Molding machine for moisture-proof anti-cracking stone-plastic plate and molding process thereof

Abstract

The invention relates to the technical field of stone-plastic plate production, and discloses a forming machine for a moisture-proof anti-crack stone-plastic plate and a forming technology thereof.The forming machine comprises a main machine frame, a plurality of hot pressing rollers are installed on the main machine frame, and a stone-plastic base plate and a decorative layer are conveyed to the main machine frame through corresponding feeding mechanisms and are subjected to hot pressing compounding through the hot pressing rollers to form the stone-plastic plate; a base plate processing piece is installed at the front end of the feeding side of the main machine frame and correspondingly matched with one of the multiple hot pressing rollers to form a traction set, high-temperature grooving is completed in the traction feeding stage, at the moment, the stone-plastic base plate is not subjected to high-pressure pressing, and a compact layer is not formed on the surface; water vapor wrapped inside can be rapidly discharged through a regular moisture discharging channel, meanwhile, the high temperature of the traction hot roller can assist grooving and accelerate evaporation of water inside a base plate, the water vapor is thoroughly removed before subsequent hot-pressing compounding, the defects of bubbles, cracks and the like caused by water vapor residues are overcome from the source, and the treated stone-plastic plate has the advantages of being high in practicability and convenient to use. And the internal structure is more compact and uniform.

Description

Technical Field

[0001] This invention relates to the field of stone-plastic composite board production technology, specifically to a molding machine and molding process for moisture-proof and crack-resistant stone-plastic composite boards. Background Technology

[0002] With the rapid development of prefabricated buildings and green home decoration, stone-plastic composite (SPC) panels, as a new type of decorative material that combines environmental friendliness, wear resistance, and cost-effectiveness, are widely used in indoor flooring, walls, and furniture finishes. The market has placed higher demands on the moisture-proof and crack-resistant performance of SPC panels—especially in humid environments with large temperature fluctuations, the cracking and delamination defects caused by residual moisture inside the panels have become a core pain point restricting their application. The current mainstream SPC panel production process is "melt plasticization - hot pressing composite - cooling and shaping," the core step of which involves bonding the molten SPC substrate to the decorative layer using hot press rollers. However, this process has not yet developed an effective solution to the problem of residual moisture inside the substrate, and there is an urgent need to optimize the process and equipment to improve the moisture-proof and crack-resistant performance of the finished product.

[0003] The core flaw of existing technology lies in its inability to fundamentally solve the problem of residual moisture inside the stone-plastic substrate: First, the main component of the stone-plastic substrate, heavy calcium carbonate powder (stone powder), has strong hygroscopicity. During the storage and mixing of raw materials, it easily absorbs trace amounts of moisture from the air. At the same time, in order to ensure the plasticizing effect of the substrate, the processing aids added to the formula and the process moisture remaining in the equipment cannot be completely evaporated during the high-temperature plasticizing stage. This is because the molten stone-plastic substrate has high fluidity and will quickly encapsulate the unevaporated water vapor and air. However, the existing process only uses a short period of high temperature heating during the plasticizing stage, resulting in the moisture being permanently sealed inside the substrate.

[0004] Secondly, the existing process directly uses hot press rollers to press the initially thick molten substrate under high pressure, which quickly forms a dense layer on the substrate surface. Under high pressure, the molten material on the substrate surface is quickly compacted, cooled and solidified, forming a dense closed structure that firmly locks in the moisture and air inside. During subsequent hot pressing and lamination, the residual moisture expands due to heat, which can easily cause bubbles and cracks to form inside the substrate. At the same time, it damages the adhesion between the substrate and the decorative layer, ultimately leading to problems such as insufficient moisture resistance and crack resistance of the finished board and shortened service life.

[0005] Therefore, this invention proposes a molding machine and molding process for moisture-proof and crack-resistant stone-plastic panels. Summary of the Invention

[0006] The purpose of this invention is to provide a molding machine and molding process for moisture-proof and crack-resistant stone-plastic panels, so as to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, in a first aspect, the present invention provides the following technical solution: a molding machine for moisture-proof and crack-resistant stone-plastic composite panels, comprising a main frame, on which a plurality of hot press rollers are installed. The stone-plastic substrate and the decorative layer are respectively conveyed to the main frame through corresponding feeding mechanisms and hot-pressed together by the hot press rollers to form a stone-plastic composite panel. A substrate processing component is installed at the front end of the feeding side of the main frame. The substrate processing component and one of the plurality of hot press rollers are correspondingly matched to form a traction group. The traction group is only used for traction and conveying of the stone-plastic substrate, while the other hot press rollers provide the hot-pressing composite function. A grooving component is provided on the substrate processing component. The grooving component shares the same heat source with the hot press rollers. The grooving component is used to groove the bottom of the stone-plastic substrate during the traction process of the traction group to form a moisture-removing channel. The moisture-removing channel is conveyed with the stone-plastic substrate to the subsequent hot press roller for hot-pressing composite and is smoothed during the hot-pressing composite process.

[0008] Preferably, the substrate processing component includes a traction hot roller rotatably mounted on the main frame. The traction hot roller shares the same drive source and the same heat source with the other hot press rollers. The traction hot roller is correspondingly engaged with one of the several hot press rollers to form a traction group.

[0009] Preferably, the circumferential surface of the traction heat roller is provided with a plurality of recesses, the recesses forming relatively protruding pressing parts on the circumferential surface of the traction heat roller, the recesses and pressing parts together forming a slotted part, when the traction heat roller rotates, the relatively protruding pressing parts on its circumferential surface press against the bottom of the stone-plastic substrate, and a gap is formed between the corresponding position of the recess and the bottom of the stone-plastic substrate, thereby forming a dehumidification channel at the bottom of the stone-plastic substrate.

