Production device for aerogel composite board and aerogel composite board product

Abstract

The present disclosure provides a kind of production device for energy-saving, environment-friendly, green and low-carbon building aerogel composite board, comprising at least one set of unwinding device, first limiting structure, second limiting structure, pressing device, sewing machine head assembly and cutting device arranged in turn along the transmission direction of aerogel blanket;The unwinding device comprises at least one set of gantry and guide shaft assembly arranged on the gantry;The pressing device comprises at least one height-adjustable power rolling shaft, which is used to cooperate with the first limiting structure and / or second limiting structure to extrude the multi-layer aerogel material to form the composite board to be sewn;The sewing machine head assembly is used to sew the composite board to be sewn to form the composite board to be cut;The cutting device comprises a cutting unit for cutting the composite board to be cut into composite board products according to the preset length.The present disclosure realizes efficient, high-quality, high-flatness and flexible continuous production of energy-saving, environment-friendly, green and low-carbon building aerogel composite board production process, which greatly improves the yield and greatly reduces the loss of raw materials.

Description

Technical Field

[0001] This disclosure relates to the field of energy-saving materials technology, and in particular to a production apparatus for aerogel composite panels and an aerogel composite panel product. Background Technology

[0002] Aerogel, as a high-performance thermal insulation material, has been widely used in construction, industry, and other fields. To meet different insulation and structural strength requirements, aerogel is often combined with fiber-based substrates to form multilayer composite panels. In continuous production processes, the synchronous conveying of multilayer materials, tension control, and the stability of each layer during transmission are fundamental challenges facing the industry. As the thickness and number of layers of the composite panel increase, the difficulty of material forming and dimensional control on the production line also increases. Traditional production equipment often has limitations in balancing smooth transmission and dimensional accuracy.

[0003] Furthermore, in the molding and subsequent processing of composite panels, the continuity between each process and the coordination of the overall equipment structure directly affect production efficiency and final product quality. Existing production lines still need improvement in terms of switching between different product specifications and the automation control of the overall process. During long-term operation, insufficient flexibility in structural adjustments or inadequate process connections can easily lead to fluctuations in product consistency or increased energy consumption. Summary of the Invention

[0004] This disclosure provides a production apparatus and aerogel composite board product for aerogel composite boards, realizing efficient, high-quality and flexible continuous production of energy-saving and environmentally friendly aerogel composite boards.

[0005] To solve the above-mentioned technical problems, this disclosure provides a production apparatus for aerogel composite panels, comprising:

[0006] At least one set of unwinding device, first limiting structure, second limiting structure, pressing device, sewing machine head assembly and cutting device are arranged sequentially along the conveying direction of aerogel blanket;

[0007] The unwinding device includes at least one set of gantry frames and a guide shaft assembly disposed on the gantry frames. The guide shaft assembly is used to support and guide each layer of aerogel blanket. The top elevation of each gantry frame is set to be flush with each other or to decrease step by step along the transport direction so that the aerogel materials to be laminated do not come into direct contact with each other during transport.

[0008] The first limiting structure is configured to apply an adjustable compressive force to the material in the transmission direction in the thickness direction to limit the thickness of the material;

[0009] The second limiting structure is configured to apply an adjustable constraint force to the material in transit in the width direction to limit the width of the material;

[0010] The pressing device includes at least one height-adjustable power rolling shaft for cooperating with the first limiting structure and / or the second limiting structure to extrude multilayer aerogel material to form a composite plate to be stitched.

[0011] The sewing machine head assembly is disposed between the pressing device and the cutting device, and is used to sew the composite board to be sewn to form the composite board to be cut.

[0012] The cutting device includes a cutting unit for cutting the composite board to be cut to a preset length to form a composite board product.

[0013] To address the aforementioned technical problems, this disclosure also provides an aerogel composite panel product.

[0014] Includes at least one layer of aerogel blanket;

[0015] The at least one layer of aerogel blanket is used to produce the aerogel composite board product according to the above-described production apparatus for aerogel composite boards.

[0016] According to the technical solution of this disclosure, compared with the prior art, this disclosure achieves stable, isolated transmission and high-precision shaping of multi-layer aerogel materials through the synergistic effect of the stepped layout of the gantry frame and multiple limiting structures; the linkage adjustment mechanism and differentiated pressing design ensure the uniformity of composite board thickness control, and the switchable sewing machine head effectively improves the interlayer bonding strength of products with different thickness specifications; at the same time, the application of simplified cutting device and closed-loop control system reduces equipment complexity and energy consumption, realizing efficient, high-quality, high-flatness and flexible continuous production of aerogel composite boards, greatly improving the user experience. Attached Figure Description

[0017] Figure 1 This is a side view and a top view schematic diagram of a production apparatus for aerogel composite panels according to an embodiment of the present disclosure.

[0018] Figure 2 This is a side view and a top view schematic diagram of a loading trolley according to an embodiment of the present disclosure.

[0019] The above and other features, advantages, etc., of the embodiments of this disclosure will become more apparent from the accompanying drawings and the following detailed description. In the drawings, the same or similar reference numerals denote the same or similar elements. It should be understood that the drawings are schematic, and the elements are not necessarily drawn to scale. Detailed Implementation

[0020] 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 disclosure belongs. The terminology used herein, in the specification of the application, is for the purpose of describing particular embodiments only and is not intended to be limiting of this disclosure. The term "comprising" and any corresponding variations thereof in the specification and claims of this disclosure are intended to cover a non-exclusive inclusion.

