A leather production line

Abstract

This utility model relates to the field of leather preparation technology, and in particular to a leather production line, including a conveying device, a coating device, a drying device, a fabric feeding device, a cooling device, a foaming machine, a fabric application device, and a separating and winding device; the conveying device is used to convey release paper, and multiple conveying devices and cooling devices are provided; the drying device includes a first drying box, a second drying box, a third drying box, and a fourth drying box; the coating device includes a first coating mechanism and a second coating mechanism. The leather production line provided by this utility model, through a continuous production system integrating coating and foaming functions, can sequentially complete multiple processes such as release paper coating, foaming material preparation, foaming molding, and drying and curing on the same machine, effectively improving production efficiency.

Description

Technical Field

[0001] This utility model relates to the field of leather preparation technology, and in particular to a leather production line. Background Technology

[0002] In traditional leather manufacturing, the production of synthetic or artificial leather is typically divided into two separate production lines: one for creating the coating on release paper, and the other for the foaming process. While this separate production method ensures quality control at each step, it also brings significant problems, particularly inefficiency and high costs.

[0003] The segmented production process involves first applying one or more layers of a specially formulated liquid material to the release paper on the first production line to form a base coating. These coatings can be materials such as polyurethane (PU) and polyvinyl chloride (PVC), which provide support and adhesion for subsequent foaming layers. However, this process itself requires precise temperature and humidity control as well as uniform coating quality; any deviation can lead to defects in the final product.

[0004] Foaming Process Line: Next, the semi-finished product needs to be transferred to a second production line for foaming. This involves complex processes such as material preparation, spontaneous reaction, foaming, and high-temperature baking. During the foaming process, gases (such as carbon dioxide) generated by chemical reactions cause the liquid material to expand into a foam, which is then solidified at high temperatures to form an elastic and flexible surface layer. Because the transfer between these two production lines increases operational difficulty and time consumption, it not only reduces overall production efficiency but may also lead to a decline in product quality due to accidents during handling.

[0005] High costs and inefficiencies: The segmented production model described above requires more equipment investment, space occupancy, and human resources, while also increasing energy consumption and waste generation. For example, each time a product is transferred from one production line to another, downtime is required, directly leading to a waste of production capacity. Furthermore, difficulties in coordinating between different production lines can easily result in batch-to-batch variations, affecting product stability and consistency.

[0006] With the growing market demand for high-quality, low-cost synthetic leather, traditional segmented production processes can no longer meet the requirements of modern manufacturing. To improve production efficiency, reduce costs, and ensure consistent product quality, the industry urgently needs an integrated solution that completes all necessary processing steps on a single production line. Utility Model Content

[0007] This utility model addresses the problems of the prior art by providing a leather production line that uses a foaming machine. By combining the foaming machine with the same production line, both the base coating and the foaming layer can be processed simultaneously, achieving efficient leather production.

[0008] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a leather production line, including a conveying device, a coating device, a drying device, a fabric feeding device, a cooling device, a foaming machine, a fabric applicator, and a separating and winding device; the conveying device is used to convey release paper, and multiple conveying devices and cooling devices are provided.

[0009] The drying device includes a first drying box, a second drying box, a third drying box, and a fourth drying box; the coating device includes a first coating mechanism and a second coating mechanism.

[0010] The conveying device transports the release paper to the first coating mechanism, which uniformly coats the release paper with a first coating layer and then transports the release paper to the first drying oven for drying. After drying, the release paper with the first coating layer enters the cooling device between the first drying oven and the foaming machine for cooling.

[0011] After cooling, the release paper with the first coating layer is conveyed to the foaming machine by a conveying device. The foaming machine coats the first coating layer with a foaming layer and controls the foaming process. After foaming is completed, the release paper is conveyed to the second drying box for drying. After drying, it is cooled by a cooling device and then conveyed to the second coating mechanism by a conveying device.

[0012] The second coating layer is applied to the foam layer by the second coating mechanism, and the release paper is transferred to the third drying box for drying by the conveying device.

[0013] The fabric feeding device is located between the third and fourth drying boxes and is used to provide the fabric. After the release paper is dried and cooled in the third drying box, the fabric is bonded to the dried release paper by the fabric bonding device and then conveyed to the fourth drying box for drying by the conveying device.

[0014] The separation and rewinding device is used to separate the dried release paper from the fabric and to recycle the formed fabric.

[0015] Preferably, the length of the first drying box is 20m, the length of the second drying box is 35m, the length of the third drying box is 15m, and the length of the fourth drying box is 15m.

[0016] Preferably, the first drying chamber includes a plurality of first drying zones, each with a different temperature; the second drying chamber includes a plurality of second drying zones, each with a different temperature; the third drying chamber includes a plurality of third drying zones, each with a different temperature; and the fourth drying chamber includes a plurality of fourth drying zones, each with a different temperature.