[0010] Preferably, the surface of the traction heat roller is detachably equipped with a plurality of protrusions, and the plurality of protrusions together constitute the grooving component. The protrusions rotate with the traction heat roller to groove the bottom of the stone-plastic substrate during the traction process, forming the dehumidification channel.

[0011] Preferably, the detachable installation method of the protrusion includes, but is not limited to, welding and bonding. Welding is suitable for scenarios where the protrusion needs to be fixed with high strength, while bonding is suitable for scenarios where long-term fixing is not required and the protrusion can be easily replaced later. The choice can be made flexibly according to actual production needs.

[0012] Preferably, the protrusion adopts a split structure, with several split protrusions spaced apart along the circumference of the traction hot roller. Each split protrusion is fixedly mounted with a connecting block, and a bolt is threaded between every two oppositely arranged connecting blocks. By tightening the bolt, several split protrusions can be tightly clamped and fixed to the surface of the traction hot roller.

[0013] Preferably, a grooved suction device is provided between the substrate processing component and the hot press roller for subsequent hot pressing and lamination. A negative pressure module is fixedly provided at the bottom of the grooved suction device. The top contour of the grooved suction device is adapted to the shape of the dehumidification channel at the bottom of the stone-plastic substrate, and the top of the grooved suction device is correspondingly provided with the dehumidification channel.

[0014] Preferably, the trough system includes a diversion plate fixedly connected to the main frame, the negative pressure module fixedly connected to the bottom of the diversion plate, and a plurality of hollow suction strips fixedly connected to the top of the diversion plate. The number of the plurality of hollow suction strips is consistent with the number of dehumidification channels, and the shape of the hollow suction strips is adapted to the shape of the dehumidification channels. The hollow suction strips are located inside the dehumidification channels.

[0015] Preferably, the hollow suction strip consists of a suction strip body, several inclined sections, and several output ports. The suction strip body is fixedly connected to the top of the diversion plate. Several inclined sections are symmetrically installed on the surface of the suction strip body. The inclined sections have a gradually tapering structure along the conveying direction of the stone-plastic substrate. The output ports are all opened on the inclined surface of the inclined sections. A gap is maintained between the inclined sections and the inner wall of the dehumidification channel. Each pair of adjacent inclined sections and the inner wall of the dehumidification channel enclose a relatively independent negative pressure adsorption space.

[0016] Secondly, the present invention provides the following technical solution: a moisture-proof and crack-resistant stone-plastic board molding process, comprising the following steps: Step 1: Feeding and Conveying: The stone-plastic substrate and the decorative layer are respectively conveyed to the front end of the feeding side of the main frame through the corresponding feeding mechanism; Step 2: Traction and grooving: The traction group pulls and transports the stone-plastic substrate, while the grooving part on the substrate processing component grooves the bottom of the stone-plastic substrate to form a dehumidification channel. Step 3: Negative pressure dehumidification: The suction components of the trough system use negative pressure to draw water vapor from the exhaust channel, reducing the moisture content inside the stone-plastic substrate. Step 4: Hot pressing and bonding: The subsequent hot pressing and bonding process uses hot press rollers to hot press and bond the grooved and dehumidified stone-plastic substrate with the decorative layer. At the same time, the dehumidification channels are smoothed during the hot pressing process. Step 5: Finished Product Output: The formed moisture-proof and crack-resistant stone-plastic board is conveyed from the discharge side of the main frame.

[0017] Preferably, in step two, the traction speed of the traction group is 5-15 m / min, and the temperature of the slotted part is consistent with the temperature of the hot press roller, which is 160-190℃. In step three, the negative pressure value of the negative pressure module is -0.02MPa to -0.08MPa; In step four, the hot pressing pressure of the hot pressing roller for hot pressing composite is 1-3 MPa, and the hot pressing temperature is 170-200℃.

[0018] Compared with the prior art, the beneficial effects of the present invention are: 1. By completing high-temperature grooving during the traction feeding stage, the stone-plastic substrate has not yet been pressed under high pressure, and a dense layer has not yet formed on the surface. The moisture trapped inside can be quickly discharged through the regular dehumidification channels. At the same time, the high temperature of the traction hot roller not only assists in grooving but also accelerates the evaporation of moisture inside the substrate, so that the moisture is completely removed before subsequent hot pressing and lamination. This avoids defects such as bubbles and cracks caused by residual moisture from the source. The treated stone-plastic board has a denser and more uniform internal structure. In humid environments or scenarios with large temperature differences, it is not easy to cause stress concentration due to moisture expansion or contraction, which greatly improves the service life and environmental adaptability of the board. It can meet the application scenarios with high requirements for moisture resistance, such as coastal areas and rainy southern regions.

[0019] 2. The design of the integrated traction hot roller with recessed grooves to form the pressing part eliminates the need for an additional grooving mechanism, reducing the number of equipment parts and potential failure points, lowering maintenance costs and downtime risks. At the same time, the integrated structure has extremely low thermal resistance, allowing heat to be quickly and evenly transferred to the pressing part, ensuring stable temperature during grooving and avoiding problems such as poor substrate plasticization or poor groove formation caused by uneven local temperature. This integrated design also simplifies the equipment installation and commissioning process, enabling rapid adaptation to existing stone-plastic board production lines. It can be put into use without large-scale modifications, saving enterprises time and money on equipment upgrades.

