move under the drive of the traction device and enters the plating mechanism. Driven by the fifth power unit, the plating roller actively rotates circumferentially. The plating roller applies contact pressure to the paper. Under this pressure, the relative movement between the roller surface and the paper produces a crushing effect on the plating liquid adhering to the paper surface. The mesh can break up or shear locally aggregated plating clumps during the crushing process, allowing the plating liquid to flow from enriched areas to deficient areas, achieving a preliminary redistribution of the plating liquid across the paper width and in the direction of travel. After plating is completed, the decorative paper leaves the plating roller and, guided by the transition roller, enters the coating mechanism.

[0032] In this embodiment, the coating mechanism may further include: Second power unit 410; The slide 450 is connected to the second power device, which drives the slide to slide. The glue-spreading roller is installed on the slide.

[0033] Specifically, the second power unit can be a pneumatic cylinder, hydraulic cylinder, or servo electric cylinder, or it can be a servo motor, stepper motor, gear and rack mechanism 420, belt drive mechanism, sprocket drive mechanism, or screw drive mechanism connected to the slide. The second power unit drives the slide to rise and fall vertically as a whole. The glue-spreading mechanism also includes a fixed frame, on which the second power unit is fixedly mounted. The slide slides on the fixed frame, which is fixedly mounted on the upright frame. In this embodiment, the second power unit drives the glue-spreading roller to rise and fall vertically. The distance or contact pressure between the glue-spreading roller and the decorative paper can be flexibly adjusted according to the thickness, material, and required glue layer thickness of the decorative paper. This allows the glue-spreading roller to adapt to decorative papers of different specifications, and to perform preliminary pressing and homogenization of the glue on the surface of the impregnated decorative paper, further improving the problem of uneven glue impregnation.

[0034] In addition, the dip coating equipment also includes a control unit, which is communicatively connected to the first power unit. The control unit acquires raw material data, calculates the initial immersion depth based on the raw material data, obtains the initial penetration depth, calculates the immersion depth of the dip roller based on the initial immersion depth, and generates an immersion control signal based on the immersion depth of the dip roller and sends it to the first power unit so that the first power unit drives the dip roller to rise or fall to a preset depth. The raw material data includes paper basis weight and adhesive density.

[0035] Specifically, the method for calculating the initial immersion depth based on raw material data is as follows: ; in, l0 represents the initial immersion depth, in meters; M The basis weight of paper is expressed in grams per square meter. β This refers to the density of the adhesive solution, expressed in grams per cubic meter. α This is a process experience coefficient, calibrated through experiments; δ To compensate for depth, the unit is meters.

[0036] After obtaining the initial immersion depth using the above formula, the immersion depth of the impregnation roller is then calculated based on the initial immersion depth. The specific calculation method is as follows: ; in, l t The immersion depth of the impregnation roller is expressed in meters. ∇l Adjust the depth to the target, in meters; T This is the time constant for depth adjustment, in seconds; t 0 This is the time, in seconds, elapsed from the issuance of this deep adjustment command until the control system begins to execute the adjustment action. K 1 This is the proportional gain coefficient; e v ( t ) represents the normalized value of the speed deviation.

[0037] The normalized value of the velocity deviation is calculated as follows: ; in, v 0 represents the preset paper running linear speed, in meters per second; v In order to be in t The actual linear speed of the paper, measured in real time by sensors, is measured in meters per second.

[0038] The immersion depth of the impregnation roller is calculated using the method described above.

[0039] This embodiment uses a control unit based on raw material data (paper basis weight) M Glue density βThe system calculates the initial immersion depth and performs real-time, dynamic, closed-loop adjustment, reducing glue volume fluctuations caused by inconsistent initial conditions. This minimizes glue splashing, drastic changes in paper tension, or brief periods of uneven immersion due to sudden depth changes, ensuring product quality continuity and pass rates during process parameter switching, and reducing production losses. The entire control strategy integrates multi-source information such as raw material properties, process experience, dynamic targets, equipment response characteristics, and real-time production status, and outputs execution instructions. This transforms the immersion process from one reliant on manual experience to a data-driven, automated, and intelligent process. It reduces dependence on operator experience and improves process replicability.

