High-density uniform flocking process

Abstract

The invention discloses a high-density uniform flocking process which comprises the process steps of unwinding and storing cloth, gluing and preheating, homogenizing flock falling, electrostatic dispersion guiding, floating pressing, heavy pressing, winding and curing, during homogenizing flock falling, a metering, homogenizing and blanking device is arranged above the cloth, flocking fibers are added into the metering, homogenizing and blanking device, and the flocking fibers are uniformly distributed in the metering, homogenizing and blanking device; the flocking fibers are metered, dispersed and homogenized by the metering, homogenizing and blanking device and then uniformly scattered downwards by virtue of the weight of the flocking fibers; wherein the metering homogenizing blanking device comprises a double-metering three-brush thickness grading blanking hopper, three brush rollers and three arc-shaped blanking silk screens are arranged in the double-metering three-brush thickness grading blanking hopper, the mesh diameter of the first arc-shaped blanking silk screen is the largest, and the mesh diameter of the second arc-shaped blanking silk screen is the same as the mesh diameter of the third arc-shaped blanking silk screen. The mesh diameter of the second arc-shaped blanking silk screen is smaller than that of the first arc-shaped blanking silk screen, and the mesh diameter of the third arc-shaped blanking silk screen is smaller than that of the second arc-shaped blanking silk screen. According to the invention, the flocking density and uniformity are improved.

Description

Technical Field

[0001] This invention relates to the field of textile finishing and surface functional materials, specifically to a high-density uniform flocking process. Background Technology

[0002] Flocking is a technique that vertically fixes short fibers onto the surface of a substrate coated with an adhesive using physical or chemical methods. Because it imparts properties such as softness, wear resistance, aesthetics, and functionality to the substrate, it is widely used in clothing, home décor, automotive interiors, packaging, and industrial materials. Traditional flocking methods mainly include mechanical flocking and electrostatic flocking. Mechanical flocking relies on fiber weight and vibration dispersion, which easily leads to uneven fiber distribution, low density, and weak control over fiber orientation. While electrostatic flocking utilizes an electric field to vertically implant fibers, improving orientation and density to some extent, it still has the following inherent drawbacks: First, the fiber dispersion uniformity is poor: during the feeding and unloading process, the fibers are prone to agglomeration or clusters due to electrostatic adsorption and entanglement between fibers, resulting in uneven density phenomena such as cloud spots and stripes on the substrate surface, affecting the appearance and feel.

[0003] Secondly, density and uniformity are difficult to improve simultaneously: increasing the amount of down shedding to improve density exacerbates fiber agglomeration and further deteriorates uniformity; while pursuing uniformity often requires controlling down shedding, which makes it difficult to achieve high density. This contradiction is particularly prominent in applications that pursue a high-end texture.

[0004] Third, fiber gradation and layering control are difficult: existing technologies struggle to achieve orderly, layered implantation of fibers of different lengths or coarseness. Disorderly mixed flocking can easily lead to coarse fibers covering fine fibers, or inconsistent implantation depths, affecting the bulk, resilience, and abrasion resistance uniformity of the final flocked layer.

[0005] Fourth, the process parameters are highly coupled and lack stability: flocking density and uniformity are affected by multiple parameters such as adhesive viscosity, coating uniformity, electric field strength, fiber supply rate, and substrate travel speed, and these parameters are mutually coupled. Traditional open-loop control methods are difficult to compensate for disturbances in real time, resulting in large fluctuations in product quality between different batches or within the same batch.

[0006] Fifth, there is a contradiction between efficiency and quality: during high-speed production, insufficient time for fiber dispersion, directional implantation, and adhesive penetration can easily lead to problems such as sparse flocking, lodging, or poor bonding, which limits the realization of high-quality flocking at high yield.

[0007] Therefore, the industry urgently needs an innovative process that can fundamentally improve fiber dispersion and orderly supply, achieve precise coordination and online control of process parameters, and thus stably obtain high-density and highly uniform flocked layers. Summary of the Invention

[0008] To address the problems of poor flocking uniformity, difficulty in increasing density, insufficient process stability, and difficulty in ensuring quality under high-speed production in the aforementioned background technologies, this invention proposes a high-density uniform flocking process. This process aims to achieve a simultaneous and significant improvement in flocking density, uniformity, bonding strength, and production efficiency through integrated precision fiber metering and homogenization, electrostatic synergistic dispersion guidance, graded pressure combination, and online intelligent feedback control. The specific technical solution is as follows: A high-density uniform flocking process includes the following steps: S1. Unwinding and storing fabric: The fabric is unwound forward through the unwinding device and enters the fabric storage device; S2. Glue application and preheating: The fabric is output from the fabric storage device to the preheating glue application device, where a layer of reactive polyurethane PUR hot melt adhesive is uniformly coated on its surface. At the same time, the preheating function is used to maintain the appropriate working viscosity and leveling properties of the adhesive layer, creating the best bonding conditions for subsequent fiber implantation. S3, uniform shedding: A metering and uniform shedding device is set above the fabric. The flocked fibers are added into the metering and uniform shedding device. After being metered, dispersed and uniformized by the metering and uniform shedding device, the flocked fibers fall evenly downwards by their own weight. S4. Electrostatic dispersion guidance: An electrostatic dispersion guidance device is set below the metering and homogenizing feeding device. After the flocked fibers pass through the electrostatic mesh of the electrostatic dispersion guidance device, they are further dispersed and oriented downwards to be implanted onto the fabric with PUR adhesive below. S5. Floating pressure: A floating pressure device is used to apply light pressure to the flocked fibers distributed on the fabric, increasing the depth of the flocked fibers embedded in the PUR adhesive layer without causing the fibers to fall over or the adhesive to be over-extruded, laying the foundation for subsequent deep bonding. S6. Heavy pressure: Heavy pressure rollers are used to apply heavy pressure to the flocked fibers distributed on the fabric to achieve deep bonding with the PUR adhesive. S7. Winding and Curing: The fabric with flocked fibers is wound up by a winding device, and the wound flocked fibers are placed on a curing rack. After natural curing for N hours, the flocked fiber base fabric is formed.

