WO2022242560A1 - 防排水一体板成型机、防排水一体板及其成型工艺 - Google Patents

防排水一体板成型机、防排水一体板及其成型工艺 Download PDF

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Publication number
WO2022242560A1
WO2022242560A1 PCT/CN2022/092685 CN2022092685W WO2022242560A1 WO 2022242560 A1 WO2022242560 A1 WO 2022242560A1 CN 2022092685 W CN2022092685 W CN 2022092685W WO 2022242560 A1 WO2022242560 A1 WO 2022242560A1
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Prior art keywords
roller
concave
waterproof
drainage
convex
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Ceased
Application number
PCT/CN2022/092685
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English (en)
French (fr)
Inventor
周勤
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Zhejiang Junheng Machinery Manufacturing Co Ltd
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Zhejiang Junheng Machinery Manufacturing Co Ltd
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Publication date
Application filed by Zhejiang Junheng Machinery Manufacturing Co Ltd filed Critical Zhejiang Junheng Machinery Manufacturing Co Ltd
Priority to US18/290,136 priority Critical patent/US20250073973A1/en
Publication of WO2022242560A1 publication Critical patent/WO2022242560A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D7/00—Producing flat articles, e.g. films or sheets
    • B29D7/01—Films or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0011—Combinations of extrusion moulding with other shaping operations combined with compression moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/002—Combinations of extrusion moulding with other shaping operations combined with surface shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0021—Combinations of extrusion moulding with other shaping operations combined with joining, lining or laminating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/28—Storing of extruded material, e.g. by winding up or stacking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/302—Extrusion nozzles or dies being adjustable, i.e. having adjustable exit sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/35—Extrusion nozzles or dies with rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/885—External treatment, e.g. by using air rings for cooling tubular films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/91—Heating, e.g. for cross linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/92—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D31/00—Protective arrangements for foundations or foundation structures; Ground foundation measures for protecting the soil or the subsoil water, e.g. preventing or counteracting oil pollution
    • E02D31/02—Protective arrangements for foundations or foundation structures; Ground foundation measures for protecting the soil or the subsoil water, e.g. preventing or counteracting oil pollution against ground humidity or ground water
    • E02D31/025—Draining membranes, sheets or fabric specially adapted therefor, e.g. with dimples
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/92609—Dimensions
    • B29C2948/92647—Thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92819—Location or phase of control
    • B29C2948/92857—Extrusion unit
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92819—Location or phase of control
    • B29C2948/92923—Calibration, after-treatment or cooling zone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0068—Permeability to liquids; Adsorption
    • B29K2995/0069—Permeability to liquids; Adsorption non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • the invention relates to the technical field of forming equipment for building engineering components, in particular to a forming machine for an integrated waterproof and drainage panel, an integrated waterproof and drainage panel and a forming process thereof.
  • Drainage engineering is widely used in construction engineering, traffic engineering, garden engineering and municipal engineering.
  • plastic drainage boards are widely used.
  • the plastic drainage board is formed by blistering the plastic base plate, and the space between the adjacent bosses forms a drainage channel, and the base surface such as the ground, soil or rock stratum is laid to prevent water seepage.
  • the inventor's Chinese invention patent 2011103758741 discloses a drainage board forming machine.
  • the formed drainage board is a common single-layer structure, but due to the forming thickness of the drainage board (for example, the thickness is thinner for saving materials), the material (for example, for Reduce cost, use mixed materials), working environment (for example, it is easy to cut the plastic layer when used in sandstone areas), and plastic aging, so cracks will occur, especially in the boss part, because the boss part protrudes outside and needs to be loaded Forced, so it is more vulnerable to damage; once damaged, water seepage and leakage will occur, and leakage points will appear. In actual construction, it is also necessary to lay an asphalt waterproof layer on the surface of the soil and other bases to achieve the waterproof effect.
  • the applicant provides a waterproof and drainage integrated board forming machine with a reasonable structure, a waterproof and drainage integrated board and its forming process, which have good drainage and waterproof effects at the same time, and reduce the input cost of the production line and inventory costs.
