Synthetic leather refining, bonding, heating and texture absorbing integrated experimental method

Abstract

This invention discloses an integrated experimental method for synthetic leather refining, bonding, heating, and texturing. It employs an integrated experimental machine consisting of a two-roller refining machine with a rotary refining and bonding device and a sliding heating and texturing device. The method includes refining material preparation, base fabric clamping, online bonding, material connection, intermittent multi-segment heating and texturing, and fixed-length cutting sampling steps. This invention integrates the entire process of refining, online bonding, heating and softening, vacuum texturing, and fixed-length cutting into a continuous operation, eliminating the need for manual process switching, fully utilizing the residual heat from refining to reduce energy consumption, and not interfering with conventional refining operations. The intermittent conveying mode allows for the preparation of multiple sets of parallel samples on a single material strip. The samples exhibit uniform bonding strength, high texture reproduction, and strong consistency among parallel samples, effectively improving the reliability of experimental data, significantly shortening the synthetic leather R&D sampling cycle, and adapting to various laboratory refining equipment and diverse texture sampling needs.

Description

Technical Field

[0001] This invention belongs to the field of synthetic leather experimental preparation technology, specifically involving an integrated laboratory sampling method for synthetic leather that integrates plasticizing, online bonding, intermittent heating, and vacuum texturing. Background Technology

[0002] In the research and development of new synthetic leather, it is necessary to first verify the formula and prepare small samples using a laboratory two-roll mill to confirm the compliance of the material formula, color, and texture. Traditional laboratory prototyping processes are fragmented; the mill can only complete the mixing and plasticizing of polymer materials, while the bonding of the hot sheet to the base fabric and the shaping of the leather texture require separate manual operations, which has the following drawbacks: 1. Uneven pressure during manual bonding results in poor consistency in bonding strength, leading to large deviations in test data such as sample tensile strength and feel, which cannot accurately reflect the performance of the formula; 2. Texture forming requires separate equipment, the prototyping process is long and inefficient, it cannot quickly present the final product effect, and the research and development cycle is long; 3. Manual operation relies on experience, and the samples prepared by different operators and different batches vary greatly. The consistency of parallel samples is poor, the reproducibility of experiments is weak, and the value of guiding research and development is limited. 4. Only a single sample can be prepared per batch. When conducting multiple sets of performance comparison tests, repeated sampling is required, which is labor-intensive and the condition of different batches of sample varies, resulting in weak comparability of test data.

[0003] Currently, there is no laboratory-integrated experimental method that can achieve continuous connection of the entire process, which cannot meet the needs of efficient and high-quality synthetic leather research and development sampling. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing laboratory synthetic leather prototyping processes, such as fragmented processes, high reliance on manual labor, and poor consistency of parallel samples. It provides an integrated experimental method for synthetic leather refining, bonding, heating, and texturing, which realizes the automated connection of online bonding of molten material, intermittent heating and texturing, and fixed-length cutting. Multiple sets of highly consistent test samples can be prepared on a single strip of material, thereby improving prototyping efficiency and sample quality stability.

[0005] To achieve the above-mentioned objectives, this invention employs a dedicated integrated experimental machine to perform the entire process. The overall technical solution is as follows: (I) Main Structure of the Integrated Experimental Machine The integrated testing machine is composed of a two-roller plasticizer and a heating and suction device connected in the front and rear along the material flow direction. The entire process does not require manual transfer of samples (only manual guidance and cutting of samples are required).

[0006] 1. Rotary plastic bonding module This module is installed on the upper front side of a two-roller plasticizer, using the existing baffle plate as the installation reference, without requiring any modification to the main structure of the plasticizer. The module uses a rotating shaft as the core rotating component, with symmetrically arranged adjustable rotating arms on both sides. Along the radial direction of each rotating arm, a fabric clamping roller, a bonding roller, and a base fabric roller are sequentially installed, all three rollers being parallel to the plasticizer's rollers. The rotating shaft is driven by a rotary power unit, enabling precise switching of the entire rotating arm between two positions: when rotating upwards to the plasticizer clearance position, all rollers rise above the rollers, completely clearing the plasticizer operating space without affecting routine operations such as manual feeding and material turning; when rotating downwards to the bonding working position, the bonding roller presses the base fabric onto the molten material layer on the roller surface with constant pressure, achieving online bonding of the molten material and the base fabric.

[0007] The module is equipped with a rotation angle limiting device. Through a limit rod and a double limit switch, it precisely limits the extreme rotation angles of the two stations, ensuring that the pressing amount and pressure are completely consistent for each bonding operation. The fabric clamping roller is synchronously driven by dual-path, same-source cylinders, applying uniform tension to the entire fabric width to prevent misalignment and wrinkling. The rotating arm uses an adjustable structure with elongated holes in the upper and lower arm plates, allowing for flexible adjustment of the effective arm length to accommodate laboratory two-roller plasticizers with different roller diameters. The fabric roller adopts a rotating mounting structure, with a coaxially connected magnetic powder brake on the right end. This allows for real-time adjustment of damping to counteract changes in roll diameter during unloading, achieving constant tension unloading of the fabric and completely preventing fabric breakage, wrinkling, or misalignment.

[0008] 2. Heating and Texture Absorption Integrated Module This module uses a sliding cabinet as its carrier and adopts a vertically layered layout inside. From top to bottom, it is equipped with a front and rear horizontal telescopic mesh belt conveyor, a rotating heating cover, a lifting vacuum suction assembly, and a front and rear pull-out tray. The upper rear side of the cabinet integrates a fabric cutting assembly. The compact structure is suitable for the limited space of the laboratory.

[0009] The front and rear horizontal telescopic mesh belt conveyor uses a breathable conveyor mesh belt and is equipped with movable guide rollers that can extend and retract forward and backward. With the overall sliding of the cabinet, the receiving position can be adjusted in two dimensions to accurately connect with the discharge end of the bonding process. The mesh belt adopts an intermittent conveying mode, which can accurately control the conveying step length and realize segmented processing of multiple sections of a single material belt.

[0010] The rotary heating cover has a built-in electric heating tube and can be rotated within a 90° range by a swing cylinder. When in the heating position, it is in a horizontal state, which provides uniform radiation heating to the leather surface on the mesh belt from below, softening the surface polymer material. When in the texturing position, it is flipped upward to a vertical folded state, completely avoiding the lifting space and preventing interference with the rising texturing components.

[0011] The lifting vacuum texturing assembly consists of a lifting drive, a vacuum pump, and a vacuum texturing device. The top of the vacuum texturing device is fitted with a quickly replaceable breathable pattern plate, and an array of conical support blocks are set inside to form a horizontally penetrating and uniform negative pressure chamber in the groove, which solves the problem of uneven suction between the center and the edge when texturing a large area. The negative pressure acts on the leather surface through the micropores of the breathable pattern plate, so that the softened leather surface can absorb and replicate the texturing pattern, which is then set after cooling.

[0012] The fabric cutting assembly consists of a cutting pad with a horizontal slit and a cutting blade. The slit provides a guide for cutting, ensuring straight cuts without fraying or rough edges, while also preventing the cutting blade from scratching the mesh belt and the equipment body. After cutting, the finished product can fall directly into the pull-out tray below, making sampling and cleaning convenient.

[0013] (II) Core Procedures of the Integrated Experimental Method This method is based on the core logic of "online bonding without transfer of orders, and intermittent processing to produce parallel samples", and proceeds in the following steps: S1. Plasticizing preparation: First, rotate and lift the rotary plasticizing bonding device to the plasticizing clearance position. After confirming that there is no interference in the operating space, start the two-roll plasticizing machine, put in the weighed polymer mixture for heating and mixing. When the material is completely plasticized and a uniform molten material layer is formed on the roller surface, the plasticizing preparation is completed.

[0014] S2. Base fabric clamping: The base fabric is fed simultaneously during the plasticizing process. The base fabric roll is installed on the base fabric roller. After the free end of the base fabric is pulled around the bonding roller, the base fabric is clamped and tensioned by the synchronous clamping cylinder to ensure that the tension of the base fabric is uniform and without wrinkles or skew, which provides a foundation for subsequent uniform bonding.