[0021] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this disclosure. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0022] Example 1

[0023] Reference Figure 1 As shown, this embodiment provides a production apparatus for aerogel composite boards. The apparatus, arranged sequentially along the aerogel blanket conveying direction, includes at least one unwinding device, a first limiting structure, a second limiting structure, a pressing device, a sewing machine head assembly, and a cutting device. Through the coordinated operation of these devices, the present invention achieves efficient and high-quality continuous composite production of multilayer aerogel materials.

[0024] Unwinding device

[0025] In the above embodiments, the unwinding device includes at least one set of gantry frames 101 and guide shaft assemblies 1011 disposed on the gantry frames. Specifically, multiple sets of gantry frames 101 can be set as needed along the production line direction, such as 2 sets, 5 sets, 10 sets, 15 sets, 20 sets, etc., without limitation. For example, when used for composite three-layer aerogel blankets, three sets of gantry frames are set, corresponding to the upper, middle, and lower layers of materials respectively. The guide shaft assembly 1011 on each set of gantry frames 101 is used to support and guide the corresponding layer of aerogel blanket. According to the production needs of the composite board product, each layer of material can be entirely aerogel blanket, or it can be partially aerogel blanket. For example, the upper and lower layers can be made of materials such as mesh cloth or aluminum foil fiberglass cloth, and the middle layer can be entirely aerogel blanket. Alternatively, mesh cloth and aerogel blanket can be alternately arranged, without limitation.

[0026] The guide shaft assembly 1011 is used to support and guide each layer of aerogel blanket. To ensure that the multilayer aerogel materials do not come into direct contact with each other during transport, and to avoid affecting the composite quality due to material adhesion or misalignment, the top elevation of each gantry 101 is set to be flush with each other or gradually decreasing along the transport direction. When the top elevation is set to be flush, the multilayer materials can be independently guided at the same horizontal level by guide shaft assemblies 1011 of different heights, parallel to each other and without contact. When set to decrease, the transport path of the upper layer material forms a certain slope with the lower layer material in space, which also achieves physical isolation. Through this stepped or flush layout design, the aerogel materials to be composite remain isolated from each other and do not come into direct contact during transport, fundamentally avoiding the interlayer adhesion and misalignment problems that easily occur in the unwinding and transport stages of multilayer materials in traditional processes.

[0027] Furthermore, to facilitate rapid material loading and rewinding, the unwinding device also includes a loading trolley 102. For example... Figure 2 As shown, the loading trolley 102 includes a support frame 201, a reel 202, a baffle 203, a positioning component 204, a fixing component (not shown), and rollers 205. A reel 202 for holding an aerogel blanket roll is rotatably mounted on the frame 201. A baffle 203 is adjustablely mounted on the reel 202. The operator can adjust the axial position of the baffle 203 on the reel 202 according to the width of the aerogel blanket roll. The baffle 203 restricts the axial position of the aerogel blanket roll, thus playing a basic guiding role during loading and unloading. This allows the aerogel blanket roll to achieve a certain degree of automatic directional adjustment during passive or active unloading, providing self-adaptive correction and ensuring uniform tension.

[0028] The loading trolley 102 can move flexibly via the rolling wheels 205. When loading is required, the loading trolley 102 carrying the new roll is moved to the corresponding gantry 101, and a sliding or rolling connection is achieved between the trolley and the guide rail on the gantry 101 via positioning components 204 (such as sliders or guide wheels), thereby ensuring precise docking of the loading trolley. Finally, the loading trolley 102 is fixed relative to the gantry 101 by fasteners (such as locking bolts or pins), and the unwinding operation can begin. This design enables rapid docking and positioning of materials, significantly reducing downtime for roll changes.

[0029] First limiting structure

[0030] In the above embodiment, the first limiting structure is disposed after the unwinding device and is used to apply an adjustable compressive force to the material being transported in the thickness direction, to pre-compress and shape the preliminary composite of the unwound multilayer material in the thickness direction, so as to limit the thickness of the material.

[0031] Specifically, the first limiting structure includes a fixed bracket 103, on which a first limiting shaft 1031 and a first pressure shaft 1032 are mounted. The first limiting shaft 1031 has adjustable-height first baffles on both sides, the distance between which covers the transmission path to prevent undesirable material deviation in the transmission width direction. The first pressure shaft 1032 is positioned above the material and is driven, for example, by a pressure regulating mechanism (such as a lead screw, cylinder, or hydraulic cylinder) to apply vertical pressure to the passing material. Combined with height adjustment, this precisely compresses the material thickness to a preset size. In actual operation, the compressive force applied by the first limiting structure can operate based on a preset pressure formula. For example, for a multi-layered material with an initial total thickness of 60mm, the pressure of the first pressure shaft 1032 can be adjusted to compress it to approximately 54mm to 57mm (i.e., a compression rate of 5%-10%), ensuring the internal bonding force of the material while preventing excessive damage to the microstructure of the aerogel, and simultaneously enhancing the bonding strength between the layers of aerogel blankets.