[0020] 3. The suction components and dehumidification channels correspond one-to-one, forming a relatively closed negative pressure chamber. This concentrates the suction force, enabling rapid removal of moisture from the channels and preventing localized residue. The inclined surface design of the sloping section decomposes the suction force into forward propulsion and vertical adsorption components. This ensures the stability of substrate transport and enhances moisture adsorption. Simultaneously, the weak thermal convection formed by the gaps precisely controls the local temperature of the substrate, preventing over-plasticization or channel deformation. This ensures that the substrate maintains good plasticity and a regular channel shape throughout the dehumidification process, laying a solid foundation for subsequent hot pressing and smoothing.

[0021] 4. The regular and uniform moisture-removing channels can be completely smoothed during hot-pressing, leaving no residual grooves or protrusions on the bottom of the substrate. The flatness error is controlled within a very small range, meeting the stringent requirements of high-end decoration for the appearance of the board. At the same time, because the moisture is completely removed, the substrate and the decorative layer can achieve a tighter bond during hot pressing, with no air bubbles or gaps remaining. This greatly improves the adhesion of the decorative layer and reduces the risk of delamination and warping during later use. This high-quality bonding effect also allows the wear-resistant, stain-resistant and other surface properties of the stone-plastic board to be fully utilized, further expanding its application scenarios.

[0022] 5. The detachable protrusion design allows for flexible adjustment of the channel size and position to meet different production needs. It adapts to the production of various specifications of SPC panels without replacing the entire traction heating roller, significantly reducing equipment replacement and maintenance costs. The split-type protrusion clamping and fixing structure allows for quick adjustment of the protrusion height by adding shims, further enhancing the equipment's versatility and adaptability. This flexible design enables companies to respond quickly to changes in market demand, providing a stronger advantage in small-batch, multi-variety production while also reducing inventory backlog and capital tied up.

[0023] 6. The process and equipment design of this invention are fully adapted to the needs of continuous industrial production. The entire production process is highly compatible with existing SPC (Stone Plastic Composite Board) production lines, enabling capacity upgrades without large-scale modifications, thus ensuring production continuity and stability. The integrated equipment structure and efficient dehumidification process reduce energy consumption and labor costs per unit capacity, improving production efficiency and product qualification rate. Furthermore, the process is highly replicable, enabling rapid application and promotion in different production bases, helping enterprises achieve large-scale production, further increasing market share and profitability, and providing a feasible solution for technological upgrading in the SPC industry. Attached Figure Description

[0024] Figure 1 This is a frontal perspective three-dimensional schematic diagram of the main structure in Embodiment 1 of the present invention; Figure 2 This is a three-dimensional cross-sectional view of the main structure in Embodiment 1 of the present invention; Figure 3 This is a three-dimensional schematic diagram of the substrate processing component in Embodiment 1 of the present invention; Figure 4 This is a three-dimensional schematic diagram of the substrate processing component in Embodiment 2 of the present invention; Figure 5 This is a three-dimensional schematic diagram of the cooperation relationship between the traction heating roller and the protrusion in Embodiment 2 of the present invention; Figure 6 This is a three-dimensional schematic diagram of the protrusion in Embodiment 2 of the present invention; Figure 7 This is a three-dimensional cross-sectional view of the main structure in Embodiment 3 of the present invention; Figure 8 This is a three-dimensional disassembly diagram of the grooved suction component and negative pressure module in Embodiment 3 of the present invention; Figure 9 This is a partial three-dimensional schematic diagram of the main structure in Embodiment 3 of the present invention; Figure 10 This is a schematic diagram of the cooperation relationship between the hollow suction strip and the dehumidification channel in Embodiment 3 of the present invention; Figure 11 This is a three-dimensional schematic diagram of the hollow suction strip in Embodiment 3 of the present invention; Figure 12This is a flowchart of Embodiment 4 of the present invention.

[0025] In the picture: 1. Main frame; 11. Hot press roller; 12. Stone-plastic substrate; 13. Decorative layer; 2. Substrate processing component; 21. Traction hot roller; 22. Recess; 23. Protrusion; 231. Connecting block; 232. Bolt component; 3. Groove suction component; 31. Diverter plate; 32. Hollow suction strip; 321. Suction strip body; 322. Inclined part; 323. Output port; 4. Negative pressure module. Detailed Implementation

[0026] 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 protection scope of the present invention.

[0027] It should be noted that the hot press roller 11 in this invention only provides the function of hot pressing the stone-plastic substrate 12 and the decorative layer 13 together, and smoothing the dehumidification channel, while also providing support for the traction assembly. This can be achieved through a hot pressing structure using an existing metal press roller with a built-in heating tube, a matching temperature control sensor, and a pressure regulating cylinder assembly. The negative pressure module 4 only provides the function of delivering a stable negative pressure to the suction component 3 of the channel system, thereby actively sucking water vapor from the dehumidification channel. This can be achieved through a negative pressure generating structure using an existing rotary vane vacuum pump, a temperature-resistant negative pressure pipeline, and a pressure monitoring assembly. Currently, the traction hot roller 21 only serves to cooperate with the corresponding hot press roller 11 to form a traction group to traction and transport the stone-plastic substrate 12. At the same time, it uses high temperature to achieve the function of grooving the bottom of the substrate, such as through the existing stainless steel roller body with built-in heating source and matching synchronous belt drive assembly traction grooving structure; the external feeding mechanism only provides the function of transporting the stone-plastic substrate 12 and the decorative layer 13 to the feeding side of the main frame 1 respectively to achieve continuous and stable supply of raw materials, such as through the existing roll unwinding frame, photoelectric correction device and guide conveying roller group feeding and conveying structure.