[0040] In addition, the control unit is also communicatively connected to the second power unit, the third power unit, the fourth power unit, the fifth power unit, and the sixth power unit; The control unit acquires the paper type, calculates the contact pressure between the glue-spreading roller and the paper based on the paper type, and generates a glue-spreading lifting control signal based on the contact pressure between the glue-spreading roller and the paper, which is then sent to the second power device to drive the glue-spreading roller to lift and lower, so that the pressure between the glue-spreading roller and the paper reaches a preset value. The paper running linear velocity is obtained, the corresponding angular velocity is matched according to the paper running linear velocity, the rotation speed of the glue-spreading roller is calculated according to the angular velocity corresponding to the paper running linear velocity, and the rotation signal of the glue-spreading roller is generated based on the rotation speed of the glue-spreading roller and sent to the sixth power device so that the sixth power device drives the glue-spreading roller to rotate at a preset speed. The paper adhesive layer uniformity is obtained, and the uniformity error and error change rate are calculated based on the paper adhesive layer uniformity. The brush roller gap is calculated based on the uniformity error and error change rate. The brush roller lifting control signal is generated based on the brush roller gap and sent to the fourth power device so that the fourth power device drives the brush roller to rise or fall to a preset height. The relative speed of the brush roller is calculated based on the paper running line speed, glue density, and glue viscosity. A brush roller rotation signal is generated based on the relative speed of the brush roller and sent to the third power unit so that the third power unit drives the brush roller to rotate at a preset speed. The thickness of the adhesive layer before application is obtained. The squeegee pressure is calculated based on the thickness of the adhesive layer before application and the target adhesive layer thickness. A squeegee lifting control signal is generated based on the squeegee pressure and sent to the fifth power unit, so that the fifth power unit drives the squeegee to lift and lower, thereby making the pressure between the squeegee and the paper surface reach the preset value.

[0041] Specifically, the method for calculating the contact pressure between the glue roller and the paper based on the paper type is as follows: ; in, P t fort The contact pressure between the glue-spreading roller and the paper at all times, measured in Newtons; P 0 The base pressure is measured in Newtons and is set according to the paper type. K 2 represents the differential gain coefficient, in seconds; The instantaneous rate of change of paper tension, measured in Newtons per second; τ This is the integral gain coefficient, expressed in seconds. t The device uptime is measured in seconds. P c for t The actual measured pressure at any given time, in Newtons; P m The pressure setpoint required by the current process can be determined by... P 0 Generated by fine-tuning based on operating conditions, initially... P m = P 0 .

[0042] The specific method for calculating the rotational speed of the glue-spreading roller based on the angular velocity corresponding to the linear velocity of the paper is as follows: ; in, ω y The angular velocity of the glue-spreading roller; ω z The angular velocity corresponding to the linear velocity of the paper; σ This refers to the amplitude coefficient of micro-vibration; f The vibration frequency is expressed in Hertz (Hz). t Time is measured in seconds.

[0043] The specific method for calculating the brush roller gap based on uniformity error and error change rate is as follows: ; in, G t For the current moment t The target brush roller gap value, in millimeters; G t-1 For the previous moment t -1 is the brush roller gap value, in millimeters; ∇G This represents the maximum single-step adjustment amount of the brush roller gap, in millimeters. ∂ ( E , ∇E ) represents the output value of the fuzzy inference engine; E represents the uniformity error; ∇E This represents the rate of change of error.

[0044] Specifically, a series of "IF-THEN" rules based on expert experience are preset within the fuzzy controller. The system will then clearly define the input values ​​(…). E , ΔE The value is converted into a fuzzy quantity, inferred through a rule base, and then the fuzzy output is defuzzified into a precise value. ∂ The sign determines the direction of adjustment (a positive sign indicates that the gap should be reduced to enhance brushing, and a negative sign indicates that the gap should be increased to weaken brushing). ∂ The absolute value of the value determines the urgency or intensity of the adjustment at the current moment.

[0045] The specific method for calculating the relative speed of the brush roller based on the paper running line speed, adhesive density, and adhesive viscosity is as follows: ; in, v x The relative speed of the brush rollers is expressed in meters per second. ϵ The viscosity of the adhesive is expressed in millipascal-seconds. H The target adhesive layer thickness is expressed in micrometers.

[0046] The specific method for calculating the scraper pressure based on the thickness of the adhesive layer before application and the target adhesive layer thickness is as follows: ; in, The scraper pressure is expressed in Newtons (N). h The thickness of the adhesive layer before application is expressed in micrometers. θ The equivalent working width of the scraper is expressed in meters.

