A kind of for TMP integrated tile roller compaction molding machine and molding method

Abstract

This application provides a roll forming machine and method for TMP integrated tile. The roll forming machine includes multiple sets of rollers. The roll forming of TMP composite profiles is divided into four roll forming processes. The first roll forming process includes a first upper roller and a first lower roller. The first upper roller includes a first protrusion, and the first lower roller is provided with a corresponding first groove. The second roll forming process includes a second upper roller and a second lower roller. The second upper roller includes a second groove, a relief structure, and an inclined pressing surface. The second lower roller is provided with a second protrusion corresponding to the second groove. The third roll forming process includes an upper pressure roller set and a lower pressure roller set symmetrically arranged on both sides of the second upper roller and the second lower roller. The fourth roll forming process includes a third upper roller and a third lower roller. The third upper roller includes a third groove, and the third lower roller is provided with a corresponding third protrusion. The forming method adopts a "first lower pressure - then upper support" process to form the nose structure.

Description

Technical Field

[0001] This application relates to the technical field of micro-hole processing, and more particularly to a roll forming machine and forming method for TMP integrated tiles. Background Technology

[0002] In existing continuous production lines for TMP (hot melt adhesive film) integrated tile composite layers 101, the three-dimensional forming of the middle "nose wing" portion 102 generally adopts a "vertical roller inclined pressing" process: two sets of lateral rollers clamp the sheet from both sides, and simultaneously press the film-sheet composite upwards using an inclined wedge method, forming a raised nose wing as it is pressed up. The nose wing forming process is referenced... Figure 1 .

[0003] However, this process has the following defects: the guide roller is wedge-shaped and unevenly stressed during the inclined pressing process. The film is subjected to lateral shear and peeling forces, which makes it very easy to detach from the substrate locally, forming bubbles or peeling. The guide roller is a single-roller structure, and the film and the guide roller are in rigid contact. Under high speed, the film surface will be scratched and cracked due to the inclined pressing of the guide roller. The film layer is easily stretched and deformed during inclined pressing, and excess film material is easy to overflow, resulting in cracks in the film layer. Summary of the Invention

[0004] In view of the above practical problems and the shortcomings of the existing technology, the main technical problem to be solved by the present invention is to provide a roll forming machine and forming method for TMP integrated tiles, which changes the "vertical sliding oblique pressing" to "horizontal rolling downward pressing", thereby solving problems such as film wear, blistering or peeling.

[0005] To solve the above-mentioned technical problems, this application provides a roll forming machine for TMP integrated tiles, adopting the following technical solution:

[0006] A roll forming machine for TMP integrated tiles includes a frame and multiple sets of roller groups arranged sequentially along the direction from the feed end to the discharge end. The frame has multiple upper and lower rotating shafts arranged vertically opposite each other along the feed direction. Each set of roller groups is a horizontal roller structure, and each set of roller groups includes an upper roller and a lower roller fixed to the upper and lower rotating shafts, as well as an upper transport roller and a lower transport roller that are matched axially with the upper and lower rollers. The roll forming of TMP composite profiles is divided into a first roll forming process, a second roll forming process, a third roll forming process, and a fourth roll forming process according to the distribution of the multiple sets of roller groups.

[0007] Each set of rollers in the first rolling process includes a first upper roller and a first lower roller. The rolling surface of the first upper roller includes a first protrusion that protrudes radially outward, and the first lower roller is provided with a first groove corresponding to the position of the first protrusion. The first protrusion and the first groove form a pressing cavity for rolling the TMP composite profile downward, which is used to gradually form a V-shaped concave structure on the TMP composite profile.

[0008] Each set of rollers in the first rolling process is used to symmetrically form two recessed structures on the TMP composite profile, with the two recessed structures spaced apart.

[0009] Each set of rollers in the second rolling process includes a second upper roller and a second lower roller. The rolling surface of the second upper roller includes a second groove that is concave in the radial direction. The second lower roller has a second protrusion at the position corresponding to the second groove. The second lower roller has relief structures symmetrically arranged on both sides of the second protrusion. The relief structures are concave in the radial direction. The second lower roller has upwardly protruding inclined pressing surfaces on both sides of the second protrusion. The highest edge of the inclined pressing surface is connected to the relief structure.

[0010] The second groove and the second protrusion form a pressing cavity for rolling the TMP composite profile upward, which is used to gradually form an Ω-shaped upper convex structure on the TMP composite profile, the upper convex structure being located between the intervals of the two lower concave structures;

[0011] The inclined pressing surface is used to roll and press the TMP composite profile upwards. The protrusion is located on the outside of the concave structure. Under the combined rolling and pressing of the inclined pressing surface, the second groove and the second protrusion, the concave structure is squeezed into the relief structure.

[0012] Each roller group in the third rolling process includes a second upper roller and a second lower roller adapted to the roller structure of the second rolling process, as well as an upper roller group and a lower roller group symmetrically arranged on both sides of the second upper roller and the second lower roller, respectively; the upper roller group and the lower roller group cooperate to roll the TMP composite profile upward to form raised ribs; the second upper roller and the second lower roller are the continuing roller structure of the second rolling process;

[0013] Each set of rollers in the fourth rolling process includes a third upper roller and a third lower roller. The rolling surface of the third upper roller includes a third groove that is concave in the radial direction. The third lower roller has a third protrusion at the position corresponding to the third groove. The third groove and the third protrusion are used to shape and roll the upper convex structure.

[0014] In a preferred embodiment, each set of rollers in the first rolling process is provided with two first upper rollers and two first lower rollers spaced apart along the axial direction, and one first upper roller and one first lower roller cooperate to form a concave structure.

[0015] In the first rolling process, the height of the first protrusion of the first upper roller of the first set of rollers gradually increases along the feeding direction, and the depth of the first groove of the first lower roller gradually increases along the feeding direction.

[0016] In a preferred embodiment, the first upper roller includes a first bearing structure, and a first pressure sleeve is fitted on the outer ring of the first bearing structure. The first pressure sleeve includes the first protrusion.