[0028] The working principles of the above components (such as the heating and temperature control principle and hot pressing pressure adjustment principle of the hot pressing roller 11, the negative pressure generation and stability adjustment principle of the negative pressure module 4, the synchronous transmission principle and slotting thermoplastic adaptation principle of the traction hot roller 21, and the unwinding tension adjustment and correction positioning principle of the external feeding mechanism) and their specific structures (such as the roller body material, diameter parameters, and heating power of the hot pressing roller 11, the vacuum pump speed and negative pressure range of the negative pressure module 4, the heating temperature range and transmission speed of the traction hot roller 21, and the unwinding frame load-bearing capacity and correction accuracy of the external feeding mechanism) are all existing technologies. Given the universality of these structures, their specific principles will not be elaborated further.

[0029] Example 1, as Figure 1 and Figure 2 As shown, a molding machine for moisture-proof and crack-resistant stone-plastic composite panels includes a main frame 1. Several hot press rollers 11 are installed on the main frame 1. The stone-plastic substrate 12 and the decorative layer 13 are respectively conveyed to the main frame 1 through corresponding feeding mechanisms and hot-pressed together by the hot press rollers 11 to form a stone-plastic composite panel. A substrate processing component 2 is installed at the front end of the feeding side of the main frame 1. The substrate processing component 2 and one of the hot press rollers 11 are correspondingly matched to form a traction group. The traction group is only used to traction and convey the stone-plastic substrate 12. The other hot press rollers 11 provide the hot-pressing composite function. The substrate processing component 2 is provided with a grooving component. The grooving component and the hot press rollers 11 share the same heat source. The grooving component is used to groove the bottom of the stone-plastic substrate 12 during the traction process of the traction group to form a dehumidification channel. The dehumidification channel is conveyed with the stone-plastic substrate 12 to the hot press roller 11 for subsequent hot-pressing composite and is smoothed during the hot-pressing composite process.

[0030] like Figure 1 and Figure 2 As shown, the substrate processing component 2 includes a traction hot roller 21 rotatably mounted on the main frame 1. The traction hot roller 21 shares the same drive source and the same heat source with the other hot pressing rollers 11. The traction hot roller 21 is correspondingly engaged with one of the several hot pressing rollers 11 to form a traction group.

[0031] It should be noted that, as Figure 3 As shown, the circumferential surface of the traction heat roller 21 is provided with a number of recesses 22. The recesses 22 form relatively protruding pressing parts on the circumferential surface of the traction heat roller 21. The recesses 22 and the pressing parts together constitute a slotted part. When the traction heat roller 21 rotates, the relatively protruding pressing parts on its circumferential surface press against the bottom of the stone-plastic substrate 12. A gap is formed between the corresponding position of the recesses 22 and the bottom of the stone-plastic substrate 12, thereby forming a dehumidification channel at the bottom of the stone-plastic substrate 12.

[0032] It should be added that the stone-plastic substrate 12 is a thermoplastic stone-plastic substrate, whose main components are polyvinyl chloride resin and heavy calcium carbonate powder, and it is also compounded with moisture-proof agent, toughening and crack-resistant agent, heat stabilizer and processing aid. The decorative layer 13 is a functional decorative layer 13 adapted to the hot-pressing composite of stone-plastic board, specifically a wear-resistant PVC decorative film, wood grain colored paper or fireproof decorative layer 13. The composite surface of the decorative layer 13 is pre-coated with a heat-bonding adhesive layer.

[0033] Specifically, after the equipment is started, the hot pressing roller 11 and the traction hot roller 21 are heated to the working temperature synchronously through a shared heat source. The drive source drives the traction hot roller 21 and the corresponding hot pressing roller 11 to rotate synchronously, forming a traction group.

[0034] The stone-plastic substrate 12 (initially thick and in a molten plasticized state) and the decorative layer 13 are respectively conveyed to the main frame 1 through their respective feeding mechanisms. The traction group drives the stone-plastic substrate 12 to feed smoothly with a small traction tension.

[0035] During the feeding process, the traction hot roller 21, with the help of the high temperature generated by sharing the heat source with the hot press roller 11, keeps the bottom of the molten stone-plastic substrate 12 in good plasticity. At this time, the relatively protruding pressing part on the surface of the traction hot roller 21, i.e. the protruding structure formed by the concave part 22, will actively perform grooving operation on the bottom of the substrate with the help of high temperature and slight bonding pressure (non-high pressure pressing). Because the temperature of the pressing part is high, it can not only easily press out grooves on the bottom of the substrate with good plasticity, but also locally heat the bottom of the substrate during the grooving process, further promoting the evaporation of moisture and water vapor inside the substrate.

[0036] The gap between the recess 22 and the bottom of the substrate forms a channel for water vapor to escape, allowing the evaporated water vapor to connect with the outside and be discharged in time, ultimately forming a regular dehumidification channel.

[0037] It should be noted that the existing technology directly uses the hot press roller 11 to press the initially thick molten stone-plastic substrate 12 under high pressure, which will quickly form a dense layer on the surface of the substrate. This dense layer will firmly lock in the water vapor and air inside the substrate, preventing them from being discharged.

[0038] The reason why there is moisture inside the stone-plastic substrate 12 is that the heavy calcium carbonate powder (stone powder) in its main component easily absorbs trace amounts of moisture in the air. In addition, during the mixing and plasticizing process of the substrate, the processing aids in the formula and a small amount of residual process moisture cannot be completely volatilized and will be wrapped inside the molten substrate, forming hidden water vapor and moisture residue.

[0039] During the substrate transport stage, if no dehumidification channels are provided, even if a dense layer is not fully formed on the substrate surface, the molten substrate itself has a certain viscosity and surface tension, so the water vapor evaporated inside cannot break through the weak barrier on the substrate surface and be discharged smoothly. During the transport process, the substrate is in a continuous and stable feeding state without any exhaust channels. The evaporated water vapor can only accumulate and stagnate inside the substrate and cannot be connected with the outside. Once it is completely sealed by the dense layer formed by high pressure, it will be permanently locked inside the substrate.