[0032] Second limiting structure

[0033] The second limiting structure is used to control the width of the composite material. It is configured to apply an adjustable constraint force to the material during transmission in the width direction to limit the width of the material. Specifically, the second limiting structure includes two second baffles 104 symmetrically arranged on both sides of the transmission path. Each second baffle 104 is driven by an independent screw adjustment mechanism or a manual adjustment screw to slide horizontally along a direction perpendicular to the transmission direction, thereby changing the distance between the two second baffles 104. This structure can quickly adapt to aerogel blankets of different widths, realizing flexible production of the equipment. For example, the distance between the two second baffles 104 can be adjusted by the adjustment mechanism to be equal to or slightly less than the target width of the currently produced aerogel composite board. When the material passes between the two second baffles 104, the baffles apply a lateral constraint force to the edges of the material to ensure a consistent material width.

[0034] Pressing device

[0035] In the above embodiments, the pressing device includes at least one height-adjustable power roller 105, used to cooperate with the first limiting structure and / or the second limiting structure to extrude multilayer aerogel material into a composite board to be sewn, at which time the interlayer bonding force between each layer of aerogel blanket is stronger. The power roller 105 itself has driving power, such as being driven by a servo motor, which can provide both the power to move the material forward and apply huge pressure. Its height adjustment mechanism (such as an eccentric sleeve, lifting screw, or hydraulic cylinder) can precisely control the gap between the roller and the lower support roller, thereby controlling the thickness of the final composite board and initially pressing and shaping the multilayer prepreg. The power roller 105 cooperates with the aforementioned first and second limiting structures to jointly ensure the dimensional accuracy of the composite board in the thickness and width directions. The pressing device can be set in front of, in the middle of, or behind the first or second limiting structure, and its relative position to the first or second limiting structure can be adjusted.

[0036] Furthermore, to achieve high-precision pressing control, the pressing device also includes multiple drive wheels. These drive wheels are divided into at least two groups, front and rear, each group containing multiple rollers arranged vertically (e.g., two rollers on each side of each group, for a total of four rollers). For this multi-roller structure, the production device also includes a linkage adjustment mechanism. This mechanism works with a winch via mechanical transmission gears. Rotating the winch allows for synchronous vertical lifting and lowering adjustment of the multiple rollers in each group through gear linkage, ensuring that the distance between these four rollers and the lower reference surface remains completely consistent, avoiding the unevenness of the pressing surface caused by separate adjustments.

[0037] Furthermore, the roller diameters and pressures of the front and rear sets of drive rollers are set as differentiated parameters. The front set of drive rollers has a larger roller diameter and applies greater pressure. This design accommodates the gradual decrease in material thickness during transport and pressing. When the material enters the pressing device, it is thicker, requiring a larger roller diameter and pressure for strong initial compression. As the material is transported forward and gradually compacted, its thickness gradually decreases, allowing the rear set to use less pressure and roller diameter to adapt to the change in material state. This design not only improves the uniformity of pressing but, more importantly, prevents abnormal healing of needle holes used for punctures due to excessive material deformation in subsequent sewing processes. This ensures clear and strong sewing stitches and guarantees the stable progress of subsequent sewing processes.

[0038] Sewing machine head assembly

[0039] After pressing, although the composite board has been initially formed, the interlayer bonding strength is still mainly achieved through physical extrusion. In order to permanently enhance the interlayer bonding strength, this device is equipped with a sewing machine head assembly 106. This assembly is located between the pressing device and the cutting device and is specifically used to sew the pressed composite board to be sewn, thereby forming a composite board to be cut. The sewing process significantly enhances the interlayer bonding strength of the multilayer composite board, solving the industry pain point of thick boards being prone to delamination.

[0040] Specifically, the sewing machine head assembly 106 is a switchable sewing machine head assembly to adapt to products of different thicknesses, comprising at least a first sewing machine head and a second sewing machine head. The first sewing machine head is equipped with a first-specification needle (e.g., a shorter, finer needle) for sewing composite panels within a first thickness range; the second sewing machine head is equipped with a second-specification needle (e.g., a slightly longer, thicker needle than the first-specification needle) for sewing composite panels within a second thickness range. The sewing machine head assembly 106 also includes a machine head switching drive mechanism, which may be, for example, a self-driving wheel type, a linear slide, a rotary platform, or a lifting mechanism. When the control system receives a production instruction and confirms the thickness specification of the current product, it automatically instructs the drive mechanism to move the corresponding sewing machine head (e.g., switching to the first sewing machine head for products with a thickness of 20-60mm) to the working position, while other sewing machine heads remain in standby or avoidance positions, thereby achieving automated switching without human intervention.

[0041] In a preferred embodiment, the sewing machine head assembly 106 includes three sewing machine heads: a first sewing machine head for sewing composite boards with a thickness of 20mm-60mm, with a needle length of 70mm-190mm and a needle diameter of 2.5mm-6.3mm; a second sewing machine head for sewing composite boards with a thickness of 70mm-100mm, with a needle length of 200mm-255mm and a needle diameter of 6.3mm-8.3mm; and a third sewing machine head for sewing composite boards with a thickness of 110mm-150mm, with a needle length of 260mm-320mm and a needle diameter of 8.3mm-10.3mm. By matching the appropriate needle diameter and length for different thicknesses, it ensures that the needle can effectively penetrate and form a strong stitch under various thicknesses, thereby significantly improving the anti-delamination performance of thick boards. It also avoids the problem of excessively large needle holes in thin aerogel blankets caused by coarse needles, which prevents the aerogel blanket from self-healing and reduces its thermal insulation performance.