[0017] In a preferred embodiment, the depth of the second groove of the second upper roller corresponding to the multiple sets of rollers in the second rolling process gradually increases along the feeding direction, and the height of the second protrusion of the corresponding second lower roller gradually increases along the feeding direction.

[0018] The inclination of the inclined pressing surface of the second lower roller of the multiple roller groups in the second rolling process gradually increases along the feeding direction; the clearance space of the clearance structure gradually increases along the feeding direction.

[0019] In a preferred embodiment, the second upper roller includes a second bearing structure, and a second pressure sleeve is fitted on the outer ring of the second bearing structure. The second pressure sleeve includes the second groove. The second lower roller includes a third bearing structure. A third pressure sleeve is fitted on the outer ring of the third bearing structure. The third pressure sleeve includes the second protrusion.

[0020] In a preferred embodiment, two upper transport rollers are symmetrically arranged on both sides of the second upper roller along the axial direction, and flat pressure surfaces are provided at both ends of the second lower roller connected to the inclined pressure surface. The position of the flat pressure surface corresponds to the position of the upper transport rollers. No matching pressure roller structure is provided above the inclined pressure surface of the second lower roller.

[0021] In a preferred embodiment, the upper pressure roller group and the lower pressure roller group include two first upper pressure rollers and two first lower pressure rollers disposed near the second upper roller and the second lower roller, and / or two second upper pressure rollers and two second lower pressure rollers disposed away from the second upper roller and the second lower roller;

[0022] The outer periphery contours of the first upper pressure roller, the first lower pressure roller, the second upper pressure roller, and the second lower pressure roller are all designed as stepped structures, and the height difference between the upper and lower step surfaces of the stepped structure gradually increases along the feeding direction.

[0023] In a preferred embodiment, the third groove is configured as a polygonal groove structure, and the opening of the third groove in the multiple sets of rollers gradually narrows inward along the feeding direction.

[0024] In a preferred embodiment, both the third upper roller and the third lower roller are bearing structures. A fourth pressure sleeve is fitted on the outer ring of the third upper roller, and a fifth pressure sleeve is fitted on the outer ring of the third lower roller. The fourth pressure sleeve includes a third groove, and the fifth pressure sleeve includes a third protrusion.

[0025] To address the aforementioned technical problems, this application also provides a method for roll forming of TMP integrated tiles, employing the following technical solution:

[0026] The forming method is based on the roller forming machine, which uses multiple sets of horizontal rollers arranged sequentially from the feed end to the discharge end to form the material in stages, including the first roller forming process, the second roller forming process, the third roller forming process, and the fourth roller forming process.

[0027] The molding method includes the following steps:

[0028] First rolling process: Pre-roll forming of the inner groove structure;

[0029] The first protrusion of the first upper roller cooperates with the first groove of the first lower roller to roll down the TMP composite profile, and two V-shaped concave structures are pre-formed symmetrically in the middle of the profile. The concave structures are used to form an inner groove structure when the nose structure protrudes.

[0030] The second rolling process: preliminary rolling forming of the nose structure;

[0031] The second groove of the second upper roller cooperates with the second protrusion of the second lower roller to roll the profile part between the two V-shaped concave structures upward, forming an Ω-shaped convex structure as the root of the nose wing. At the same time, the inclined pressing surfaces on both sides of the second lower roller push the outer part of the concave structure upward to initially form the main body of the nose wing, and transform the pre-formed concave structure into the inner groove structure on both sides of the nose wing.

[0032] The third rolling process: the nose wing structure continues to be formed and the raised ribs are rolled;

[0033] By continuously applying upward rolling pressure to the Ω-shaped convex structure through the continuous pressure type second upper roller and the continuous pressure type second lower roller, the height of the nose wing protrusion is raised to the design standard. At the same time, through the cooperation of the upper and lower pressure roller groups on both sides of the continuous pressure type second upper roller and the continuous pressure type second lower roller, the profile is pressed upward to the local positions on both sides away from the nose wing to form the protruding rib.

[0034] The fourth rolling process: shaping and rolling the root of the nose structure;

[0035] The root of the nose structure is finally shaped using a horizontal roller shaping method;

[0036] By engaging the third groove of the third upper roller with the third protrusion of the third lower roller, clamping and cold pressing is applied to the Ω-shaped upper convex structure to shape the root of the nose wing and complete the TMP integrated tile forming.

[0037] In summary, this application has the following beneficial effects:

[0038] 1. This invention provides a roll forming machine for TMP integrated tile composite layers, which can roll form the nose structure of the TMP composite profile to be formed, including the middle part and the two side protruding ribs symmetrically connected to the middle part, and adopts the process of "pressing down first and supporting up later", with all horizontal rollers rolling to form, replacing the traditional vertical roller sliding extrusion, and completely eliminating film surface scratches, bending drift and film-plate delamination defects.

[0039] 2. This invention provides a roll forming method for TMP integrated tile composite layers. Through four segmented progressive roll forming processes, using the process logic of "pre-concave, then top, then continue forming, and finally settling", it avoids the film surface scratches and structural deformation caused by "simultaneous extrusion" in traditional processes, ensuring the forming precision of the nose structure and inner groove. No additional roller device is required, the mold structure is simple, equipment costs are reduced, and structural damage caused by secondary forming of the inner groove is avoided.