[0040] During subsequent hot-pressing lamination, the residual moisture expands when heated, which can cause bubbles and cracks to form inside the substrate. It can also damage the bonding strength between the substrate and the decorative layer 13, ultimately affecting the moisture-proof and crack-resistant performance of the finished product.

[0041] In this embodiment, the core improvement is that during the traction feeding stage, before subsequent high-pressure pressing, the high-temperature raised pressing part is used to actively groove. At this time, a dense layer has not yet been formed on the surface of the substrate. The high temperature of the raised pressing part can not only smoothly groove, but also accelerate the evaporation of moisture inside the substrate. Combined with the channel formed by the recess 22, the water vapor can be quickly discharged, thus avoiding water vapor residue from the source.

[0042] After the moisture is fully discharged, the substrate enters the subsequent hot press roller 11 for high-pressure hot pressing and bonding. At this time, there is no excess moisture inside the substrate. During hot pressing, it can not only achieve a firm fit with the decorative layer 13, but also completely smooth the bottom dehumidification channel, so that the bottom of the substrate is restored to flatness, and finally formed into a moisture-proof and crack-resistant stone plastic board and output.

[0043] It should be noted that this embodiment selects to create a groove by forming a raised pressing part by opening a recess 22 in the traction hot roller 21, rather than directly processing the raised structure. This is not a conventional structural choice for those skilled in the art, but rather a creative design that combines the molding process of the stone-plastic substrate 12, the processing difficulty of the equipment, the practicality of production, and the molding quality of the substrate. The core reason is not only the optimization of processing difficulty, but also the improvement of process and equipment adaptability in multiple dimensions, as detailed below: From a processing perspective, the traction heat roller 21 is a cylindrical roller. Directly machining the protrusions can easily lead to stress concentration, roundness deviation, and difficulty in controlling dimensional accuracy. However, opening the recess 22 is a conventional milling process, which is less difficult to process and easier to control in terms of accuracy. It can ensure uniformity of the dimensions of the pressing part and open up regular dehumidification channels to ensure the implementation of subsequent processes.

[0044] From a heat transfer perspective, the recess 22 and the pressing part are integrally formed by the traction heat roller 21 without any additional splicing or assembly gaps. The thermal resistance is extremely small, and the heat from the shared heat source can be quickly and evenly transferred to the pressing part, ensuring stable temperature during grooving. In contrast, directly processing the protrusion requires splicing and fixing, and there is a gap between the external mechanism and the roller body, resulting in high thermal resistance and easy occurrence of local temperature deficiency, leading to uneven grooving and uneven plasticization of the substrate.

[0045] Example 2, based on Example 1, such as Figure 4 As shown, the surface of the traction heat roller 21 is detachably equipped with several protrusions 23, which together constitute a slotted part. The protrusions 23 rotate with the traction heat roller 21 to slot the bottom of the stone-plastic substrate 12 during the traction process, forming a dehumidification channel.

[0046] It should be noted that the detachable installation methods of the protrusion 23 include, but are not limited to, welding and bonding. Welding is suitable for scenarios where the protrusion 23 needs to be fixed with high strength, while bonding is suitable for scenarios where long-term fixing is not required and the protrusion 23 can be easily replaced later. The choice can be made flexibly according to actual production needs.

[0047] It should be noted that, as Figure 5 and Figure 6 As shown, the protrusion 23 adopts a split structure. Several split protrusions 23 are distributed at intervals along the circumference of the traction heat roller 21. Each split protrusion 23 is fixedly installed with a connecting block 231. A bolt 232 is threaded between every two oppositely arranged connecting blocks 231. By tightening the bolt 232, several split protrusions 23 can be tightly clamped and fixed to the surface of the traction heat roller 21.

[0048] Specifically, the core difference between this embodiment and Embodiment 1 lies in the structural design of the slotted part. Embodiment 1 uses a traction hot roller 21 to integrally open the recess 22 to form a pressing part for slotting. This structure is integrally formed and cannot be changed. In contrast, this embodiment uses a detachable and installable protrusion 23 as the slotted part. The core improvement is that the slotted part is detachable and modifiable, which effectively solves the irreversible problem of integral forming of the recess 22 in Embodiment 1. The working principles of traction, high-temperature slotting, water vapor discharge, and hot-press composite smoothing are completely consistent with those of Embodiment 1, and will not be repeated here.

[0049] In this embodiment, the protrusion 23, as an independent slotted component, offers excellent production flexibility due to its detachable installation feature. If installed by welding, the protrusion 23 can be welded onto the surface of the traction heat roller 21 on-site according to production needs. This method is convenient and provides a strong connection. If the size or position of the protrusion 23 needs to be adjusted later, the welded area can be ground and re-welded without replacing the entire traction heat roller 21. If installed by bonding, the operation is even simpler, requiring no complex welding process. Furthermore, the old protrusion 23 can be directly peeled off and the new protrusion 23 can be bonded without disassembling the traction heat roller 21 later, significantly reducing replacement and adjustment costs and adapting to the production needs of different specifications of dehumidification channels.

[0050] Crucially, the split structure of the protrusion 23 further optimizes the ease of disassembly and adjustment: several split protrusions 23 are distributed at intervals along the circumference of the traction heat roller 21, and are clamped and fixed by the cooperation of the connecting block 231 and the bolt 232, which can be firmly installed on the surface of the traction heat roller 21 without welding or bonding.