[0009] Preferably, the natural curing time after winding is N=24 hours.

[0010] Preferably, the preheating adhesive applicator includes an adhesive applicator, a mold temperature controller connected to the adhesive applicator via a hot oil pipe, an adhesive applicator disposed above the adhesive applicator, a scraper for smoothing the adhesive applied to the fabric, and a rectangular tube abutting against the scraper plane, the two ends of the rectangular tube being connected to the mold temperature controller via hot oil pipes.

[0011] In this invention, the metering and homogenizing feeding device includes a dual-metering, three-brush coarse-fine grading feeding hopper. The dual-metering, three-brush coarse-fine grading feeding hopper includes a feeding box, a pair of metering rollers disposed at the upper inlet of the feeding box, and a feeding hopper connected to the upper part of the pair of metering rollers. A feeding mesh is disposed at the lower part of the feeding box. The feeding mesh includes a first arc-shaped feeding mesh, a second arc-shaped feeding mesh, and a third arc-shaped feeding mesh connected adjacent to each other in the order of feeding flocked fiber coarseness. The feeding box is equipped with three brush rollers for dispersing flocked fibers, and the three brush rollers are correspondingly arranged above the three arc-shaped feeding meshes. The first arc-shaped feeding mesh has the largest mesh diameter, the second arc-shaped feeding mesh has a smaller mesh diameter than the first arc-shaped feeding mesh, and the third arc-shaped feeding mesh has a smaller mesh diameter than the second arc-shaped feeding mesh.

[0012] In this invention, adjacent brush rollers and the brush rollers and the arc-shaped feed wire mesh below them are in contact with each other through the brushes on the brush rollers; the three brush rollers rotate in the same direction, and the uppermost end of the brush roller is tangential along the rotation direction and is consistent with the conveying direction of the fabric below.

[0013] With the above settings, the flocked fibers can be sequentially fed to the first, second, and third arc-shaped feeding wire meshes, and the first arc-shaped feeding wire mesh allows coarse, medium, and fine fibers to pass through, the second arc-shaped feeding wire mesh only allows medium and fine fibers to pass through, and the third arc-shaped feeding wire mesh only allows fine fibers to pass through.

[0014] In this invention, an overflow channel for discharging excess flocking fibers is provided at one end of the third arc-shaped feed wire mesh.

[0015] After the flocked fibers fall from above onto a pair of brush rollers located above the first and second arc-shaped flocking meshes, the flocked fibers are initially dispersed by the brush rollers under the action of rotation, and are carried into the first and second arc-shaped flocking meshes by the brush rollers. Then, they pass through the first and second arc-shaped flocking meshes respectively and are evenly scattered downwards, and then pass through the electrostatic net below and fall onto the fabric moving forward below.

[0016] The function of the electrostatic net is to further disperse the flocked fibers and, under the influence of the electric field, to directionally implant the flocked fibers into the adhesive layer on the surface of the fabric.

[0017] Three co-rotating brush rollers work together to break up, comb, and transfer the fiber clumps. Under their coordinated rotation, some flocked fibers are transferred sequentially from the brush roller above the first arc-shaped feeding mesh to the brush rollers above the second and third arc-shaped feeding meshes. Each brush roller carries the flocked fibers into its corresponding arc-shaped feeding mesh, then they pass through the mesh and fall evenly downwards, before passing through the electrostatic net below and landing on the fabric moving forward. Due to the forward movement of the fabric and the different mesh diameters of the three arc-shaped feeding meshes, finer flocked fibers can easily insert into the gaps between coarser flocked fibers, thus forming a graded complementary flocking effect, which helps to increase the flocking density.

[0018] In this invention, the metering rollers are provided with material distribution grooves along the axial direction. The material distribution grooves are evenly spaced along the circumference. The flocked fibers located in the feeding hopper are quantitatively transferred to the inside of the discharge box through the material distribution grooves on a pair of metering rollers.

[0019] The above-mentioned dual-metering three-brush coarse and fine grading feeding hopper can be set in several groups, so that the feeding wire mesh of different groups of dual-metering three-brush coarse and fine grading feeding hoppers has different mesh diameters, and the mesh diameter of the feeding wire mesh gradually decreases according to the feeding order.

[0020] By setting up multiple sets of dual-metering, three-brush coarse-fine graded feeding hoppers, the running speed of the fabric during flocking can be further improved.

[0021] Preferably, the electrostatic dispersion guiding device includes an electrode plate disposed below the fabric, an electrostatic mesh disposed above the electrode plate and the fabric, and a voltage applied between the electrode plate and the electrostatic mesh to form an electrostatic field.

[0022] The working mechanism of the electrostatic dispersion guiding device is as follows: When flocked fibers pass through an electrostatic net with static electricity, the fibers repel each other due to induction charging, which further improves the dispersion effect of the fibers. Under the action of the electrostatic field, the fibers are accelerated and oriented, and can be implanted into the PUR adhesive layer of the fabric below almost vertically.

[0023] In this invention, the metering and homogenizing feeding device further includes a fiber cluster dispersion homogenizer disposed between the dual metering three-brush coarse and fine classification feeding hopper and the electrostatic net for breaking up tiny clusters of fibers.

[0024] As one of the preferred embodiments of the fiber cluster dispersion homogenizer in this invention, the fiber cluster dispersion homogenizer is a high-frequency shaking ultrasonic composite dispersion homogenizer. The high-frequency shaking ultrasonic composite dispersion homogenizer includes a horizontal shaking frame that can shake at a certain frequency in the horizontal direction, and steel wires densely arranged in parallel intervals within the horizontal shaking frame. The horizontal shaking frame is movably mounted on a slide and its horizontal shaking is achieved by a reciprocating servo electric push rod. The telescopic rod of the reciprocating servo electric push rod is connected to the horizontal shaking frame, and an ultrasonic transducer is connected between the telescopic rod of the reciprocating servo electric push rod and the horizontal shaking frame.

