A layered stable forming process and device for a composite knitted fabric

Abstract

This application relates to a layered stabilization molding process and apparatus for composite knitted fabrics, belonging to the technical field of textile fabric composite processing. The apparatus, arranged sequentially along the fabric conveying direction, includes an unwinding module, a leveling tension adjustment zone, a steam humidification module, a coating mechanism, an electrostatic generator, a hot-pressing composite zone, a cooling and setting roller group, and a winding mechanism. The leveling tension adjustment zone dynamically adjusts tension by using a cylinder to drive a rotating frame to oscillate. The coating mechanism, through planetary gears and a guide groove mechanism, keeps the coating nozzle horizontal and forms a wave-shaped coating trajectory. The electrostatic generator enables the two layers of fabric to carry opposite charges, achieving non-contact adsorption and pre-positioning. The hot-pressing composite zone achieves localized composite and dynamic pressure modulation through eccentric adjustment and textured hot-pressing rollers. This application maintains the breathability and soft hand feel of the fabric while ensuring strong interlayer bonding, improving the misalignment and hardening problems in high-elastic knitted fabric composites.

Description

Technical Field

[0001] This application relates to the technical field of composite processing of textile fabrics, and in particular to a layered stabilization molding process and apparatus for composite knitted fabrics. Background Technology

[0002] Composite knitted fabrics are layered materials made by bonding or hot pressing knitted fabrics with other functional materials (such as films and fabric layers). They are widely used in sportswear, down jacket linings, functional underwear and industrial textiles. Compared with traditional woven fabrics, knitted fabrics have excellent elasticity and soft drape, which can give clothing better comfort and freedom of movement.

[0003] Currently, Chinese patent application number CN202311197046.2 discloses a knitted elastic breathable membrane down jacket lining and its preparation method. The lining includes a coating layer, a hot melt adhesive layer, and a knitted fabric. It uses a dotted hot melt adhesive layer to bond a highly elastic and breathable membrane material onto the knitted fabric. This technical solution uses a TPU film or a PU film as the coating layer and uses a dotted adhesive method to complete the hot-press bonding at a specific temperature and speed, ultimately obtaining a composite lining with a certain elongation and weight range. This solution solves to some extent the problems of stiffness and poor comfort of traditional woven linings. By using dotted adhesive bonding, it retains some breathability and gives the finished product a certain elastic recovery ability.

[0004] However, existing technologies mostly use multi-point discrete adhesive dots for bonding during fabric processing, which can easily lead to stress concentration during multi-directional stretching and anisotropic delamination risk in interlayer bonding. Furthermore, the lack of pre-positioning methods before lamination makes it easy for high-elastic fabrics to slip and misalign, affecting the accuracy of the composite. In addition, the hot pressing method using conventional self-centering hot press rollers is not convenient for dynamically adjusting the pressure, and it is easy to over-compact and damage the fabric's fluffy structure and breathability. Summary of the Invention

[0005] The purpose of this application is to provide a layered stabilization molding process and apparatus for composite knitted fabrics to solve the problems in the prior art.

[0006] To achieve the above objectives, this application adopts the following technical solution: In a first aspect, this application provides a layered stabilization molding process for composite knitted fabrics, comprising the following steps: S1. Provide at least a first knitted fabric layer and a second knitted fabric layer, which are continuously unwound through a first unwinding module and a second unwinding module, respectively. S2. The first and second knitted fabric layers are introduced into the leveling tension adjustment area respectively. The warp and weft tensions of each fabric layer are adjusted to the preset range by multiple sets of tension adjustment rollers. The fabric is then micro-humidified using a steam humidification module to soften the fabric fibers. S3. Apply reactive hot melt adhesive to a predetermined bonding area of ​​at least one fabric layer using a coating mechanism; S4. The fabric layer after the above treatment is transported to the working area of ​​the electrostatic generator. The high voltage electrostatic field causes each fabric layer surface to carry static charges of opposite polarity. Then, before the two fabric layers enter the stacking roller group, the electrostatic adsorption force is used to achieve non-contact pre-positioning and temporary interlayer fixation between the two fabric layers. S5. The first and second knitted fabric layers, which have been pre-fixed by electrostatic adsorption, are simultaneously fed into the hot-pressing composite zone. At least one pair of hot-pressing rollers are used for heating and pressing. The roller surface of at least one hot-pressing roller has raised patterns, so that the two fabric layers are hot-melted and bonded or hot-pressed in the preset bonding area corresponding to the raised patterns, while the original breathable pore structure of the fabric layers is maintained in the recessed area of ​​the raised patterns. S6. Immediately after hot pressing, the composite fabric is introduced into the cooling and shaping roller group. Under the condition of maintaining constant tension of the composite fabric, contact cooling is carried out to solidify the thermoplastic components in each bonding area, forming a composite knitted fabric with stable interlayer bonding and overall softness and breathability. S7. The cooled and set composite knitted fabric is wound up under constant tension using a winding mechanism.