[0017] Preferably, it also includes a paper inspection device, which is used to check whether the release paper can be used normally.

[0018] Preferably, the fabric feeding device includes a fabric rack and a fabric transmission mechanism. The fabric rack is used to hold the fabric to be used, and the fabric transmission mechanism is used to transmit the fabric from the fabric rack to the fabric applicator.

[0019] Preferably, the fabric transmission mechanism includes a transmission frame, a plurality of transmission rollers mounted on the transmission frame, and a tension adjusting component for adjusting the tension of the fabric transmission. The fabric is moved to the applicator via the transmission of the plurality of transmission rollers, and the tension adjusting component is used to adjust the distance between the transmission rollers to adjust the tension of the fabric.

[0020] Preferably, the applicator includes an applicator roller and an applicator conveying mechanism. The applicator is located above the applicator. The dried release paper with coating and the applicator are applicated by the applicator roller and conveyed to the fourth drying chamber by the applicator conveying mechanism.

[0021] The beneficial effects of this utility model are:

[0022] 1. Simplified Process Flow: Through a continuous production system integrating coating and foaming functions, multiple processes such as release paper coating, foam material preparation, foaming molding, and drying and curing can be completed sequentially on the same machine. This integrated design greatly simplifies the complex operations in traditional segmented production processes, reducing time losses and logistics costs in intermediate links.

[0023] 2. Reduced Equipment and Space Requirements: Since all necessary processing steps are completed on a continuous production line, there is no longer a need for dedicated equipment and space for each individual process. This not only saves significant fixed asset investment but also effectively utilizes factory space, enabling companies to achieve higher production output within a limited area. Furthermore, reducing the number of devices also helps lower maintenance costs and energy consumption.

[0024] 3. Reduced human resource input: Increased automation ensures that each step is performed under optimal conditions, thereby reducing the need for skilled workers and reducing product quality problems caused by human error. Attached Figure Description

[0025] Figure 1 This is a flowchart of the present invention;

[0026] Figure 2 This is a schematic diagram of the production line structure of this utility model;

[0027] Figure 3 This is a schematic diagram of the fabric feeding device and fabric applicator of this utility model.

[0028] exist Figures 1 to 3 The reference numerals in the figures include:

[0029] 1-Conveying device, 2-First drying box, 3-Second drying box, 4-Third drying box, 5-Fourth drying box, 6-First coating mechanism, 7-Second coating mechanism, 8-Foaming machine, 9-Fabric feeding device, 10-Coating device, 11-Fabric application device, 12-Separation and winding device, 13-Paper inspection device, 14-Fabric rack, 15-Transmission frame, 16-Conveying roller, 17-Tension adjustment component, 18-Fabric application roller, 19-Fabric application conveying mechanism. Detailed Implementation

[0030] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to embodiments and accompanying drawings. The content mentioned in the embodiments is not intended to limit the present invention. The present invention will be described in detail below with reference to the accompanying drawings.

[0031] This embodiment provides a leather production line, such as Figures 1 to 3 It includes a conveying device 1, a coating device, a drying device, a fabric feeding device 9, a cooling device 10, a foaming machine 8, a fabric application device 11, and a separating and winding device 12; the conveying device 1 is used to convey release paper, and multiple conveying devices 1 and cooling devices 10 are provided.

[0032] The drying device includes a first drying box 2, a second drying box 3, a third drying box 4 and a fourth drying box 5, and the coating device includes a first coating mechanism 6 and a second coating mechanism 7;

[0033] The conveying device 1 transports the release paper to the first coating mechanism 6, which is used to uniformly coat the release paper with a first coating layer and transport the release paper to the first drying box 2 for drying. After drying, the release paper with the first coating layer enters the cooling device 10 between the first drying box 2 and the foaming machine 8 for cooling.

[0034] After cooling, the release paper with the first coating layer is conveyed by the conveying device 1 to the foaming machine 8. The foaming machine 8 coats the first coating layer with a foaming layer and controls the foaming process. After foaming, the release paper is conveyed to the second drying box 3 for drying. After drying, it is cooled by the cooling device 10 and then conveyed by the conveying device 1 to the second coating mechanism 7. The second coating mechanism 7 coats the foaming layer with a second coating layer and then conveys the release paper to the third drying box 4 for drying. The fabric feeding device 9 is located between the third drying box 4 and the fourth drying box 5 and is used to provide fabric. After the release paper is dried and cooled in the third drying box 4, the fabric is bonded to the dried release paper by the fabric application device 11 and then conveyed by the conveying device 1 to the fourth drying box 5 for drying. The separating and winding device 12 is used to separate the dried release paper from the fabric and recycle the formed fabric.