[0047] This embodiment achieves automatic control of the glue application, brushing, and scraping processes by acquiring real-time data on paper type, running speed, glue layer uniformity, and glue parameters, and performing dynamic calculations and feedback adjustments. The pressure of the glue-spreading roller is adjusted in real-time according to changes in paper tension; the brush roller gap is adaptively adjusted based on uniformity error and rate of change; and the scraper pressure is optimized based on the difference between the real-time glue layer thickness and the target thickness, improving the consistency, uniformity, and surface quality of the glue layer, and reducing glue waste and quality fluctuations caused by manual intervention. For different paper types, glue viscosity and density, running speeds, and other process conditions, the system can automatically match the optimal pressure, speed, and gap parameters, reducing equipment debugging time and reliance on operator experience. The introduction of micro-vibration speed adjustment improves adaptability to different glue rheological properties, and the brush roller gap is intelligently adjusted under nonlinear and strongly coupled conditions through a fuzzy inference mechanism.

[0048] In this embodiment, the dip coating equipment may further include a sensing unit. This sensing unit is communicatively connected to the control unit and is used to collect parameters from the production line in real time. Specifically, the sensing unit may include: Speed ​​sensors are used to measure the actual linear speed of paper in real time, such as encoders mounted on the ends of traction rollers or guide rollers.

[0049] Tension sensors are used to monitor the running tension of paper and its rate of change in real time, such as tension detection rollers or tension meters placed in the paper's travel path.

[0050] Thickness / uniformity detection sensors are used to scan and measure the thickness distribution of the adhesive layer in decorative paper and calculate the adhesive layer uniformity error and error change rate, such as a non-contact online thickness gauge installed behind the adhesive application mechanism.

[0051] A pressure sensor can be installed on the slide of the coating mechanism or the floating block of the scraper mechanism to measure the contact pressure between the coating roller and the paper or the actual working pressure of the scraper.

[0052] Position sensors are used to provide feedback on the real-time position of the impregnation roller, the leveling roller, the brush roller, and the scraper. For example, displacement encoders or linear potentiometers are installed on the first power unit, the second power unit, the fourth power unit, and the fifth power unit.

[0053] A viscosity sensor, an online viscometer installed in the glue tank circulation pipeline, is used to monitor changes in the viscosity of the glue solution in real time.

[0054] Through the monitoring network formed by the aforementioned sensing units, the control unit can acquire the real-time status of the production line, compare the actual production data with the preset process model, and dynamically generate precise control commands.

[0055] Example 2: This embodiment provides a dip coating method for processing impregnated decorative paper. The dip coating method employs a dip coating apparatus for processing impregnated decorative paper as described in Embodiment 1. The dip coating method includes: Acquire raw material data, which includes at least paper basis weight and adhesive density. Calculate the initial immersion depth based on the raw material data to obtain an initial immersion depth value. Generate an immersion control signal based on the initial immersion depth value and send it to a first power unit. The first power unit drives the immersion roller to move vertically up and down according to the immersion control signal, so that its immersion depth in the adhesive reaches a preset value. Specifically, the control unit receives manually input paper basis weight via a human-machine interface and obtains real-time glue density from sensors installed in the glue circulation system. This data constitutes the raw material dataset required for initial calculation. The control unit calls a preset formula to calculate the initial immersion depth; the specific calculation method can be found in the specific method for calculating the initial immersion depth described in Example 1. The control system, combined with the production status, generates the final real-time immersion depth command, which is determined by the calculation formula for the immersion depth of the immersion roller described in Example 1. The control unit converts the immersion depth of the immersion roller into a position command for the first power device (such as a servo electric cylinder). The first power device drives the mounting frame of the immersion roller to rise and fall, stabilizing the immersion depth of the roller in the glue at a position corresponding to the immersion depth of the immersion roller, thereby completing the source basis weight control.