[0040] 3. The entire process adopts horizontal roller rolling forming instead of traditional vertical roller sliding extrusion, and each process roller is equipped with a bearing structure to convert sliding friction into rolling friction. At the same time, the "passive rolling" design enables the roller and film surface linear speed to adapt to each other in real time, achieving a "zero traction" state for the soft film and completely avoiding film surface scratches, cracks, heat melting and stretching deformation. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the nose wing molding process of TMP integrated tile composite layer in the prior art;

[0042] Figure 2 This is a schematic diagram of the roll forming structure of the TMP composite profile in this embodiment;

[0043] Figure 3 This is a diagram showing the forming process of the TMP composite profile nose wing structure and raised ribs in this embodiment;

[0044] Figure 4 This is a schematic diagram of the overall structure of the rolling device for the first rolling process in this embodiment;

[0045] Figure 5 This is a cross-sectional view of the overall structure of the rolling device in the first rolling process of this embodiment;

[0046] Figure 6 This is a schematic diagram of the overall structure of the roller pressing device in the second roller pressing process in this embodiment;

[0047] Figure 7 This is a three-dimensional schematic diagram of the roller pressing device structure for the second roller pressing process in this embodiment;

[0048] Figure 8 This is a schematic diagram of the inner edge-receiving pressure roller group of the roller pressing device in this embodiment;

[0049] Figure 9 This is a schematic diagram of the outer edge-receiving pressure roller group of the roller pressing device in this embodiment;

[0050] Figure 10 This is a cross-sectional view of the overall structure of the rolling device in the third rolling process of this embodiment;

[0051] Figure 11 This is a structural diagram of the TMP integrated tile roll forming machine used in this embodiment.

[0052] Explanation of reference numerals in the attached drawings: 1. TMP composite profile; 11. Nose structure; 111. Root; 12. Raised rib; 13. Inner groove structure; 2. Roll forming machine; 21. Frame; 22. Upper shaft; 23. Lower shaft; 3. Roller assembly; 31. Upper roller; 311. First upper roller; 3111. First protrusion; 3112. First bearing structure; 3113. First pressure sleeve; 312. Second upper roller; 3121. Second groove; 3122. Second bearing structure; 313. Third upper roller; 3131. Third groove; 3132. Fourth pressure sleeve; 32. Lower roller; 321. First lower roller 3211, First groove; 322, Second lower roller; 3221, Second protrusion; 3222, Third bearing structure; 3223, Leaving structure; 3224, Inclined pressing surface; 3225, Flat pressing surface; 323, Third lower roller; 3231, Third protrusion; 3232, Fifth pressure sleeve; 33, Upper transport roller; 34, Lower transport roller; 35, First upper pressure roller; 36, First lower pressure roller; 37, Second upper pressure roller; 38, Second lower pressure roller; 39, Step structure; 201, First rolling process; 202, Second rolling process; 203, Third rolling process; 204, Fourth rolling process. Detailed Implementation

[0053] 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. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0054] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0055] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed", "equipped", "sleeved / connected", "connected", etc., should be interpreted broadly. For example, "connection" can be a wall-mounted connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0056] The following is in conjunction with the appendix Figures 2-11 This application will be described in further detail.

[0057] refer to Figure 2 This embodiment aims to form a TMP integrated tile composite layer. The TMP integrated tile composite layer is formed by laminating a 1.0mm substrate with 1.0mm thick polymer rolls on both the top and bottom using a special process. The polymer rolls are made of TPO or PVC. Figure 2 A polymer roll is attached above and below the substrate to form a TMP composite profile 1. The TMP composite profile 1 is to be formed including a nose wing structure 11 in the middle part and two side protrusions 12 that are symmetrically connected to the middle part.

[0058] Because the central nose structure 11 is relatively complex, multiple roll forming processes are required on the profile's center during roll forming. The soft film is subjected to uneven tensile force during this process, which can damage the film surface. Therefore, this embodiment provides a roll forming machine 2 for TMP integrated tiles, such as... Figure 11The roll forming machine 2 is driven by an 11kW closed-loop motor and is a horizontal roll forming machine 2. The roll forming machine 2 includes a frame 21, which is rotatably equipped with multiple upper rotating shafts 22 and lower rotating shafts 23 arranged vertically opposite each other along the feed direction of the profile. Multiple sets of roller groups 3 are arranged sequentially along the feed end to the discharge end of the frame 21. Each set of roller groups 3 is a horizontal roller structure and is divided into upper and lower roller modules. Each set of roller groups 3 includes an upper roller 31 and a lower roller 32 that are sleeved and fixed to the upper rotating shaft 22 and the lower rotating shaft 23, and an upper transport roller 33 and a lower transport roller 34 that are axially matched with the upper roller 31 and the lower roller 32. The axes of the upper roller 31 and the lower roller 32, as well as the upper transport roller 33 and the lower transport roller 34, are parallel and have a gap. This gap allows the TMP composite profile 1 to pass through, and the TMP composite profile 1 is roll-formed within this gap.

[0059] refer to Figure 3 The roll forming machine 2 performs four roll forming processes on the TMP composite profile 1 according to the distribution of multiple sets of rollers 3. Among them, the first roll forming process 201 is used to roll forming the inner groove structure 13 on both sides of the nose structure 11 simultaneously; the second roll forming process 202 is used to lift the formed inner groove structure 13 upward to form the nose structure 11; the third roll forming process 203 adds edge finishing roll forming on the basis of the second roll forming process 202; the third roll forming process 203 is used to roll forming the raised ribs 12 on both sides simultaneously; and the fourth roll forming process 204 is used to shape the root 111 of the nose structure 11.

[0060] This embodiment employs a four-stage horizontal roller pressing and segmented progressive design, using a four-step process of "first pressing down - then lifting up - then edge finishing - final shaping." All processes are formed by horizontal rollers rolling, replacing the traditional vertical roller-assisted sliding extrusion, thus completely eliminating defects such as film surface abrasion, bending drift, and film-sheet delamination. The first roller pressing process 201 uses horizontal rollers to press downwards, first forming the grooved structures on both sides of the nose wing structure 11. Then, the second roller pressing process 202 lifts it upwards to form the nose wing structure 11, solving the problems of surface abrasion caused by "simultaneous pressing" and separation of the film from the sheet due to lateral force pulling.

[0061] Because polymer roll materials are highly elastic and ductile, after roll forming, the edges on both sides cannot be effectively shaped due to elastic recoil, often resulting in excess material overflowing. Since polymer roll materials are not easily cut, the excess material cannot be removed by conventional cutting methods after forming, causing uneven edges and unstable dimensions, affecting subsequent assembly and use. Therefore, in this embodiment, a finishing roll forming process is added in the third roll forming step 203 during the nose structure 11 forming process. This process immediately presses in the excess material generated by elastic recoil to form raised ribs 12, folding the excess material back in, resulting in neat edges after forming and achieving edge finishing without cutting.