  • a water-proof and drainage integrated panel forming machine the frame is equipped with a first concave roller, a convex roller, a second concave roller and a mirror roller, the convex roller rolls relative to the first concave roller and the second concave roller respectively, and the mirror roller and the second concave roller The two concave rollers roll relative to each other;
  • the roll surface of the first concave roll is provided with some first concave cavities
  • the roll surface of the second concave roll is provided with some second concave cavities
  • the roll surface of the convex roll is correspondingly arranged with some convex grains, and the convex grains are respectively connected with the first concave cavities.
  • the second concave cavity correspondingly; the roller surface of the mirror roller is a smooth surface.
  • intersection of the convex roll and the first concave roll is located on the side of the first extruder head; the convex roll, the second concave roll and the mirror roll are arranged in sequence, and the intersection of the second concave roll and the mirror roll is located in the second extruder head side.
  • the line connecting the centers of the convex roll and the first concave roll is perpendicular to the line connecting the centers of the convex roll, the second concave roll, and the mirror roll, and the convex roll, the second concave roll, and the mirror roll are arranged side by side up and down.
  • the central axes of the first concave roller, the convex roller, the second concave roller and the mirror roller are on the same horizontal plane;
  • the angle ⁇ between the centers of the two concave rollers and the mirror rollers is greater than 90° and less than 180°.
  • the central angle ⁇ of the wrapping arc of the substrate on the convex roller is greater than or equal to 180°, and the arc length of the wrapping arc is greater than or equal to ⁇ r.
  • the second extruder head is facing the intersection of the second concave roll and the mirror roll; or the second extruder head is offset by a horizontal distance d toward the mirror roll based on the intersection.
  • a heating structure is arranged inside the second concave roller or the mirror roller, and the heating temperature range is 30-80°C.
  • a heat gun is arranged on the outside of the second concave roller to heat the bottom surface of the substrate, and the heating temperature range is 200-400°C.
  • a hot-melt adhesive film rolling roll is arranged outside the junction of the second concave roll and the mirror roll.
  • heating plate on the outside of the second concave roller, which is a certain distance away from the second concave roller. During operation, the heating area partially covers the drainage layer wound during operation; the heating plate is arc-shaped, and is arranged outside the second concave roller and close to the convex roller. the upper half of the .
  • Slide blocks are respectively provided on the supports at the two ends of the first concave roller, convex roller, and mirror roller, and slide rails are correspondingly arranged on the frame, and the slide blocks are slidably arranged on the second slide rail;
  • the first concave roller, The convex roller and the mirror roller can be driven by the linear drive mechanism to adjust the gap between the two rollers;
  • the diameter of the first concave cavity and the second concave cavity are equal, and they are both larger than the outer diameter of the convex grain;
  • the radial distance between the inner surface of the concave cavity/the second concave cavity is equal to or greater than the thickness of the substrate;
  • the gap between the mirror roller and the second concave roller is smaller than the sum of the thickness of the substrate and the waterproof layer.
  • the first concave roller is connected with the motor through the transmission mechanism; the first concave roller, the convex roller, the second concave roller and the mirror roller respectively transmit torque through the cooperation of gears; the frame is provided with a guide roller, which is connected with the motor through the transmission mechanism.
  • rollers There are a number of rollers on the opposite sides of the bottom of the frame.
  • the rollers are connected to the motor through a transmission mechanism. Hobbing fit.
  • a forming process of an integrated waterproof and drainage panel using the above-mentioned integrated waterproof and drainage panel forming machine comprising the following steps:
  • the first extruder extrudes the flat substrate
  • the substrate enters between the first concave roller and the convex roller to form a hollow boss
  • the substrate and the boss form a drainage layer, which is transferred from the convex roller to the second concave roller;
  • the second extruder extrudes the flat waterproof layer, and enters between the second concave roller and the mirror roller together with the drainage layer.