[0042] When the target thickness falls within a certain range, the control system (described later) automatically sends a command to the sewing head switching drive mechanism to move the corresponding sewing head to the working position. Simultaneously, the control system automatically adjusts sewing process parameters based on the specifications of the switched sewing head, including but not limited to: sewing speed, stitch length, thread diameter, and thread tension.

[0043] The automatic matching of the above parameters ensures that the sewing process can be optimized simultaneously when switching between products of different thicknesses, avoiding the tedious process of manually adjusting sewing parameters after manually switching the machine head, and reducing quality problems such as broken needles, broken threads, or weak sewing caused by parameter mismatch.

[0044] Cutting device

[0045] In the above embodiments, the sewn composite board to be cut is fed into a cutting device, which includes a cutting unit 107 for cutting the composite board to a preset length to form a composite board product. Specifically, depending on different production needs, the cutting unit 107 of the cutting device can be a laser cutter, a wire cutter, or a circular saw blade cutter, etc. Laser cutting is suitable for high-precision, dust-free cutting scenarios, producing clean cuts with a cutting width controllable between 1-5mm; when using wire cutting, it eliminates the need for cylinder clamps and complex dust removal systems, simplifying the equipment structure.

[0046] In addition, the cutting device also includes a meter counter set on the transmission path, which is used to measure the length of the composite board to be cut in real time and feed the signal back to the control system. The control system is preset with the required product length. When the real-time length fed back by the meter counter reaches the preset value, the control system automatically controls the cutting unit to perform the cutting action according to the preset length, so as to realize the automatic cutting of the material to the specified length.

[0047] Pushing device

[0048] A pusher device 108 can also be provided after the cutting device to automatically push the cut composite board products from the cutting station to the unloading area or collection station.

[0049] Specifically, the pushing device 108 includes a pusher plate, a drive mechanism, and a guide rail. The pusher plate is positioned above or to the side of the transmission path downstream of the cutting station, with its working surface facing the composite board product to be pushed out. The drive mechanism can employ linear drive components such as cylinders, hydraulic cylinders, electric push rods, or servo motor-driven screw-nut mechanisms to drive the pusher plate to perform a pushing action perpendicular to or along the transmission direction. The guide rail is used to ensure the linearity and stability of the pusher plate's movement.

[0050] After the cutting unit 107 of the cutting device completes one cutting operation, the control system sends a command to the pushing device. The drive mechanism drives the pusher plate forward, smoothly pushing the cut composite board product from the conveyor line to the unloading table or stacking area. After pushing is completed, the pusher plate automatically resets under the drive mechanism, waiting for the next push. The pushing device ensures that the cut products can be removed from the production line in a timely and orderly manner, avoiding the accumulation of products at the cutting station and affecting subsequent continuous production, thus improving the automation level and operating efficiency of the entire production line.

[0051] Here, the pushing speed and pushing stroke of the pushing device can be adjusted according to the thickness, length, and weight of the composite board product to meet the feeding requirements of products of different specifications. In a preferred embodiment, the pushing device is also equipped with a buffer pad layer, which covers the working surface where the pushing plate contacts the product to avoid scratches or indentations on the surface of the composite board during the pushing process.

[0052] control system

[0053] The production apparatus disclosed herein also includes a control system, which is communicatively connected to, for example, the unwinding device, the first limiting structure, the second limiting structure, the pressing device, the sewing machine head assembly, the cutting device, and the feeding device, for centralized monitoring and coordinated control of the entire production line's operating status. The control system includes, for example, a data acquisition module, a data storage module, a process parameter database, an intelligent decision-making module, and a self-learning module.

[0054] The data acquisition module includes various sensors deployed at each station of the production line, such as thickness sensors installed at the exits of the first limiting structure and the pressing device, used to collect material thickness data in real time after passing through each station. The thickness sensors are laser rangefinders or contact displacement sensors with a sampling frequency of no less than 100Hz, capable of capturing thickness fluctuations of the material in the transmission direction.

[0055] A width sensor, located at the exit of the second limiting structure, is used to collect material width data in real time. The width sensor can be a through-beam photoelectric sensor array, arranged on both sides of the transmission path. The actual width of the material is obtained by measuring the obstruction distance between the two sensors.

[0056] Tension sensors mounted on the guide shaft assembly of the unwinding device are used to monitor the tension changes of each layer of aerogel blanket in real time during the unwinding process. When the tension of a certain layer of material exceeds the preset safety threshold range, the control system will issue a warning signal or automatically adjust the damping parameters of the unwinding device.

[0057] The sewing status sensors located at the sewing machine head assembly include a needle puncture force sensor and a thread tension sensor. The needle puncture force sensor monitors the force curve of the needle in real time during each puncture, while the thread tension sensor monitors the real-time tension of the sewing thread. When abnormal fluctuations occur in the puncture force curve, the control system can determine whether the needle is worn or the material is abnormal.