[0062] Meanwhile, to avoid the problem of film surface cracking and scratching caused by rigid contact between the soft film and the rollers during the rolling process, and to prevent damage to the film surface during the rolling process, a bearing structure is added to the upper roller 31 and / or lower roller 32 used for rolling the nose structure 11 in each roller group 3. The bearing structure can be set in the middle part of the upper roller 31 and / or lower roller 32, or the bearing structure can be directly used as the upper roller 31 and / or lower roller 32. The bearing structure is used to reduce the friction between the rollers and the film surface. The bearing structure can achieve differential rolling by relying on the friction between the rollers and the soft film, so that the soft film is in a "zero tension" state, avoiding damage to the film surface due to friction during the rolling process, and the soft film is free from scratches and cracks.

[0063] In this embodiment, the bearing structure can be a rolling bearing, a sliding bearing, or other types of bearings. The number and arrangement of these bearings can be adjusted according to actual needs. By increasing the bearing structure, damage to the film surface during the rolling process can be effectively reduced, thereby improving product quality and yield.

[0064] The specific structure of the roll forming process corresponding to the four roll forming steps is as follows:

[0065] refer to Figure 4 The roller group 3 structure in the first rolling process 201 includes two first upper rollers 311 and two first lower rollers 321 spaced apart. The spacing depends on the size of the nose structure 11. The design of separate double upper and double lower rollers allows for flexible adjustment of the distance between the rollers to accommodate the forming requirements of different nose structures. Compared to the method of forming two inner groove structures simultaneously with a single integrated roller, the separate roller design effectively reduces the friction on the film surface when rolling two inner groove structures.

[0066] Specifically, integrated rollers, needing to cover two groove forming areas simultaneously, have a larger contact area with the film surface, easily generating accumulated frictional heat. This can lead to increased film surface temperature, localized tensile deformation, and even scratches. In contrast, split rollers distribute the forming function across independent roller units. Each roller has an independent contact area with the film surface, and this area is significantly reduced, allowing frictional heat to be dispersed and released, preventing concentrated heat accumulation. Furthermore, the split structure allows for independent adjustment of the pressure and speed parameters of each roller based on the groove spacing, resulting in more uniform stress on the film, higher forming accuracy, and more stable surface quality. It also reduces roller wear rate and extends mold life.

[0067] The first upper roller 311 has a roller pressing surface including a first protrusion 3111 that protrudes radially outward. The first lower roller 321 has a first groove 3211 corresponding to the first protrusion 3111. The height of the first protrusion 3111 of the first upper roller 311 in the multi-roller group 3 gradually increases along the feeding direction, and the depth of the first groove 3211 of the corresponding first lower roller 321 gradually increases along the feeding direction. The first protrusion 3111 and the first groove 3211 form a "convex-concave" pressing cavity for gradually forming the inner groove structure 13. The inner groove structure 13 is a V-shaped concave structure when the nose structure 11 is not protruding. The first pass rolls out symmetrical grooves in the inner groove structure 13 in one pass. The grooves can be deepened as needed to provide a precise reference for subsequent bending and solve the dimensional instability caused by "simultaneous pressing".

[0068] refer to Figure 1 In traditional molding processes, the groove structures on both sides of the nose wing structure 11 are formed by oblique pressing using rollers after the nose wing structure 11 has bulged out. This process requires the introduction of rollers, increasing equipment costs. Moreover, oblique pressing for inward concave molding is more difficult and can easily cause secondary deformation damage to the already bulging nose wing structure 11. In this embodiment, the inward groove structure 13 is formed first in the first roller pressing process 201, and then formed by downward pressing with horizontal rollers. The mold structure is simpler and does not require additional roller auxiliary devices. The downward pressing method has a vertical and stable force direction, and it is easier to control the forming depth and contour accuracy compared to the oblique pressing process. Furthermore, the nose wing structure 11 has not yet bulged out when the groove is formed, avoiding secondary interference from subsequent processes on the already formed features, effectively protecting the geometric integrity of the product, and improving the yield rate and process stability.

[0069] refer to Figure 5 Furthermore, the first upper roller 311 includes a first bearing structure 3112, which is fitted into the middle groove of the first upper roller 311 by an interference fit, and its outer ring surface is coaxial with the roller base surface. A first pressure sleeve 3113 is sleeved on the outer ring of the first bearing structure 3112. The first pressure sleeve 3113 is an annular structure, and its outer ring is integrally machined with a radially outward first protrusion 3111.

[0070] A first bearing structure 3112 is set in the middle section of the first upper roller 311. During the roll pressing and transportation of the TMP composite profile 1, the outer ring of the first bearing structure 3112 is passively rotated with the linear velocity of the profile and has pure rolling contact with the film surface. This transforms the sliding friction in traditional roll pressing into rolling friction, significantly reducing the coefficient of friction and preventing the film surface from being scratched, hot-melted, or stretched due to sliding and dragging.

[0071] refer to Figure 6This refers to the roller group 3 structure of the second rolling process 202. Each roller group 3 in the second rolling process 202 includes a second upper roller 312 and a second lower roller 322. Two upper transport rollers 33 are symmetrically arranged on both sides of the second upper roller 312 along the axial direction. The rolling surface of the second upper roller 312 includes a second groove 3121 that is radially concave inward. The second lower roller 322 has a second protrusion 3221 corresponding to the position of the second groove 3121. (See reference...) Figure 8 , Figure 9 The depth of the second groove 3121 of the second upper roller 312 in the multi-roller group 3 gradually increases along the feeding direction, and the height of the second protrusion 3221 of the corresponding second lower roller 322 gradually increases along the feeding direction. The second groove 3121 and the first groove 3211 form a "concave-convex" pressing cavity, which is used to lift the middle connection position of the two inner groove structures 13 upward, gradually forming the root 111 of the nose structure 11. The root 111 is an Ω-shaped upward convex structure.