  • the waterproof layer and the bottom surface of the substrate of the drainage layer are fused under a certain pressure to form a waterproof and drainage integrated board.
  • the bottom surface of the substrate is heated before the waterproof layer is fused with the bottom surface of the substrate.
  • a waterproof and drainage integrated panel produced by using the above-mentioned integrated waterproof and drainage panel forming machine.
  • the drainage layer includes a base plate and a hollow boss, and the waterproof layer and the bottom surface of the substrate are fused together to seal the bottom opening of the boss. Fuses together when molded.
  • the maximum thickness T max of the press-fit part is greater than the thickness t of the fused flat plate layer.
  • the minimum thickness T min of the press-fit part is greater than or equal to the thickness t 2 of the waterproof layer.
  • the average thickness T of the pressed-in portion is greater than the thickness t of the fused flat plate layer.
  • a hot melt adhesive layer is bonded between the drainage layer and the waterproof layer.
  • the drainage layer substrate of the present invention is extruded from the first extruder head, and the convex platform is formed by vacuum adsorption, cooled and shaped, and then followed by the second concave roller to the bottom, directly with the waterproof layer just extruded by the second extruder head Fusion, at this time the substrate and the waterproof layer are in a softened state with a high temperature, and the two are fused smoothly, and the gap between the second concave roller and the mirror roller is adjusted to apply a certain pressure to press and calender, so that The drainage layer and the waterproof layer are combined into one.
  • the hollow boss not only has good strength, but also its bottom opening is closed by the waterproof layer.
  • the layer has a double thickness, which further increases its strength and water resistance.
  • the waterproof and drainage integrated board of the present invention does not need to lay an asphalt layer or waterproof coiled material during construction, and the waterproof layer has already fully guaranteed the same waterproof effect as the asphalt layer, so it can be directly laid on the base surface.
  • the waterproof layer of the present invention is directly extruded and then fused, without the need for separate production and winding, which saves the production, winding and other equipment required for separate production, saves equipment costs, saves production line space, and reduces the need for
  • the space requirement of the production workshop further reduces the input cost of the production line; and the waterproof layer does not need to be rolled up for backup, and there is no need to reserve corresponding inventory space, which reduces the inventory cost.
  • the first concave roller, convex roller and mirror roller of the present invention adjust the radial distance through the sliding movement of the support, so as to realize matching with substrates and waterproof layers of different thicknesses, and are flexibly applicable to drainage boards of various specifications, and the scope of application Wide; By adjusting the radial distance, the pressing force between the substrate and the waterproof layer can be adjusted to improve the firmness of fusion and the reliability of the drainage board.
  • the adjustable base also makes the distance between the molding machine and the extruder adjustable to ensure the production quality of the product and facilitate the maintenance of the equipment.
  • Fig. 1 is a perspective view of the first embodiment of the present invention.
  • Fig. 2 is an enlarged view of part A in Fig. 1 .
  • Fig. 3 is a front view of the first embodiment of the present invention.
  • Fig. 4 is a sectional view of the B-B section of Fig. 3, and the arrows in the figure indicate the rotation direction of each roller.
  • FIG. 5 is an enlarged view of part C in FIG. 4 .
  • FIG. 6 is an enlarged view of part D in FIG. 4 .
  • FIG. 7 is an enlarged view of part E in FIG. 4 .
  • Fig. 8 is a left view of Fig. 3 .
  • Fig. 9 is a schematic structural diagram of the second embodiment of the present invention.
  • FIG. 10 is a schematic structural diagram of a third embodiment of the present invention.
  • Fig. 11 is a schematic structural view of the waterproof and drainage integrated board.
  • Fig. 12 is an enlarged view of part F in Fig. 11 .
  • Fig. 13 is a schematic structural view of another embodiment of the integrated waterproof and drainage board.
  • the frame 1 of the present invention has vertical support plates on opposite sides, and a first concave roller 2 and a convex roller parallel to each other are horizontally arranged between the two support plates. 3.