[0058] The data acquisition module aggregates real-time data from the aforementioned sensors to the control system's data bus. The intelligent decision-making module then performs multi-sensor data fusion processing, correlating and analyzing sensor data from different workstations. For example, when the thickness sensor at the pressing device's outlet detects an abnormal thickness deviation, the control system simultaneously retrieves data from the tension sensor of the unwinding device and the pressure data from the first limit structure. Through joint analysis of multi-dimensional data, it determines whether the root cause of the thickness deviation stems from uneven unwinding tension, limit pressure offset, or a problem with the pressing device itself, thereby achieving precise fault location and process adjustment.

[0059] In one or more embodiments, the control system further includes an intelligent thickness adaptive control function that works in conjunction with the switchable sewing head design of the sewing head assembly to form a fully closed-loop thickness adaptive control chain from detection to execution.

[0060] Specifically, the control system has pre-set product specification information, including target thickness parameters. Before production begins, the operator inputs the target product thickness (e.g., 75mm) for the current production task through a human-machine interface. Based on this target thickness value, the control system automatically retrieves the corresponding combination of process parameters from a pre-set process parameter database. This combination of process parameters includes at least: the compression ratio parameter of the first limiting structure, the width spacing parameter of the second limiting structure, the pressure and gap parameters of the front and rear drive wheels of the pressing device, and the sewing machine head switching command for the sewing machine head assembly.

[0061] During production, when the deviation between the material thickness detected in real-time by the thickness sensor and the target thickness exceeds a preset allowable range (e.g., ±2mm), the intelligent decision-making module initiates a thickness adaptive adjustment program. Based on the direction and magnitude of the deviation, the program coordinates the parameters of relevant workstations according to a preset linkage adjustment strategy. For example:

[0062] When an excessive thickness is detected, the control system first determines the magnitude of the deviation. If the deviation is within the adjustable range of the first limit structure (e.g., +1mm to +3mm), the control system prioritizes fine-tuning the downward pressure of the first pressure shaft of the first limit structure, while simultaneously making compensatory fine-tuning of the clearance of the power rolling shaft of the pressing device. If the deviation exceeds the adjustment range of the first limit structure, the control system further increases the pressure of the front set of drive wheels of the pressing device, and, if necessary, synchronously adjusts the pressure of the rear set of drive wheels to maintain the differential ratio between the front and rear pressing processes.

[0063] When the thickness is consistently too low and accompanied by an abnormally high sewing puncture force, the control system determines that the material may be over-compacted, leading to the healing of the sewing needle hole. At this point, the control system automatically reduces the pressure of the rear drive wheel of the pressing device while maintaining the pressure of the front drive wheel unchanged, in order to restore the elastic gap of the material and ensure the normal formation of the needle hole in subsequent sewing processes.

[0064] Multi-station linkage thickness adaptive control enables the entire production line to be dynamically adjusted according to the real-time status of the material, rather than relying on manual experience to adjust the parameters of each station one by one, which significantly improves the consistency of product thickness and production efficiency.

[0065] In one or more embodiments, the control system further includes, for example, an online monitoring function for sewing stitch quality. A stitch vision inspection device, comprising an industrial camera and an image processing unit, is disposed downstream of the sewing machine head assembly.

[0066] An industrial camera, for example, is mounted above the transport path downstream of the sewing station to capture images of the composite board surface after sewing, taken vertically downwards. The image processing unit processes the acquired images in real time, identifying aspects such as stitch continuity, stitch straightness, stitch spacing uniformity, and stitch density.

[0067] When the image processing unit detects that the line quality index is lower than the preset standard, the control system performs real-time parameter adjustment, line break alarm and shutdown or quality marking.

[0068] The real-time parameter adjustment includes automatically fine-tuning the sewing speed or stitch length parameters of the sewing machine head when uneven stitch spacing or stitch deviation is detected, while simultaneously adjusting the output speed of the pressing device to maintain the synchronization between the sewing speed and the transmission speed.

[0069] The thread breakage alarm and shutdown function includes the control system immediately issuing an audible and visual alarm signal when a thread breakage is detected, and controlling the sewing machine head assembly to stop working, awaiting operator intervention.

[0070] The quality marking includes recording the location information of a localized line defect when it is detected but does not meet the shutdown criteria, as well as associating it with the corresponding product number. At the same time, the control system adds a quality marking signal (such as marking the product edge) when pushing the product, so that subsequent quality inspection processes can focus on checking it.

[0071] The control system is also connected in communication with the pressure adjustment mechanism of each drive wheel of the pressing device to realize intelligent adjustment of differentiated pressure.

[0072] As mentioned earlier, the front and rear sets of drive rollers in the pressing device are designed with differentiated parameters: the front set has a larger roller diameter and applies greater pressure, while the rear set has a smaller roller diameter and applies less pressure. The control system has a pre-set differentiated pressure ratio model that defines the proportional relationship between the front and rear pressures.

[0073] During the production process, the control system dynamically adjusts differentiated pressure parameters based on factors such as the number of material layers, material thickness, and sewing puncture force feedback.

[0074] The differentiated pressure intelligent adjustment function enables the pressing device to operate without relying on fixed parameters. Instead, it can dynamically optimize based on the material condition and feedback from downstream processes, ensuring the best balance between pressing effect and sewing quality.

[0075] In one or more embodiments, the control system further includes a data storage module and a self-learning module. During each production process, the data storage module stores the following data in association: production batch number, product specifications, real-time data and statistical characteristic values ​​of each sensor, actual control parameters of each actuator, stitch quality inspection results and records of quality anomalies, and interlayer bonding force detection data (when equipped with an online or offline bonding force detection device).