[0015] S3. Online bonding: After the molten material layer reaches the required state, the rotary plasticizing bonding device is driven to rotate downwards to the bonding work position, where it is precisely positioned and locked by the limiting device. The bonding roller presses the base fabric with constant pressure on the surface of the molten material layer on the roller. The base fabric moves forward synchronously by the traction force of the roller rotation. Under the combined action of pressure and residual heat from plasticizing, the molten material is evenly adhered to the lower surface of the base fabric and is compacted twice by the gap between the two rollers to form a continuous synthetic leather semi-finished material strip. No manual peeling and transfer is required throughout the process.

[0016] S4. Material Receiving and Joining: Before the bonding start, drive the heating and suction cabinet to move horizontally towards the plasticizing machine. At the same time, extend the movable guide roller of the mesh belt. Adjust in two dimensions to ensure that the rear end of the conveyor mesh belt accurately connects with the material discharge position, smoothly receiving the semi-finished material belt and avoiding bending or scratching the molten material surface.

[0017] S5. Intermittent Multi-Segment Heating and Texture Absorption: Employing an intermittent (convey-stop-process) operation mode, the bonding station and the texture absorption station are linked and controlled: The conveyor belt feeds material forward at preset steps, stopping after conveying one sample segment length; first, a rotating heating hood radiates heat to soften the surface of the current segment, then the heating hood flips to avoid interference, and the vacuum texture absorption component rises to bond with the leather surface, initiating vacuum negative pressure to complete texture shaping; after texture absorption, the component descends to reset, and the conveyor belt continues to convey the next segment, repeating this cycle to complete the processing of multiple sample segments on the same continuous material belt. The same material belt shares completely consistent plasticizing, bonding, and heating process conditions, eliminating batch-to-batch preparation errors at the source and producing highly consistent parallel test samples.

[0018] S6. Fixed-length cutting and sampling: After all sample sections are processed, the material strip is attached to the surface of the cutting mat, the cutter is aligned with the seam and then slid along the guide to cut the material strip flat in one go; the finished sample falls from the mesh into the tray below by its own weight, and the sample can be taken out by pulling out the tray to complete the whole process experiment.

[0019] In summary, the present invention has the following overall beneficial effects: This invention addresses the industry pain points of fragmented laboratory synthetic leather prototyping processes, high reliance on manual labor, and poor consistency among parallel samples. Through an integrated architecture design combining "rotary online bonding + intermittent heating and texturing + integrated fixed-length cutting," it achieves systematic improvements in multiple dimensions, including R&D efficiency, sample quality, equipment compatibility, and operational safety, compared to traditional manual sequential prototyping methods. Specific beneficial effects are as follows: 1. The entire process chain is integrated, significantly shortening the R&D prototyping cycle and improving the efficiency of experimental iteration. Traditional laboratory prototyping requires multiple steps: "hot material sheet from plasticizer → manual sheet removal and transfer → manual bonding to base fabric → transfer to texturing equipment → secondary heating and texturing." The entire process involves manual transfer at multiple workstations, and each batch of samples takes a long time. Furthermore, the natural cooling during the hot material transfer process can easily lead to problems such as poor bonding and poor texture formation, often requiring repeated rework.

[0020] This invention integrates six core processes—plasticizing, online bonding, continuous conveying, heating and softening, vacuum texturing, and fixed-length cutting—into a single device. The bonding process is completed online directly on the rollers of the plasticizing machine, and the texturing process is automatically connected via a mesh belt, eliminating the need for manual handling and transfer of samples. This reduces the single-batch sampling cycle by more than 60% compared to traditional methods. At the same time, it fully utilizes the residual heat from plasticizing to complete the initial bonding, reducing the waiting time for secondary heating. This allows for rapid formula verification and texture adjustment, significantly accelerating the speed of new product development and iteration.

[0021] 2. The molding quality is uniform and stable, with strong consistency among parallel samples, significantly improving the reliability of experimental data. In terms of bonding quality: a rotary hydraulic cylinder drives the bonding roller for constant pressure pressing, and a rotation angle limiting device precisely positions the pressing station, ensuring that the pressing amount and pressing force are completely consistent for each bonding operation; dual-air-source synchronous fabric clamping cylinders achieve uniform tension across the entire width of the base fabric, avoiding unilateral slack, fabric deviation, and wrinkling; a through-shaft rotating arm ensures that the bonding roller and the plasticizer roller are parallel throughout the entire process, resulting in uniform bonding strength across the entire width of the base fabric. Compared to manual bonding, the bonding strength data dispersion of the samples prepared by this invention can be reduced by 80%. A magnetic powder brake is used for constant tension feeding, which in real time offsets tension fluctuations caused by changes in roll diameter, completely avoiding problems such as base fabric breakage, slack, and wrinkling, and further improving the uniformity of bonding thickness; the test results for tensile strength, hand feel, etc., are more in line with actual mass production, significantly improving the guidance value for formula optimization.

[0022] Texture absorption quality: The array of cone support blocks constructs a fully penetrating negative pressure chamber, solving the problem of uneven negative pressure between the center and edges when absorbing large areas of texture; combined with a rotating heating cover with uniform radiant heating, the softening degree and absorption force of the entire leather surface are completely consistent, the texture depth is uniform, the edges and corners are clear, and there are no defects such as local shallowness or missing texture; the breathable patterned plate has uniformly distributed micropores throughout, with high fidelity to the fine texture, and the visual effect of the sample is highly consistent with the mass-produced product; the bonding and texturing stations are linked to start and stop, eliminating the defects of molten material accumulation and overflow during intermittent processing, and the thickness of the material strip is more consistent.

[0023] Parallel sample consistency dimension: The intermittent conveying mode allows for the heating and texturing of multiple sample sections on the same continuous material strip; the formulation, plasticizing state, bonding degree, and heating temperature of the same material strip are completely consistent, eliminating batch-to-batch preparation errors. The deviation of parallel sample data is minimal, making it particularly suitable for comparative experiments such as formulation comparison and process parameter optimization, and the test results have higher reference value.

[0024] 3. Multi-dimensional adjustable and adaptable, with strong equipment versatility, compatible with mainstream laboratory equipment and diverse R&D needs. Adaptable to different specifications of plasticizers: The rotating arm adopts an elongated hole adjustment structure with an upper arm plate and a lower arm plate, which can flexibly adjust the effective arm length and adapt to laboratory two-roll plasticizers with different roller diameters; the support plate is directly fixed to the plasticizer baffle plate without the need to drill holes or modify the main body of the equipment, and most conventional models of laboratory plasticizers can be directly upgraded by adding it.

[0025] Adaptable to different widths of base fabric: The axial position of the rotating arm can be adjusted by the fixing sleeve and the first set screw. With the help of each roller shaft that can be axially positioned, it can adapt to experimental base fabrics of different widths to meet the preparation needs of small-sized samples to wide-width samples.

[0026] Adaptable to diverse texture requirements: The breathable patterned plate adopts an embedded structure, which can quickly replace the patterned plate with different textures and depths according to R&D needs. It can achieve sampling of various textures such as lychee texture, sheepskin texture, and pinhole texture without replacing the whole machine. It is a multi-purpose machine that greatly reduces the cost of R&D equipment.

[0027] The station spacing is flexible and adjustable: the cabinet can slide back and forth along the guide rail, and the end of the mesh belt can be extended and adjusted. The receiving station can be flexibly adjusted according to the material discharge position to adapt to different laboratory space layouts; the conveying step length can be set as needed to prepare sample intervals of different lengths to adapt to different testing project requirements.

[0028] 4. Safe and convenient to operate, reducing manual labor intensity and operational risks. Uninterrupted workstation switching: During the plasticizing process, the rotary bonding device retracts upwards to the top of the plasticizing machine, completely avoiding the plasticizing operation space. This does not affect routine plasticizing operations such as manual feeding, turning, and scraping, and there is no need to repeatedly disassemble and reassemble the device.

[0029] Reduce the risk of high-temperature operation: The entire process of bonding, heating and texturing is automated, and operators do not need to directly contact the high-temperature molten material and heating components, avoiding the risk of burns; the rear-side knife-seam guide cutting and pull-out tray sampling design eliminate the need to reach into the cabinet, and the operation safety distance is sufficient.