  • the second concave roller 4 and the mirror roller 5 also known as smooth roller.
  • the first concave roller 2 is located on the rear side of the convex roller 3, and the central axes of the two are located on the same horizontal plane; the second concave roller 4 and the mirror roller 5 are arranged directly below the convex roller 3 from top to bottom, and the central axes of the three are located at the same horizontal plane.
  • the line connecting the centers of the convex roll 3 and the first concave roll 2 is set at right angles to the line connecting the centers of the convex roll 3 , the second concave roll 4 and the mirror roll 5 .
  • the radial distance between the top surface of the convex grain 31 and the bottom surface of the first concave cavity 21/second concave cavity 41 is equivalent to the thickness of the substrate 100, or greater than the thickness of the substrate 100, to ensure that the height of the boss 101 punched out by the convex grain 31 on the substrate 100 meets the requirements;
  • the peripheral surface of the mirror roller 5 is a smooth surface, and the gap between the mirror roller 5 and the second concave roller 4 is smaller than the sum of the thicknesses of the substrate 100 and the waterproof layer 200 to ensure that the substrate 100 and the waterproof layer 200 are smoothly combined into one.
  • the first concave roller 2 is connected with the motor through a transmission mechanism, the driving wheel 10 is sleeved on the first concave roller 2, the primary driven wheel 11 is sleeved on the convex roller 3, and the second concave roller 4 is sleeved
  • the secondary driven wheel 12, the mirror roller 5 is sleeved with the tertiary driven wheel 13, the driving wheel 10, the primary driven wheel 11, the secondary driven wheel 12 and the tertiary driven wheel 13 are all gears, and the torque is transmitted through gear cooperation respectively;
  • the motor drives the first concave roller 2 to rotate through the transmission mechanism, and drives the convex roller 3, the second concave roller 4, and the mirror roller 5 to rotate in turn through gear transmission.
  • the first extruder head 24 of the first extruder (not the structure of this patent) is arranged above the intersection of the first concave roller 2 and the convex roller 3, and the first extruder
  • the substrate 100 is extruded through the first extruder head 24, and the substrate 100 continuously enters the mating position of the first concave roller 2 and the convex roller 3 from the intersection of the first concave roller 2 and the convex roller 3.
  • the corresponding part is pressed into the first concave cavity 21 of the first concave roller 2, and at the same time, the vacuum adsorption mechanism on the convex roller 3 is used for plastic forming, so that several hollow bosses with an open bottom surface arranged in an array are formed on the substrate 100 101; at this time, the drainage plate structure including the substrate 100 and the boss 101 is formed, which is defined as the drainage layer in this patent.
  • the convex roller 3 rotates with the formed drainage layer to the mating position with the second concave roller 4.
  • the convex platform 101 of the drainage layer is transferred into the second concave cavity 41 , and keep the boss 101 trapped in the second concave cavity 41 and follow the second concave roller 4 to rotate to the confluence with the mirror roller 5; the process of the second concave roller 4 rotating makes the boss 101 obtain a certain cooling time , which is beneficial to improve the forming stability and strength of the boss 101 and prevent the boss 101 from being deformed.
  • the second extruder head 25 of the second extruder (non-patented structure) is arranged on the side where the second concave roll 4 meets the mirror roller 5, and the second extruder passes through the second extruder head 25
  • the waterproof layer 200 is extruded, and the waterproof layer 200 continuously enters the confluence part from the intersection of the second concave roller 4 and the mirror roller 5, and is melted and combined with the bottom surface of the substrate 100 of the drainage layer brought down by the second concave roller 4 .
  • the second concave roller 4 is provided with an arc-shaped heating plate 7 at a certain distance from the second concave roller 4 around the outer side of the side with the drainage layer.
