Roll Forming Device Calender Segmentation
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Solution Overview
Problem
Conventional plastic flooring production using substrates with low oil content results in decreased efficiency and poor surface embossing quality due to the difficulty in laminating layers effectively.
Innovation Solution
A roll forming device with a five-roller calender system, including an extruder, printed layer and wear-resisting layer unwinding mechanisms, and a calender with gauging, pre-bonding, and laminating rollers, which uses heating units to pre-bond and emboss the layers, enhancing the lamination process and surface pattern clarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional four-roller calender is used to laminate substrate, printed layer, and wear-resisting layer, then the production process is simple, but the production efficiency decreases and surface embossing quality is poor when substrate has low oil content
Solution Approach 1:
The calender is divided into five independent rollers (first conveying roller, second conveying roller, mirror roller, patterned roller, and embossing roller) instead of the conventional four-roller design. Each roller performs a specific function in the lamination and embossing process, allowing optimized control over substrate handling, heating, and pattern formation to improve both efficiency and quality
Solution Approach 2:
The invention adds a new functional dimension by introducing a dedicated embossing roller with heating capability. This creates an additional processing stage that simultaneously applies pressure and heat for superior embossing quality, while the five-roller configuration provides an extra degree of freedom in controlling material flow and lamination pressure
2Quantity of substance
If substrate with low oil content is used, then material cost is reduced, but lamination efficiency decreases and bonding quality deteriorates
Solution Approach 1:
The invention changes the thermal parameter by introducing heating units in both the patterned roller and embossing roller. This thermal treatment modifies the physical state of the low-oil substrate, enhancing its bonding characteristics and allowing efficient lamination despite reduced oil content. The heating enables the substrate to achieve proper adhesion without requiring high oil content
3Device complexity
If conventional rolling method is used, then device complexity is low, but surface pattern clarity is poor
Solution Approach 1:
The calender structure is segmented into five specialized rollers with distinct functions. The embossing roller is further segmented with circumferential grooves to create specific pattern designs. This segmentation allows each component to be optimized for its specific task, resulting in clear and prominent surface patterns
Solution Approach 2:
The patterned roller acts as an intermediary between the mirror roller and the embossing roller. It transfers the pattern from the mirror roller to the substrate while the embossing roller applies pressure and heat to imprint the pattern clearly on the wear-resisting layer, ensuring high pattern clarity
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
The device increases production efficiency and produces a clear, prominent embossed pattern on the plastic flooring by effectively laminating substrate, printed, and wear-resisting layers, even with substrates having low oil content.
Implementation Method 1
at least one first heating unit being disposed inside the large roller or at a position corresponding to an outer edge of a roller surface of the large roller, is configured to heat the substrate layer, the printed layer and the wear-resisting layer which are pre-bonded
Implementation Method 2
The extruder is configured to form a substrate layer, with one end having a discharge port, and the substrate layer is extruded outward from the discharge port
Data Source
AI summary
A roll forming device for plastic flooring utilizes a printed layer unwinding mechanism, a wear-resisting unwinding mechanism and a calender to laminate a substrate layer formed by an extruder, a printed layer and a wear-resisting layer into a whole. The calender includes a gauging roller group, a pre-bonding roller group and a laminating roller group disposed on a rack. The gauging roller group, which is disposed at one side of the pre-bonding roller group and linearly opposite to a discharge port of the extruder. The pre-bonding roller group includes a large roller and a plurality of guide rollers disposed around the large roller, and at least one first heating unit is disposed in the large roller or a position corresponding to an outer edge of the roller surface. The laminating roller group, which is disposed at the other side of the pre-bonding roller group.