[0007] Preferably, in step S4, the electrostatic generator includes a first high-voltage electrode group and a second high-voltage electrode group. The first high-voltage electrode group causes the lower surface of the first knitted fabric layer to carry a positive or negative charge, and the second high-voltage electrode group causes the upper surface of the second knitted fabric layer to carry a charge of opposite polarity to the lower surface of the first knitted fabric layer. The operating voltage of the electrostatic generator is 5kV-30kV, and is dynamically adjusted according to the fabric layer weight and fiber material, so that the electrostatic adsorption force between the fabric layers is 0.1N / cm. 2 -2.5N / cm 2 .

[0008] Preferably, in step S5, the raised pattern on the surface of the hot press roller includes uniformly distributed raised dots, raised strips, or mesh-like raised ridges, and the height of the raised pattern is 0.1mm-2.0mm, accounting for 20%-60% of the circumferential area of ​​the entire hot press roller; during the hot pressing composite process, the temperature of the hot press roller is controlled within a range of 5℃-30℃ higher than the softening point of the thermoplastic fiber, and the applied linear pressure is 10N / cm-150N / cm.

[0009] Preferably, in step S3, when applying the reactive hot melt adhesive, the adhesive nozzle is reciprocated with a set frequency and amplitude in the fabric width direction, so that the hot melt adhesive applied to the fabric surface presents a continuous sine wave or sawtooth wave trajectory; the amplitude of the wave trajectory does not exceed 90% of the fabric width.

[0010] Preferably, in step S5, the hot press roller is controlled to rotate eccentrically while rotating, so that the instantaneous linear pressure of the hot press roller on the composite fabric presents a sinusoidal waveform change within one rotation cycle.

[0011] Secondly, the present invention provides a layered stabilizing forming device for composite knitted fabrics used in implementing the above-mentioned process. The device includes a housing, on which a first unwinding module, a second unwinding module, a leveling tension adjustment zone, a steam humidification module, a coating mechanism, an electrostatic generator, a hot-pressing composite zone, a cooling and setting roller group, and a winding mechanism are sequentially arranged along the fabric conveying direction. The first unwinding module is located above the second unwinding module. Two leveling tension adjustment zones and two steam humidification modules are provided, each corresponding to one of the two unwinding modules. The steam outlet of the steam humidification module faces... A guide roller is correspondingly arranged above the coating mechanism in the tension adjustment area for leveling; the coating mechanism is located upstream of the electrostatic generator and is used to coat a reactive hot melt adhesive in a preset bonding area of ​​a fabric layer; the electrostatic generator includes a first high-voltage electrode group located on the conveying path of the first knitted fabric layer and a second high-voltage electrode group located on the conveying path of the second knitted fabric layer, and the two high-voltage electrode groups are respectively connected to the positive and negative terminals of a high-voltage DC power supply; the cooling and shaping roller group includes no less than two cooling rollers with cooling medium flowing inside, and at least one cooling roller is equipped with a tension sensor.

[0012] Preferably, the leveling tension adjustment area includes a support fixed to the shroud on one side, a rotating frame rotatably connected to the front side of the support, a first rotating roller and a second rotating roller rotatably connected to the front right and left sides of the rotating frame respectively, and the end of the rotating frame away from the support is connected to the cylinder output shaft, the side of the cylinder away from the rotating frame is rotatably connected to the shroud, a third rotating roller is provided downstream of the second rotating roller, and the steam humidification module is provided between the second rotating roller and the third rotating roller.

[0013] Preferably, the coating mechanism includes a frame whose bottom is fastened to the hopper cover. A first motor is locked and fixed to the top front side of the frame. The output shaft of the first motor rotates through the middle side of the fixed gear disk, and the front of the fixed gear disk is fixed to the frame. The output end of the first motor is connected to the support frame. The rear side of the fixed gear disk is in rotatable contact with the support frame. The top side of the fixed gear disk meshes with the moving gear disk through an intermediate gear. The rear of both the intermediate gear and the moving gear disk are rotatably connected to the support frame. A circular opening is provided through the support frame, and an adhesive coating structure is provided inside the circular opening. The front side of the adhesive coating structure is fastened to the moving gear disk to keep the horizontal state of the adhesive coating structure unchanged when the support frame rotates.