[0072] refer to Figure 7 Furthermore, the second upper roller 312 includes a second bearing structure 3122, and the second lower roller 322 includes a third bearing structure 3222. In this embodiment, the second upper roller 312 as a whole is the second bearing structure 3122. The third bearing structure 3222 is embedded in the middle groove of the second lower roller 322 by interference fit. The diameter of the third bearing structure 3222 is larger than the maximum diameter of the second lower roller 322. The third bearing structure 3222 protrudes outward from the second lower roller 322 to form a second protrusion 3221.

[0073] A second pressure sleeve is fitted on the outer ring of the second bearing structure 3122. A radially inward second groove 3121 is integrally machined on the outer circumference of the second pressure sleeve. A third pressure sleeve is fitted on the outer ring of the third bearing structure 3222. A radial second protrusion 3221 is provided on the outer circumference of the third pressure sleeve corresponding to the second groove 3121.

[0074] Furthermore, the second lower roller 322 is symmetrically provided with relief structures 3223 on both sides of the second protrusion 3221. The relief structures 3223 are concave inward along the radial direction. The second lower roller 322 is provided with upwardly protruding inclined pressure surfaces 3224 on both sides of the second protrusion 3221. The highest edge of the inclined pressure surface 3224 is close to the third bearing structure 3222 and connected to the relief structures 3223. Flat pressure surfaces 3225 are provided at both ends of the second lower roller 322 connected to the inclined pressure surfaces 3224. The position of the flat pressure surface 3225 corresponds to the position of the upper conveying roller 33. The two cooperate to form a roll pressing and conveying of the TMP composite profile 1. The inclination angle of the inclined pressure surface 3224 of the second lower roller 322 in the multi-roller group 3 gradually increases along the feeding direction.

[0075] When the TMP composite profile 1 is rolled through, the middle connection position of the two inner groove structures 13 is lifted upward by the cooperation of the second groove 3121 and the second protrusion 3221. The two sides of the two inner groove structures 13 are rolled upward by the inclined pressing surface 3224. Under the rolling of the second groove 3121, the second protrusion 3221 and the inclined pressing surface 3224, the inner groove structure 13 is gradually squeezed inward into the relief structure 3223, and finally forms the three-dimensional protrusion of the nose structure 11.

[0076] Through the "double passive rolling" setting of the second bearing structure 3122 and the third bearing structure 3222, the second roller pressing device always changes the relative motion between the film surface and the roller body from sliding to rolling throughout the entire process of forming the nose structure 11: the outer ring of the second bearing structure 3122 rotates synchronously with the TMP composite profile 1, and the outer ring of the third bearing structure 3222 also passively follows the rotation when the second protrusion 3221 lifts the profile. The linear speed of the two is adaptive in real time, completely eliminating sliding shear; at the same time, the "progressive material collection space" formed by the inclined pressing surface 3224 and the relief structure 3223 allows the inner groove structure 13 to be squeezed into the relief structure 3223 while bending upward, realizing tension-free and tear-free three-dimensional forming, thereby ensuring that the radius, height and surface quality of the root 111 of the nose structure 11 meet the finished product requirements in one go.

[0077] It should be noted that as the rolling process progresses, the tilt angle of the inclined surface 3224, the clearance space of the clearance structure 3223, and the protrusion height of the second protrusion 3221 gradually increase, such as... Figure 9 Alternatively, the second lower roller 322 can be used as the third bearing structure 3222 as a whole, and two lower transport rollers 34 can be symmetrically arranged on both sides of the second lower roller 322 along the axial direction. The gap between the lower transport rollers 34 and the third bearing structure 3222 forms a clearance structure 3223. The inclined pressure surface 3224 and the flat pressure surface 3225 are both arranged on the lower transport rollers 34.

[0078] In the second rolling process 202, the protrusion forming of the nose structure 11 and the rolling forming of its root 111 are carried out using separate rolling. The rolling forming of the root 111 is carried out by the cooperation of upper and lower rollers, while the protrusion forming of the nose structure 11 is carried out only by the inclined pressing surface 3224 of the second lower roller 322. This separate rolling design decouples the two forming actions of the root 111 compaction and the main protrusion of the nose structure 11, so that the forming parameters of each part can be independently adjusted according to the film material thickness and structural strength. The root 111 is fully compacted by the pressure of the upper and lower rollers to ensure the bonding strength with the substrate; the nose structure 11 achieves progressive plastic deformation by single-roller inclined pressing, avoiding the constraint of the upper and lower rollers on both sides that would cause film accumulation or tearing. At the same time, omitting the upper roller directly participating in the protrusion forming reduces the frictional restraint on the upper part of the film surface, making the soft film material flow more smoothly and naturally, and reducing the local film surface stretching deformation caused by excessive stretching.

[0079] refer to Figure 8 , Figure 9 This refers to the roller group 3 structure of the third rolling process 203. Due to the high elasticity and strong ductility of the polymer roll material, the edge finishing process is divided into a first forming stage and a second forming stage. The first forming stage is the rolling on the right side of the raised rib 12, that is, the rolling on the side closer to the nose structure 11 (e.g., Figure 8 The second forming stage is the rolling process on the left side of the raised rib 12, that is, the rolling process on the side away from the nose structure 11 (e.g. Figure 9 ).

[0080] Each roller group 3 in the first forming stage includes two first upper pressure rollers 35 and two first lower pressure rollers 36. The first upper pressure rollers 35 and the two first lower pressure rollers 36 are symmetrically arranged on both sides of the second upper roller 312 and the second lower roller 322, respectively. The outer periphery of the first upper pressure rollers 35 and the first lower pressure rollers 36 are both set as stepped structures 39, and the height difference between the upper and lower stepped surfaces of the stepped structure 39 gradually increases along the feeding direction. Through the mutual cooperation of the two stepped surfaces of the first upper pressure rollers 35 and the first lower pressure rollers 36, the two sides of the TMP composite profile 1 connecting the nose structure 11 are simultaneously bent to form a "Z" shaped bending structure (e.g., Figure 3 ).

