Forming apparatus for three-dimensional honeycomb woven fabric core

Abstract

The application discloses a forming device for a three-dimensional honeycomb woven fabric core layer, comprising a conveying belt, a forming box, a heating assembly and a circulating fan module, wherein the circulating fan module is installed in the forming box; the forming box is provided with a first drying cavity and a second drying cavity arranged in sequence along the conveying direction of the conveying belt; the circulating fan module comprises a first circulating fan group and a second circulating fan group; the first drying cavity is provided with air inlet at the bottom and air outlet at the top through the first circulating fan group; and the second drying cavity is provided with air inlet at the top and air outlet at the bottom through the second circulating fan group. The core layer is conveyed by the conveying belt and sequentially passes through the first drying cavity and the second drying cavity; the first circulating fan group and the second circulating fan group are used to realize the action of first downward blowing and then upward blowing in the drying cavities, so that the middle shrinkage silk of the core layer can be freely shrunk as much as possible to achieve the purpose of uniform arching, the core layer movement after forming is reduced to achieve the purpose of improving the surface flatness, and the quality of the core layer after forming is improved as a whole.

Description

Technical Field

[0001] This application relates to the technical field of textile production and manufacturing equipment, and in particular to a forming device for a three-dimensional honeycomb woven fabric core layer. Background Technology

[0002] Three-dimensional spacer fabric, also known as 3D mesh or honeycomb fabric, consists of two layers of fabric and a connecting monofilament in the middle, forming a hollow three-dimensional structure. After being set at high temperature, the monofilament in the middle forms a stable arch or honeycomb support, giving the material high elasticity and support.

[0003] The invention patent with publication number CN115584582A discloses "a method for producing an elastic space woven mat", which includes warping, heddle threading, weft selection, weaving, heating and finishing steps. The heating process involves heating the fabric in an oven, causing the warp threads to deform and shrink, the weft threads to melt and the warp threads to bond together. After the heat treatment, the A-axis warp threads and the B-axis warp threads form a wave structure, resulting in an elastic space fabric.

[0004] In actual manufacturing processes, the fabric may experience uneven shrinkage after passing through the drying oven, leading to issues such as arching, skewing, or localized wrinkles, which affect the forming quality of the core layer. Summary of the Invention

[0005] To improve the molding quality of the core layer, this application provides a molding apparatus for a three-dimensional honeycomb woven fabric core layer.

[0006] The molding apparatus for a three-dimensional honeycomb woven fabric core layer provided in this application adopts the following technical solution: A forming apparatus for a three-dimensional honeycomb woven fabric core layer includes: Conveyor belt, the surface of which has a mesh structure; A molding box, wherein the conveyor belt portion is housed within the molding box; Heating components are located inside the molding chamber; and A circulating fan module, wherein the circulating fan module is installed in the molded housing; The molding box has a first drying chamber and a second drying chamber arranged sequentially along the conveying direction of the conveyor belt; the circulating fan module includes a first circulating fan unit and a second circulating fan unit, the first drying chamber is supplied with air from the bottom and the top through the first circulating fan unit, and the second drying chamber is supplied with air from the top and the bottom through the second circulating fan unit.

[0007] Preferably, the heating assembly includes a first heating tube group and a second heating tube group arranged on the upper and lower sides of the conveyor belt, and each of the first heating tube group and the second heating tube group includes a plurality of heating tubes arranged at intervals along the conveying direction of the conveyor belt.

[0008] Preferably, the first circulating fan unit includes a plurality of first circulating fans arranged at intervals perpendicular to the conveying direction of the conveyor belt; the second circulating fan unit includes a plurality of second circulating fans arranged at intervals perpendicular to the conveying direction of the conveyor belt.

[0009] Preferably, it further includes a suspension assembly disposed within the first drying cavity, the suspension assembly comprising: Two spaced-apart guide rollers, which abut against the inner surface of the conveyor belt; A tension roller, positioned between two guide rollers, abuts against the outer surface of the conveyor belt; and At least one support roller is placed between the two guide rollers; The conveyor belt forms an overhead suspended area between the two guide rollers. The support roller is housed in the suspended area and is tangent to the conveying direction of the conveyor belt. The support roller can undergo horizontal displacement within the suspended area parallel to the conveying direction.