[0014] Preferably, the adhesive application structure includes a boat-shaped compartment that is fastened to the front of the moving gear disk. A pad is locked and fixed inside the bottom of the boat-shaped compartment. A second motor is locked and fixed on the side of the pad away from the moving gear disk. A guide rod is connected to the front output end of the second motor, and the guide rod is rotatably connected to the top side inside the pad. A displacement head is slidably connected to the bottom of the guide rod to drive the displacement head to perform reciprocating displacement. A sliding sleeve is connected to the bottom of the displacement head, and a guide rod slides through the sliding sleeve. The guide rod is fixed to the bottom side inside the pad. An adhesive application nozzle is locked and fixed to the bottom of the sliding sleeve. The adhesive application nozzle is connected to an external adhesive source end through a connecting pipe.

[0015] Preferably, the hot-pressing composite zone includes a stand with its bottom fixed to the shroud cover. At least one set of positioning frames is provided on the upper part of the stand. An adjustment structure is provided inside the middle of the positioning frame. The adjustment structure includes a third motor locked and fixed to the middle of the rear of the positioning frame. A rocker arm is connected to the front output end of the third motor. A connecting rod is rotatably connected to both ends of the rocker arm. A sliding block is rotatably connected to the other side of each of the two connecting rods. The two sliding blocks slide longitudinally on the upper and lower sides inside the positioning frame, respectively. A fourth motor is locked and fixed to the middle of the rear side of each of the two sliding blocks. A connector is connected to the front output end of the fourth motor. The connector passes through and rotates inside the middle of the sliding block. A disc frame is fixedly connected to the front side of the connector. A screw is passed through the disc frame perpendicular to the axis. A support plate is threadedly connected to the outer surface of the screw. A hot-pressing roller is locked and fixed to the side of the support plate away from the connector.

[0016] In summary, this application includes the following beneficial technical effects: 1. In terms of process control and fabric pretreatment, this application utilizes an independently set leveling tension adjustment zone in conjunction with a steam micro-humidification module. Addressing the characteristic of easily fluctuating warp and weft tension in high-elasticity knitted fabrics, a cylinder is used to drive the rotating frame to swing around the support, dynamically changing the roll wrap angle and spatial position to decouple and adjust the tension. Simultaneously, the humid heat effect of a small amount of steam softens the fibers and releases internal stress, effectively preventing wrinkles and misalignments during subsequent lamination. Furthermore, the coating mechanism employs a planetary gear constraint structure and a transverse reciprocating guide groove mechanism in a coordinated manner. This not only ensures that the coating nozzle always maintains a horizontal working posture parallel to the fabric but also allows the coating trajectory to exhibit a regular waveform distribution, thereby optimizing the stress dispersion characteristics of the interlayer bonding interface and improving the structural integrity of the composite fabric under dynamic tensile conditions.

[0017] 2. In terms of device structure, this application introduces an electrostatic generator as the core execution unit for interlayer pre-positioning. By applying electrostatic charges of opposite polarities to the opposing surfaces of the two fabric layers before lamination, Coulomb force is used to achieve spontaneous adsorption alignment without mechanical contact, ensuring the accuracy of warp and weft alignment and pattern alignment after lamination. At the same time, the eccentric adjustment structure of the hot-pressing composite zone cooperates with the surface textured hot-pressing roller to achieve a local composite mode in which hot pressure is applied only to the preset raised area. The dynamic pressure change generated by the eccentric rotation further promotes the penetration and diffusion of hot-melt components inside the bonding point, enhances the single-point anchoring strength, and thus, while ensuring the interlayer bonding strength, preserves the natural pore structure and original fluffy feel of the non-composite area of ​​the fabric to the maximum extent.

[0018] 3. The process of this application, through electrostatic pre-positioning, local embossed hot pressing, dynamic pressure modulation, and constant tension cooling and shaping, enables the resulting composite knitted fabric to possess both excellent interlayer peel strength and superior softness and breathability. The non-contact pre-positioning and local composite process ensures that the original elastic recovery rate and breathability of the fabric are fully maintained. The wavy adhesive trajectory and mesh welding network effectively disperse local stress concentration during use, significantly extending the service life of the fabric under repeated washing and mechanical rubbing conditions.

[0019] 4. The process of this application has wide applicability and can flexibly switch between coating and self-melting composite modes according to different material combinations. The fabrics made from this process show significant advantages in terms of hand feel, breathability, dimensional stability and weather resistance. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the layered stabilizing molding device of this application; Figure 2 This is a schematic diagram of the coating mechanism of this application; Figure 3 This application Figure 2Side view of the connection between the central moving gear and the adhesive coating structure; Figure 4 This is a schematic diagram of the adhesive coating structure of this application; Figure 5 This is a schematic diagram of the hot-pressed composite region of this application; Figure 6 This is a schematic diagram of the connection between the positioning frame and the adjustment structure in this application; Figure 7 This is a schematic diagram of the connection between the plate frame, screw, and support plate in this application.