[0081] Each roller group 3 in the second forming stage includes two first upper pressure rollers 35 and two first lower pressure rollers 36, as well as two second upper pressure rollers 37 and two second lower pressure rollers 38 spaced apart from the two first upper pressure rollers 35 and the two first lower pressure rollers 36. The second upper pressure rollers 37 and the second lower pressure rollers 38 are located on the side away from the second upper rollers 312 and the second lower rollers 322. The outer periphery of the second upper pressure rollers 37 and the second lower pressure rollers 38 is set as a stepped structure 39, and the height difference between the upper and lower stepped surfaces of the stepped structure 39 gradually increases along the feeding direction. Through the mutual cooperation of the two stepped structures 39 of the second upper pressure rollers 37 and the second lower pressure rollers 38, the two sides of the "Z"-shaped bending structure connecting the TMP composite profile 1 to the first forming stage are simultaneously bent to form a "Z"-shaped bending structure (e.g., Figure 3 ), ultimately forming raised rib 12.

[0082] Similarly, the third rolling process 203 is also used to further shape the nose structure. In the roller group 3 of the third rolling process 203, based on the second upper roller 312 and the second lower roller 322 of the second rolling process 202, a subsequent second upper roller 312 and a subsequent second lower roller 322 with matching structure are added. The dimensions of the second groove 3121 of the subsequent second upper roller 312, the height of the second protrusion 3221 of the subsequent second lower roller 322, and the inclination angle of the inclined pressing surface 3224 are all adapted to the rollers of the second rolling process 202 and slightly adjusted to ensure that they fit the initially formed nose structure 11. Subsequently, the second upper roller 312 and the second lower roller 322 cooperate to apply continuous upward roller pressure to the initially formed nose structure 11, so that the protrusion height of the nose structure 11 is gradually increased to the design standard, while further compacting the root 111 and the inner groove structure 13 of the nose structure 11 to ensure clear structural outline and accurate dimensions.

[0083] Referring to 10, the roller group 3 structure of the fourth rolling process 204 is shown. Each roller group 3 in the fourth rolling process 204 includes a third upper roller 313 and a third lower roller 323. Two upper transport rollers 33 are symmetrically arranged on both sides of the third upper roller 313 along the axial direction, and two lower transport rollers 34 are symmetrically arranged on both sides of the third lower roller 323 along the axial direction. The rolling surface of the third upper roller 313 includes a third groove 3131 that is radially concave inward. The third lower roller 323 has a third protrusion 3231 corresponding to the position of the third groove 3131. The third groove 3131 is configured as a polygonal groove structure. The opening of the third groove 3131 in the multiple roller groups 3 gradually narrows inward along the feeding direction, used to finally shape the root 111 of the nose structure 11 (e.g., ...). Figure 3 ).

[0084] Furthermore, both the third upper roller 313 and the third lower roller 323 are bearing structures. A fourth pressure sleeve 3132 is fitted on the outer ring of the third upper roller 313, and a fifth pressure sleeve 3232 is fitted on the outer ring of the third lower roller 323. A radially concave third groove 3131 is integrally machined on the outer circumference of the fourth pressure sleeve 3132. The shape of the third groove 3131 is set to correspond to the shape of the root 111 of the nose structure 11. The fifth pressure sleeve 3232 has a third protrusion 3231 at the position corresponding to the third groove 3131, forming a "concave-convex" closed cold pressing cavity, which is used to finally press the shape of the root 111 of the nose structure 11 so that it will not spring back after discharge.

[0085] Based on the TMP integrated tile roll forming machine 2 provided above, this embodiment provides a TMP integrated tile roll forming method. The roll forming machine 2 uses multiple sets of horizontal rollers 3 arranged sequentially from the feed end to the discharge end to progressively form the tile in stages: a first roll forming process 201, a second roll forming process 202, a third roll forming process 203, and a fourth roll forming process 204. The TMP integrated tile roll forming method includes the following steps:

[0086] 1. First rolling process 201: Pre-roll forming of inner groove structure 13

[0087] This process uses a horizontal roller to press the roller downwards to pre-form the inner groove structures 13 on both sides of the nose structure 11 of the TMP composite profile 1, providing a precise reference for the subsequent protrusion of the nose structure 11.

[0088] In the first rolling process 201 of the roll forming machine 2, the first upper roller 311 and the first lower roller 321 are arranged opposite each other in the roller group 3. The first protrusion 3111 and the first groove 3211 cooperate to form a pressing cavity that adapts to the V-shaped concave structure. After the TMP composite profile 1 enters the pressing cavity along the feeding direction, under the downward pressure of the first upper roller 311 and the supporting action of the first lower roller 321, the corresponding position of the profile is gradually pressed into two symmetrical and spaced V-shaped concave structures. This concave structure is not the inner groove of the final product, but serves as a pre-formed structure when the nose structure 11 protrudes. Its symmetrical arrangement ensures that the force is uniform during the subsequent protrusion of the nose structure 11, avoids lateral displacement, and solves the problem of dimensional instability caused by the "simultaneous pressing" of the traditional process.

[0089] 2. Second rolling process 202: Preliminary rolling forming of nose structure 11

[0090] This process uses a horizontal roller pressing roller method to complete the initial forming of the nose wing structure 11 based on the pre-formed concave structure in the first process, and at the same time transforms the pre-formed concave structure into the inner grooves on both sides of the nose wing structure 11.

[0091] After the first process, the TMP composite profile 1 enters the roller group 3 of the second rolling process 202. This roller group includes a second upper roller 312 and a second lower roller 322. During the rolling process, the second groove 3121 of the second upper roller 312 cooperates with the second protrusion 3221 of the second lower roller 322 to roll the profile part between the two concave structures upward, gradually forming an Ω-shaped upward convex structure. This upward convex structure is the root 111 of the nose structure 11. Its Ω-shaped design can enhance the structural strength and stability of the nose structure 11. At the same time, the inclined pressing surfaces 3224 on both sides of the second lower roller 322 apply upward rolling pressure to the profile part on the outside of the concave structure, pushing the part upward to convex, initially forming the main body of the nose structure 11. Under the combined action of the thrust of the inclined pressing surface 3224 and the upward pushing force of the second groove 3121 and the second protrusion 3221, the V-shaped profile formed in the first process is rolled upward. The concave structure is squeezed into the clearance structure 3223 of the second lower roller 322, ultimately forming the inner groove structure 13 on both sides of the nose structure 11, achieving the coordinated forming of "pre-concave-top-side push".