[0010] Preferably, the air inlet of the first drying cavity is located below the suspended area.

[0011] Preferably, the suspension assembly further includes: Synchronizer, connecting two guide rollers, is used to drive the two guide rollers to move towards or away from each other; The first driving component, connected to the tension roller, is used to drive the tension roller to move perpendicular to the conveying direction; and The second driving component is connected to the support roller and is used to drive the support roller to move horizontally.

[0012] Preferably, the conveyor belt includes an input section and an output section placed on both sides of the forming box, and a correction mechanism is provided at the input section.

[0013] Preferably, the correction mechanism includes: The first straightening roller abuts against one side of the outer surface of the conveyor belt, and one end of the first straightening roller is hinged to the frame; The second correction roller abuts against the inner surface of one side of the conveyor belt, and one end of the second correction roller is hinged to the frame; Sensors are installed on both sides of the conveyor belt; and The third driving component connects the other end of the first and second correction rollers, and the third driving component is electrically connected to the sensor. When the outer edge of either side of the conveyor belt is offset above the sensor, the third driving member drives the first and second correction rollers to rotate around the hinge point to squeeze the conveyor belt.

[0014] Preferably, the output section is provided with several air coolers at intervals along the conveying direction.

[0015] Preferably, the surface of the conveyor belt is coated with a hydrophobic film.

[0016] In summary, this application includes at least one of the following beneficial technical effects: 1. The core layer is conveyed into the forming chamber by a conveyor belt and passes through the first and second drying chambers. The first and second drying chambers are respectively equipped with a first circulating fan unit and a second circulating fan unit to achieve a downward and then upward blowing action. When the core layer passes through the first drying chamber, the downward blowing reduces the friction between the core layer and the conveyor belt, achieving a lifting action for the core layer, allowing the middle shrinkage filaments of the core layer to shrink as freely as possible to achieve the purpose of uniform arching. When the core layer enters the second drying chamber, the middle shrinkage filaments have basically completed their shrinkage deformation. The downward blowing increases the friction between the core layer and the conveyor belt, reduces the core layer's movement, and improves the surface flatness, thus improving the overall quality of the core layer after forming. 2. During the shrinkage and arching process of the core layer in the first drying chamber, the front fabric and the conveyor belt achieve zero contact and near-zero friction when passing through the suspended area. The front of the core layer is supported by the support rollers and crosses the suspended area, so that the core layer reaches the optimal automatic shrinkage state, further improving the uniformity of shrinkage and thus improving the molding quality. 3. The horizontal opposing and separating movements of the two guide rollers are combined with the tension roller to adjust the size of the suspended area. The size of the suspended area can be selected according to the core layer of different thicknesses. The movable support roller supports the front core layer when the core layer crosses the suspended area to prevent the core layer from falling into the suspended area and achieve stable conveying. 4. Try adjusting the direction of the conveyor belt to the core layer through the correction mechanism to reduce the force on the core layer caused by the conveyor belt running off-center, which would affect the uniformity of shrinkage. At the same time, the surface of the conveyor belt is coated with a hydrophobic film to reduce the friction between the core layer and the conveyor belt. Of course, this is on the premise that there is enough static friction between the conveyor belt and the core layer to drive the core layer forward. Reducing friction allows the core layer to achieve a better free shrinkage state and improves the molding effect. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the forming device for the three-dimensional honeycomb woven fabric core layer in Example 1; Figure 2 This is a cross-sectional view of the forming device for the three-dimensional honeycomb woven fabric core layer in Example 1; Figure 3 The first embodiment mainly shows the structural diagrams of the input and output segments; Figure 4 The schematic diagram shown in Embodiment 1 mainly illustrates the structure of the correction mechanism in the input segment; Figure 5 This is a schematic diagram of the swinging of the two straightening rollers when the conveyor belt is biased to one side in Example 1; Figure 6This is a schematic diagram of the swinging of the two straightening rollers when the conveyor belt is biased to the other side in Example 1; Figure 7 This is a schematic diagram of the structure of the forming device for the three-dimensional honeycomb woven fabric core layer in Example 2; Figure 8 This is a dynamic process diagram of the core layer passing through the suspension assembly in Example 2; Figure 9 This is a physical image of the 3D honeycomb fabric core layer after molding.