[0021] Explanation of reference numerals in the attached drawings: 1. First unwinding module; 2. Second unwinding module; 3. Leveling tension adjustment area; 31. Support; 32. Rotating frame; 33. First rotating roller; 34. Second rotating roller; 35. Cylinder; 36. Third rotating roller; 4. Steam humidification module; 5. Coating mechanism; 51. Carrier; 52. First motor; 53. Fixed gear plate; 54. Support and rotating frame; 55. Intermediate gear; 56. Moving gear plate; 57. Glue coating structure; 571. Boat-shaped compartment; 572. Pad; 573. Second motor; 574. Guide groove rod; 575. Shifting head; 5 76. Sliding sleeve; 577. Guide rod; 578. Glue spray nozzle; 6. Electrostatic generator; 61. First high-voltage electrode group; 62. Second high-voltage electrode group; 7. Hot pressing composite zone; 71. Stand; 72. Positioning frame; 73. Adjustment structure; 74. Hot pressing roller; 731. Third motor; 732. Cradle; 733. Connecting rod; 734. Sliding block; 735. Fourth motor; 736. Connector; 737. Disc frame; 738. Screw; 739. Support plate seat; 8. Cooling and shaping roller group; 9. Winding mechanism; 10. Storage cover; 11. Guide roller. Detailed Implementation

[0022] The following is in conjunction with the appendix Figure 1 -Appendix Figure 7 This application will be described in further detail below.

[0023] Example 1 I. Overall Layout of the Equipment: like Figure 1 As shown, this embodiment provides a layered stabilizing forming device for composite knitted fabrics, including a housing 10. The housing 10 serves as the mounting base for each functional module. Along the fabric conveying direction (arrow direction in the figure), a first unwinding module 1, a second unwinding module 2, a leveling tension adjustment zone 3, a steam humidification module 4, a coating mechanism 5, an electrostatic generator 6, a hot-pressing composite zone 7, a cooling and shaping roller group 8, and a winding mechanism 9 are arranged in sequence.

[0024] The first unwinding module 1 is located directly above the second unwinding module 2. The two modules are used to carry the rolls of the first knitted fabric layer (upper layer) and the second knitted fabric layer (lower layer), respectively. The leveling tension adjustment zone 3 and the steam humidification module 4 are each provided in two sets, located downstream of the first unwinding module 1 and the second unwinding module 2, respectively, to independently perform tension leveling and humidification treatment on the two fabric layers.

[0025] The coating mechanism 5 is located after a set of leveling tension adjustment areas 3 below, and is used to coat the upper surface of the second knitted fabric layer (i.e. the preset bonding area that is in contact with the first knitted fabric layer) with reactive hot melt adhesive. A guide roller 11 is correspondingly arranged above the coating mechanism 5, and the guide roller 11 guides the first knitted fabric layer to the conveying plane that intersects with the second knitted fabric layer.

[0026] The electrostatic generator 6 is located downstream of the coating mechanism 5 and includes a first high-voltage electrode group 61 and a second high-voltage electrode group 62. The hot-pressing composite zone 7 is located downstream of the electrostatic generator 6. The cooling and shaping roller group 8 includes a cooling roller with cooling water circulating inside. The winding mechanism 9 adopts a constant tension winding mode to neatly wind the finished composite fabric.

[0027] II. Layered stabilization molding process: Please see Figures 1 to 7 This embodiment provides a specific process for achieving stable layering and forming of composite knitted fabrics using the above-mentioned device.

[0028] The process steps are as follows: Step S1, Layered unwinding: First, the first knitted fabric layer (upper layer) and the second knitted fabric layer (lower layer) to be laminated are loaded onto the air shafts of the first unwinding module 1 and the second unwinding module 2, respectively. The first unwinding module 1 is located above the second unwinding module 2, and both release the fabric continuously at a set initial linear speed under the drive of the servo motor. During the unwinding process, the change in roll diameter is monitored in real time by an ultrasonic sensor, and the speed of the unwinding motor is adjusted accordingly to achieve initial constant linear speed unwinding and prevent sudden tension changes caused by the reduction in roll diameter.

[0029] Step S2, Leveling tension adjustment and steam micro-humidification: The fabric drawn from the unwinding module enters the leveling tension adjustment zone 3 on its respective path, combined with... Figure 1 As shown, the specific structure and process of this area are as follows: The leveling tension adjustment zone 3 includes a support 31 fixed to the inner wall of the shroud 10 on one side. A rotating frame 32 is rotatably connected to the front side of the support 31 via a bearing. A first rotating roller 33 and a second rotating roller 34 are rotatably connected to the right and left sides of the front part of the rotating frame 32, respectively. The end of the rotating frame 32 away from the support 31 is hinged to the output shaft of the cylinder 35. The tail end of the cylinder body of the cylinder 35 is rotatably connected to the inner wall of the shroud 10.