[0035] Specifically, such as Figures 1 to 3 As shown, the production line in this embodiment, from left to right, consists of: a conveying device 1, a first coating mechanism 6, a first drying chamber 2, a cooling device 10, a conveying device 1, a foaming machine 8, a second drying chamber 3, a cooling device 10, a conveying device 1, a second coating mechanism 7, a third drying chamber 4, a cooling device 10, a conveying device 1, a fabric applicator 11, a fourth drying chamber 5, a cooling device 10, and a separating and winding device 12. A coating mechanism can be added before or after the foaming machine 8, depending on the actual leather thickness and softness. This embodiment uses the foaming machine 8, combining foaming and basic coating processes on the same production line, which greatly improves production efficiency. Furthermore, using the foaming machine 8 to create the foam layer allows for real-time monitoring and adjustment of key parameters (such as temperature, pressure, and flow rate), ensuring consistent performance indicators for each batch of products. Especially for processes sensitive to environmental conditions, such as foaming molding and drying curing, precise temperature and humidity control can reduce product variability.

[0036] Furthermore, in this embodiment, the length of the first drying chamber 2 is 20m, the length of the second drying chamber 3 is 35m, the length of the third drying chamber 4 is 15m, and the length of the fourth drying chamber 5 is 15m. Each drying chamber is divided into multiple drying zones; that is, the first drying chamber 2 includes several first drying zones with different temperatures; the second drying chamber 3 includes several second drying zones with different temperatures; the third drying chamber 4 includes several third drying zones with different temperatures; and the fourth drying chamber 5 includes several fourth drying zones with different temperatures. The temperature of each drying zone can be adjusted according to actual needs, thereby helping to protect the coating layer.

[0037] This embodiment also includes a release paper inspection device 13. Since the release paper can be reused after being peeled from the adhesive, it needs to be inspected before each use. As one implementation, the inspection device 13 may include an image acquisition unit. This unit acquires image information of the release paper in real time and transmits it to a corresponding controller. The controller compares the acquired image information with the image information of standard release paper to determine if the release paper has defects. If a problem is found, the device immediately stops the release paper's transmission and notifies staff for handling, thereby improving the final product's quality pass rate. Additionally, sensors can be used to detect whether the release paper's thickness and flatness are normal. If they do not meet standards, staff are notified for handling, further reducing defects in the final product.

[0038] like Figures 1 to 3 As shown, the fabric feeding device 9 in this embodiment includes a fabric rack 14 and a fabric transmission mechanism. The fabric rack 14 is used to place the fabric to be used, and the fabric transmission mechanism is used to transmit the fabric from the fabric rack 14 to the fabric applicator 11. The fabric transmission mechanism includes a transmission frame 15, a plurality of transmission rollers 16 mounted on the transmission frame 15, and a tension adjusting component 17 for adjusting the tension of the fabric transmission. The fabric is moved to the fabric applicator 11 via the transmission of the plurality of transmission rollers 16, and the tension adjusting component 17 is used to adjust the distance between the transmission rollers 16 to adjust the tension of the fabric.

[0039] Specifically, the roll of fabric to be used is placed on the fabric rack 14, and the fabric is moved by the fabric transmission mechanism. The transmission frame 15 is equipped with two rows of conveyor rollers 16, which are divided into upper and lower rows, as shown in the figure. The tension adjustment component 17 can adopt a pulley structure to adjust the height of the lower row of conveyor rollers 16, thereby adjusting the distance between the upper and lower rows of conveyor rollers 16, thus adjusting the conveying tension of the fabric and avoiding pulling the fabric.

[0040] like Figures 1 to 3 As shown, the fabric applicator 11 includes an applicator roller 18 and an applicator conveying mechanism 19. The fabric feeding device 9 is located above the applicator 11. The dried release paper with coating and the fabric are bonded together at the applicator roller 18 and then conveyed to the fourth drying chamber 5 by the applicator conveying mechanism 19. Specifically, before applicating, there is an adhesive layer on the release paper. Therefore, the fabric is conveyed to the applicator roller 18 so that the fabric is bonded to the adhesive layer. Under the rotation of the applicator roller 18, the fabric and the release paper are evenly bonded. After drying in the fourth drying chamber 5, the release paper is separated by the separation and winding device 12, and the finished product is recycled. The separation and winding device 12 is prior art and will not be described in detail here.

[0041] The coating layer preparation process in this embodiment is prior art, and the cooling device 10 is also prior art, so it will not be limited or described in detail here.