[0018] Explanation of reference numerals in the attached drawings: 1. Frame; 11. Pressure roller; 12. Drive roller; 2. Conveyor belt; 21. Input section; 22. Output section; 23. Suspension assembly; 231. Guide roller; 232. Tensioning roller; 233. Support roller; 234. Suspension area; 235. Synchronizing component; 3. Forming box; 31. First drying chamber; 32. Second drying chamber; 4. First circulating fan unit; 41. First circulating fan; 411. First air inlet. ; 412, First air outlet; 5, Second circulating fan unit; 511, Second air inlet; 512, Second air outlet; 51, Second circulating fan; 6, First heating tube group; 7, Second heating tube group; 8, Correction mechanism; 81, First correction roller; 82, Second correction roller; 83, First bearing seat; 84, Second bearing seat; 85, Mounting plate; 86, Third drive component; 87, Sensor; 9, Air cooler; 10, Core layer. Detailed Implementation

[0019] The present application will be further described in detail below with reference to the accompanying drawings.

[0020] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly attached to the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items. Example 1

[0022] Figure 1 and Figure 2A forming device for the core layer of a three-dimensional honeycomb woven fabric is shown. After warping, heddle threading, weft selection, and weaving, the fabric forms a core layer 10. After passing through this forming device, the core layer 10 forms an arched 3D honeycomb structure. The forming device includes a frame 1, a conveyor belt 2 mounted on the frame 1, and a forming box 3. The forming box 3 is located in the middle region of the frame 1. The two sides of the forming box 3 form an input section 21 and an output section 22 of the conveyor belt 2, respectively. The core layer 10 is introduced from the input section 21, passes through the forming box 3, and is output from the output section 22.

[0023] The molding box 3 has an inlet and an outlet on both sides for the conveyor belt 2 to pass through. The molding box 3 has a first drying chamber 31 and a second drying chamber 32 arranged along the conveying direction of the conveyor belt 2. The first drying chamber 31 and the second drying chamber 32 are connected to each other, and a partition can be set in the middle or the connection can be completely made.

[0024] The molding device also includes a circulating fan module installed on the top of the molding box 3. The circulating fan module includes a first circulating fan group 4 and a second circulating fan group 5. The first circulating fan group 4 is arranged at the first drying chamber 31, and the second circulating fan group 5 is arranged at the second drying chamber 32. The first circulating fan group 4 includes a plurality of first circulating fans 41 arranged at intervals perpendicular to the conveying direction of the conveyor belt 2; the second circulating fan group 5 includes a plurality of second circulating fans 51 arranged at intervals perpendicular to the conveying direction of the conveyor belt 2.

[0025] The molding box 3 is also equipped with a heating component, which includes a first heating tube group 6 and a second heating tube group 7 arranged on the upper and lower sides of the conveyor belt 2. Both the first heating tube group 6 and the second heating tube group 7 include several heating tubes arranged at intervals along the conveying direction of the conveyor belt 2, and the direction of each heating tube is perpendicular to the conveying direction of the conveyor belt 2.

[0026] The first outlet 412 of the first circulating fan 41 is located below the first drying chamber 31, and the first inlet 411 of the first circulating fan 41 is located above the first drying chamber 31. Under the action of the first circulating fan 41, the heat in the first drying chamber 31 flows upward from the bottom of the conveyor belt 2 and is carried in by the first inlet 411 to form circulating air. The second outlet 512 of the second circulating fan 51 is located above the second drying chamber 32, and the second inlet 511 of the second circulating fan 51 is located below the second drying chamber 32. Under the action of the second circulating fan 51, the heat in the second drying chamber 32 flows downward from the top of the conveyor belt 2 and is carried in by the second inlet 511 to form circulating air.