[0076] The self-learning module, based on historical production data, uses statistical learning methods to model the relationship between process parameters and product quality. For example, it analyzes the differences in process parameters between batches that meet and fail to meet product quality standards in historical data, identifies the key parameters with the greatest impact on product quality and their optimal value ranges, and updates the optimized parameter recommendations to the process parameter database for automatic use in subsequent production tasks. It can also establish a needle wear trend prediction model through time series analysis of sewing puncture force curves. When the remaining service life of the needle is predicted to be lower than a preset threshold, the control system issues an early needle replacement warning to avoid a decline in sewing quality due to excessive needle wear. The self-learning module can also correlate interlayer bonding force detection data (bonding strength of 100N to 8000N within a thickness range of 20mm to 150mm) with the corresponding batch's sewing parameters (needle specifications, needle pitch, sewing thread diameter and tension) and pressing parameters (pressure and gap between front and rear groups) to establish a bonding strength prediction model. This model can predict the interlayer bonding strength of the product in real time based on the current process parameters during the production process. When the predicted value is lower than the target bonding strength requirement, the control system automatically adjusts the sewing parameters or pressing parameters to achieve feedforward control of the bonding strength.

[0077] Aerogel composite board products

[0078] The present invention also provides an aerogel composite board product. This product comprises at least one aerogel blanket, obtained by the aforementioned production apparatus for aerogel composite boards.

[0079] Specifically, the aerogel composite board product is continuously processed from multiple layers of aerogel blankets through processes such as unwinding and guiding, isolation and transmission, dual limiting and shaping in the thickness and width directions, multi-level differentiated rolling composite, sewing reinforcement, and fixed-length cutting. Each layer of aerogel blanket remains physically isolated before entering the pressing process, preventing premature adhesion and misalignment between layers. After being constrained by both the first and second limiting structures, the material achieves precise dimensional control in both the thickness and width directions. The differentiated roller design at the front and rear of the pressing device ensures a uniform transition from thick to thin material during pressing, while preserving the needle hole channels required for subsequent sewing. The sewing machine head assembly automatically switches to the appropriate needle according to the board thickness, forming a sewing stitch that penetrates multiple layers of material, significantly enhancing the interlayer bonding force.

[0080] The aerogel composite board product produced by this invention has the following characteristics:

[0081] (1) Wide range of thickness: The product thickness can be flexibly adjusted from 20mm to 150mm to meet the needs of different insulation levels and application scenarios. Through the three-level switching mechanism of the sewing machine head assembly, products in the three thickness ranges of 20mm-60mm, 70mm-100mm and 110mm-150mm can achieve high-quality sewing.

[0082] (2) High dimensional accuracy: Due to the dual constraints of the thickness and width imposed by the first and second limiting structures, as well as the synchronous control of the pressing plane by the linkage adjustment mechanism, the thickness deviation of the product can be controlled within ±2mm, the width deviation can be controlled within ±3mm, and the edges are neat and the cuts are flat.

[0083] (3) Excellent interlayer bonding strength: The interlayer bonding strength of the produced aerogel composite board products was tested. The test results showed that the interlayer bonding strength of aerogel composite boards with a sewing thickness of 20mm to 150mm ranged from 100N to 8000N. Among them, the interlayer bonding strength of thinner composite boards (such as 20mm-60mm) is usually in the range of 100N to a lower value due to the relatively fewer sewing layers and moderate stitch density. As the board thickness increases, the needle size increases accordingly (needle diameter increases from 6.3mm to 10mm), and the thread diameter also increases. In addition, the interlayer friction of the thicker board itself is greater, so the interlayer bonding strength of thicker composite boards (such as 110mm-150mm) can reach a high value of up to 8000N. This wide range of bonding strength fully demonstrates that the sewing reinforcement process of the present invention can effectively improve the interlayer bonding performance under different thickness specifications, solving the industry pain point of easy delamination of traditional pure press-fit composite boards.

[0084] (4) Good cut quality: Laser cutting or wire cutting is used for cutting, the cut width is controllable, the cut surface is neat and burr-free, and no secondary trimming is required.

[0085] (5) Good product consistency: The closed-loop cooperation between the meter counter and the control system ensures the precise consistency of the length of each product, and the overall size consistency of the batch of products is high, which is beneficial to subsequent engineering installation and construction.

[0086] It should be noted that the accompanying drawings and the above embodiments are only used to exemplify the principles and core concepts of the present invention, and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0087] The features of the embodiments according to this disclosure are briefly summarized and listed below.

[0088] According to one or more embodiments of this disclosure, an apparatus for producing aerogel composite panels is provided, comprising:

[0089] At least one set of unwinding device, first limiting structure, second limiting structure, pressing device, sewing machine head assembly and cutting device are arranged sequentially along the conveying direction of aerogel blanket;

[0090] The unwinding device includes at least one set of gantry frames and a guide shaft assembly disposed on the gantry frames. The guide shaft assembly is used to support and guide each layer of aerogel blanket. The top elevation of each gantry frame is set to be flush with each other or to decrease step by step along the transport direction so that the aerogel materials to be laminated do not come into direct contact with each other during transport.