[0092] 3. Third rolling process 203: Continue forming of nose wing structure 11 and roll forming of raised rib 12.

[0093] This process uses a horizontal roller to press the raised part of the nose structure 11. On the one hand, it completes the further forming of the nose structure 11, so that the raised height of the nose structure 11 reaches the design requirements. On the other hand, it simultaneously completes the forming of the raised ribs 12 on both sides, so as to eliminate the need for cutting the excess material edges.

[0094] The TMP composite profile 1, initially formed after the second process, enters the roller group 3 of the third rolling process 203. This roller group, based on the second upper roller 312 and second lower roller 322 of the second process, adds a structurally adapted subsequent second upper roller 312 and subsequent second lower roller 322. The dimensions of the second groove 3121 of the subsequent second upper roller 312, the height of the second protrusion 3221 of the subsequent second lower roller 322, and the inclination angle of the inclined pressing surface 3224 are all adapted to and slightly adjusted from the rollers of the second process to ensure a close fit with the initially formed nose structure 11. The subsequent second upper roller 312 and subsequent second lower roller 322 work together to apply continuous upward rolling pressure to the initially formed nose structure 11, gradually increasing the protrusion height of the nose structure 11 to the design standard, while further compacting the root 111 and inner groove of the nose structure 11, ensuring a clear structural outline and precise dimensions.

[0095] Meanwhile, in the third process, roller group 3 also has upper and lower pressure roller groups symmetrically arranged on both sides of the subsequent second upper roller 312 and subsequent second lower roller 322. The rolling surface contours of the upper and lower pressure roller groups are adapted to the shape of the raised rib 12. During the rolling process, the upper and lower pressure roller groups cooperate to apply upward rolling pressure to the local positions on both sides of the TMP composite profile 1 away from the middle nose structure 11, forming the raised rib 12 in this area. Since the polymer roll material has the characteristics of high elasticity and strong extensibility, it is easy to generate excess material edges due to elastic shrinkage during the forming process. This process, by simultaneously forming the raised rib 12, directly folds the excess material edges into the raised rib 12 structure, achieving edge trimming without cutting. This solves the problem of uneven edges and unstable dimensions caused by the inability to cut polymer roll materials in a conventional way, and improves the edge quality and assembly adaptability of the product.

[0096] 4. Fourth rolling process 204: Nose wing structure 11 root 111 shaping and rolling.

[0097] This process uses a horizontal roller shaping method to finally shape the root 111 of the nose structure 11, ensuring that the formed structure does not spring back and guaranteeing the dimensional stability of the product.

[0098] After the third process, the TMP composite profile 1 enters the roller group 3 of the fourth rolling process 204. This roller group includes a third upper roller 313 and a third lower roller 323. The rolling surface of the third upper roller 313 is provided with a third groove 3131 that is radially recessed inward, and the third lower roller 323 is provided with a third protrusion 3231 that is radially protruding outward at the corresponding position. The third groove 3131 and the third protrusion 3231 cooperate to form a closed pressing cavity that is completely adapted to the Ω-shaped upward convex structure (nose root 111). During the rolling process, the third upper roller 313 and the third lower roller 323 apply stable clamping pressure to the Ω-shaped upward convex structure. The elastic shrinkage stress of the polymer roll material is eliminated by cold pressing and shaping, so that the shape of the root 111 of the nose structure 11 is fixed, ensuring that no springback deformation occurs after the material is discharged, and finally completing the overall molding of the TMP integrated tile.

[0099] The above description is merely a preferred embodiment of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantial modifications made to the present invention by those skilled in the art within the scope of the technology disclosed in the present invention using this concept shall be deemed as an infringement of the protection scope of the present invention.

Claims

1. A roll forming machine for TMP integrated tiles, characterized in that: The machine includes a frame and multiple sets of rollers arranged sequentially along the direction from the feed end to the discharge end. The frame has multiple upper and lower rotating shafts arranged vertically opposite each other along the feed direction. Each set of rollers is a horizontal roller structure, and each set of rollers includes an upper roller and a lower roller fixed to the upper and lower rotating shafts, as well as an upper transport roller and a lower transport roller that are matched with the upper and lower rollers along the axial direction. According to the distribution of the multiple sets of rollers, the roll forming of TMP composite profiles is divided into a first roll forming process, a second roll forming process, a third roll forming process, and a fourth roll forming process. Each set of rollers in the first rolling process includes a first upper roller and a first lower roller. The rolling surface of the first upper roller includes a first protrusion that protrudes radially outward, and the first lower roller is provided with a first groove corresponding to the position of the first protrusion. The first protrusion and the first groove form a pressing cavity for rolling the TMP composite profile downward, which is used to gradually form a V-shaped concave structure on the TMP composite profile. Each set of rollers in the first rolling process is used to symmetrically form two recessed structures on the TMP composite profile, with the two recessed structures spaced apart. Each set of rollers in the second rolling process includes a second upper roller and a second lower roller. The rolling surface of the second upper roller includes a second groove that is concave in the radial direction. The second lower roller has a second protrusion at the position corresponding to the second groove. The second lower roller has relief structures symmetrically arranged on both sides of the second protrusion. The relief structures are concave in the radial direction. The second lower roller has upwardly protruding inclined pressing surfaces on both sides of the second protrusion. The highest edge of the inclined pressing surface is connected to the relief structure. The second groove and the second protrusion form a pressing cavity for rolling the TMP composite profile upward, which is used to gradually form an Ω-shaped upper convex structure on the TMP composite profile, the upper convex structure being located between the intervals of the two lower concave structures; The inclined pressing surface is used to roll and press the TMP composite profile upwards. The protrusion is located on the outside of the concave structure. Under the combined rolling and pressing of the inclined pressing surface, the second groove and the second protrusion, the concave structure is squeezed into the relief structure. Each roller group in the third rolling process includes a second upper roller and a second lower roller adapted to the roller structure of the second rolling process, as well as an upper roller group and a lower roller group symmetrically arranged on both sides of the second upper roller and the second lower roller, respectively; the upper roller group and the lower roller group cooperate to roll the TMP composite profile upward to form raised ribs; The continuous pressing type second upper roller and the continuous pressing type second lower roller are the continuous pressing roller structures for the second rolling process; Each set of rollers in the fourth rolling process includes a third upper roller and a third lower roller. The rolling surface of the third upper roller includes a third groove that is concave in the radial direction. The third lower roller has a third protrusion at the position corresponding to the third groove. The third groove and the third protrusion are used to shape and roll the upper convex structure.

