Horizontal Calender Roller Rack for Floor Production
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Solution Overview
Problem
Traditional calenders with vertically arranged rollers occupy excessive vertical space, making them difficult to transport and requiring high factory building heights, and the vertical arrangement complicates roller replacement, especially for the frequently replaced embossing roller.
Innovation Solution
The calender features a set of calendering rollers arranged in a horizontal line on a rack with walking wheels, allowing the rack to move on a ground track, and includes a front-end cooling device and film laminating assemblies to facilitate efficient processing and reduce space occupation, with a production method involving stepwise heating and compacting for enhanced film lamination and foaming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If calendering rollers are arranged vertically, then the processing function is achieved, but the vertical space occupation increases and transportation becomes difficult
Solution Approach 1:
The patent transforms the traditional vertical arrangement of calendering rollers into a horizontal arrangement. The calendering roller rack is designed to move horizontally along a ground track, allowing multiple rollers to be arranged in a horizontal line rather than stacked vertically. This dimensional change reduces the calender's vertical height from several meters to a manageable level, enabling container transportation while maintaining all processing functions.
Solution Approach 2:
The calendering roller rack is made movable along a ground track through walking wheels, transforming from a static vertical structure to a dynamic horizontal system. This allows the rack to move into position for processing and be relocated for roller replacement, eliminating the need for crane hoisting and reducing height requirements for factory buildings.
2Productivity
If the embossing roller is positioned at the top for vertical arrangement, then the processing sequence is maintained, but roller replacement requires crane hoisting and high factory building height
Solution Approach 1:
The embossing roller is repositioned from the top of a vertical stack to a horizontal position within the moving rack system. All calendering rollers including the embossing roller are arranged horizontally on the rack, allowing ground-level access for replacement without requiring crane hoisting or high factory buildings, while maintaining the processing sequence through controlled horizontal movement.
Solution Approach 2:
The movable rack system allows operators to easily replace rollers at ground level by manually guiding the rack along the track, eliminating the need for complex crane operations and high-altitude work, thereby improving maintenance ease and reducing operational complexity.
3Volume of moving object
If vertical arrangement is used, then the compact structure is achieved, but the factory building height requirement increases
Solution Approach 1:
The patent redistributes the calendering rollers from a vertical stack occupying minimal floor space but requiring great height, to a horizontal arrangement on a movable rack that occupies more floor space but reduces height to container-transportable levels. This dimensional redistribution allows standard factory building heights while maintaining compact overall footprint through the movable rack design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces the overall height of the calender, simplifies roller replacement, and enhances film lamination quality, making it easier to transport and assemble, while producing high-quality, cost-effective foamed floors.
Implementation Method 1
a blank enters a feed end of the set of calendering rollers from a discharge end of the front-end cooling device to realize cooling of the blank
Implementation Method 2
the set of calendering rollers includes a lower mirror-surface roller, an upper mirror-surface roller, a bottom pattern roller, and an embossing roll, all of which are vertically arranged, and a blank to be machined passes through the calendering rollers
Implementation Method 3
a production method involving stepwise heating and compacting for enhanced film lamination and foaming
Data Source
AI summary
The present application provides a calender, a floor production line and a production method using the calender, wherein the calender comprises a calendering roller rack and a set of calendering rollers arranged on the calendering roller rack. The set of calendering rollers comprises a plurality of calendering rollers arranged in a line and not vertically. The present application changes the arrangement of the calendering rollers. The calendering rollers are arranged in a line, not vertically. This arrangement reduces the overall height of the calender, decreases the requirements of the calender on the height of the factory building and facilitates long-distance transportation by containers. Using the calender to assemble the floor production line, the height space of the factory building occupied by the production line can be saved.