[0030] Multiple safety protections: The rotation angle limit device is equipped with double limit mechanical limit to prevent the rotating arm from swinging excessively and colliding with the plasticizing machine; the left side of the cabinet is equipped with a sliding glass door, which not only facilitates real-time observation of the process operation status, but also isolates high temperature and prevents foreign objects from being drawn in, thus combining protection and observation functions.

[0031] Easy to adjust and maintain: Each roller adopts a set screw locking structure, and no special tools are required for replacement and maintenance; the whole machine has few vulnerable parts and low daily maintenance costs.

[0032] 5. Compact and economical structure, suitable for small-scale laboratory R&D scenarios. High space utilization: The heating and suction device adopts a vertical layered layout, with conveying, heating, suction, and receiving arranged sequentially from top to bottom. The whole machine occupies a small area and does not require a large laboratory space, making it suitable for conventional laboratory spaces.

[0033] Low equipment cost: The overall structure is mainly composed of standard mechanical parts, without complex precision components. The manufacturing cost is only about one-tenth of that of production line-level bonding and texturing equipment, which greatly reduces the investment in laboratory R&D equipment.

[0034] Low operating energy consumption: It makes full use of the residual heat from the plasticizing process for bonding, the heating hood only needs to be replenished to soften the leather surface, and the vacuum pump can be started and stopped as needed. The overall operating energy consumption is low, which is suitable for small-batch experimental use scenarios.

[0035] 6. Strong traceability of experimental data facilitates refined R&D management. All core parameters of the entire process (bonding pressure, heating temperature, suction negative pressure, holding time, and conveying step length) can be quantified and recorded. The preparation conditions for each sample range are traceable, which makes it easy for R&D personnel to establish a corresponding database of "formula-process-performance", gradually accumulate R&D experience, and shorten the R&D cycle of subsequent new products. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the overall structure of the integrated experimental machine used in this invention; Figure 2 This is an enlarged view of the structure of a two-roll plasticizer and a rotary plasticizer bonding device; Figure 3 for Figure 2 The right view; Figure 4 This is a schematic diagram of a rotary plastic bonding device. Figure 5 This is a structural diagram of the left and right support plates; Figure 6 This is a schematic diagram of the upper arm plate. Figure 7 This is a structural schematic diagram of the lower arm plate; Figure 8 This is an enlarged view of the heating and suction device; Figure 9 A schematic diagram of the heating and texturing device in standby mode; Figure 10 This is a schematic diagram of the structure of a vacuum fingerprint scanner; Figure 11 This is a schematic diagram of the structure of the suction disc; Figure 12 This is a schematic diagram of the standby state of the method of the present invention; Figure 13 This is a schematic diagram of the molding and bonding processes in the method of the present invention; Figure 14 This is a schematic diagram showing the conveyor belt in a taut state with the movable guide roller extended backward. Figure 15 This is a schematic diagram showing the state of the heated texturing device moving backward and the movable guide roller docking with the bonding roller; Figure 16 A schematic diagram showing the conveyor belt conveying the material backward and the rotating heating hood heating the leather surface; Figure 17 This is a schematic diagram showing the heating cover folded vertically and the vacuum suction assembly raised to suction the text. Figure 18 This is a schematic diagram showing the vacuum suction assembly falling and the finished product falling into the tray. Figure 19This is a schematic diagram showing the sampling state of the cutting blade cutting the material strip.

[0037] Explanation of reference numerals in the attached figures 1-Left support plate; 2-Right support plate; 3-Rotating shaft; 4-Fitting rotation power device; 5-Clothing clamping roller; 6-Fitting roller; 7-Base fabric roller; 8-Left baffle plate; 9-Right baffle plate; 10-Through shaft hole; 11-First bushing; 12-Coupling; 13-Fixing sleeve; 14-First set screw; 15-Upper arm plate; 16-Adjusting bolt; 17-Lower arm plate; 18-Round hole; 19-Elongated hole ; 20-Second bushing; 21-First roller shaft; 22-Second set screw; 23-Mounting hole; 24-Cylinder seat; 25-Fabric clamping cylinder; 26-Third bushing; 27-Second roller shaft; 28-Third set screw; 29-Limit sleeve; 30-Limit switch; 31-Limit rod; 32-Plasticizing machine roller assembly; 33-Base fabric; 34-Front roller; 40-Cabinet; 41-Front and rear sliding glass door ; 42-Front and rear pull-out tray; 43-Guide rail; 44-Cast wheel; 45-Hydraulic cylinder; 46-Conveyor motor; 47-Telescopic cylinder; 48-Modible guide roller; 49-Upper fixed guide roller; 50-Lower fixed guide roller; 51-Conveyor mesh belt; 52-Mesh belt drop limit guide roller; 53-Swing cylinder; 54-Heating cover; 55-Lifting cylinder; 56-Vacuum pump; 57-Vacuum suction device; 58-Suction plate; 59-Breathable patterned plate; 60-Connecting plate; 61-Support block; 62-Negative pressure chamber; 63-Negative pressure pipe; 64-Lower support pulley; 65-Upper limit pulley; 66-Push-pull handle; 67-Groove; 68-Cutter; 69-Cloth cutting pad; 100-Two-roll plasticizing machine; 101-Floor; 102-Rotary plasticizing and bonding device; 200-Heating suction device. Detailed Implementation

[0038] The technical solution and complete implementation process of the present invention will be described in detail below with reference to the accompanying drawings. The embodiments described are only used to illustrate the technical solution of the present invention and do not limit the scope of protection of the present invention. Any substitutions and adjustments made by those skilled in the art based on the solution of the present invention without creative effort shall fall within the scope of protection of the present invention.

[0039] like Figures 1 to 11As shown, the integrated testing machine used in this embodiment of the synthetic leather plasticizing, bonding, heating, and texturing integrated experimental method includes a two-roll plasticizing mill 100 and a heating and texturing device 200 located on the front side of the two-roll plasticizing mill 100. The two-roll plasticizing mill 100 is fixedly installed on the floor 101 of the laboratory, and a rotary plasticizing and bonding device 102 is provided on the upper part of the front frame of the two-roll plasticizing mill 100. The heated texturing device 200 includes a cabinet 40 that can slide back and forth on the floor 101. A sliding glass door 41 is installed on the left side of the cabinet 40, which facilitates real-time observation of the process operation status and can also isolate high temperature and prevent foreign objects from being drawn in. Inside the cabinet 40, from top to bottom, there are a front and rear horizontal telescopic mesh belt conveyor, a rotary heating cover, a lifting vacuum texturing component, and a front and rear pull-out tray 42. A fabric cutting pad 69 is provided on the upper rear side of the cabinet 40. A slit extending horizontally in the left and right direction is opened on the rear side of the fabric cutting pad 69. The cutting blade 68 can slide horizontally along the slit to cut the base fabric 33 and the synthetic leather semi-finished product.

[0040] (I) Specific structure of rotary plastic bonding device The rotary plasticizing and bonding device 102 includes a vertically arranged and parallel left support plate 1 and a right support plate 2. The left support plate 1 and the right support plate 2 have the same structure and are arranged symmetrically. The lower part of the left support plate 1 is fixedly connected to the left side of the left baffle plate 8 of the two-roll plasticizer 100 by bolts, and the lower part of the right support plate 2 is fixedly connected to the right side of the right baffle plate 9 of the two-roll plasticizer 100 by bolts. The left support plate 1 and the right support plate 2 serve as the installation reference and load-bearing components of the rotary plasticizing and bonding device 102, without requiring modification to the main structure of the plasticizer, and are easy to assemble and disassemble. The upper part of the left support plate 1 and the right support plate 2 are both provided with through-shaft holes 10, and first bushings 11 aligned with the through-shaft holes 10 are fixedly connected thereto. The rotating shaft 3 is rotatably connected in the two first bushings 11, which ensures that the axis of the rotating shaft 3 is strictly parallel to the axis of the plasticizer roller, thereby ensuring that the bonding roller 6 has uniform pressing force across the entire width.