2. The roll forming machine for TMP integrated tiles according to claim 1, characterized in that: In each group of rollers in the first rolling process, there are two first upper rollers and two first lower rollers spaced apart along the axial direction. One first upper roller and one first lower roller cooperate to form a concave structure. In the first rolling process, the height of the first protrusion of the first upper roller of the first set of rollers gradually increases along the feeding direction, and the depth of the first groove of the first lower roller gradually increases along the feeding direction.

3. The roll forming machine for TMP integrated tiles according to claim 2, characterized in that: The first upper roller includes a first bearing structure, and a first pressure sleeve is fitted on the outer ring of the first bearing structure. The first pressure sleeve includes the first protrusion.

4. The roll forming machine for TMP integrated tiles according to claim 1, characterized in that: In the second rolling process, the depth of the second groove of the second upper roller of the multi-roller group gradually increases along the feeding direction, and the height of the second protrusion of the corresponding second lower roller gradually increases along the feeding direction. The inclination of the inclined pressing surface of the second lower roller of the multiple roller groups in the second rolling process gradually increases along the feeding direction; the clearance space of the clearance structure gradually increases along the feeding direction.

5. A roll forming machine for TMP integrated tiles according to claim 4, characterized in that: The second upper roller includes a second bearing structure, and a second pressure sleeve is fitted on the outer ring of the second bearing structure. The second pressure sleeve includes the second groove. The second lower roller includes a third bearing structure. A third pressure sleeve is fitted on the outer ring of the third bearing structure. The third pressure sleeve includes the second protrusion.

6. A roll forming machine for TMP integrated tiles according to claim 5, characterized in that: Two upper conveying rollers are symmetrically arranged on both sides of the second upper roller along the axial direction. The two ends of the second lower roller are connected to the inclined pressure surface and are provided with flat pressure surfaces. The position of the flat pressure surfaces corresponds to the position of the upper conveying rollers. No matching pressure roller structure is provided above the inclined pressure surface of the second lower roller.

7. A roll forming machine for TMP integrated tiles according to claim 1, characterized in that: The upper pressure roller group and the lower pressure roller group include two first upper pressure rollers and two first lower pressure rollers arranged close to the second upper roller and the second lower roller, and / or two second upper pressure rollers and two second lower pressure rollers arranged away from the second upper roller and the second lower roller; The outer periphery contours of the first upper pressure roller, the first lower pressure roller, the second upper pressure roller, and the second lower pressure roller are all designed as stepped structures, and the height difference between the upper and lower step surfaces of the stepped structure gradually increases along the feeding direction.

8. A roll forming machine for TMP integrated tiles according to claim 1, characterized in that: The third groove is configured as a polygonal groove structure, and the opening of the third groove in the multiple sets of rollers gradually narrows inward along the feeding direction.

9. A roll forming machine for TMP integrated tiles according to claim 8, characterized in that: Both the third upper roller and the third lower roller are bearing structures. A fourth pressure sleeve is fitted on the outer ring of the third upper roller, and a fifth pressure sleeve is fitted on the outer ring of the third lower roller. The fourth pressure sleeve includes a third groove, and the fifth pressure sleeve includes a third protrusion.

10. A method for roll forming of TMP integrated tiles, characterized in that: The forming method is based on the roll forming machine according to any one of claims 1-9. The roll forming machine uses multiple sets of horizontal roll structures arranged sequentially from the feed end to the discharge end to form the roll in stages, including the first roll forming process, the second roll forming process, the third roll forming process and the fourth roll forming process. The molding method includes the following steps: First rolling process: Pre-roll forming of the inner groove structure; The first protrusion of the first upper roller cooperates with the first groove of the first lower roller to roll down the TMP composite profile, and two V-shaped concave structures are pre-formed symmetrically in the middle of the profile. The concave structures are used to form an inner groove structure when the nose structure protrudes. The second rolling process: preliminary rolling forming of the nose structure; The second groove of the second upper roller cooperates with the second protrusion of the second lower roller to roll the profile part between the two V-shaped concave structures upward, forming an Ω-shaped convex structure as the root of the nose wing. At the same time, the inclined pressing surfaces on both sides of the second lower roller push the outer part of the concave structure upward to initially form the main body of the nose wing, and transform the pre-formed concave structure into the inner groove structure on both sides of the nose wing. The third rolling process: the nose wing structure continues to be formed and the raised ribs are rolled; By continuously applying upward rolling pressure to the Ω-shaped convex structure through the continuous pressure type second upper roller and the continuous pressure type second lower roller, the height of the nose wing protrusion is raised to the design standard. At the same time, through the cooperation of the upper and lower pressure roller groups on both sides of the continuous pressure type second upper roller and the continuous pressure type second lower roller, the profile is pressed upward to the local positions on both sides away from the nose wing to form the protruding rib. The fourth rolling process: shaping and rolling the root of the nose structure; The root of the nose structure is finally shaped using a horizontal roller shaping method; By engaging the third groove of the third upper roller with the third protrusion of the third lower roller, clamping and cold pressing is applied to the Ω-shaped upper convex structure to shape the root of the nose wing and complete the TMP integrated tile forming.

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