[0030] In the process, the first knitted fabric layer passes around the first roller 33, then through the second roller 34, and finally around the fixed third roller 36. The controller sends a command to the electronically controlled proportional valve based on the real-time data fed back by the tension sensor installed on the guide roller, controlling the extension and retraction of the cylinder 35. When the piston rod of the cylinder 35 extends or retracts, it pushes the rotating frame 32 to swing around the axis of the support 31, thereby dynamically changing the wrap angle and spatial relative position of the first roller 33 and the second roller 34 to the fabric. This allows for the decoupling and adjustment of the warp and weft elastic tension unique to the knitted fabric, stabilizing it within the preset process window of 50N-200N.

[0031] Next, in the open section between the second roller 34 and the third roller 36, the steam humidification module 4 sprays out a small amount of saturated steam at a temperature of 80℃-105℃. This steam acts on the fabric surface which is in a slightly tense state, and through the effect of humid heat, the hydrogen bonds between the fiber macromolecular chains are temporarily opened, the fabric fibers are quickly softened and the internal winding stress is eliminated.

[0032] Step S3: Apply reactive hot melt adhesive along a waveform trajectory. After being steam-treated, the lower knitted fabric enters the working area of ​​the coating mechanism 5 under the guidance of the guide roller 11; in this embodiment, only the upper surface of the lower fabric is locally coated with adhesive.

[0033] Reference Figures 2 to 4 The specific structure and process linkage of the coating mechanism 5 are as follows: The coating mechanism 5 includes a carrier frame 51 whose bottom is fastened to the shroud 10. A first motor 52 is locked and fixed to the top front of the carrier frame 51. The output shaft of the first motor 52 rotates through the middle of the fixed gear disk 53, and the front of the fixed gear disk 53 is fixed to the carrier frame 51. The output end of the first motor 52 is connected to the support frame 54. The top side of the fixed gear disk 53 is driven by the meshing of the intermediate gear 55 and the moving gear disk 56. The rear of the intermediate gear 55 and the moving gear disk 56 are rotatably connected to the support frame 54. A circular opening is provided through the inside of the support frame 54, and an adhesive coating structure 57 is provided inside the circular opening. The front side of the adhesive coating structure 57 is fastened to the moving gear disk 56.

[0034] When the gluing operation begins, the first motor 52 drives the support frame 54 to rotate, adjusting the gluing structure 57 to the working angle facing the fabric running plane. During this process, due to the planetary gear constraint relationship of the fixed gear plate 53, the intermediate gear 55, and the meshing rotation of the moving gear plate 56, the gluing structure 57 always maintains a horizontal state when it revolves with the support frame 54, ensuring the parallelism between the gluing nozzle 578 and the fabric surface. At the same time, after the fabric passes over the pivot of the support frame 54, it exits from the bottom of the gluing structure 57, further improving the tension effect on the fabric.

[0035] The adhesive application structure 57 specifically includes: a boat-shaped compartment 571 that is fastened to the front of the moving gear disk 56; a pad 572 is locked and fixed inside the bottom of the boat-shaped compartment 571; a second motor 573 is locked and fixed on the side of the pad 572 away from the moving gear disk 56; a guide rod 574 is connected to the front output end of the second motor 573; the guide rod 574 is rotatably connected to the top inside the pad 572; a shift head 575 is slidably connected to the bottom of the guide rod 574; a sliding sleeve 576 is connected to the bottom of the shift head 575; a guide rod 577 slides through the sliding sleeve 576; the guide rod 577 is fixed to the bottom inside the pad 572; and an adhesive application nozzle 578 is locked and fixed to the bottom of the sliding sleeve 576.

[0036] During process execution, the second motor 573 starts, driving the guide rod 574 to rotate. The curved guide groove on the guide rod 574 drives the shift head 575 and drives the sliding sleeve 576 to make a high-frequency transverse reciprocating motion along the guide rod 577. At the same time, the fabric is continuously conveyed forward below. Through the combination of transverse reciprocating motion and longitudinal linear motion, the adhesive spray nozzle 578 applies a continuous sinusoidal or sawtooth waveform trajectory of reactive hot melt adhesive on the fabric surface. By adjusting the speed of the second motor 573, the transverse reciprocating oscillation frequency is controlled to be 10-50Hz.

[0037] Step S4: Electrostatic non-contact pre-positioning and temporary interlayer fixing: The lower layer of fabric, after completing the wave-shaped adhesive coating, continues to be conveyed forward, entering the active area of ​​the electrostatic generator 6 along with the uncoated upper first knitted fabric layer. Figure 1 As shown, the electrostatic generator 6 includes a first high-voltage electrode group 61 located on the conveying path of the first knitted fabric layer and a second high-voltage electrode group 62 located on the conveying path of the second knitted fabric layer. The first high-voltage electrode group 61 is aligned with the lower surface of the upper fabric layer and connected to the positive terminal of the high-voltage DC power supply; the second high-voltage electrode group 62 is aligned with the upper surface of the lower coated fabric layer and connected to the negative terminal of the high-voltage DC power supply.