[0041] The right end of the rotating shaft 3 is connected to a bonding rotation power device 4. In this embodiment, the bonding rotation power device 4 is a rotary hydraulic cylinder, and the output shaft of the rotary hydraulic cylinder is coaxially connected to the right end of the rotating shaft 3 through a coupling 12. The rotating shaft 3 serves as the output shaft for rotational motion, enabling the switching of posture between the plasticizing station and the bonding station. The entire through-shaft structure ensures that the rotation angles of the left and right rotating arms are completely consistent, avoiding asynchrony on both sides that could lead to skewness of the bonding roller 6 and uneven pressing. The bonding rotation power device 4 provides a stable rotational driving force and pressing holding force for station switching. The hydraulic drive output torque is stable, and the rotation angle control accuracy is high. It can continuously output a constant torque in the bonding station, ensuring stable pressure of the bonding roller 6 on the roller. The connection with the rotating shaft 3 through the coupling 12 can compensate for minor coaxiality errors and avoid rotational jamming.

[0042] A rotation angle limiting device is provided between the left side of the left support plate 1 and the left end of the rotating shaft 3 to precisely limit the extreme rotation angles of the two workstations, thereby achieving workstation positioning and safety protection. The rotation angle limiting device includes a limiting sleeve 29 fixedly sleeved on the left end of the rotating shaft 3, and two limit switches 30 fixedly installed on the left side of the left support plate 1. The two limit switches 30 are arranged vertically, corresponding to the extreme positions of the device in the plasticizing avoidance state and the contact working state, respectively. A limiting rod 31 is fixed radially on the outer circle of the limiting sleeve 29. The limiting rod 31 rotates synchronously with the rotating shaft 3 and can touch the two limit switches 30 respectively to trigger a stop signal. Limit sleeve 29, limit rod 31, and limit switch 30 work together: Limit sleeve 29 rotates synchronously with rotating shaft 3, causing limit rod 31 to swing; upper limit switch 30 corresponds to the plasticizing avoidance station, and after being triggered, it ensures that the rotating arm is raised high enough and does not obstruct the operating space; lower limit switch 30 corresponds to the bonding work station, and after being triggered, it precisely controls the pressing amount of bonding roller 6 to ensure stable pressing force.

[0043] A left and right rotating arm, both adjustable in length, are mounted on the rotating shaft 3. The left and right rotating arms have the same structure and are symmetrically arranged. Each rotating arm includes a fixed sleeve 13 fitted onto the rotating shaft 3. A first set screw 14 is threaded onto the fixed sleeve 13, and the inner end of the first set screw 14 presses against the surface of the rotating shaft 3. The fixed sleeve 13 and the first set screw 14 achieve circumferential fixation and axial position adjustment of the rotating arm and the rotating shaft 3. Tightening the first set screw 14 achieves circumferential and axial locking by friction. Loosening the set screw allows adjustment of the axial position of the rotating arm to accommodate base fabrics 33 of different widths. An upper arm plate 15 is fixedly connected to the outer circle of the fixed sleeve 13, which can transmit the torque of the rotating shaft 3 to the entire rotating arm assembly.

[0044] An upper arm plate 15 is connected to a lower arm plate 17 via two adjusting bolts 16. The upper arm plate 15 has two circular holes 18 through which the adjusting bolts 16 pass, and one end of the lower arm plate 17 has two elongated holes 19 through which the adjusting bolts 16 pass. The centerlines of the upper arm plate 15, the lower arm plate 17, and the elongated holes 19 are all perpendicular to and intersect the centerline of the rotating shaft 3. The upper arm plate 15, lower arm plate 17, and adjusting bolts 16 together form an adjustable cantilever structure, adaptable to rollers of different diameters in a plasticizing machine. Loosening the adjusting bolts 16 allows the lower arm plate 17 to slide along the elongated holes 19, changing the overall effective length of the rotating arm. Tightening the bolts locks the lower arm plate, ensuring that the bonding rollers 6 of different diameters can press against the roller surface at the optimal angle.

[0045] A second bushing 20 with left and right openings is fixedly installed in the middle of the lower arm plate 17. The center of the bonding roller 6 is rotatably connected to the first roller shaft 21. The left and right ends of the first roller shaft 21 extend into the second bushing 20 of the left and right lower arm plates 17, respectively. A second set screw 22 is threaded onto the second bushing 20. The inner end of the second set screw 22 presses against the outer circle of the first roller shaft 21 to achieve axial fixation of the bonding roller 6. The bonding roller 6, as a pressing execution component, achieves uniform bonding between the molten material and the base fabric 33. The lower roller surface of the bonding station presses the base fabric 33 onto the molten material layer of the plasticizer roller. As the roller and the base fabric 33 rotate passively, the heat and pressure of the roller make the molten material evenly adhere to the surface of the base fabric 33. The passive rotation has no speed difference, so it will not scratch the molten material layer or produce wrinkles on the material surface.

[0046] The other end of the lower arm plate 17 has a through mounting hole 23. The left end of the base fabric roller 7 extends into and is rotatably connected to the mounting hole 23 of the left lower arm plate 17, and the right end of the base fabric roller 7 extends into and is rotatably connected to the mounting hole 23 of the right lower arm plate 17. The base fabric roller 7 is wrapped with a base fabric roll to release the base fabric 33 for the bonding process. A magnetic powder brake 70 is fixedly installed on the outer side of the right lower arm plate 17. The magnetic powder brake 70 is coaxially connected to the right end of the central shaft of the base fabric roller 7 to control the base fabric 33 to maintain a constant tension.

[0047] The base fabric roller 7 serves a dual function of structural support and constant tension feeding. Structurally, both ends are connected to the left and right lower arm plates 17 via rotating pairs, forming a stable roller system frame with the clamping roller and bonding roller, balancing the force on both rotating arms and preventing the arms from twisting and deforming during swinging. In terms of feeding function, the base fabric 33 is continuously subjected to forward traction during the bonding process, driving the base fabric roll and base fabric roller 7 to rotate synchronously for feeding. The magnetic powder brake 70 outputs a stable damping torque through the central axis of the base fabric roller 7, adjusting the damping magnitude in real time to offset the tension fluctuations caused by changes in the base fabric roll diameter, ensuring that the feeding tension of the base fabric 33 remains constant throughout the process. This prevents the base fabric from breaking due to excessive tension or wrinkling and deviation due to insufficient tension, ensuring uniform bonding quality of the entire base fabric. The axes of the clamping roller 5, bonding roller 6, and base fabric roller 7 are all parallel to the rotating shaft 3, and the distance between the three and the rotating shaft 3 increases sequentially.

[0048] The right side and left side of the left lower arm plate 17 are both fixedly connected to cylinder seats 24 by adjusting bolts 16 on the same side. Each of the two cylinder seats 24 is fixedly installed with a fabric clamping cylinder 25. The two fabric clamping cylinders 25 are controlled by the same air source to ensure synchronous extension and retraction of the piston rod. The outer ends of the piston rods of the two fabric clamping cylinders 25 are fixed with third bushings 26. The center of the fabric clamping roller 5 is rotatably connected to a second roller shaft 27. The left and right ends of the second roller shaft 27 extend into the third bushings 26 on the left and right sides, respectively. The third bushing 26 is threaded with a third set screw 28. The inner end of the third set screw 28 presses against the outer circle of the second roller shaft 27 to achieve axial fixation of the fabric clamping roller 5. The clamping roller 5 and the clamping cylinder 25 are used to clamp the base fabric 33 and keep it taut, ensuring that the base fabric 33 entering the bonding area is flat and wrinkle-free; the two clamping cylinders 25 share the same air source, and the piston rod extends and retracts completely synchronously, driving the clamping roller 5 to move closer to or away from the bonding roller 6; during clamping, the cylinder outputs constant pressure, so that the base fabric 33 maintains uniform tension between the clamping roller 5 and the bonding roller 6; the clamping roller 5 rolls passively with the base fabric 33, and the rolling friction with the base fabric 33 does not scratch the surface of the base fabric 33.

[0049] (II) Specific Structure of the Heating and Absorbing Device Two parallel guide rails 43 are laid on the floor 101 along the front-to-back direction. Casters 44 are installed at the bottom of the cabinet 40 and are tactilely connected to the guide rails 43. A hydraulic cylinder 45 is hinged to the floor 101, and the piston rod end of the hydraulic cylinder 45 is hinged to the bottom of the cabinet 40. The hydraulic cylinder 45 is arranged parallel to the guide rails 43. The cabinet 40, casters 44, guide rails 43, and hydraulic cylinder 45 serve as an integrated carrier for the heating and texturing module, enabling the entire unit to move back and forth to dock with or avoid the plasticizing station. The hydraulic cylinder 45 extends and retracts to drive the cabinet 40 to slide back and forth along the guide rails 43. The casters 44 bear the weight of the cabinet 40, converting sliding friction into rolling friction, resulting in smooth movement and low resistance. The cabinet 40 has conveying, heating, texturing, and receiving components installed in layers from top to bottom, resulting in a compact structure with a small footprint, suitable for laboratory space.