[0025] The ultrasonic transducer is connected to the ultrasonic generator.

[0026] Preferably, a rubber buffer pad is provided between the telescopic rod of the duplex servo electric actuator and the ultrasonic transducer.

[0027] When the reciprocating servo electric actuator drives the horizontal oscillating frame to move back and forth, the high-frequency oscillation of the horizontal oscillating frame can intercept the clustered fibers at high frequency and load ultrasonic energy onto the clustered fibers, thereby breaking them up. One advantage of the high-frequency oscillation ultrasonic composite dispersant homogenizer is its good effect on breaking up small clustered fibers with strong adhesion.

[0028] As a second preferred embodiment of the fiber cluster dispersion homogenizer in this invention, the fiber cluster dispersion homogenizer is a high-frequency shaking and vibrating composite dispersion homogenizer. The high-frequency shaking and vibrating composite dispersion homogenizer includes a horizontal shaking frame that can shake at a certain frequency in the horizontal direction, and steel wires densely arranged in parallel intervals within the horizontal shaking frame. The horizontal shaking frame is movably mounted on a slide and its horizontal shaking is achieved by a reciprocating servo electric push rod. The telescopic rod of the reciprocating servo electric push rod is connected to the horizontal shaking frame, and a rack for meshing with each of the steel wires is fixedly arranged above one side of the steel wires. The rack is arranged perpendicular to the steel wires.

[0029] When the reciprocating servo electric actuator drives the horizontal oscillating frame to move back and forth, the high-frequency oscillation of the horizontal oscillating frame can intercept the clustered fibers at high frequencies. At the same time, the plucking teeth on the rack can pluck the steel wire string to generate audio vibrations of a certain frequency, thereby breaking up the clustered fibers. One advantage of the high-frequency oscillating string vibration composite dispersion homogenizer is that it can simultaneously apply a strong plucking action to each steel wire string, and its wide amplitude and large vibration energy are more conducive to breaking up larger clustered fibers.

[0030] Preferably, a steel wire string audio adjuster is provided on one side of the horizontal rocking frame. The steel wire string audio adjuster includes a movable bar and a pair of guide posts disposed on one side of the movable bar. A pair of guide holes and a string penetration groove are provided on one side of the horizontal rocking frame. The guide posts on the movable bar are movably disposed in the guide holes on one side of the horizontal rocking frame. One end of the steel wire string passes through the string penetration groove on the horizontal rocking frame and is fixed on the movable bar. An adjusting bolt for pressing against the horizontal rocking frame to adjust the tension of the steel wire string is provided on the movable bar.

[0031] Preferably, the adjusting bolt is a butterfly adjusting bolt, and a locking nut is provided on the butterfly adjusting bolt.

[0032] Preferably, the rack has fixing blocks at both ends, and the fixing blocks are installed on the upper end of the slide.

[0033] By setting a wire string audio tuner, the dispersing effect of different flocked fibers can be optimized.

[0034] Preferably, the steel wire is parallel to the direction of fabric movement, and the reciprocating direction of the reciprocating servo electric actuator is perpendicular to the direction of fabric movement.

[0035] Preferably, the above-mentioned high-frequency shaking ultrasonic composite dispersion homogenizer and high-frequency shaking string vibration composite dispersion homogenizer can be used simultaneously to further enhance the dispersion and homogenization effect of clustered fibers. When both are used simultaneously, their reciprocating servo electric actuators can serve as a common reciprocating motion drive device.

[0036] The aforementioned metering and homogenizing feeding device can further disperse and homogenize some of the still incompletely dispersed micro-flocked fiber clusters through the synergistic effect of high-frequency shaking and ultrasonic vibration or string vibration, thereby further enhancing the uniformity of flocking.

[0037] In this invention, an online flocking density measuring device is also provided at the winding entry side of the winding device. The control system of the high-density uniform flocking process adjusts the flocking process parameters online according to the flocking density measured by the online flocking density measuring device to meet the design requirements of the flocking density.

[0038] The adjustment of the flocking process parameters includes the adjustment of the fabric travel speed.

[0039] Preferably, the adjustment of the flocking process parameters also includes adjusting the rotational speed parameters of the metering rollers in the dual-metering, three-brush coarse-fine grading hopper.

[0040] Preferably, the adjustment of the flocking process parameters also includes the adjustment of the floating pressure of the floating pressure device and the adjustment of the heavy pressure of the heavy pressure roller.

[0041] Preferably, the adjustment of the flocking process parameters also includes the adjustment of the electric field strength.

[0042] Preferably, the flocking density online measuring device includes an inverted V-shaped fabric bending device positioned below the fabric to make the fabric arch upwards in an inverted V shape, and a visual recognition camera positioned above the fabric bending device and the fabric.

[0043] Preferably, the inverted V-shaped fabric bending device includes a triangular support body mounted on the lifting device, fabric guide rollers positioned above the fabric and on the left and right sides of the triangular support body, an active roller and a passive roller respectively mounted on the lower sides of the triangular support body, and a guide belt surrounding and connecting the small-radius arc top of the triangular support body and between the active roller and the passive roller. The small-radius arc top of the triangular support body and both sides of the triangular support body are provided with a polytetrafluoroethylene anti-friction coating. The active roller is driven to rotate by a servo motor to achieve synchronous movement of the guide belt and the fabric.

[0044] Preferably, mounting grooves are provided on both sides of the lower part of the triangular support body, and the active roller and the passive roller are respectively located in the mounting grooves.

[0045] Preferably, the number of the lifting devices is one pair, and support blocks are provided at the front and rear ends of the triangular support body, with the upper end of the lifting device fixed on the support blocks.

[0046] After the fabric is supported upward by the triangular support body and forms a certain bending angle, the density fibers at the bending point are forcibly dispersed. The dispersion pattern of the fabric is analyzed and judged by the visual recognition camera above to obtain the actual flocking density. The detection sensitivity and accuracy are high.

[0047] Preferably, different flocking densities can be pre-made into density samples. The visual recognition system can quickly detect the flocking density by comparing the shape of the samples with the density samples at the same bending angle.