[0038] Depending on the fabric weight and fiber material, the high-voltage power supply output voltage is dynamically adjusted from 12kV to 18kV. When the distance between the two layers of fabric at the overlapping roller is reduced to 5mm-10mm, the electrostatic adsorption force generated by Coulomb force reaches 0.5N / cm. 2 -1.2N / cm 2 This allows the two layers of fabric to be quickly adsorbed and bonded together without the contact of mechanical pressure rollers.

[0039] Step S5: Localized raised texture hot pressing composite and eccentric pressure modulation: The pre-fixed composite fabric layers via electrostatic adsorption then enter the hot-pressing lamination zone 7, as shown in the reference. Figures 5 to 7 The specific structure and process linkage of the hot-pressed composite zone 7 are as follows: The hot-pressing composite zone 7 includes a stand 71 whose bottom is fastened to the cover 10. At least one set of positioning frames 72 is provided on the upper part of the stand 71. An adjustment structure 73 is provided in the middle of the interior of the positioning frame 72. The adjustment structure 73 includes a third motor 731 that is locked and fixed to the middle of the rear of the positioning frame 72. The front output end of the third motor 731 is connected to a rocker arm 732. A connecting rod 733 is rotatably connected to both ends of the rocker arm 732. A sliding block 734 is rotatably connected to the other side of the two connecting rods 733. The two sliding blocks 734 slide longitudinally on the upper and lower sides of the interior of the positioning frame 72, respectively. Before hot pressing, the third motor 731 rotates, and through the crank-slider mechanism formed by the rocker arm 732 and the connecting rod 733, it drives the two upper and lower sliding blocks 734 to move synchronously towards each other along the longitudinal groove, so that the two hot-pressing rollers 74 clamp the fabric, adjust the gap, and apply a basic value of linear pressure of 10N / cm-100N / cm.

[0040] Each sliding block 734 has a fourth motor 735 locked and fixed in the middle of its rear side. The output end of the fourth motor 735 is connected to a connector 736, which rotates through the middle of the sliding block 734. A plate frame 737 is fixedly connected to the front of the connector 736. A screw 738 is installed through the plate frame 737 perpendicular to the axis. A support plate seat 739 is threaded to the outer surface of the screw 738. A hot press roller 74 is locked and fixed on the side of the support plate seat 739 away from the connector 736. During the process, high-temperature heat transfer oil is introduced into the hot press roller 74, and the roller surface temperature is precisely controlled at 250°C. The surface of the hot press roller 74 is evenly distributed with raised dot patterns with a height of 0.8mm. When the stacked fabric passes through the hot press roller, only the area in contact with the raised dots is subjected to high temperature and high pressure and melts and bonds.

[0041] Meanwhile, during the hot pressing rotation process, the fourth motor 735 drives the hot pressing roller 74 to rotate, and by adjusting the screw 738, the support plate 739 is made to generate an eccentricity relative to the plate frame 737, so that the hot pressing roller 74 rotates eccentrically, and the instantaneous linear pressure changes in a sinusoidal waveform, which promotes the penetration of the molten colloid.

[0042] Step S6: Constant tension cooling and shaping: The composite fabric that has just come out of the hot-pressing composite zone 7 is immediately introduced into the cooling and shaping roller group 8. The fabric comes into contact with two cooling rollers and is rapidly cooled to below 40°C through contact heat conduction. During this process, the tension sensor located at the end of the cooling roller group monitors the fabric tension in real time and feeds it back to the control system of the winding mechanism 9.

[0043] Step S7, constant tension winding: After cooling and setting, the composite knitted fabric finally enters the winding mechanism 9. The winding motor performs closed-loop speed regulation based on the feedback from the tension sensor, and winds the finished fabric into a tube smoothly and tightly with constant surface tension.

[0044] Example 2 The difference between this embodiment and Embodiment 1 lies in steps S3 and S5. In this embodiment, the coating mechanism 5 in step S3 does not work and does not coat any liquid hot melt adhesive. Instead, the first and second knitted fabric layers are both knitted fabrics containing low-melting-point core-sheath composite fibers.

[0045] During hot pressing in step S5, the adjusting structure 73 drives two hot pressing rollers 74 to approach each other. The surface of the hot pressing rollers 74 has a mesh pattern of raised ridges. The temperature is controlled at 125℃ and the linear pressure is 120N / cm. At this time, in the mesh area corresponding to the raised ridges, the low melting point leather fibers of the upper and lower fabrics directly melt and fuse together to form a welded network.

[0046] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.