[0091] The first limiting structure is configured to apply an adjustable compressive force to the material in the transmission direction in the thickness direction to limit the thickness of the material;

[0092] The second limiting structure is configured to apply an adjustable constraint force to the material in transit in the width direction to limit the width of the material;

[0093] The pressing device includes at least one height-adjustable power rolling shaft for cooperating with the first limiting structure and / or the second limiting structure to extrude multilayer aerogel material to form a composite plate to be stitched.

[0094] The sewing machine head assembly is disposed between the pressing device and the cutting device, and is used to sew the composite board to be sewn to form the composite board to be cut.

[0095] The cutting device includes a cutting unit for cutting the composite board to be cut to a preset length to form a composite board product.

[0096] According to one or more embodiments of this disclosure, an apparatus for producing aerogel composite panels is provided, comprising:

[0097] The unwinding device also includes a feeding trolley;

[0098] The loading trolley includes a frame, a roller mounted on the frame, baffles adjustablely mounted on the roller, positioning components, fixing components, and rolling wheels;

[0099] The spool is used to hold the aerogel blanket roll, and the baffle is used to limit the axial position of the aerogel blanket roll within a certain range, so that the aerogel blanket roll can automatically adjust its direction during transmission.

[0100] The loading trolley is slidably or rollably connected to the gantry frame via the positioning component, and is fixed relative to the gantry frame via the fixing component.

[0101] According to one or more embodiments of this disclosure, an apparatus for producing aerogel composite panels is provided, comprising:

[0102] The first limiting structure includes:

[0103] A fixed bracket is provided with a first limiting shaft and a first pressure shaft;

[0104] The first limiting shaft is provided with adjustable height first baffles on both sides, and the distance between the first baffles on both sides covers the transmission path;

[0105] The first pressure shaft is used to apply vertical pressure to the material passing through it to achieve a preset thickness.

[0106] According to one or more embodiments of this disclosure, an apparatus for producing aerogel composite panels is provided, comprising:

[0107] The second limiting structure includes:

[0108] Two second baffles symmetrically positioned on either side of the transmission path;

[0109] Each second baffle is driven by an independent screw adjustment mechanism or a manual adjustment screw, allowing it to slide horizontally along the direction perpendicular to the transmission direction to change the spacing between the two second baffles, thus accommodating aerogel blankets of different widths.

[0110] According to one or more embodiments of this disclosure, an apparatus for producing aerogel composite panels is provided, comprising:

[0111] The pressing device also includes multiple drive wheels, which are divided into at least two groups, front and rear, and each group includes multiple rollers arranged vertically and vertically.

[0112] The production device also includes a linkage adjustment mechanism, which works with a winch through mechanical transmission gears to achieve synchronous adjustment of the uniform height of multiple rollers in each group.

[0113] According to one or more embodiments of this disclosure, an apparatus for producing aerogel composite panels is provided, comprising:

[0114] The roller diameter and pressure of the two sets of drive wheels are set as differentiated parameters;

[0115] The front set of drive rollers has a larger roller diameter than the rear set and applies greater pressure to accommodate the gradual decrease in material thickness during transmission and pressing, while preventing abnormal healing of the needle holes used for puncture due to material deformation.

[0116] According to one or more embodiments of this disclosure, an apparatus for producing aerogel composite panels is provided, comprising:

[0117] The sewing machine head assembly is a switchable sewing machine head assembly, comprising at least a first sewing machine head and a second sewing machine head;

[0118] The first sewing machine head is equipped with a needle of a first specification for sewing composite panels of a first thickness range;

[0119] The second sewing machine head is equipped with a needle of a second specification for sewing composite panels of a second thickness range, which is different from the first thickness range.

[0120] The sewing machine head assembly also includes a machine head switching drive mechanism, which is used to automatically switch the sewing machine head corresponding to the current sheet thickness to the working position according to the production instructions.

[0121] According to one or more embodiments of this disclosure, an apparatus for producing aerogel composite panels is provided, comprising:

[0122] The first sewing machine head is used to sew composite boards with a thickness of 20mm-60mm, and its needle length is 190mm and its needle diameter is 6.3mm;

[0123] The second sewing machine head is used to sew composite boards with a thickness of 70mm-100mm, and its needle length is 255mm and its needle diameter is 8.3mm;

[0124] The sewing machine head assembly also includes a third sewing machine head for sewing composite boards with a thickness of 110mm-150mm, with a needle length of 320mm and a needle diameter of 10mm.

[0125] According to one or more embodiments of this disclosure, an apparatus for producing aerogel composite panels is provided, comprising:

[0126] The cutting unit of the cutting device is a laser cutting machine or a wire cutting machine;

[0127] The cutting device also includes a meter set on the transmission path for measuring the length of the composite board to be cut in real time and feeding the signal back to the control system. The control system controls the cutting unit to perform the cutting action according to the preset length.

[0128] According to one or more embodiments of this disclosure, an aerogel composite board product is provided, comprising: at least one aerogel blanket;

[0129] The at least one layer of aerogel blanket is produced by the aerogel composite panel product obtained by the production apparatus for aerogel composite panels according to any one of the preceding claims;

[0130] The interlayer bonding strength of the aerogel composite board product ranges from 100N to 8000N.