[0048] The aforementioned online measuring device and process control system together form a real-time feedback closed loop: by obtaining the actual value of flocking density through online measurement, comparing it with the set value, and then automatically adjusting the relevant process parameters to stabilize the output value within the set range, thereby ensuring the consistency of product quality.

[0049] The aforementioned online flocking density measuring device can operate in an intermittent mode, primarily used for initial density detection during operation and subsequent periodic density stability monitoring. During measurement pauses, the triangular support retracts via a lift, completely disengaging from the fabric.

[0050] Preferably, a negative pressure flocking fiber recovery device is provided behind the heavy pressure roller to recover excess flocking fibers by negative pressure adsorption.

[0051] The beneficial effects of this invention are: First, the high-density uniform flocking process of the present invention fundamentally solves the problem of fiber agglomeration through a dual homogenization mechanism of "double metering three-brush coarse and fine classification of material" and "electrostatic secondary dispersion guidance", realizing the discrete uniform flocking of fibers, effectively eliminating defects such as cloud spots and stripes, thereby greatly improving the uniformity of flocking.

[0052] Secondly, the high-density uniform flocking process of the present invention has a graded flocking mechanism that allows coarse, medium and fine fibers to be implanted in an orderly manner, forming a dense and fluffy complementary structure. Under the same fiber usage per unit area, higher visual density and tactile density can be obtained. With the help of an online density feedback system, the flocking density is significantly improved and controllable.

[0053] Third, the high-density uniform flocking process of the present invention adopts a gradient pressure process of "preheating and applying glue → floating pressure (preliminary positioning) → heavy pressure (deep bonding)," which is conducive to more effective contact between the fibers and the glue layer, thereby increasing the flocking density; and allows the PUR glue to fully wrap the fiber roots and achieve deep penetration. After sufficient curing, the fiber pull-out strength is significantly improved, and the product has good abrasion resistance and peel resistance.

[0054] Fourth, the high-density uniform flocking process of the present invention, with an intelligent closed-loop control system based on online density monitoring, can compensate for disturbances caused by changes in raw materials, environment, speed, etc. in real time, greatly reducing the dependence on operating experience and ensuring that the product quality of different batches and long-term continuous production is highly consistent. Its process adaptability is strong and its stability is high.

[0055] Fifth, the high-density uniform flocking process of the present invention uses a double-metering, three-brush coarse-fine grading hopper in the metering and homogenizing feeding device. After the flocking fibers enter the feeding box through the metering rollers, they are effectively dispersed by three co-rotating brush rollers. The mutual contact between the brushes of adjacent brush rollers and the contact between the brushes and the mesh below constitute a flexible transmission and combing channel for the fibers. Combined with the arc-shaped feeding mesh with a gradient change in mesh diameter below, the fibers are graded by coarseness, layer by layer, and uniformly scattered. This facilitates the smooth insertion of finer flocking fibers into the gaps between coarser flocking fibers, thereby forming graded complementary flocking, improving the volume density, fullness, and fiber bonding strength of the flocked layer, and contributing to a finer surface texture.

[0056] Sixth, in a high-density uniform flocking process of the present invention, the fiber cluster dispersion homogenizer in the metering and homogenizing feeding device consists of a frame that can be horizontally oscillated at high frequency and parallel steel wires densely distributed thereon, and is driven by a reciprocating servo electric push rod. When the fiber flow passes through this area, it is subjected to the synergistic effect of mechanical oscillation and optional ultrasonic vibration or string vibration, which can effectively separate those tiny fiber clusters and achieve an ultra-uniform dispersion state.

[0057] Seventh, the present invention provides a high-density uniform flocking process, which includes an online flocking density measuring device. This measuring device uses an inverted V-shaped fabric bending device to make the flocked fabric form an arch at a specific angle, forcing the fibers at the arch to unfold. Then, a visual recognition camera above captures the unfolded shape, and the current flocking density is calculated in real time by comparing it with a preset density sample library. Based on this feedback signal, the control system can dynamically adjust the fabric travel speed, metering roller speed, electric field strength, floating pressure / heavy pressure parameters, etc., online to form a closed-loop control, ensuring that the density is always stable within the set range. Attached Figure Description

[0058] Figure 1 This is a schematic diagram of a high-density uniform flocking process according to the present invention. Figure 2 This is a schematic diagram of the preheating adhesive applicator used in a high-density uniform flocking process according to the present invention. Figure 3 This is a schematic diagram of the metering and homogenizing material feeding device used in a high-density uniform flocking process according to the present invention. Figure 4 yes Figure 3 A top view of the fiber cluster dispersion homogenizer using a high-frequency shaking ultrasonic composite dispersion homogenizer. Figure 5 yes Figure 3 A top view of the fiber cluster dispersion homogenizer using a high-frequency vibrating string vibration composite dispersion homogenizer. Figure 6 yes Figure 3 A top view of the fiber cluster dispersion homogenizer that simultaneously employs a high-frequency shaking ultrasonic composite dispersion homogenizer and a high-frequency shaking string vibration composite dispersion homogenizer. Figure 7 This is a schematic diagram of the structure of an online flocking density measuring device.

[0059] In the diagram: 1. Preheating adhesive applicator; 2. Metering and homogenizing material feeding device; 3. Electrostatic dispersion and guiding device; 4. Material distribution; 5. Adhesive application table; 6. Hot oil pipe; 7. Mold temperature controller; 8. Glue application device; 9. Scraper; 10. Rectangular tube; 11. Double metering triple brush coarse and fine classification feeding hopper; 12. Feeding box; 13. Metering roller; 14. Feeding hopper; 15. First arc-shaped feeding wire mesh; 16. Second arc-shaped feeding wire mesh; 17. Third arc-shaped feeding wire mesh; 18. Brush roller; 19. Overflow channel; 20. Distribution groove; 21. Electrode plate; 22. Electrostatic mesh; 23. Fiber cluster dispersion and homogenizer; 24. Horizontal shaking. 25. Frame, 26. Steel wire string, 27. Slide, 28. Reciprocating servo electric actuator, 29. Ultrasonic transducer, 30. Online flocking density measuring device, 31. Inverted V-shaped fabric bending device, 32. Vision recognition camera, 33. Lifter, 34. Triangular support, 35. Fabric guide roller, 36. Small radius arc top, 37. Active roller, 38. Passive roller, 39. Guide belt, 40. Servo motor, 41. Mounting slot, 42. Support block, 43. Rack, 44. Steel wire string audio adjuster, 45. Movable bar, 46. Guide column, 47. Fixing block, 48. Adjusting bolt, 49. Locking nut. Detailed Implementation

[0060] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings and examples. The following examples are only used to more clearly illustrate the technical solutions of the present invention and should not be construed as limiting the scope of protection of the present invention.