[0051] During production, the bolts 232 can be loosened according to the actual position and size requirements of the dehumidification channel, and the spacing and installation position of the split protrusions 23 can be adjusted in real time. If it is necessary to increase the radius of the protrusions 23 to open a deeper and wider dehumidification channel, a shim can be added between the protrusions 23 and the surface of the traction heat roller 21. The slotting size can be flexibly adjusted without replacing the protrusions 23 body.

[0052] Compared to the one-piece molded structure of the recess 22 in Embodiment 1, the design of the protrusion 23 in this embodiment completely solves the drawbacks of the one-piece molded slotted parts being unable to be adjusted or replaced: In Embodiment 1, after the recess 22 is opened, its size and position remain fixed. If subsequent production needs change and different specifications of dehumidification channels need to be replaced, only the entire traction heat roller 21 can be replaced, which is costly and cumbersome. However, the protrusion 23 in this embodiment can be flexibly disassembled and assembled through welding and bonding. The split structure simplifies the adjustment steps, which can not only adapt to the production of multiple specifications of stone-plastic substrate 12, but also reduce equipment maintenance and replacement costs, improve production versatility and convenience. At the same time, the protrusion 23 rotates with the traction heat roller 21, and with the help of the high temperature of the shared heat source and slight bonding pressure, it can achieve the same regular slotting effect as Embodiment 1, ensuring that moisture is discharged smoothly.

[0053] Example 3, based on Examples 1 and 2, as follows: Figures 7 to 11 As shown, a grooved suction component 3 is provided between the substrate processing component 2 and the hot press roller 11 used for subsequent hot pressing and lamination. A negative pressure module 4 is fixedly provided at the bottom of the grooved suction component 3. The top contour of the grooved suction component 3 is adapted to the shape of the dehumidification channel at the bottom of the stone-plastic substrate 12, and the top of the grooved suction component 3 is correspondingly provided with the dehumidification channel.

[0054] like Figures 7 to 11 As shown, the trough suction component 3 includes a diversion plate 31 fixedly connected to the main frame 1, a negative pressure module 4 fixedly connected to the bottom of the diversion plate 31, and a number of hollow suction strips 32 fixedly connected to the top of the diversion plate 31. The number of hollow suction strips 32 is consistent with the number of dehumidification channels, and the shape of the hollow suction strips 32 is adapted to the shape of the dehumidification channels. The hollow suction strips 32 are located inside the dehumidification channels.

[0055] like Figures 7 to 11 As shown, the hollow suction strip 32 consists of a suction strip body 321, several inclined portions 322, and several output ports 323. The suction strip body 321 is fixedly connected to the top of the diverter plate 31. Several inclined portions 322 are symmetrically installed on the surface of the suction strip body 321. The inclined portions 322 have a gradually narrowing structure along the conveying direction of the stone-plastic substrate 12. The output ports 323 are all opened on the inclined surface of the inclined portions 322. A gap is maintained between the inclined portions 322 and the inner wall of the dehumidification channel. Each pair of adjacent inclined portions 322 and the inner wall of the dehumidification channel form a relatively independent negative pressure adsorption space.

[0056] Specifically, based on embodiments one and two, this embodiment adds a grooved suction component 3 and a negative pressure module 4 between the substrate processing component 2 and the subsequent hot-pressing composite hot-pressing roller 11. The original overall process flow of grooving, traction, and hot-pressing composite smoothing remains unchanged, except for the addition of a negative pressure active dehumidification step after grooving and before hot pressing: After the stone-plastic substrate 12 completes grooving to form a dehumidification channel through the traction hot roller 21, it continues to be smoothly conveyed towards the subsequent hot-pressing roller 11 under the traction force of the traction group. During this process, the negative pressure module 4 is activated simultaneously to divert the flow. Plate 31 delivers negative pressure to each hollow suction strip 32, creating a stable negative pressure environment in the space enclosed by the hollow suction strip 32 and the inner wall of the dehumidification channel. The negative pressure is used to actively draw water vapor from the channel, achieving active dehumidification under negative pressure on the basis of the original high-temperature grooving natural dehumidification, thus doubly improving dehumidification efficiency and thoroughness. The core working principle of grooving, traction, and hot-pressing composite smoothing is the same as that in Examples 1 and 2, and will not be repeated here. The following focuses on the structural design of the channel suction component 3 and the corresponding technical advantages and working logic of each design.

[0057] In this embodiment, several hollow suction strips 32 are arranged one-to-one with the dehumidification channels at the bottom of the stone-plastic substrate 12. The inclined portion 322 on each hollow suction strip 32 and the inner wall of the corresponding dehumidification channel form a relatively independent negative pressure adsorption space. The negative pressure module 4 supplies pressure to each hollow suction strip 32 evenly through the diversion plate 31, so as to realize independent dehumidification of each dehumidification channel, effectively avoiding the diffusion of water vapor in a single channel to other channels and causing local residue, and ensuring the uniformity of dehumidification of the entire board.

[0058] The inclined section 322 has a gradually tapering structure along the conveying direction of the stone-plastic substrate 12. The core design is adapted to the state of the substrate immediately after grooving and the subsequent conveying deformation requirements: When the stone-plastic substrate 12 has just finished grooving, the temperature is at a high level and it still maintains good molten plasticity. At this time, the inclined section 322 is in the initial state without shrinkage, and the corresponding width is slightly wider, resulting in a relatively large adsorption force. This larger adsorption force can not only assist the molten substrate in forming the channel with the help of negative pressure, but also prevent the channel from collapsing or deforming due to insufficient plasticity. At the same time, it can flexibly compensate for the width according to the actual width of the substrate immediately after grooving, adapting to the slight width fluctuation that may occur due to the high temperature and strong plasticity of the substrate at this time. This ensures that the inclined section 322 and the inner wall of the channel are always in close contact and fit, and will not weaken the negative pressure effect due to excessive gap caused by substrate width deviation, or scratch the substrate due to insufficient gap.