Claims

1. A layered stabilization molding process for composite knitted fabrics, characterized in that, Includes the following steps: S1. Provide at least a first knitted fabric layer and a second knitted fabric layer, which are continuously unwound through a first unwinding module (1) and a second unwinding module (2), respectively. S2. The first knitted fabric layer and the second knitted fabric layer are introduced into the leveling tension adjustment area (3) respectively. The warp tension and weft tension of each fabric layer are adjusted to the preset range by multiple sets of tension adjustment rollers. The fabric is then micro-humidified using the steam humidification module (4) to soften the fabric fibers. S3. Apply reactive hot melt adhesive to a pre-defined bonding area of ​​at least one fabric layer using a coating mechanism (5); S4. The fabric layer after the above treatment is transported to the working area of ​​the electrostatic generator (6). The high voltage electrostatic field causes each fabric layer surface to carry static charges of opposite polarity. Then, before the two fabric layers enter the stacking roller group, the electrostatic adsorption force is used to achieve non-contact pre-positioning and temporary interlayer fixation between the two fabric layers. S5. The first and second knitted fabric layers, which have been pre-fixed by electrostatic adsorption, are simultaneously fed into the hot-pressing composite zone (7). At least one pair of hot-pressing rollers (74) are used for heating and pressing. At least one hot-pressing roller (74) has raised patterns on its roller surface, so that the two fabric layers are hot-melted and bonded or hot-pressed in the pre-defined bonding area corresponding to the raised patterns, while the original breathable pore structure of the fabric layers is maintained in the recessed area of ​​the raised patterns. S6. Immediately after hot pressing, the composite fabric is introduced into the cooling and shaping roller group (8). Under the condition of maintaining constant tension of the composite fabric, contact cooling is carried out to solidify the thermoplastic components in each bonding area, forming a composite knitted fabric with stable interlayer bonding and overall softness and breathability. S7. The cooled and set composite knitted fabric is wound up under constant tension by the winding mechanism (9).

2. The layered stabilization molding process for a composite knitted fabric according to claim 1, characterized in that, In step S4, the electrostatic generating device (6) includes a first high-voltage electrode group (61) and a second high-voltage electrode group (62). The first high-voltage electrode group (61) causes the lower surface of the first knitted fabric layer to carry positive or negative charges, and the second high-voltage electrode group (62) causes the upper surface of the second knitted fabric layer to carry charges with opposite polarity to the lower surface of the first knitted fabric layer. The electrostatic generator (6) operates at a voltage of 5kV-30kV, which is dynamically adjusted according to the fabric layer weight and fiber material, so that the electrostatic adsorption force between the fabric layers is 0.1N / cm. 2 -2.5N / cm 2 .

3. The layered stabilization molding process for a composite knitted fabric according to claim 1, characterized in that, In step S5, the raised pattern on the surface of the hot press roller includes uniformly distributed raised dots, raised strips, or mesh-like raised ridges. The height of the raised pattern is 0.1mm-2.0mm, accounting for 20%-60% of the circumferential area of ​​the entire hot press roller. During the hot pressing process, the temperature of the hot press roller is controlled within a range of 5℃-30℃ higher than the softening point of at least one thermoplastic fiber constituting the knitted fabric, and the linear pressure applied by the hot press roller is 10N / cm-150N / cm.

4. The layered stabilization molding process for a composite knitted fabric according to claim 1, characterized in that, In step S3, when applying the reactive hot melt adhesive, the adhesive nozzle (578) is reciprocated in the fabric width direction with a set frequency and amplitude, so that the hot melt adhesive applied to the fabric surface presents a continuous sine wave or sawtooth wave trajectory; the amplitude of the sine wave or sawtooth wave trajectory does not exceed 90% of the fabric width.

5. The layered stabilization molding process for a composite knitted fabric according to claim 1, characterized in that, In step S5, the hot press roller (74) is controlled to rotate eccentrically while rotating, so that the instantaneous linear pressure of the hot press roller (74) on the composite fabric presents a sinusoidal waveform change within one rotation cycle.

6. A layered stabilizing molding apparatus for composite knitted fabrics, used to implement the layered stabilizing molding process for composite knitted fabrics as described in any one of claims 1 to 5, characterized in that, The device includes a hood (10), on which a first unwinding module (1), a second unwinding module (2), a leveling tension adjustment zone (3), a steam humidification module (4), a coating mechanism (5), an electrostatic generator (6), a hot-pressing composite zone (7), a cooling and shaping roller group (8), and a winding mechanism (9) are arranged sequentially along the fabric conveying direction. The first unwinding module (1) is located above the second unwinding module (2). There are two of each of the leveling tension adjustment zone (3) and the steam humidification module (4), which are respectively arranged corresponding to the two sets of unwinding modules. The steam outlet of the steam humidification module (4) faces the leveling tension adjustment zone (3). The coating mechanism (5) is provided with a guide roller (11) above it; the coating mechanism (5) is located upstream of the electrostatic generator (6) and is used to coat a reactive hot melt adhesive in a preset bonding area of ​​a fabric layer; the electrostatic generator (6) includes a first high-voltage electrode group (61) located on the conveying path of the first knitted fabric layer and a second high-voltage electrode group (62) located on the conveying path of the second knitted fabric layer, and the two high-voltage electrode groups are respectively connected to the positive and negative poles of the high-voltage DC power supply; the cooling and shaping roller group (8) includes no less than two cooling rollers with cooling medium inside, and at least one cooling roller is equipped with a tension sensor.