[0061] like Figures 1 to 7 The following is an embodiment of a high-density uniform flocking process according to the present invention, comprising the following steps: S1. Unwinding and storing fabric: The fabric 4 is unwound forward through the unwinding device and enters the fabric storage device; S2, Glue application and preheating: Fabric 4 is output from the fabric storage device to the preheating glue application device 1, where a layer of reactive polyurethane PUR hot melt adhesive is uniformly coated on its surface. At the same time, the preheating function is used to maintain the appropriate working viscosity and leveling properties of the adhesive layer, creating the best bonding conditions for subsequent fiber implantation. S3, uniform shedding: A metering and uniform shedding device 2 is set above the fabric 4. The flocked fibers are added into the metering and uniform shedding device 2. After being metered, dispersed and uniformized by the metering and uniform shedding device 2, the flocked fibers fall evenly downwards by their own weight. S4. Electrostatic dispersion guidance: An electrostatic dispersion guidance device 3 is set below the metering and homogenizing feeding device 2. After the flocked fibers pass through the electrostatic net 22 of the electrostatic dispersion guidance device 3, they are further dispersed and oriented downwards to be implanted onto the fabric 4 with PUR adhesive material below. S5. Floating pressure: A floating pressure device is used to apply light floating pressure to the flocked fibers distributed on the fabric 4, which increases the depth of the flocked fibers implanted into the PUR adhesive layer without causing the fibers to fall over or the adhesive to be over-extruded, laying the foundation for subsequent deep bonding. S6. Heavy pressure: Heavy pressure rollers are used to apply heavy pressure to the flocked fibers distributed on fabric 4 to achieve deep bonding with PUR adhesive. S7. Winding and Curing: The fabric 4 with flocked fibers is wound up by a winding device, and the wound flocked fibers are placed on a curing rack. After natural curing for N hours, a flocked fiber base fabric is formed.

[0062] Preferably, the natural curing time after winding is N=24 hours.

[0063] Preferably, the preheating adhesive applicator 1 includes an adhesive applicator 5, a mold temperature controller 7 connected to the adhesive applicator 5 via a hot oil pipe 6, an adhesive applicator 8 disposed above the adhesive applicator 5, a scraper 9 for smoothing the adhesive applied to the fabric 4, and a rectangular tube 10 abutting against the plane of the scraper 9, the two ends of the rectangular tube 10 being connected to the mold temperature controller 7 via the hot oil pipe 6.

[0064] In this embodiment, the metering and homogenizing feeding device 2 includes a dual-metering three-brush coarseness and fineness grading feeding hopper 11. The dual-metering three-brush coarseness and fineness grading feeding hopper 11 includes a feeding box 12, a pair of metering rollers 13 disposed at the upper inlet of the feeding box 12, and a feeding hopper 14 connected to the upper part of the pair of metering rollers 13. A feeding wire mesh is disposed at the lower part of the feeding box 12. The feeding wire mesh includes a first arc-shaped feeding wire mesh 15, a second arc-shaped feeding wire mesh 16, and a third arc-shaped feeding wire mesh 17, which are connected adjacent to each other in the order of feeding flocked fiber coarseness. Two arc-shaped feeding wire meshes 16 and a third arc-shaped feeding wire mesh 17 are provided. The feeding box 12 is equipped with three brush rollers 18 for dispersing flocked fibers, and the three brush rollers 18 are correspondingly arranged above the three arc-shaped feeding wire meshes. The first arc-shaped feeding wire mesh 15 has the largest mesh diameter, the second arc-shaped feeding wire mesh 16 has a smaller mesh diameter than the first arc-shaped feeding wire mesh 15, and the third arc-shaped feeding wire mesh 17 has a smaller mesh diameter than the second arc-shaped feeding wire mesh 16.

[0065] In this embodiment, adjacent brush rollers 18 are in contact with each other and the brush roller 18 is in contact with the arc-shaped material feeding wire mesh below it through the brushes on the brush roller 18; the three brush rollers 18 rotate in the same direction, and the uppermost end of the brush roller 18 is tangential along the rotation direction and is consistent with the conveying direction of the fabric 4 below.

[0066] With the above settings, the flocked fibers can be sequentially fed to the first arc-shaped feeding wire mesh 15, the second arc-shaped feeding wire mesh 16, and the third arc-shaped feeding wire mesh 17. The first arc-shaped feeding wire mesh 15 allows coarse, medium, and fine fibers to pass through, the second arc-shaped feeding wire mesh 16 only allows medium and fine fibers to pass through, and the third arc-shaped feeding wire mesh 17 only allows fine fibers to pass through.

[0067] In this embodiment, an overflow channel 19 for discharging excess flocking fibers is provided at one end of the third arc-shaped feed wire mesh 17.

[0068] After the flocked fibers fall from above onto a pair of brush rollers 18 located above the first arc-shaped feed wire mesh 15 and the second arc-shaped feed wire mesh 16, the flocked fibers are initially dispersed by the pair of brush rollers 18 under the rotation of the brush rollers 18, and are carried into the first arc-shaped feed wire mesh 15 and the second arc-shaped feed wire mesh 16 by the brush rollers 18. Then, they pass through the first arc-shaped feed wire mesh 15 and the second arc-shaped feed wire mesh 16 respectively and are evenly scattered downwards, and then pass through the electrostatic net 22 below and fall onto the fabric 4 that is moving forward below.