[0042] In this embodiment, a continuous production system integrating coating and foaming functions allows for the sequential completion of multiple processes, including release paper coating, foam material preparation, foaming molding, and drying and curing, on a single machine. This integrated design significantly simplifies the complex operations of traditional segmented production processes, reducing time losses and logistics costs in intermediate stages. Compared to the traditional two-line production model, the new technology significantly shortens the production cycle and increases the overall throughput of the production line. The introduction of the continuous production system makes the entire production process more transparent and controllable. Utilizing advanced sensor technology and an automatic control system, key parameters (such as temperature, pressure, and flow rate) can be monitored and adjusted in real time to ensure consistent performance indicators for each batch of products. Precise temperature and humidity control is particularly important for processes sensitive to environmental conditions, such as foaming molding and drying and curing. This approach not only avoids batch-to-batch variations common in traditional methods but also significantly improves the quality of the finished product.

[0043] Since all necessary processing steps are completed on a continuous production line, there is no longer a need for dedicated equipment and space for each individual process. This not only saves significant fixed asset investment but also effectively utilizes factory space, enabling companies to achieve higher production output within a limited area. Furthermore, reducing the number of equipment helps lower maintenance costs and energy consumption. Additionally, it reduces product quality issues caused by human error. Moreover, the use of a foaming machine (8) optimizes the formulation and application of foaming materials, ensuring the uniformity and stability of the foam layer. This contributes to the formation of a finer, denser, and more elastic synthetic leather surface, enhancing its physical properties such as abrasion resistance, tear resistance, and flexibility. Furthermore, by reducing potential damage during handling, the final product has a smoother and more even appearance, offering better visual appeal and tactile feel.

[0044] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model. Any person skilled in the art can make some changes or modifications to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes, and modifications made to the above embodiments based on the present utility model without departing from the scope of the present utility model shall fall within the scope of the present utility model.

Claims

1. A leather production line, characterized in that: It includes a conveying device, a coating device, a drying device, a fabric feeding device, a cooling device, a foaming machine, a fabric application device, and a separating and winding device; the conveying device is used to convey release paper, and multiple conveying devices and cooling devices are provided. The drying device includes a first drying box, a second drying box, a third drying box, and a fourth drying box; the coating device includes a first coating mechanism and a second coating mechanism. The conveying device transports the release paper to the first coating mechanism, which uniformly coats the release paper with a first coating layer and then transports the release paper to the first drying oven for drying. After drying, the release paper with the first coating layer enters the cooling device between the first drying oven and the foaming machine for cooling. After cooling, the release paper with the first coating layer is conveyed to the foaming machine by a conveying device. The foaming machine coats the first coating layer with a foaming layer and controls the foaming process. After foaming is completed, the release paper is conveyed to the second drying box for drying. After drying, it is cooled by a cooling device and then conveyed to the second coating mechanism by a conveying device. The second coating layer is applied to the foam layer by the second coating mechanism, and the release paper is transferred to the third drying box for drying by the conveying device. The fabric feeding device is located between the third and fourth drying boxes and is used to provide the fabric. After the release paper is dried and cooled in the third drying box, the fabric is bonded to the dried release paper by the fabric bonding device and then conveyed to the fourth drying box for drying by the conveying device. The separation and rewinding device is used to separate the dried release paper from the fabric and to recycle the formed fabric.

2. A leather production line according to claim 1, characterized in that: The first drying box has a length of 20m, the second drying box has a length of 35m, the third drying box has a length of 15m, and the fourth drying box has a length of 15m.

3. A leather production line according to claim 1, characterized in that: The first drying chamber includes several first drying zones, each with a different temperature; the second drying chamber includes several second drying zones, each with a different temperature; the third drying chamber includes several third drying zones, each with a different temperature; and the fourth drying chamber includes several fourth drying zones, each with a different temperature.

4. A leather production line according to claim 1, characterized in that: It also includes a paper inspection device, which is used to check whether the release paper can be used normally.

5. A leather production line according to claim 1, characterized in that: The fabric feeding device includes a fabric rack and a fabric transmission mechanism. The fabric rack is used to hold the fabric to be used, and the fabric transmission mechanism is used to transmit the fabric from the fabric rack to the fabric applicator.

6. A leather production line according to claim 5, characterized in that: The fabric transmission mechanism includes a transmission frame, several transmission rollers mounted on the transmission frame, and a tension adjustment component for adjusting the tension of the fabric transmission. The fabric is moved to the applicator via the transmission rollers, and the tension adjustment component is used to adjust the distance between the transmission rollers to adjust the tension of the fabric.

7. A leather production line according to claim 1, characterized in that: The fabric applicator includes an applicator roller and an applicator conveying mechanism. The fabric feeding device is located above the applicator. The dried release paper with coating and the fabric are bonded together by the applicator roller and conveyed to the fourth drying chamber by the applicator conveying mechanism.

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