[0050] The front-to-back horizontal telescopic mesh belt conveyor includes a conveyor motor 46, telescopic cylinders 47, movable guide rollers 48, upper fixed guide rollers 49, lower fixed guide rollers 50, and a conveyor mesh belt 51. Two telescopic cylinders 47 are spaced apart on the left and right sides, with the cylinder bodies fixedly installed inside the cabinet 40 along the front-to-back direction. The movable guide rollers 48 are located on the rear side of the cabinet 40, with their left and right ends connected to the rear ends of the piston rods of the two telescopic cylinders 47, respectively. The telescopic cylinders 47 and movable guide rollers 48 extend the mating end of the conveyor mesh belt 51, ensuring smooth reception of the laminated synthetic leather sample. When the piston rods of the telescopic cylinders 47 extend, the movable guide rollers 48 move backward, extending the rear end of the mesh belt below the laminating roller 6. When retracted, the movable guide rollers 48 move forward, and the mesh belt retracts to the side of the cabinet 40. The dual cylinders drive synchronously, ensuring the two ends of the movable guide rollers 48 are aligned, preventing the mesh belt from deviating.

[0051] An opening is provided on the upper rear side of the cabinet 40 for the piston rod of the telescopic cylinder 47 and the conveyor belt 51 to pass through. Three upper fixed guide rollers 49 are located above the telescopic cylinder 47 and are rotatably mounted on the inner wall of the cabinet 40 at intervals along the front-to-back direction. Two lower fixed guide rollers 50 are located below the telescopic cylinder 47 and are rotatably mounted on the front and rear sides of the cabinet 40, respectively. The conveyor motor 46 is fixedly mounted below the lower fixed guide roller 50 on the front side and is connected to the lower fixed guide roller 50 on the front side via a belt drive mechanism or a chain drive mechanism. The conveyor belt 51 has a breathable mesh structure and sequentially wraps around the roller surfaces of the movable guide roller 48, the upper fixed guide roller 49, and the lower fixed guide roller 50 to form a closed-loop transmission circuit.

[0052] The upper fixed guide roller 49, the lower fixed guide roller 50, the conveyor motor 46, and the conveyor belt 51 together form a closed-loop conveying system to achieve stable sample transfer. The conveyor motor 46 drives the front lower fixed guide roller 50 to rotate, and the conveyor belt 51 is driven to circulate by friction. Multiple fixed guide rollers support the belt to ensure that the upper layer of the belt remains horizontal. The conveyor belt 51 has a breathable mesh structure, which supports the sample without blocking the negative pressure transmission, and the sample does not need to be transferred during the texturing process. The intermittent conveying mode can precisely control the step length and realize continuous processing of multiple sections of a single material belt. After lamination, the molten material adheres to the lower surface of the base fabric 33. When the semi-finished product falls onto the conveyor belt 51, the leather side (polymer material side) faces down and contacts the belt. The top surface of the breathable patterned plate 59 can directly contact the lower surface of the synthetic leather, which facilitates the direct action of the heating and texturing processes on the leather surface and also makes it easy to place and replace the breathable patterned plate 59.

[0053] A belt drop limiting guide roller 52 is fixed to the outer rear side of the cabinet 40, located below and behind the lower fixed guide roller 50. The belt drop limiting guide roller 52 is used to limit the downward sag of the lower side of the belt, support the slack section of the belt, prevent the belt from drooping excessively due to its own weight and interfering with the heating cover 54 and the suction plate 58 below, and at the same time ensure the belt tension is stable and the conveyor does not slip.

[0054] The rotary heating cover includes a swing cylinder 53 and a heating cover 54. A row of electric heating tubes is installed inside the heating cover 54 to generate radiant heat to soften the leather surface. The cylinder seat of the swing cylinder 53 is fixedly connected to the inside of the rear side wall of the cabinet 40 and is located in front of and below the lower rear guide roller 50. The rear side of the heating cover 54 is fixedly connected to the output shaft of the swing cylinder 53. Driven by the swing cylinder 53, the heating cover 54 can swing back and forth within a 90° range, switching between a horizontal heating state and a vertical folding state. In the horizontal state, the heating cover 54 is located below the upper layer of the conveyor belt 51, uniformly heating the synthetic leather surface on the belt from below. In the vertical state, the heating cover 54 is folded up against the inner rear wall of the cabinet 40, completely avoiding the lifting space. The swing cylinder 53, heating cover 54, and electric heating tube work together to radiate heat to the bonded leather surface, softening the surface polymer material and ensuring the clarity of the suction molding. In the heating station, the heating cover 54 swings to a horizontal position, parallel to the leather surface, and the radiant heat generated by the electric heating tube is evenly applied to the leather surface. In the suction molding station, the heating cover 54 swings upward 90° to a vertically folded state, completely avoiding the lifting space. The flip-type avoidance structure is compact, has a fast response, and high temperature control accuracy of electric heating, making it suitable for intermittent heating needs.

[0055] The lifting vacuum texturing assembly includes a lifting cylinder 55, a vacuum pump 56, and a vacuum texturing device 57. The lifting cylinder 55 is vertically fixed inside the cabinet 40 on the left side, and the vacuum pump 56 is fixedly fixed on the right side of the lifting cylinder 55. The lifting cylinder 55 is used to drive the vacuum texturing device 57 to rise and fall, realizing texturing adhesion and material return; when the piston rod extends, the texturing plate 58 rises, lifting the mesh belt and the sample, so that the leather surface is tightly attached to the breathable patterned plate 59; when it retracts, the texturing plate 58 descends, and the sample falls back with the mesh belt and falls naturally; the connection between the connecting plate 60 and the bottom of the texturing plate 58 ensures that the lifting process is horizontal, stable, and without tilting.

[0056] The vacuum texture extractor 57 includes a horizontally arranged texture-absorbing disc 58 and a breathable patterned plate 59. The bottom of the texture-absorbing disc 58 is fixedly connected to the upper end of the piston rod of the lifting cylinder 55 via a connecting plate 60. The lifting cylinder 55 can drive the texture-absorbing disc 58 to move vertically up and down. The top surface of the texture-absorbing disc 58 has a groove 67 with an open top. Several arrayed support blocks 61 are fixed at the bottom of the groove 67. The vertical cross-section of the support blocks 61 is a conical structure with a smaller top and a larger bottom. The breathable patterned plate 59 is embedded in the groove 67, with its bottom surface contacting the upper end of the support blocks 61. The breathable patterned plate 59 has several vertically permeable air-absorbing micropores inside, and its top surface is pre-fabricated with the required synthetic leather texture. The bottom surface of the groove 67, the side wall of the support blocks 61, and the bottom surface of the breathable patterned plate 59 enclose a horizontally penetrating negative pressure chamber 62.

[0057] The suction plate 58, support block 61, and negative pressure chamber 62 together form a uniform negative pressure chamber to support the breathable patterned plate 59. The groove 67 at the top of the suction plate 58 serves as the foundation of the negative pressure chamber. The upper ends of the arrayed conical support blocks 61 support the patterned plate. The side walls of each support block 61 at the bottom of the groove 67 and the bottom surface of the groove 67 and the bottom surface of the breathable patterned plate 59 together enclose and form a horizontally connected negative pressure chamber 62. The conical structure is smaller at the top and larger at the bottom, which maximizes the negative pressure flow space while ensuring support strength, avoiding insufficient local suction, and solving the problem of uneven negative pressure between the center and the edge when suctioning a large area. The breathable patterned plate 59 serves as a mold carrier for pattern forming and also transmits negative pressure. The plate is densely covered with vertically penetrating micropores for air intake, and the target pattern is pre-formed on the top surface. The negative pressure acts on the back of the leather surface through the micropores, causing the softened leather surface to adhere tightly to the pattern surface and solidify after cooling. It is embedded in the groove 67 of the suction plate 58, and different breathable patterned plates 59 can be quickly replaced according to experimental needs.