7. The layered stabilizing forming device for composite knitted fabrics according to claim 6, characterized in that: The leveling tension adjustment zone (3) includes a support (31) fixed to the shroud (10) on one side. A rotating frame (32) is rotatably connected to the front side of the support (31). A first rotating roller (33) and a second rotating roller (34) are rotatably connected to the right and left sides of the front part of the rotating frame (32), respectively. The end of the rotating frame (32) away from the support (31) is connected to the output shaft of the cylinder (35). The side of the cylinder (35) away from the rotating frame (32) is rotatably connected to the shroud (10). A third rotating roller (36) is provided downstream of the second rotating roller (34). The steam humidification module (4) is located between the second rotating roller (34) and the third rotating roller (36).

8. The layered stabilizing forming device for composite knitted fabrics according to claim 6, characterized in that: The coating mechanism (5) includes a frame (51) whose bottom is fastened to the shroud (10). A first motor (52) is locked and fixed to the top front side of the frame (51). The output shaft of the first motor (52) rotates through the middle side of the fixed gear plate (53). The front of the fixed gear plate (53) is fixed to the frame (51). The output end of the first motor (52) is connected to the support frame (54). The rear side of the fixed gear plate (53) is in rotatable contact with the support frame (54). The fixed gear plate (53) is driven by the meshing of the moving gear plate (56) through the intermediate gear (55) on the top side. The rear of the intermediate gear (55) and the moving gear plate (56) are rotatably connected to the support frame (54). The support frame (54) has a circular opening through it, and a glue coating structure (57) is provided on the inner side of the circular opening. The front side of the glue coating structure (57) is fastened to the moving gear plate (56) to keep the horizontal state of the glue coating structure (57) unchanged when the support frame (54) is rotated.

9. The layered stabilizing forming device for composite knitted fabrics according to claim 8, characterized in that: The adhesive coating structure (57) includes a boat-shaped compartment (571) fastened to the front of the moving gear disk (56). A pad (572) is locked and fixed inside the bottom side of the boat-shaped compartment (571). A second motor (573) is locked and fixed on the side of the pad (572) away from the moving gear disk (56). A guide rod (574) is connected to the front output end of the second motor (573), and the guide rod (574) is rotatably connected to the top side inside the pad (572). 574) A shift head (575) is slidably connected to the bottom for driving the shift head (575) to perform reciprocating shifting action; a sliding sleeve (576) is connected to the bottom of the shift head (575), and a guide rod (577) slides through the inside of the sliding sleeve (576). The guide rod (577) is fixed to the bottom side inside the pad (572). A glue spray nozzle (578) is locked and fixed to the bottom of the sliding sleeve (576). The glue spray nozzle (578) is connected to the external glue source end through a connecting pipe.

10. The layered stabilizing forming device for composite knitted fabrics according to claim 6, characterized in that: The hot-pressed composite zone (7) includes a stand (71) whose bottom is fastened to the shroud (10). At least one set of positioning frames (72) is provided on the upper part of the stand (71). An adjustment structure (73) is provided on the middle side inside the positioning frame (72). The adjustment structure (73) includes a third motor (731) locked and fixed to the middle side of the rear of the positioning frame (72). The front output end of the third motor (731) is connected to a rocker arm (732). A connecting rod (733) is rotatably connected to both ends of the rocker arm (732). A sliding block (734) is rotatably connected to the other side of each of the two connecting rods (733). The two sliding blocks (734) are respectively The sliding blocks (734) slide longitudinally on the upper and lower sides inside the positioning frame (72). A fourth motor (735) is locked and fixed in the middle of the rear side of each of the two sliding blocks (734). The output end of the fourth motor (735) is connected to a connector (736), and the connector (736) rotates through the middle side inside the sliding block (734). A disc frame (737) is fixedly connected to the front side of the connector (736). A screw (738) is installed through the disc frame (737) perpendicular to the axis. A support plate seat (739) is threaded on the outer surface of the screw (738). A hot pressure roller (74) is locked and fixed on the side of the support plate seat (739) away from the connector (736).

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