[0027] In particular, the first air outlet 412 and the second air outlet 512 can be configured as flared or equipped with a deflector to increase the air intake range.

[0028] See also Figure 3 and Figure 4 The forming device also includes a correction mechanism 8 located at the input section 21 and several cooling fans 9 located at the output section 22. The correction mechanism 8 includes a first correction roller 81 and a second correction roller 82 arranged at intervals. One end of the first correction roller 81 and the second correction roller 82 are ball-jointed with a first bearing seat 83, and the other end of the first correction roller 81 and the second correction roller 82 are guided and slidable on a second bearing seat 84. The second bearing seat 84 is located on a mounting plate 85. A third driving member 86 is connected to one side of the mounting plate 85. The third driving member 86 is a cylinder that can drive the mounting plate 85 to slide along a guide rail provided at the bottom, thereby causing the first correction roller 81 and the second correction roller 82 to swing around the first bearing seat 83. Specifically, the first correction roller 81 abuts against one outer surface of the conveyor belt 2, and the second correction roller 82 abuts against one inner surface of the conveyor belt 2, with the two clamping the conveyor belt 2. The correction mechanism 8 also includes two sensors 87 disposed on the frame 1. The probes of the sensors 87 are placed below the conveyor belt 2 and on both sides of the conveyor belt 2. The sensors 87 are electrically connected to the third drive unit 86. In this embodiment, the sensors 87 are photoelectric sensors 87.

[0029] Combination Figure 5 and Figure 6 When the conveyor belt 2 deviates during operation, one of the sensors 87 detects the outer edge of the conveyor belt 2, sends a signal to the third drive unit 86, and drives the first correction roller 81 and the second correction roller 82 to swing. During the swing, the force on the conveyor belt 2 is perpendicular to the axis. After the force is decomposed, it is divided into a first component perpendicular to the conveying direction of the conveyor belt 2 and a second component perpendicular to the conveying direction of the conveyor belt 2. The second component acts on the conveyor belt 2 to make it return from the bias state A1 to A2 or from the bias state B1 to B2. Both A2 and B2 are in the positive direction.

[0030] During operation, the core layer 10 of the semi-finished product is first partially introduced between the drive roller 12 and the pressure roller 11 on the frame 1. The vertical distance between the pressure roller 11 and the drive roller 12 can be adjusted to accommodate core layers 10 of different thicknesses. The drive roller 12 is driven by a motor to rotate and bring the core layer 10 into the input section 21. The conveyor belt 2 carries the core layer 10 into the forming chamber 3. Hot air is blown in from below the core layer 10 in the first drying chamber 31. The conveyor belt 2 has a mesh structure with good air permeability, which reduces the friction between the core layer 10 and the conveyor belt 2 and improves its free shrinkage. Furthermore, the surface of the conveyor belt 2 is coated with a hydrophobic film to further reduce the friction between the core layer 10 and the conveyor belt 2. However, the static friction between the conveyor belt 2 and the core layer 10 is sufficient to drive the core layer 10 to move synchronously. After basic forming, the core layer 10 enters the second drying chamber 32, where an upward blowing method is used to increase the friction between it and the conveyor belt 2, reducing the movement of the core layer 10 and making it flat. Finally, the core layer 10 enters the output section 22, where several air coolers 9 arranged along the conveying direction strongly cool the core layer 10 before it is finally output and recycled.

[0031] The hydrophobic membrane is made of any one of PTFE coating, fluorosilicone composite coating or modified organosilicon high temperature resistant coating, and can withstand working environments above 200 degrees Celsius. Example 2

[0032] See also Figure 7 and Figure 8 A three-dimensional honeycomb woven fabric core layer forming device, which differs from Embodiment 1 in that a suspension assembly 23 is also provided in the first drying chamber 31. The suspension assembly 23 includes two spaced guide rollers 231, a tension roller 232, and at least one support roller 233.