[0058] A negative pressure tube 63 is connected to the side of the suction plate 58. The inner end of the negative pressure tube 63 is connected to the negative pressure chamber 62, and the outer end is connected to the air extraction port of the vacuum pump 56. The vacuum pump 56 and the negative pressure tube 63 provide a stable negative pressure power source. The vacuum pump 56 draws air to form a vacuum in the negative pressure chamber 62, and the negative pressure is transmitted to the chamber of the suction plate 58 through the negative pressure tube 63. The amount of negative pressure is adjustable to adapt to textures of different depths and fineness.

[0059] A lower support pulley 64 and an upper limit pulley 65 are fixedly installed on the inner wall of the cabinet 40. The lower support pulley 64 supports the bottom of the front and rear pull-out tray 42 to reduce the pulling resistance, while the upper limit pulley 65 presses down on the top of the front and rear pull-out tray 42 to limit the tray's upward movement and prevent it from tilting and derailing during pulling. It also ensures the stability and reliability of the cantilevered state of the front and rear pull-out tray 42 after it is pulled out backward. A push-pull handle 66 is fixed to the rear end of the front and rear pull-out tray 42 to facilitate the operator to pull out and clean up the remaining material and take out the finished product. The front and rear pull-out tray 42, the lower support pulley 64, the upper limit pulley 65, and the push-pull handle 66 work together to support the finished sample and scrap material after the texturing is completed.

[0060] The fabric cutting pad 69 is fixedly installed on the outer rear side of the cabinet 40, located below the movable guide roller 48. The upper surface of the fabric cutting pad 69 is flush with the upper conveying surface of the conveyor belt 51, and is used to support the base fabric 33 and the laminated synthetic leather semi-finished product. The horizontal slit on the rear side provides a guide reference for the cutter 68, ensuring that the cut is straight and free of burrs during cutting, and preventing the cutter 68 from scratching the conveyor belt and the equipment body. This results in high cutting accuracy and safe operation. The fabric cutting pad 69 and the cutter 68 together constitute the execution component for fixed-length cutting of the base fabric 33.

[0061] (III) Specific implementation steps of an integrated experimental method for synthetic leather refining, bonding, heating, and texturing. Combination Figures 12 to 19 This method is executed in the following steps in sequence, and each action can be automatically linked through the control system: Step 1: Plasticizing and Material Preparation and Workstation Avoidance In the initial standby state, the control system sends a reset signal to the bonding rotation power device 4, which drives the rotating shaft 3 to rotate counterclockwise, causing the limit sleeve 29 and the limit rod 31 to swing synchronously. When the limit rod 31 touches and triggers the limit switch 30 on the upper left side of the left support plate 1, the bonding rotation power device 4 stops outputting and maintains the hydraulic locking state.

[0062] At this time, the left and right rotating arms are tilted in a forward-high-backward-low posture. The clamping roller 5, bonding roller 6, and base fabric roller 7 are all raised to the area above the 100 rollers of the two-roll plasticizer, maintaining a safe distance from the roller surface, completely avoiding the feeding and operating space of the plasticizer. Operators can carry out normal plasticizing operations such as feeding, turning, and scraping without being interfered with by the device.

[0063] Then, the two-roll plasticizer 100 is started, and the polymer mixture weighed according to the experimental formula is put into the two plasticizer rollers 32 rotating in opposite directions. The rollers are filled with heating oil or electric heating components to continuously heat and plasticize the material. After multiple tumbling and rolling, the material is mixed evenly and completely plasticized, forming a molten material layer with uniform thickness and stable state on the roller surface.

[0064] Step 2: Base fabric clamping and tensioning The base fabric 33 can be prepared simultaneously during the plasticizing process, shortening the process connection time.

[0065] Select a base fabric roll of the corresponding width, loosen the threaded connection at one end of the base fabric roller 7, and loosely fit the base fabric roll onto the outside of the roller body of the base fabric roller 7. Adjust the axial position of the base fabric roll so that it is centered and aligned with the working width of the plasticizer roller. Install elastic retaining rings at both ends of the base fabric roller 7 to limit the axial movement of the base fabric roll during the feeding process, and then tighten and reset the threads of the base fabric roller 7.

[0066] The free end of the traction base fabric roll is led out downwards, passes over the front roller surface of the bonding roller 6 from below, and then passes into the gap between the clamping roller 5 and the bonding roller 6, leaving a free end of 5-10cm upwards; the base fabric 33 is manually straightened to ensure that the base fabric 33 is wrinkle-free, skew-free, and in a flat and taut state.

[0067] When the control air source of the clamping cylinder 25 is turned on, the piston rods of the two clamping cylinders 25 extend synchronously and at a uniform speed, pushing the third bushing 26 and the clamping roller 5 to move horizontally towards the bonding roller 6. When the roller surface of the clamping roller 5 contacts the base fabric 33 and presses the base fabric 33 tightly onto the surface of the bonding roller 6, the air source maintains a constant output pressure, ensuring that the clamping force of the clamping roller 5 on the base fabric 33 is uniform and consistent across the entire width. Since the two clamping cylinders 25 share the same air source, the air intake and output pressure are completely synchronized, which avoids the problem of the base fabric 33 shifting or wrinkling due to insufficient clamping force on one side, ensuring that the base fabric 33 remains taut and flat throughout the subsequent bonding process, providing a foundation for uniform bonding.

[0068] Step 3: Online bonding and pressing When the material reaches the plasticization standard and a uniform and stable molten material layer is formed on the roller surface, the control system sends a bonding station switching signal. The bonding rotation power device 4 drives the rotating shaft 3 to rotate clockwise at a uniform speed, and the left and right rotating arms swing downward synchronously. The clamping roller 5 and the bonding roller 6 clamp the base fabric 33 together and move closer to the front roller 34 of the plasticizer. When the limit rod 31 rotates with the rotating shaft 3 and touches the limit switch 30 below, the bonding rotation power device 4 stops rotating and maintains the locking torque.

[0069] At this point, the surface of the bonding roller 6 evenly presses the base fabric 33 onto the surface of the molten material layer on the front roller 34 of the plasticizer. The pressing position is located slightly below the horizontal center line of the roller, ensuring sufficient contact angle between the molten material and the base fabric 33, thus improving the bonding strength. As the plasticizer rollers continue to rotate, the molten material on the roller surface adheres evenly to the lower surface of the base fabric 33 under the combined action of pressure and residual heat. As the rollers rotate, the base fabric 33, with the molten material bonded to it, continues to move forward. When passing through the gap between the two rollers, it is subjected to secondary extrusion by the two rollers, further compacting and bonding the molten material and the base fabric 33. The interfacial bonding force is significantly improved, forming a continuous synthetic leather semi-finished material strip with the leather side facing down, which is output downward from the front side of the bonding roller 6.

[0070] During the bonding process, the base fabric 33 is continuously subjected to forward traction, which drives the base fabric winding roller 7 to rotate passively and release the base fabric 33 at a uniform speed, ensuring that the tension of the base fabric 33 is stable and that there will be no breakage or loosening and wrinkling.

[0071] Step 4: Material receiving station docking Before the bonding process starts, the control system first controls the hydraulic cylinder 45 to start. The piston rod of the hydraulic cylinder 45 extends at a constant speed, pushing the cabinet 40 to move horizontally backward along the guide rail 43 towards the two-roller plasticizer 100. At the same time, the piston rods of the two telescopic cylinders 47 extend backward synchronously, driving the movable guide roller 48 to move horizontally backward. Under the traction of the movable guide roller 48, the rear end of the conveyor belt 51 extends backward.

[0072] By pre-setting the extension stroke of the hydraulic cylinder 45 and the extension length of the telescopic cylinder 47, the upper rear end of the conveyor belt 51 is positioned directly below the front discharge end of the bonding roller 6, maintaining a small gap. This ensures that the synthetic leather semi-finished product output from the bonding roller 6 can fall smoothly onto the surface of the conveyor belt 51, preventing the sample from bending, falling, or scratching the molten material surface. After the cabinet 40 moves into position, the hydraulic cylinder 45 remains locked to prevent the cabinet 40 from shifting; the telescopic cylinder 47 maintains its extension pressure to maintain the tension of the conveyor belt 51, preventing the belt from slipping or deviating during conveying.