[0069] The function of the electrostatic net 22 is to further disperse the flocked fibers and, under the action of the electric field, to directionally implant the flocked fibers into the adhesive layer on the surface of the fabric 4.

[0070] Three co-rotating brush rollers 18 work together to break up, comb, and transfer the fiber clumps. Under the action of the three brush rollers 18 rotating in the same direction, some flocking fibers are transferred sequentially from the brush roller 18 above the first arc-shaped feeding mesh 15 to the brush roller 18 above the second arc-shaped feeding mesh 16 and the brush roller 18 above the third arc-shaped feeding mesh 17. Each brush roller 18 carries the flocking fibers into the corresponding arc-shaped feeding mesh, then passes through the arc-shaped feeding mesh and falls evenly downwards, and then passes through the electrostatic net 22 below and falls onto the fabric 4 moving forward below. Due to the forward movement of the fabric 4 and the different mesh diameters of the three arc-shaped feeding meshes, it is easy for finer flocking fibers to be smoothly inserted into the gaps between coarser flocking fibers, thereby forming graded complementary flocking, which is beneficial to improving the flocking density.

[0071] In this embodiment, the metering roller 13 is provided with a material distribution groove 20 along the axial direction. The material distribution groove 20 is evenly spaced along the circumference. The flocked fibers located in the feeding hopper 14 are quantitatively transferred into the material dropping box 12 through the material distribution groove 20 on a pair of metering rollers 13.

[0072] The above-mentioned dual-metering three-brush coarse and fine grading feeding hopper 11 can be set in several groups, so that the feeding wire mesh of different groups of dual-metering three-brush coarse and fine grading feeding hopper 11 has different mesh diameters, and the mesh diameter of the feeding wire mesh gradually decreases according to the feeding order.

[0073] By setting up multiple sets of dual-metering, three-brush coarse and fine graded feeding hoppers 11, the running speed of the fabric 4 during flocking can be further improved.

[0074] Preferably, the electrostatic dispersion guiding device 3 includes an electrode plate 21 disposed below the fabric 4, an electrostatic mesh 22 disposed above the electrode plate 21 and the fabric 4, and a voltage applied between the electrode plate 21 and the electrostatic mesh 22 to form an electrostatic field.

[0075] The working mechanism of the electrostatic dispersion guiding device 3 is as follows: When the flocked fibers pass through the electrostatic net 22 with static electricity, the fibers repel each other due to induction charging, which further improves the dispersion effect of the fibers. Under the action of the electrostatic field, the fibers are accelerated and oriented, and can be implanted into the PUR adhesive layer of the fabric 4 below almost vertically.

[0076] In this embodiment, the metering and homogenizing feeding device 2 further includes a fiber cluster dispersion homogenizer 23, which is disposed between the dual metering three-brush coarse and fine classification feeding hopper 11 and the electrostatic net 22 for breaking up small clusters of fibers.

[0077] As one of the preferred embodiments of the fiber cluster dispersion homogenizer 23 in this invention, the fiber cluster dispersion homogenizer 23 is a high-frequency shaking ultrasonic composite dispersion homogenizer. The high-frequency shaking ultrasonic composite dispersion homogenizer includes a horizontal shaking frame 24 that can shake at a certain frequency in the horizontal direction, and steel wires 25 densely arranged in parallel intervals within the horizontal shaking frame 24. The horizontal shaking frame 24 is movably mounted on a slide block 26 and horizontal shaking is achieved by a reciprocating servo electric push rod 27. The telescopic rod of the reciprocating servo electric push rod 27 is connected to the horizontal shaking frame 24, and an ultrasonic transducer 28 is connected between the telescopic rod of the reciprocating servo electric push rod 27 and the horizontal shaking frame 24.

[0078] The ultrasonic transducer 28 is connected to an ultrasonic generator.

[0079] Preferably, a rubber buffer pad is provided between the telescopic rod of the duplex servo electric push rod 27 and the ultrasonic transducer 28.

[0080] When the reciprocating servo electric actuator 27 drives the horizontal shaking frame 24 to move reciprocally, the high-frequency shaking of the horizontal shaking frame 24 can intercept the clustered fibers at high frequency and load ultrasonic energy onto the clustered fibers, thereby breaking them up. One advantage of the high-frequency shaking ultrasonic composite dispersant is its good effect on breaking up small clustered fibers with strong adhesion.

[0081] As a second preferred embodiment of the fiber cluster dispersion homogenizer 23 in this invention, the fiber cluster dispersion homogenizer 23 is a high-frequency shaking and vibrating composite dispersion homogenizer. The high-frequency shaking and vibrating composite dispersion homogenizer includes a horizontal shaking frame 24 that can shake at a certain frequency in the horizontal direction, and steel wires densely arranged in parallel intervals within the horizontal shaking frame 24. The horizontal shaking frame 24 is movably mounted on a slide block 26 and horizontal shaking is achieved by a reciprocating servo electric push rod 27. The telescopic rod of the reciprocating servo electric push rod 27 is connected to the horizontal shaking frame 24, and a rack 42 for meshing with each of the steel wires 25 is fixedly arranged above one side of the steel wires 25. The rack 42 is arranged perpendicularly to the steel wires 25.

[0082] When the reciprocating servo electric actuator 27 drives the horizontal oscillating frame 24 to move reciprocally, the high-frequency oscillation of the horizontal oscillating frame 24 can intercept the clustered fibers at high frequencies. At the same time, the plucking teeth on the rack 42 can pluck the steel wire string 25 to emit audio vibrations of a certain frequency, thereby breaking up the clustered fibers. One advantage of the high-frequency oscillating string vibration composite dispersion homogenizer is that it can simultaneously exert a strong plucking action on each steel wire string 25, and its wide amplitude and large vibration energy are more conducive to breaking up larger clustered fibers.