[0059] On the other hand, as the substrate continues to be transported, the temperature gradually decreases slightly and a slight shrinkage deformation occurs. The inclined part 322 shrinks gradually along the transport direction in sync. This not only accurately matches the shrinkage of the substrate and maintains a stable matching gap, but also gradually strengthens the negative pressure adsorption force along the transport direction, realizing progressive suction of water vapor. This allows the water vapor in the channel to be gradually removed as the substrate is fed, preventing water vapor backflow and further ensuring thorough dehumidification.

[0060] Meanwhile, a reasonable gap is maintained between the inclined portion 322 and the inner wall of the dehumidification channel. This not only avoids hard contact that could scratch the inner wall of the molten substrate channel, but more importantly, the gap, in conjunction with the structure of the inclined portion 322, allows the two to enclose a relatively closed negative pressure chamber. This is the basis for the efficient functioning of negative pressure dehumidification. It ensures that the suction force generated by the negative pressure module 4 is not lost and is more concentrated, avoiding the attenuation of the dehumidification effect due to chamber leakage. At the same time, the weak heat convection formed by the gap can be used to briefly assist in controlling the local temperature of the substrate and prevent abnormal plasticization.

[0061] The design of the inclined surface is the key ingenuity of this embodiment. The output port 323 is opened on the inclined surface of the inclined part 322. Combined with the relatively closed negative pressure chamber, when the negative pressure module 4 is working, the concentrated suction force generated by the output port 323 acts on the inner wall of the dehumidification channel and is decomposed into two precise components: one is the forward component along the substrate conveying direction, which can provide a slight boost to the substrate. Together with the traction force of the traction group, it can effectively counteract the feeding stagnation and positioning problems that may be caused by negative pressure adsorption, and ensure the smooth conveying of the substrate. The other is the adsorption component perpendicular to the inner wall of the channel. As the core force of dehumidification, it can firmly adsorb the water vapor and air in the channel. Because the chamber is relatively closed, this component can maximize its effect, ensuring that water vapor is quickly drawn into the output port 323 and smoothly discharged through the hollow suction strip 32 and the diverter plate 31, which greatly improves the dehumidification efficiency and thoroughness.

[0062] In summary, this embodiment, through the multi-dimensional structural design of the grooved suction component 3, adds a negative pressure active dehumidification step to the high-temperature grooved natural dehumidification of embodiments one and two. This achieves dual dehumidification while taking into account airflow temperature control, substrate feeding stability, and groove forming protection. This allows for more thorough removal of moisture from the inside of the stone-plastic substrate 12, fundamentally solving the problems of limited natural dehumidification efficiency and localized moisture residue. Furthermore, through temperature control and non-contact design, the forming quality of the substrate is guaranteed, resulting in a stronger bond between the stone-plastic substrate 12 and the decorative layer 13 during subsequent hot-pressing lamination. The moisture-proof and crack-resistant properties and flatness of the finished stone-plastic board are also further improved.

[0063] Example 4, as Figure 12 As shown, the molding process of moisture-proof and crack-resistant stone-plastic board includes the following steps: Step 1: Feeding and conveying: The stone-plastic substrate 12 and the decorative layer 13 are respectively conveyed to the front end of the feeding side of the main frame 1 through the corresponding feeding mechanism; Step 2: Traction and grooving: The traction group pulls and transports the stone-plastic substrate 12, while the grooving part on the substrate processing part 2 grooves the bottom of the stone-plastic substrate 12 to form a dehumidification channel. Step 3: Negative pressure dehumidification: The suction component 3 of the trough system uses negative pressure to draw water vapor from the dehumidification channel, reducing the moisture content inside the stone-plastic substrate 12. Step 4: Hot pressing and bonding: The hot pressing roller 11 is used to hot press and bond the grooved and dehumidified stone-plastic substrate 12 with the decorative layer 13 to form a composite. At the same time, the dehumidification groove is smoothed during the hot pressing process. Step 5: Finished Product Output: The formed moisture-proof and crack-resistant stone-plastic board is conveyed from the discharge side of the main frame 1.

[0064] It should be noted that in step two, the traction speed of the traction group is 5-15 m / min, and the temperature of the slotted part is consistent with the temperature of the hot pressure roller 11, which is 160-190℃. In step three, the negative pressure value of negative pressure module 4 is -0.02MPa to -0.08MPa; In step four, the hot pressing pressure of the hot pressing roller 11 for hot pressing composite is 1-3 MPa, and the hot pressing temperature is 170-200℃.

[0065] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply 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. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0066] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A molding machine for moisture-proof and crack-resistant stone-plastic composite panels, comprising a main frame (1), wherein a plurality of hot press rollers (11) are installed on the main frame (1), and the stone-plastic substrate (12) and decorative layer (13) are respectively fed to the main frame (1) by corresponding feeding mechanisms, and are hot-pressed together by the hot press rollers (11) to form a stone-plastic composite panel, characterized in that: The front end of the feeding side of the main frame (1) is equipped with a substrate processing component (2). The substrate processing component (2) and one of the several hot press rollers (11) are correspondingly matched to form a traction group. The traction group is only used to traction and transport the stone-plastic substrate (12). The other hot press rollers (11) provide hot press composite function. The substrate processing component (2) is provided with a grooving component. The grooving component and the hot press roller (11) share the same heat source. The grooving component is used to groove the bottom of the stone-plastic substrate (12) during the traction process of the traction group to form a dehumidification channel. The dehumidification channel is transported with the stone-plastic substrate (12) to the hot press roller (11) for subsequent hot press composite and is smoothed during the hot press composite process.