[0033] Two guide rollers 231 abut against the inner surface of one side of the conveyor belt 2 and are connected to a synchronizing element 235. The synchronizing element 235 is used to drive the two guide rollers 231 to move towards each other or away from each other. In this embodiment, the synchronizing element 235 includes a bidirectional lead screw and a drive motor connected to the bidirectional lead screw. One end of the guide roller 231 is threadedly connected to the bidirectional lead screw. The drive motor drives the bidirectional lead screw to rotate, thereby driving the two guide rollers 231 to move towards each other or away from each other.

[0034] The tension roller 232 is positioned between the two guide rollers 231 and abuts against the outer surface of the conveyor belt 2. Under the pressure of the tension roller 232, the conveyor belt 2 partially concaves, forming a suspended area 234 between the two guide rollers 231. The first air inlet 411 is arranged below the suspended area 234. The tension roller 232 is connected to a first driving component, which is used to drive the tension roller 232 to make a displacement perpendicular to the conveying direction, thereby adjusting the concave depth. The first driving component is a hydraulic cylinder or an electric cylinder.

[0035] The support roller 233 is positioned between the two guide rollers 231 and housed within the suspended area 234. The support roller 233 is tangent to the inner surface of the conveyor belt 2 in the conveying direction, and thus, when the core layer 10 is conveyed, the support roller 233 is positioned at the lower end face of the core layer 10. The support roller 233 is connected to a second driving component for driving the support roller 233 to move horizontally. This second driving component is either a hydraulic cylinder or an electric cylinder. Notably, the aforementioned fixing component, first driving component, and second driving component are all installed on the outside of the forming box 3. One end of the guide roller 231, tension roller 232, and support roller 233 extends out from inside the forming box 3 and connects to the aforementioned transmission components. The sliding joint between the guide roller 231, tension roller 232, and support roller 233 and the forming box 3 is sealed with a heat insulation sheet. Alternatively, the aforementioned fixing component, first driving component, and second driving component can all be made of high-temperature resistant material and housed within the forming box 3. Each transmission component can also be periodically inspected after a period of operation to ensure its performance.

[0036] When the core layer 10 is supported and conveyed in this molding device, the core layer 10 enters the first drying chamber 31 and is driven by a photoelectric switch to move the support roller 233 toward the guide roller 231 on the side closest to the inlet of the molding box 3 and to its maximum stroke. The front end of the core layer 10 is conveyed by the conveyor belt 2 and moves onto the support roller 233. The support roller 233 is moved by the gravity sensor 87, and its movement speed is the same as the conveying speed of the conveyor belt 2, so that there is no relative displacement between the core layer 10 and the support roller 233 until the support roller 233 moves to the minimum position of the other guide roller 231. There are certain requirements for the length of the core layer 10 and the distance between the two guide rollers 231 to ensure that most of the front end of the core layer 10 passes through the area of ​​the first drying chamber 31, and that the tail end can be smoothly output even if it falls into the suspended area 234. Of course, the reciprocating motion of the support roller 233 can also be used to support the core layer 10 and smoothly pass through the suspended area 234. The surface of the support roller 233 is smooth to minimize friction with the core layer 10.

[0037] Figure 9 The image shows a core layer formed by the molding apparatus of Example 1 or Example 2. It can be seen that the surface is flat, the middle shrinkage layer is evenly arched, and the molding quality is high.

[0038] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A molding apparatus for a three-dimensional honeycomb woven fabric core layer, characterized in that, include: Conveyor belt (2), the surface of which has a grid structure; The forming box (3) is partially housed within the conveyor belt (2); Heating components are located inside the molding box (3); and A circulating fan module is installed in the molded housing (3). The molding box (3) has a first drying chamber (31) and a second drying chamber (32) arranged sequentially along the conveying direction of the conveyor belt (2); the circulating fan module includes a first circulating fan unit (4) and a second circulating fan unit (5). The first drying chamber (31) is supplied with air from the bottom and the top through the first circulating fan unit (4), and the second drying chamber (32) is supplied with air from the top and the bottom through the second circulating fan unit (5).