[0056] The paper type and paper running line speed are obtained. The target contact pressure between the glue roller and the paper is calculated based on the paper type. A glue roller lifting control signal is generated based on the target contact pressure and sent to the second power unit. The second power unit drives the glue roller to lift and lower according to the glue roller lifting control signal so that the pressure between the roller and the paper reaches a preset value. Specifically, the control unit retrieves the corresponding base pressure from a preset process database or empirical formula based on the type of paper currently being produced (e.g., plain paper, printing paper, high basis weight paper, etc.). This value is a benchmark pressure obtained from numerous experiments, capable of providing good initial coating effect for this type of paper without affecting the operating tension. Simultaneously, the system acquires the instantaneous tension of the paper in real time via a tension sensor and calculates its rate of change, and acquires the actual measured pressure between the coating roller and the paper in real time via a pressure sensor. The control unit calculates the target contact pressure at the current moment using a fixed control cycle (e.g., 10ms). The specific calculation method can be found in the specific method of measuring the contact pressure between the coating roller and the paper described in Example 1. The control unit converts the calculated real-time target pressure into a position or force control command for the second power unit (e.g., a high-response servo electric cylinder), forming a coating lifting and lowering control signal. The second power unit drives the slide mounting the coating roller to perform fine-tuning of lifting and lowering based on this signal, thereby dynamically changing the degree of pressure of the coating roller on the paper.

[0057] The paper running linear velocity is obtained, the corresponding angular velocity is matched according to the paper running linear velocity, the rotation speed of the glue-spreading roller is calculated according to the angular velocity corresponding to the paper running linear velocity, and the rotation signal of the glue-spreading roller is generated based on the rotation speed of the glue-spreading roller and sent to the sixth power device so that the sixth power device drives the glue-spreading roller to rotate at a preset speed. Specifically, the control unit calculates the theoretical angular velocity that is synchronized with the paper's linear velocity based on the real-time paper running linear velocity and the known radius of the glue-spreading roller. Finally, it calculates the target angular velocity of the glue-spreading roller. For the specific calculation method, please refer to the specific method of the glue-spreading roller rotation speed described in Example 1. The control unit converts the calculated glue-spreading roller rotation speed into a rotation speed command and sends it to the sixth power device (such as a servo motor) that drives the glue-spreading roller to rotate, so that it rotates at this dynamic speed.

[0058] Obtain paper adhesive layer uniformity information, calculate uniformity error and error change rate based on the paper adhesive layer uniformity information; calculate the target gap of the brush roller based on the uniformity error and error change rate; generate a brush roller lifting control signal based on the target gap and send it to the fourth power device; drive at least one set of brush rollers to slide vertically according to the brush roller lifting control signal through the fourth power device to adjust the gap between the two sets of brush rollers to a preset value. Specifically, an online thickness gauge installed after the glue-applying mechanism continuously scans the paper to obtain full-width glue layer thickness distribution data. The control unit calculates the current glue layer uniformity deviation (such as the thickness standard deviation or the maximum deviation from the target value) and its rate of change. The deviation and the rate of change are input to a fuzzy inference engine. The fuzzy inference engine has preset rules such as "if the deviation is large and rapidly increasing, the brush roller gap needs to be significantly increased to weaken the brushing." After fuzzification, rule evaluation, and defuzzification, a dimensionless adjustment coefficient is output, with a value in the range [-1, +1]. The sign represents the adjustment direction (positive for reducing the gap), and the absolute value represents the adjustment intensity. The target gap of the brush rollers is updated according to the specific method for calculating the brush roller gap described in Example 1. The control unit converts the updated brush roller gap into a position command for a fourth power device (such as a servo cylinder), driving the first slider to vertically slide a set of brush rollers, adjusting the gap between the upper and lower brush rollers to a preset position, thus achieving adaptive correction of the glue layer uniformity.

[0059] The target relative speed of the brush rollers is calculated based on the paper running line speed, adhesive density, and adhesive viscosity; a brush roller rotation signal is generated based on the target relative speed and sent to the third power unit; the third power unit drives the two sets of brush rollers to rotate towards each other at a preset speed according to the brush roller rotation signal. Specifically, the control unit calculates the optimal linear velocity of the brush roller relative to the paper surface based on real-time process parameters. The specific calculation method can be found in the detailed method for calculating the relative velocity of the brush roller described in Example 1. Based on the relative velocity of the brush roller and the paper speed, the linear velocities of the upper and lower brush rollers are set respectively. The control unit converts the linear velocity into angular velocity commands and sends them to the third power unit driving the upper and lower brush rollers (or uses a dual-axis motor for independent control), causing the two sets of brush rollers to rotate in opposite directions at preset speeds with a speed difference, thereby achieving brushing and coating of the upper and lower surfaces of the paper.