2. The molding machine for moisture-proof and crack-resistant stone-plastic board according to claim 1, characterized in that: The substrate processing component (2) includes a traction hot roller (21) rotatably mounted on the main frame (1). The traction hot roller (21) shares the same drive source and the same heat source with the other hot press rollers (11). The traction hot roller (21) is matched with one of the several hot press rollers (11) to form a traction group.

3. The molding machine for moisture-proof and crack-resistant stone-plastic board according to claim 2, characterized in that: The circumferential surface of the traction heat roller (21) is provided with a number of recesses (22). The recesses (22) form relatively protruding pressing parts on the circumferential surface of the traction heat roller (21). The recesses (22) and the pressing parts together constitute a slotted part. When the traction heat roller (21) rotates, the relatively protruding pressing parts on its circumferential surface press against the bottom of the stone-plastic substrate (12). A gap is formed between the corresponding position of the recesses (22) and the bottom of the stone-plastic substrate (12), thereby forming a dehumidification channel at the bottom of the stone-plastic substrate (12).

4. The molding machine for moisture-proof and crack-resistant stone-plastic board according to claim 2, characterized in that: The surface of the traction heat roller (21) is detachably equipped with several protrusions (23), and the several protrusions (23) together constitute the slotted part. The protrusions (23) rotate with the traction heat roller (21) to slot the bottom of the stone-plastic substrate (12) during the traction process, forming the dehumidification channel.

5. A molding machine for moisture-proof and crack-resistant stone-plastic board according to claim 4, characterized in that: The protrusion (23) adopts a split structure. Several split protrusions (23) are distributed at intervals along the circumference of the traction heat roller (21). Each split protrusion (23) is fixedly installed with a connecting block (231). A bolt (232) is threaded between each pair of opposite connecting blocks (231). By tightening the bolt (232), several split protrusions (23) can be tightly clamped and fixed to the surface of the traction heat roller (21).

6. A molding machine for moisture-proof and crack-resistant stone-plastic panels according to claim 2, 3 or 4, characterized in that: A grooved suction component (3) is provided between the substrate processing component (2) and the hot press roller (11) for subsequent hot pressing and bonding. A negative pressure module (4) is fixedly provided at the bottom of the grooved suction component (3). The top outline of the grooved suction component (3) is adapted to the shape of the dehumidification channel at the bottom of the stone-plastic substrate (12), and the top of the grooved suction component (3) is correspondingly provided to the dehumidification channel.

7. A molding machine for moisture-proof and crack-resistant stone-plastic board according to claim 6, characterized in that: The trough suction component (3) includes a diversion plate (31) fixedly connected to the main frame (1), the negative pressure module (4) is fixedly connected to the bottom of the diversion plate (31), and the top of the diversion plate (31) is fixedly connected to a number of hollow suction strips (32). The number of hollow suction strips (32) is consistent with the number of dehumidification channels, and the shape of the hollow suction strips (32) is adapted to the shape of the dehumidification channels. The hollow suction strips (32) are located inside the dehumidification channels.

8. A molding machine for moisture-proof and crack-resistant stone-plastic board according to claim 7, characterized in that: The hollow suction strip (32) consists of a suction strip body (321), several inclined sections (322) and several output ports (323). The suction strip body (321) is fixedly connected to the top of the diversion plate (31). Several inclined sections (322) are symmetrically installed on the surface of the suction strip body (321). The inclined sections (322) have a gradually shrinking structure along the conveying direction of the stone-plastic substrate (12). The output ports (323) are all opened on the inclined surface of the inclined section (322). The inclined section (322) maintains a gap with the inner wall of the dehumidification channel, and each pair of adjacent inclined sections (322) and the inner wall of the dehumidification channel form a relatively independent negative pressure adsorption space.

9. A molding process for moisture-proof and crack-resistant stone-plastic composite panels, applied to a molding machine for moisture-proof and crack-resistant stone-plastic composite panels as described in claim 1, characterized in that: Includes the following steps: Step 1: Feeding and conveying: The stone-plastic substrate (12) and the decorative layer (13) are respectively conveyed to the front end of the feeding side of the main frame (1) through the corresponding feeding mechanism; Step 2: Traction and grooving: The traction group pulls and transports the stone-plastic substrate (12), while the grooving part on the substrate processing part (2) grooves the bottom of the stone-plastic substrate (12) to form a dehumidification channel. Step 3: Negative pressure dehumidification: The suction unit (3) of the trough system performs negative pressure suction to remove water vapor in the dehumidification channel, thereby reducing the moisture content inside the stone-plastic substrate (12); Step 4: Hot pressing composite: The hot pressing roller (11) is used to hot press the grooved and dehumidified stone-plastic substrate (12) and the decorative layer (13) into a composite shape, while smoothing the dehumidification groove during the hot pressing process. Step 5: Finished product output: The formed moisture-proof and crack-resistant stone plastic board is conveyed from the discharge side of the main frame (1).

10. The molding process for moisture-proof and crack-resistant stone-plastic composite panels according to claim 9, characterized in that: In step two, the traction speed of the traction group is 5-15m / min, and the temperature of the slotted part is consistent with the temperature of the hot pressing roller (11), which is 160-190℃. In step three, the negative pressure value of the negative pressure module (4) is -0.02MPa to -0.08MPa; In step four, the hot pressing pressure of the hot pressing roller (11) for hot pressing composite is 1-3 MPa, and the hot pressing temperature is 170-200℃.

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