2. The forming apparatus for the three-dimensional honeycomb woven fabric core layer according to claim 1, characterized in that, The heating assembly includes a first heating tube group (6) and a second heating tube group (7) arranged on the upper and lower sides of the conveyor belt (2). Both the first heating tube group (6) and the second heating tube group (7) include a number of heating tubes arranged at intervals along the conveying direction of the conveyor belt (2).

3. The forming apparatus for the three-dimensional honeycomb woven fabric core layer according to claim 1, characterized in that, The first circulating fan unit (4) includes a plurality of first circulating fans (41) arranged at intervals perpendicular to the conveying direction of the conveyor belt (2); the second circulating fan unit (5) includes a plurality of second circulating fans (51) arranged at intervals perpendicular to the conveying direction of the conveyor belt (2).

4. The forming apparatus for the three-dimensional honeycomb woven fabric core layer according to claim 1, characterized in that, It also includes a suspension assembly (23) disposed within the first drying cavity (31), the suspension assembly (23) comprising: Two spaced guide rollers (231) are arranged in contact with the inner surface of the conveyor belt (2); A tension roller (232) is positioned between two guide rollers (231), and the tension roller (232) abuts against the outer surface of the conveyor belt (2); and At least one support roller (233) is placed between the two guide rollers (231); The conveyor belt (2) forms an overhead suspended area (234) between the two guide rollers (231), and the support roller (233) is housed in the suspended area (234) and is tangent to the conveying direction of the conveyor belt (2). The support roller (233) can be horizontally displaced in the suspended area (234) parallel to the conveying direction.

5. The forming apparatus for the three-dimensional honeycomb woven fabric core layer according to claim 4, characterized in that, The air inlet of the first drying cavity (31) is located below the suspended area (234).

6. The forming apparatus for the core layer of a three-dimensional honeycomb woven fabric according to claim 4, characterized in that, The suspension assembly (23) also includes: Synchronizer (235) connects two guide rollers (231) and is used to drive the two guide rollers (231) to move towards each other or away from each other; The first driving component, connected to the tension roller (232), is used to drive the tension roller (232) to a displacement perpendicular to the conveying direction; and The second driving component is connected to the support roller (233) and is used to drive the support roller (233) to move horizontally.

7. The forming apparatus for the core layer of a three-dimensional honeycomb woven fabric according to claim 1, characterized in that, The conveyor belt (2) includes an input section (21) and an output section (22) located on both sides of the forming box (3), and a correction mechanism (8) is provided at the input section (21).

8. The forming apparatus for the three-dimensional honeycomb woven fabric core layer according to claim 7, characterized in that, The correction mechanism (8) includes: The first correction roller (81) abuts against the outer surface of one side of the conveyor belt (2), and one end of the first correction roller (81) is hinged to the frame (1). The second correction roller (82) abuts against the inner surface of one side of the conveyor belt (2), and one end of the second correction roller (82) is hinged to the frame (1). Sensors (87) are disposed on both sides of the conveyor belt (2); and The third drive unit (86) connects the other end of the first correction roller (81) and the second correction roller (82), and the third drive unit (86) is electrically connected to the sensor (87); When the outer edge of either side of the conveyor belt (2) is offset above the sensor (87), the third drive member (86) drives the first correction roller (81) and the second correction roller (82) to rotate around the hinge point to squeeze the conveyor belt (2).

9. The forming apparatus for the three-dimensional honeycomb woven fabric core layer according to claim 7, characterized in that, The output section (22) is provided with several air coolers (9) at intervals along the conveying direction.

10. The forming apparatus for the core layer of a three-dimensional honeycomb woven fabric according to claim 1, characterized in that, The surface of the conveyor belt (2) is coated with a hydrophobic film.

Images