  • the heating plate 7 is arranged outside the second concave roller 4 and is close to the upper half of the convex roller 3 On the side, the heating area of the heating plate 7 partially covers the drainage layer wound during work, and the heating plate 7 heats or heats the bottom surface of the substrate 100 of the drainage layer, which is beneficial to the smooth fusion of the substrate 100 and the waterproof layer 200. At this time, the drainage layer
  • the boss 101 remains in the second concave cavity 41, and the second concave cavity 41 plays a protective role for the boss 101, avoiding the further heating of the boss 101 due to the heating effect of the heating plate 7, which is conducive to improving the performance of the boss 101 of the drainage layer. Molding stability, to avoid deformation of the boss 101 .
  • the two ends of the first concave roller 2 have a first support 14, the first support 14 is connected with the motor, the bottom surface of the first support 14 is fixed with a first slider 15, the machine
  • the first slide rail 16 is correspondingly arranged on the frame 1, and the first slide block 15 is slidably arranged on the first slide rail 16.
  • the first support 14 can be driven by the motor to slide back and forth along the first slide rail 16, and the The radial distance between a concave roller 2 and the convex roller 3 is adjusted radially.
  • the two ends of the convex roller 3 have a second support 17, the second support 17 is connected with the motor, the side of the second support 17 is fixed with a second slide block 18, and the frame 1 is correspondingly provided with a second slide rail 19,
  • the second slide block 18 is slidably arranged on the second slide rail 19, and the second bearing 17 can be driven by a motor to slide up and down along the second slide rail 19, and the diameter of the convex roller 3 and the second concave roller 4 Adjust radially towards the distance.
  • the two ends of the mirror roller 5 have a third support 20, the third support 20 is connected with the motor, the side of the third support 20 is fixed with a third slide block 26, and the frame 1 is correspondingly provided with a third slide rail 22,
  • the third slider 26 is slidably arranged on the third slide rail 22, and the third bearing 20 can be driven by a motor to slide up and down along the third slide rail 22, and the radial direction of the mirror roller 5 and the second concave roller 4 Distance radial adjustment.
  • Both ends of the second concave roller 4 have fourth supports 23, and the fourth supports 23 are fixed on the frame 1 by fasteners.
  • the first concave roller 2, convex roller 3, and mirror roller 5 adjust the radial distance through the sliding movement of the support, so as to achieve matching with the substrate 100 and waterproof layer 200 of different thicknesses, and are flexibly applicable to various specifications
  • the drainage board has a wide range of applications; by adjusting the radial distance, the pressing force between the substrate 100 and the waterproof layer 200 can be adjusted to improve the firmness of fusion and the reliability of the drainage board.
  • the first concave roller 2, the convex roller 3, and the mirror roller 5 can also be driven by other linear drive mechanisms to realize sliding and adjust the radial distance.
  • a guide roller 6 is arranged on the rear lower side of the mirror roller 5, and the guide roller 6 is connected with the motor through a transmission mechanism; The integrated waterproof and drainage board is transported to the next process section.
  • two rails 8 are arranged parallel to the conveying direction of the drainage board on the floor of the workshop, and several hobbing teeth 81 are uniformly provided on the upper surface of the rails 8; the opposite sides of the bottom of the frame 1 correspond to the rails 8
  • a plurality of rollers 9 are respectively arranged, and the outer circumference of the rollers 9 has gear teeth 91, and the teeth 91 of the rollers 9 cooperate with the hobbing teeth 81 of the track 8;
  • the rollers 9 are connected with the motor through a transmission mechanism, and the motor can drive the rollers 9 to rotate through the transmission mechanism, Realize walking on the track 8 and adjust the position of the equipment.
  • the substrate 100 is extruded from the first extruder head 24, and after the first concave roller 2 and the convex roller 3 are blister-formed into a drainage layer, the substrate 100 follows the convex roller 3 and transfers to the contact with the second concave roller 4.
  • the waterproof layer 200 is formed from The second extruder head 25 extrudes and fuses with the drainage layer at the junction of the second concave roller 4 and the mirror roller 5;
  • the first concave roller 2, the convex roller 3, the second concave roller 4 and the mirror roller 5 are horizontally arranged side by side, the central axes of the four rollers are on the same horizontal plane, and the four rollers are arranged in pairs. The junctions are also on the same level.