[0131] The above description is merely a preferred embodiment of this disclosure and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of this disclosure is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the above-described concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features disclosed in this disclosure that have similar functions.

Claims

1. A production apparatus for aerogel composite panels, characterized in that, include: At least one set of unwinding device, first limiting structure, second limiting structure, pressing device, sewing machine head assembly and cutting device are arranged sequentially along the conveying direction of aerogel blanket; The unwinding device includes at least one set of gantry frames and a guide shaft assembly disposed on the gantry frames. The guide shaft assembly is used to support and guide each layer of aerogel blanket. The top elevation of each gantry frame is set to be flush with each other or to decrease step by step along the transport direction so that the aerogel materials to be laminated do not come into direct contact with each other during transport. The first limiting structure is configured to apply an adjustable compressive force to the material in the transmission direction in the thickness direction to limit the thickness of the material; The second limiting structure is configured to apply an adjustable constraint force to the material in transit in the width direction to limit the width of the material; The pressing device includes at least one height-adjustable power rolling shaft for cooperating with the first limiting structure and / or the second limiting structure to extrude multilayer aerogel material to form a composite plate to be stitched. The sewing machine head assembly is disposed between the pressing device and the cutting device, and is used to sew the composite board to be sewn to form the composite board to be cut. The cutting device includes a cutting unit for cutting the composite board to be cut to a preset length to form a composite board product.

2. The production apparatus for aerogel composite panels according to claim 1, characterized in that, The unwinding device also includes a feeding trolley; The loading trolley includes a frame, a roller mounted on the frame, baffles adjustablely mounted on the roller, positioning components, fixing components, and rolling wheels; The spool is used to hold the aerogel blanket roll, and the baffle is used to limit the axial position of the aerogel blanket roll within a certain range, so that the aerogel blanket roll can automatically adjust its direction during transmission. The loading trolley is slidably or rollably connected to the gantry frame via the positioning component, and is fixed relative to the gantry frame via the fixing component.

3. The production apparatus for aerogel composite panels according to claim 1, characterized in that, The first limiting structure includes: A fixed bracket is provided with a first limiting shaft and a first pressure shaft; The first limiting shaft is provided with adjustable height first baffles on both sides, and the distance between the first baffles on both sides covers the transmission path; The first pressure shaft is used to apply vertical pressure to the material passing through it to achieve a preset thickness.

4. The production apparatus for aerogel composite panels according to claim 1, characterized in that, The second limiting structure includes: Two second baffles symmetrically positioned on either side of the transmission path; Each second baffle is driven by an independent screw adjustment mechanism or a manual adjustment screw, allowing it to slide horizontally along the direction perpendicular to the transmission direction to change the spacing between the two second baffles, thus accommodating aerogel blankets of different widths.

5. The production apparatus for aerogel composite panels according to claim 1, characterized in that, The pressing device also includes multiple drive wheels, which are divided into at least two groups, front and rear, and each group includes multiple rollers arranged vertically and vertically. The production device also includes a linkage adjustment mechanism, which works with a winch through mechanical transmission gears to achieve synchronous adjustment of the uniform height of multiple rollers in each group.

6. The production apparatus for aerogel composite panels according to claim 5, characterized in that, The roller diameter and pressure of the two sets of drive wheels are set as differentiated parameters; The front set of drive rollers has a larger roller diameter than the rear set and applies greater pressure to accommodate the gradual decrease in material thickness during transmission and pressing, while preventing abnormal healing of the needle holes used for puncture due to material deformation.

7. The production apparatus for aerogel composite panels according to claim 1, characterized in that, The sewing machine head assembly is a switchable sewing machine head assembly, comprising at least a first sewing machine head and a second sewing machine head; The first sewing machine head is equipped with a needle of a first specification for sewing composite panels of a first thickness range; The second sewing machine head is equipped with a needle of a second specification for sewing composite panels of a second thickness range, which is different from the first thickness range. The sewing machine head assembly also includes a machine head switching drive mechanism, which is used to automatically switch the sewing machine head corresponding to the current sheet thickness to the working position according to the production instructions.

8. The production apparatus for aerogel composite panels according to claim 7, characterized in that: The first sewing machine head is used to sew composite boards with a thickness of 20mm-60mm, and its needle length is 70mm-190mm and the needle diameter is 2.5mm-6.3mm; The second sewing machine head is used to sew composite boards with a thickness of 70mm-100mm, and its needle length is 200mm-255mm, and the needle diameter is 6.3mm-8.3mm; The sewing machine head assembly also includes a third sewing machine head for sewing composite boards with a thickness of 110mm-150mm, with a needle length of 260mm-320mm and a needle diameter of 8.3mm-10.3mm.

9. The production apparatus for aerogel composite panels according to claim 1, characterized in that, The cutting unit of the cutting device is a laser cutting machine or a wire cutting machine; The cutting device also includes a meter set on the transmission path for measuring the length of the composite board to be cut in real time and feeding the signal back to the control system. The control system controls the cutting unit to perform the cutting action according to the preset length.

10. An aerogel composite board product, characterized in that, Includes at least one layer of aerogel blanket; The at least one layer of aerogel blanket is produced by the aerogel composite board product obtained by the production apparatus for aerogel composite boards according to any one of claims 1-9. The interlayer bonding strength of the aerogel composite board product ranges from 100N to 8000N.

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