[0073] After the workstation docking is completed, the first material belt is threaded. The synthetic leather semi-finished product with polymer material is manually guided to be laid flat on the upper surface of the conveyor belt 51 and run synchronously with the conveyor belt 51. It does not need to go around the guide rollers, ensuring that the material belt is free from deviation and jamming.

[0074] Step 5: Intermittent multi-segment heating and texturing This equipment adopts an intermittent conveying mode, which can process multiple independent sample sections on the same synthetic leather semi-finished material belt for performance testing of different projects. The specific process is as follows: Interval conveying and positioning: The conveyor motor 46 drives the conveyor belt 51 to move forward intermittently according to the preset step length. After each sample interval is advanced, the conveyor belt 51 stops immediately, so that the material segment to be processed is accurately positioned directly above the vacuum suction device 57.

[0075] Bonding pause to avoid air gap: When the conveying stops, the bonding rotation power device 4 starts, driving the rotating shaft 3 to rotate the upper arm plate 15 and the lower arm plate 17 upward, so that the bonding roller 6 separates from the front roller 34 of the plasticizing machine roller group 32, temporarily stopping the bonding of molten material onto the base fabric 33, and avoiding the continuous discharge and accumulation of molten material when the conveying is paused.

[0076] Heating and softening of leather surface: When the conveying stops, the swing cylinder 53 drives the heating cover 54 to swing downward to a horizontal state; the electric heating tube inside the heating cover 54 is energized and heats up, radiating heat from below to the downward-facing leather surface of the material section, so that the surface polymer material of this section is heated and softened to a plastic state; the heating time and heating power can be preset and adjusted according to the formula characteristics.

[0077] Vacuum texturing and shaping: After heating is completed, the swing cylinder 53 drives the heating cover 54 to swing upward 90° to a vertically folded state, completely avoiding the lifting space; then the lifting cylinder 55 starts, driving the texturing plate 58 and the breathable pattern plate 59 to rise synchronously. The breathable pattern plate 59 passes through the mesh of the conveyor belt 51 and adheres tightly to the leather surface; at the same time, the vacuum pump 56 starts, and the negative pressure chamber 62 is formed by the negative pressure pipe 63. The negative pressure is evenly applied to the leather surface through the air suction micropores of the breathable pattern plate 59, so that the softened leather surface tightly adsorbs the replicated texture. After holding the pressure for a set time, the texturing and shaping of this section is completed.

[0078] Material drop reset: After the suction is completed, the vacuum pump 56 stops and the negative pressure disappears; the lifting cylinder 55 drives the suction plate 58 to descend and reset, and the conveyor belt 51 droops down accordingly, and the finished material section in this section returns to the surface of the belt.

[0079] Bonding restoration: After the material is reset, the bonding rotation power device 4 is started in reverse, driving the rotating shaft 3 to rotate the upper arm plate 15 and the lower arm plate 17 downwards, so that the bonding roller 6 is pressed back onto the surface of the front roller 34 of the plasticizing machine roller group 32, restoring the bonding operation between the molten material and the base fabric 33.

[0080] Cyclic processing: After processing a sample section is completed, the conveyor motor 46 drives the conveyor belt 51 to advance one step again, sending the next material section to be processed to the suction station. The heating and suction steps are repeated, and multiple independent heating and suction sample sections can be formed on the entire continuous material belt.

[0081] All sample sections on the same strip share the same plasticizing, bonding, and heating process conditions, resulting in strong consistency among parallel samples. They can be used for different performance tests such as bonding strength, tensile strength, abrasion resistance, and color fastness, providing high reference value for comparative test data.

[0082] Step 6: Cutting to length and removing finished product After all sample areas have been processed, the operator will flatten the material strip on the back side of the cutting mat 69 at the back of the cabinet 40, align the preset cutting position with the cut seam on the cutting mat 69; hold the cutting knife 68 and insert it into the cut seam, slide it at a uniform speed along the horizontal direction of the cut seam, and the base fabric 33 and the surface synthetic leather can be cut flat in one go, with a straight cut and no pulling or rough edges.

[0083] After being cut, the finished sample, no longer supported, falls vertically through the gaps in the mesh of the conveyor belt 51 under gravity, landing smoothly into the front and rear pull-out tray 42 below. The operator holds the push-pull handle 66 to pull out the front and rear pull-out tray 42 to remove the finished sample. After sampling, the corners and waste materials inside the tray are cleaned, and the tray is pushed back into the cabinet 40 to proceed to the next round of processing.

[0084] (iv) Equipment reset procedure After all sample testing is completed, the equipment should be reset to standby mode in the following order to avoid prolonged stress or accidental contact with components: Clamping mechanism reset: Cut off the clamping air source of the clamping cylinder 25, and the piston rods of the two clamping cylinders 25 contract synchronously, driving the clamping roller 5 away from the bonding roller 6 and releasing the remaining base fabric 33.

[0085] Reset of bonding device: The bonding rotation power device 4 drives the rotating shaft 3 to rotate counterclockwise, which in turn lifts the rotating arm upward until the limit rod 31 touches the upper limit switch 30. The bonding rotation power device 4 stops locking and the device returns to the plasticizing avoidance position.

[0086] Reset of conveying and heating device: The piston rod of telescopic cylinder 47 retracts, driving the movable guide roller 48 to retract forward, and the conveyor belt 51 then retracts to the side of cabinet 40; the swing cylinder 53 drives the heating cover 54 to swing back to the horizontal standby state, and the electric heating tube is de-energized and stops heating.

[0087] Cabinet body reset: The piston rod of hydraulic cylinder 45 retracts, pulling cabinet body 40 to slide forward along guide rail 43, returning to the initial standby position and maintaining a safe distance from the two-roll plasticizer 100.

[0088] Final steps: Remove the remaining base fabric roll from the base fabric roller 7, clean the residual materials from the plasticizing machine rollers, conveyor belt 51 and front and rear pull-out trays 42, turn off the main power supply, air supply and vacuum pump 56 of the equipment, and complete all reset operations.

[0089] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A synthetic leather processing, bonding, heating, and texturing integrated experimental method, characterized in that, The experiment is conducted using an integrated testing machine, which includes a two-roll plasticizer and a heating and texturing device located at the front of the two-roll plasticizer. A rotary plasticizing and bonding device is located on the upper front of the two-roll plasticizer. This device includes a rotating shaft, an adjustable-length rotating arm, and fabric clamping rollers, bonding rollers, and base fabric rollers mounted parallel to the rotating arm. The rotating shaft drives the rotating arm to rotate, allowing the device to switch between a plasticizing clearance station and a bonding work station. The heating and texturing device includes a sliding cabinet. Inside the cabinet, from top to bottom, are arranged a front and rear horizontal telescopic mesh belt conveyor with a breathable conveyor belt, a rotary heating cover that can swing to switch positions, a lifting vacuum texturing assembly, and a front and rear pull-out tray. The front and rear horizontal telescopic mesh belt conveyor is equipped with movable guide rollers that can extend and retract. A fabric cutting pad is located on the upper rear of the cabinet. The fabric cutting pad has slits extending in the left and right directions, which, in conjunction with a cutting blade, achieve fixed-length cutting of the material strip. The method includes the following steps: (1) Plasticizing preparation: Rotate the rotary plasticizing bonding device to the plasticizing clearance position, and put the polymer mixture into the two-roll plasticizing machine for heating and plasticizing, so that the material forms a uniform molten material layer on the surface of the plasticizing machine rollers. (2) Base fabric clamping: Install the base fabric roll on the base fabric roller, pull the free end of the base fabric around the bonding roller, and clamp and tension the base fabric through the clamping roller; (3) Online bonding: Rotate the rotary plastic bonding device to the bonding work position so that the bonding roller presses the base fabric against the surface of the molten material layer of the plastic mill roller; the rotation of the plastic mill roller drives the base fabric to move forward synchronously, and the molten material adheres evenly to the lower surface of the base fabric under the action of pressure and residual heat, forming a continuous synthetic leather semi-finished material strip with the leather side facing down. (4) Material receiving and docking: Drive the cabinet to slide towards the two-roller plasticizer, and at the same time control the movable guide roller to extend backward so that the rear end of the conveyor belt receives the synthetic leather semi-finished material belt that is bonded and output. (5) Intermittent multi-segment heating and texturing: The conveyor belt is intermittently conveying the material belt forward. After conveying the length of a preset sample section, the conveying stops. At the same time as the conveying stops, the rotary plastic bonding device drives the bonding roller to lift up and separate from the plasticizing machine roller, pausing the molten material bonding and discharge. The rotary heating cover swings to the horizontal heating state and radiates heat the leather surface of the current sample section from below, softening the polymer material on the surface of the leather. After heating, the rotary heating cover swings to the vertical folding state to avoid the lifting space. The lifting vacuum texturing component rises and performs vacuum texturing and shaping on the softened leather surface from below. After texturing is completed, the lifting vacuum texturing component descends and resets, and the rotary plastic bonding device drives the bonding roller to reset and press the base fabric onto the plasticizing machine roller, resuming the bonding operation. The conveyor belt continues to convey the next sample section forward, and the heating and texturing steps are repeated to complete the processing of multiple sample sections on the same material belt, preparing multiple sets of parallel test samples. (6) Fixed-length cutting and sampling: After all sample sections are processed, the material strip is attached to the surface of the cutting mat, the cutter is aligned with the seam, and the material strip is cut along the seam with the cutter. The finished sample falls into the front and rear pull-out tray below. The sample is taken out to complete the experiment.