[0083] Preferably, a steel wire string audio adjuster 43 is provided on one side of the horizontal rocking frame 24. The steel wire string audio adjuster 43 includes a movable bar 44 and a pair of guide posts 45 disposed on one side of the movable bar 44. A pair of guide holes and a string penetration groove are provided on one side of the horizontal rocking frame 24. The guide posts 45 on the movable bar 44 are movably disposed in the guide holes on one side of the horizontal rocking frame 24. One end of the steel wire string 25 passes through the string penetration groove on the horizontal rocking frame 24 and is fixed on the movable bar 44. An adjusting bolt 47 is provided on the movable bar 44 for pressing against the horizontal rocking frame 24 to adjust the tension of the steel wire string 25.

[0084] Preferably, the adjusting bolt 47 is a butterfly adjusting bolt, and a locking nut 48 is provided on the butterfly adjusting bolt 47.

[0085] Preferably, the rack 42 is provided with fixing blocks 46 at both ends, and the fixing blocks are installed on the upper end of the slide block 26.

[0086] By setting the wire string audio tuner 43, the dispersing effect of different flocked fibers can be optimized.

[0087] Preferably, the steel wire 25 is parallel to the moving direction of the fabric 4, and the reciprocating moving direction of the reciprocating servo electric push rod 27 is perpendicular to the moving direction of the fabric 4.

[0088] Preferably, the above-mentioned high-frequency shaking ultrasonic composite dispersion homogenizer and high-frequency shaking string vibration composite dispersion homogenizer can be used simultaneously to further enhance the dispersion and homogenization effect of clustered fibers. When both are used simultaneously, the reciprocating servo electric push rod 27 can serve as a shared reciprocating motion drive device.

[0089] The aforementioned metering and homogenizing feeding device 2 can further disperse and homogenize some of the still incompletely dispersed micro-flocked fiber clusters through the synergistic effect of high-frequency shaking and ultrasonic vibration or string vibration, thereby further enhancing the uniformity of flocking.

[0090] In this embodiment, an online flocking density measuring device 29 is also provided at the winding entry side of the winding device. The control system of the high-density uniform flocking process adjusts the flocking process parameters online according to the flocking density measured by the online flocking density measuring device 29 to meet the design requirements of the flocking density.

[0091] The adjustment of the flocking process parameters includes the adjustment of the fabric 4 travel speed.

[0092] Preferably, the adjustment of the flocking process parameters also includes adjusting the rotation speed parameters of the metering roller 13 of the double metering three-brush coarse and fine grading hopper 11.

[0093] Preferably, the adjustment of the flocking process parameters also includes the adjustment of the floating pressure of the floating pressure device and the adjustment of the heavy pressure of the heavy pressure roller.

[0094] Preferably, the adjustment of the flocking process parameters also includes the adjustment of the electric field strength.

[0095] Preferably, the flocking density online measuring device 29 includes an inverted V-shaped fabric bending device 30 positioned below the fabric 4 to make the fabric 4 arch upwards in an inverted V shape, and a visual recognition camera 31 positioned above the inverted V-shaped fabric bending device 30 and the fabric 4.

[0096] Preferably, the inverted V-shaped fabric bending device 30 includes a triangular support body 33 disposed on the lifting device 32, fabric guide rollers 34 disposed above the fabric 4 and positioned on the left and right sides of the triangular support body 33, an active roller 36 and a passive roller 37 disposed on the lower sides of the triangular support body 33, and a guide belt 38 that surrounds and connects the small radius arc top 35 of the triangular support body 33, the active roller 36 and the passive roller 37. The small radius arc top 35 of the triangular support body 33 and both sides of the triangular support body 33 are provided with a polytetrafluoroethylene anti-friction coating. The active roller 36 is driven to rotate by a servo motor 39 to realize the synchronous movement of the guide belt 38 and the fabric 4.

[0097] Preferably, mounting grooves 40 are provided on both sides of the lower part of the triangular support 33, and the active roller 36 and the passive roller 37 are respectively located in the mounting grooves 40.

[0098] Preferably, the number of the lifting devices 32 is a pair, and the front and rear ends of the triangular support body 33 are provided with support blocks 41, and the upper end of the lifting device 32 is fixed on the support blocks 41.

[0099] After the fabric 4 is bent at a certain angle by the upward support action of the triangular support 33, the density fibers at the bend are forcibly dispersed. The visual recognition camera 31 above analyzes and judges the dispersed shape of the fabric 4 to obtain the actual flocking density. The detection sensitivity and accuracy are high.

[0100] Preferably, different flocking densities can be pre-made into density samples. The visual recognition system can quickly detect the flocking density by comparing the shape of the samples with the density samples at the same bending angle.

[0101] The aforementioned online measuring device and process control system together form a real-time feedback closed loop: by obtaining the actual value of flocking density through online measurement, comparing it with the set value, and then automatically adjusting the relevant process parameters to stabilize the output value within the set range, thereby ensuring the consistency of product quality.

[0102] The aforementioned online flocking density measuring device 29 can operate in an intermittent mode, primarily used for initial density detection during operation and subsequent density stability monitoring at regular intervals. During measurement pauses, the triangular support 33 retracts via the lifter 32, completely disengaging from the fabric 4.

[0103] Preferably, a negative pressure flocking fiber recovery device is provided behind the heavy pressure roller to recover excess flocking fibers by negative pressure adsorption.

[0104] After adopting this process, a sampling test was conducted on the flocked base fabric (sampling size 150mm×30mm). The results are as follows: the flocking density increased by more than 30%; the uniformity (CV value) decreased by 30%; and the peel strength increased by more than 40%.