[0060] The thickness of the adhesive layer before scraping is obtained, and the target pressure of the scraper is calculated based on the thickness of the adhesive layer before scraping and the preset target adhesive layer thickness. Based on the target pressure, a scraper lifting control signal is generated and sent to the fifth power device. The fifth power device drives the scraper to slide vertically to the reference position according to the scraper lifting control signal. Through the floating block and elastic element, the scraper contacts the surface of the decorative paper with a preset pressure based on the reference position, thereby scraping off excess adhesive and making the final adhesive layer thickness reach the target adhesive layer thickness.

[0061] Specifically, the thickness of the adhesive layer before application is detected at a pre-application detection point using a line thickness gauge. The control unit calculates the required theoretical squeegee pressure based on the pre-application adhesive layer thickness, the target adhesive layer thickness, and other process parameters. The specific calculation method can be found in Example 1. The control unit uses the calculated squeegee pressure as the target pressure and sends a position command to the fifth power unit (such as a servo cylinder), driving the second slider to move the entire squeegee mechanism to a reference position, which corresponds to the expected starting point for generating pressure. During the actual application process, the flexible mechanism consisting of the floating block and the elastic element begins to operate. When there are slight undulations on the paper surface, the floating block compresses or releases the spring, causing the squeegee to float, thereby dynamically maintaining the actual contact pressure between the squeegee blade and the paper surface at a relatively constant level near the theoretical squeegee pressure.

[0062] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A coating apparatus for processing impregnated decorative paper, characterized in that, The device includes a glue tank containing a limited amount of impregnation glue. The glue tank is provided with a paper feed roller, an impregnation mechanism, a coating mechanism and a glue scraping mechanism in sequence from one side to the other. The paper feed roller is located above one side of the glue tank and can rotate around its own circumference. The impregnation mechanism includes an impregnation roller disposed in a glue tank, and the impregnation roller can rotate circumferentially. The coating mechanism is located above the glue tank. The coating mechanism includes two sets of brush rollers, which are arranged symmetrically above and below each other. The two sets of brush rollers are driven to rotate around their own circumference by a third power device. The glue scraping mechanism is located above the glue tank. The glue scraping mechanism includes two sets of scrapers, which are symmetrically arranged vertically.

2. The dipping and coating equipment for processing decorative paper according to claim 1, characterized in that, The application mechanism also includes: Fourth power unit; The first slider is mounted on a set of brush rollers, which are driven to slide vertically by a fourth power device.

3. The dipping and coating equipment for processing impregnated decorative paper according to claim 1, characterized in that, The adhesive scraping mechanism also includes: Fifth power unit; The second slider is connected to the scraper and is driven to slide vertically by the fifth power device.

4. The dipping and coating equipment for processing impregnated decorative paper according to claim 3, characterized in that, The adhesive scraping mechanism also includes a floating block, on which the adhesive scraper is fixedly mounted. The floating block is connected to the second slider or the mounting side plate via an elastic element.

5. The dipping and coating equipment for processing impregnated decorative paper according to claim 2 or 3, characterized in that, The impregnation mechanism also includes a first power unit, which drives the impregnation roller to move vertically up and down.

6. The dipping and coating equipment for processing decorative paper according to claim 5, characterized in that, The dip coating equipment also includes: A coating mechanism is provided between the coating mechanism and the dipping mechanism. The coating mechanism includes a coating roller with mesh openings on its circumferential surface. The coating roller is driven to rotate around its own circumference by a fifth power device. Transition rollers are arranged alternately with the coating mechanism.

7. The dipping and coating equipment for processing decorative paper according to claim 6, characterized in that, The spin coating mechanism includes: Second power unit; The slide is connected to a second power device, which drives the slide to slide. The glue-spreading roller is installed on the slide.

8. The dipping and coating equipment for processing decorative paper according to claim 7, characterized in that, The dipping equipment also includes a control unit, which is communicatively connected to the first power unit. The control unit acquires raw material data, calculates the initial immersion depth based on the raw material data, obtains the initial penetration depth, calculates the immersion depth of the dipping roller based on the initial immersion depth, and generates an immersion control signal based on the immersion depth of the dipping roller and sends it to the first power unit so that the first power unit drives the dipping roller to rise or fall to a preset depth. The raw material data includes paper basis weight and adhesive density.