2. The integrated experimental method for synthetic leather refining, bonding, heating, and texturing as described in claim 1, characterized in that: The rotary plastic bonding device includes a left support plate and a right support plate arranged vertically in parallel. A rotating shaft is mounted between the upper parts of the left and right support plates. A bonding rotation power device is connected to the right end of the rotating shaft, and a rotation angle limiting device is provided at the left end of the rotating shaft. The rotation angle limiting device includes a limiting sleeve fixed to the rotating shaft and two limit switches. A limiting rod is provided on the outer circle of the limiting sleeve, and the two limit switches correspond to the extreme positions of the plastic avoidance station and the bonding work station, respectively. In step (1), the fitting rotation power device drives the rotating shaft to rotate, causing the rotating arm to swing upward until the limit rod touches the limit switch of the corresponding plasticizing station, the rotating shaft is locked, and the device is in the plasticizing avoidance station. In step (3), the bonding rotation power device drives the rotating shaft to rotate in the opposite direction, causing the rotating arm to swing downward until the limit rod touches the limit switch of the corresponding bonding station, the rotating shaft is locked, and the bonding roller presses the base fabric onto the surface of the molten material layer with constant pressure.

3. The integrated experimental method for synthetic leather refining, bonding, heating, and texturing according to claim 2, characterized in that: The left and right rotating arms each include an upper arm plate and a lower arm plate, which are connected by adjusting bolts. The lower arm plate has an elongated hole to adjust the overall length of the rotating arm and adapt to plasticizer rollers of different diameters. Before step (3), according to the diameter of the plasticizer roller, loosen the adjusting bolt to adjust the fixed position of the lower arm plate, change the effective length of the rotating arm, and make the bonding roller contact the roller surface at a preset pressing angle.

4. The integrated experimental method for synthetic leather refining, bonding, heating, and texturing according to claim 2, characterized in that: The two ends of the clamping roller are respectively connected to clamping cylinders. The two clamping cylinders are driven by the same air source to ensure synchronous extension and contraction. In step (2), the air source of the clamping cylinder is turned on, and the two clamping cylinders extend synchronously, driving the clamping roller to move towards the bonding roller, pressing the base fabric evenly on the surface of the bonding roller, and keeping the tension of the base fabric consistent throughout the width. The lower arm plate has a through mounting hole at the end, and the two ends of the central shaft of the base fabric roller are rotatably connected to the mounting holes of the lower arm plates on the left and right sides respectively. The base fabric roll is wound around the outside of the base fabric roller, and a magnetic powder brake is fixed on the outer side of the right lower arm plate. The magnetic powder brake is coaxially connected to the right end of the central shaft of the base fabric roller. During the bonding process in step (3), the base fabric is driven by the traction force to rotate synchronously with the base fabric roll and the base fabric roller to release the material. The magnetic powder brake outputs a stable damping torque and adjusts the damping in real time to offset the tension fluctuation caused by the change in the diameter of the base fabric roll, so that the tension of the base fabric release is constant throughout the process.

5. The integrated experimental method for synthetic leather refining, bonding, heating, and texturing according to claim 1, characterized in that: The front and rear horizontal telescopic mesh belt conveyor also includes a conveyor motor, a telescopic cylinder, an upper fixed guide roller, and a lower fixed guide roller; the telescopic cylinder is set in the cabinet along the front and rear direction, and the movable guide roller is connected to the rear end of the telescopic cylinder; the conveyor mesh belt is wound around the movable guide roller, the upper fixed guide roller, and the lower fixed guide roller to form a closed-loop transmission. In step (4), the telescopic cylinder extends synchronously to drive the movable guide roller to move backward, so that the rear end of the conveyor belt extends to below the discharge end of the bonding roller, and smoothly receives the synthetic leather semi-finished material belt; In step (5), the conveyor motor drives the conveyor belt to move forward intermittently according to the preset step length, and precisely controls the conveying length of each sample section.

6. The integrated experimental method for synthetic leather refining, bonding, heating, and texturing according to claim 1, characterized in that: The rotary heating cover includes a swing cylinder and a heating cover with an internal electric heating tube. The rear side of the heating cover is connected to the output shaft of the swing cylinder. In step (5), the swing cylinder drives the heating cover to swing downward to a horizontal state, and the electric heating tube is energized to generate radiant heat, which heats the leather surface on the conveyor belt evenly from below; after the heating is completed, the swing cylinder drives the heating cover to swing upward 90° to a vertical folded state, completely avoiding the lifting space of the lifting vacuum suction assembly.

7. The integrated experimental method for synthetic leather refining, bonding, heating, and texturing according to claim 1, characterized in that: The lifting vacuum suction assembly includes a lifting cylinder, a vacuum pump, and a vacuum suction device; the vacuum suction device includes a suction plate and a breathable patterned plate. The top surface of the suction plate has a groove, and the bottom of the groove has an array of support blocks. The breathable patterned plate is embedded in the groove. The bottom surface of the groove, the side wall of the support block, and the bottom surface of the breathable patterned plate form a negative pressure chamber. The negative pressure chamber is connected to the vacuum pump through a negative pressure pipe. In step (5), the lifting cylinder drives the suction plate to rise, and the breathable pattern plate passes through the mesh of the conveyor belt and adheres tightly to the leather surface; the vacuum pump starts to create a vacuum in the negative pressure chamber, and the negative pressure acts on the leather surface through the micropores of the breathable pattern plate, so that the softened leather surface is adsorbed and adhered to the surface of the pattern plate to complete the pattern shaping; after the pressure is held for a set time, the vacuum pump stops, and the lifting cylinder drives the suction plate to descend and reset.

8. The integrated experimental method for synthetic leather refining, bonding, heating, and texturing according to claim 7, characterized in that: The vertical cross-section of the support block is a cone structure with a smaller top and a larger bottom. The upper end supports a breathable patterned plate, and a horizontally connected negative pressure chamber is formed between the side walls. During the suction process in step (5), the negative pressure in the negative pressure chamber is evenly diffused to the entire board surface through the cone structure, ensuring that the adhesion force of each area of ​​the leather surface is consistent.

9. The integrated experimental method for synthetic leather refining, bonding, heating, and texturing according to claim 1, characterized in that: The cabinet is equipped with casters and guide rails at the bottom, and a hydraulic cylinder drives the cabinet to slide back and forth along the guide rails. In step (4), the hydraulic cylinder extends and pushes the cabinet to move along the guide rail towards the two-roller plasticizer, adjusting the distance between the cabinet and the plasticizer so that the conveyor belt accurately connects to the discharge position.

10. The integrated experimental method for synthetic leather refining, bonding, heating, and texturing according to claim 1, characterized in that: In step (5), multiple sample sections processed on the same strip share the same plasticizing, bonding and heating parameters, and the preparation conditions of all samples are completely consistent.

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