[0105] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A high-density uniform flocking process, characterized in that, Includes the following steps: S1. Unwinding and storing fabric: The fabric is unwound forward through the unwinding device and enters the fabric storage device; S2. Glue application and preheating: The fabric is output from the fabric storage device to the preheating glue application device, where a layer of reactive polyurethane PUR hot melt adhesive is uniformly coated on its surface. At the same time, the preheating function is used to maintain the appropriate working viscosity and leveling properties of the adhesive layer, creating the best bonding conditions for subsequent fiber implantation. S3, uniform shedding: A metering and uniform shedding device is set above the fabric. The flocked fibers are added into the metering and uniform shedding device. After being metered, dispersed and uniformized by the metering and uniform shedding device, the flocked fibers fall evenly downwards by their own weight. S4. Electrostatic dispersion guidance: An electrostatic dispersion guidance device is set below the metering and homogenizing feeding device. After the flocked fibers pass through the electrostatic mesh of the electrostatic dispersion guidance device, they are further dispersed and oriented downwards to be implanted onto the fabric with PUR adhesive below. S5. Floating pressure: A floating pressure device is used to apply light pressure to the flocked fibers distributed on the fabric, increasing the depth of the flocked fibers embedded in the PUR adhesive layer without causing the fibers to fall over or the adhesive to be over-extruded, laying the foundation for subsequent deep bonding. S6. Heavy pressure: Heavy pressure rollers are used to apply heavy pressure to the flocked fibers distributed on the fabric to achieve deep bonding with the PUR adhesive. S7. Winding and Curing: The fabric with flocked fibers is wound up by a winding device, and the wound flocked fibers are placed on a curing rack. After natural curing for N hours, the flocked fiber base fabric is formed.

2. The high-density uniform flocking process according to claim 1, characterized in that, The preheating adhesive applicator includes an adhesive applicator table, a mold temperature controller connected to the adhesive applicator table via a hot oil pipe, an adhesive applicator mounted above the adhesive applicator table, a scraper for smoothing the adhesive applied to the fabric, and a rectangular tube abutting against the scraper plane, the two ends of which are connected to the mold temperature controller via hot oil pipes.

3. The high-density uniform flocking process according to claim 1, characterized in that, The metering and homogenizing feeding device includes a dual-metering, three-brush coarse-fine grading feeding hopper. The dual-metering, three-brush coarse-fine grading feeding hopper includes a feeding box, a pair of metering rollers disposed at the upper inlet of the feeding box, and a feeding hopper connected to the upper part of the pair of metering rollers. A feeding mesh is disposed at the lower part of the feeding box. The feeding mesh includes a first arc-shaped feeding mesh, a second arc-shaped feeding mesh, and a third arc-shaped feeding mesh connected sequentially in the order of feeding flocked fiber coarseness. Three brush rollers for dispersing flocked fibers are disposed inside the feeding box, and the three brush rollers are correspondingly arranged above the three arc-shaped feeding meshes. The first arc-shaped feeding mesh has the largest mesh diameter, the second arc-shaped feeding mesh has a smaller mesh diameter than the first arc-shaped feeding mesh, and the third arc-shaped feeding mesh has a smaller mesh diameter than the second arc-shaped feeding mesh.

4. The high-density uniform flocking process according to claim 3, characterized in that, The adjacent brush rollers and the brush rollers and the arc-shaped feed wire mesh below them are in contact with each other through the brushes on the brush rollers; the three brush rollers rotate in the same direction, and the uppermost part of the brush roller is tangential along the rotation direction and is consistent with the conveying direction of the fabric below.

5. The high-density uniform flocking process according to claim 3, characterized in that, An overflow channel for discharging excess flocking fibers is provided at one end of the third arc-shaped feed wire mesh.

6. The high-density uniform flocking process according to claim 3, characterized in that, The metering rollers are provided with material distribution grooves along the axial direction. The material distribution grooves are evenly spaced along the circumference. The flocked fibers located in the feeding hopper are quantitatively transferred to the inside of the discharge box through the material distribution grooves on a pair of metering rollers.

7. The high-density uniform flocking process according to claim 1, characterized in that, The electrostatic dispersion guiding device includes an electrode plate disposed below the fabric, an electrostatic mesh disposed above the electrode plate and the fabric, and a voltage applied between the electrode plate and the electrostatic mesh to form an electrostatic field.

8. The high-density uniform flocking process according to claim 7, characterized in that, The metering and homogenizing feeding device also includes a fiber cluster dispersion homogenizer positioned between the dual-metering three-brush coarse and fine grading feeding hopper and the electrostatic net to disperse tiny clusters of fibers. The fiber cluster dispersion homogenizer is a high-frequency shaking ultrasonic composite dispersion homogenizer. The high-frequency shaking ultrasonic composite dispersion homogenizer includes a horizontal shaking frame that can shake at a certain frequency in the horizontal direction and steel wires densely arranged in parallel intervals within the horizontal shaking frame. The horizontal shaking frame is movably mounted on a slide and its horizontal shaking is achieved by a reciprocating servo electric push rod. The telescopic rod of the reciprocating servo electric push rod is connected to the horizontal shaking frame, and an ultrasonic transducer is connected between the telescopic rod of the reciprocating servo electric push rod and the horizontal shaking frame.

9. The high-density uniform flocking process according to claim 7, characterized in that, The metering and homogenizing feeding device also includes a fiber cluster dispersion homogenizer positioned between the dual-metering three-brush coarse and fine grading feeding hopper and the electrostatic net to disperse tiny clusters of fibers. The fiber cluster dispersion homogenizer is a high-frequency shaking and string vibration composite dispersion homogenizer. The high-frequency shaking and string vibration composite dispersion homogenizer includes a horizontal shaking frame that can shake at a certain frequency in the horizontal direction and steel wires densely arranged in parallel intervals within the horizontal shaking frame. The horizontal shaking frame is movably mounted on a slide and its horizontal shaking is achieved by a reciprocating servo electric push rod. The telescopic rod of the reciprocating servo electric push rod is connected to the horizontal shaking frame, and a rack for meshing with each of the steel wires is fixedly provided above one side of the steel wires. The rack is arranged perpendicular to the steel wires.

10. The high-density uniform flocking process according to claim 1, characterized in that, An online flocking density measuring device is also provided at the winding entry side of the winding device. The control system of the high-density uniform flocking process adjusts the flocking process parameters online according to the flocking density measured by the online flocking density measuring device to meet the design requirements of the flocking density.

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