9. The dipping and coating equipment for processing impregnated decorative paper according to claim 8, characterized in that, The control unit is also communicatively connected to the second power unit, the third power unit, the fourth power unit, the fifth power unit, and the sixth power unit. The control unit acquires the paper type, calculates the contact pressure between the glue-spreading roller and the paper based on the paper type, and generates a glue-spreading lifting control signal based on the contact pressure between the glue-spreading roller and the paper, which is then sent to the second power device to drive the glue-spreading roller to lift and lower, so that the pressure between the glue-spreading roller and the paper reaches a preset value. The paper running linear velocity is obtained, the corresponding angular velocity is matched according to the paper running linear velocity, the rotation speed of the glue-spreading roller is calculated according to the angular velocity corresponding to the paper running linear velocity, and the rotation signal of the glue-spreading roller is generated based on the rotation speed of the glue-spreading roller and sent to the sixth power device so that the sixth power device drives the glue-spreading roller to rotate at a preset speed. The paper adhesive layer uniformity is obtained, and the uniformity error and error change rate are calculated based on the paper adhesive layer uniformity. The brush roller gap is calculated based on the uniformity error and error change rate. The brush roller lifting control signal is generated based on the brush roller gap and sent to the fourth power device so that the fourth power device drives the brush roller to rise or fall to a preset height. The relative speed of the brush roller is calculated based on the paper running line speed, glue density, and glue viscosity. A brush roller rotation signal is generated based on the relative speed of the brush roller and sent to the third power unit so that the third power unit drives the brush roller to rotate at a preset speed. The thickness of the adhesive layer before application is obtained. The squeegee pressure is calculated based on the thickness of the adhesive layer before application and the target adhesive layer thickness. A squeegee lifting control signal is generated based on the squeegee pressure and sent to the fifth power unit, so that the fifth power unit drives the squeegee to lift and lower, thereby making the pressure between the squeegee and the paper surface reach the preset value.

10. A method for impregnating decorative paper, characterized in that, The dip-coating method employs the dip-coating equipment for processing impregnated decorative paper as described in claim 9, and the dip-coating method includes: Acquire raw material data, which includes at least paper basis weight and adhesive density. Calculate the initial immersion depth based on the raw material data to obtain an initial immersion depth value. Generate an immersion control signal based on the initial immersion depth value and send it to a first power unit. The first power unit drives the immersion roller to move vertically up and down according to the immersion control signal, so that its immersion depth in the adhesive reaches a preset value. The paper type and paper running line speed are obtained. The target contact pressure between the glue roller and the paper is calculated based on the paper type. A glue roller lifting control signal is generated based on the target contact pressure and sent to the second power unit. The second power unit drives the glue roller to lift and lower according to the glue roller lifting control signal so that the pressure between the roller and the paper reaches a preset value. The paper running linear velocity is obtained, the corresponding angular velocity is matched according to the paper running linear velocity, the rotation speed of the glue-spreading roller is calculated according to the angular velocity corresponding to the paper running linear velocity, and the rotation signal of the glue-spreading roller is generated based on the rotation speed of the glue-spreading roller and sent to the sixth power device so that the sixth power device drives the glue-spreading roller to rotate at a preset speed. Obtain paper adhesive layer uniformity information, calculate uniformity error and error change rate based on the paper adhesive layer uniformity information; calculate the target gap of the brush roller based on the uniformity error and error change rate; generate a brush roller lifting control signal based on the target gap and send it to the fourth power device; drive at least one set of brush rollers to slide vertically according to the brush roller lifting control signal through the fourth power device to adjust the gap between the two sets of brush rollers to a preset value. The target relative speed of the brush rollers is calculated based on the paper running line speed, adhesive density, and adhesive viscosity; a brush roller rotation signal is generated based on the target relative speed and sent to the third power unit; the third power unit drives the two sets of brush rollers to rotate towards each other at a preset speed according to the brush roller rotation signal. The thickness of the adhesive layer before scraping is obtained, and the target pressure of the scraper is calculated based on the thickness of the adhesive layer before scraping and the preset target adhesive layer thickness. Based on the target pressure, a scraper lifting control signal is generated and sent to the fifth power device. The fifth power device drives the scraper to slide vertically to the reference position according to the scraper lifting control signal. Through the floating block and elastic element, the scraper contacts the surface of the decorative paper with a preset pressure based on the reference position, thereby scraping off excess adhesive and making the final adhesive layer thickness reach the target adhesive layer thickness.

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