  • the first extruder head 24 is vertically arranged directly above the junction of the first concave roller 2 and the convex roller 3, and extrudes the substrate 100 vertically downward toward the junction of the first concave roller 2 and the convex roller 3; 100 enters the entry point 102 where the first concave roller 2 and the convex roller 3 meet, and forms a number of hollow bosses 101 arranged in an array on the substrate 100; the entry point 102 is separated from the convex roller 3 and the second concave roller.
  • the arc segment between the breakaway points 103 at the 4 intersections is the wrapping arc 104 wrapped on the convex roller 3.
  • the central angle ⁇ of the wrapping arc 104 is 180°, and the arc length L of the wrapping arc 104 is ⁇ r(r is the radius of the convex roller 3, the arc length L is equal to the semi-circumferential arc length of the convex roller 3), compared with the first embodiment, the central angle of the wrapping arc 104 of this embodiment is larger, and the arc length is longer.
  • the travel distance on the convex roller 3 is longer, and the duration of the stay is longer, that is, the substrate 100 obtains a longer shaping stroke and time on the convex roller 3, which is more conducive to the shaping of the hollow boss 101 on the substrate 100 and reduces the substrate 100.
  • the shrinkage rate after detaching from the convex roller 3 improves the molding stability and strength of the substrate 100 .
  • the second extruder head 25 is vertically arranged directly above the intersection of the second concave roll 4 and the mirror roll 5, and extrudes the waterproof layer 200 vertically downward toward the intersection of the second concave roll 4 and the mirror roll 5;
  • the second concave roller 4 and the mirror roller 5 are arranged horizontally, which is beneficial to the vertical casting of the waterproof layer 200, and the vertical casting of the waterproof layer 200 is more conducive to the intersection and hot-melt compounding with the substrate 100, which can improve the flatness after compounding.
  • the machine head 25 is facing the intersection of the second concave roller 4 and the mirror roller 5, so that the waterproof layer 200 can enter the intersection vertically, which is more conducive to the composite of the substrate 100 and the waterproof layer 200, and improves the adhesion between the substrate 100 and the waterproof layer 200 strength.
  • the second concave roller 4 and the mirror roller 5 are respectively provided with heating structures to heat the roller surfaces of the second concave roller 4 and the mirror roller 5 respectively, and the heating temperature range of the roller surfaces is controlled at 30-80°C Heating the roller surface of the second concave roller 4 can prevent the boss 101 of the substrate 100 from shrinking and staying in the second concave cavity 41, thereby causing the phenomenon of internal jamming; heating the roller surface of the mirror roller 5 is beneficial to the waterproof layer 200 After being extruded, it meets with the substrate 100 and is hot-melt-composited, so as to improve the bonding strength after compounding, and the compounding effect is better.
  • a heat gun 27 is arranged outside the second concave roller 4, and the bottom surface of the substrate 100 is heated by the heat gun 27.
  • the heating temperature range Controlled at 200-400°C the temperature of the heat gun 27 is determined according to the linear speed of the substrate 100, the temperature of the heat gun 27 is lower when the linear speed is slow, and the temperature of the heat gun 27 is higher if the linear speed is fast; the wind speed of the heat gun 27 is also controllable Yes, the air volume is adjusted by frequency conversion.
  • a roll film roll 28 can be arranged outside the intersection of the second concave roll 4 and the mirror roll 5 for placing heat.
  • the melt adhesive film roll, the hot melt adhesive film roll sends the hot melt adhesive film 300 to the intersection of the second concave roller 4 and the mirror roller 5, between the substrate 100 and the waterproof layer 200, and is bonded to the substrate 100 and the waterproof layer 200 by hot melting. Between the waterproof layers 200, the bonding strength is improved.
  • the second concave roller 4 and mirror roller 5 of this embodiment are arranged horizontally, and the first concave roller 2 and convex roller 3 are arranged obliquely upward at a certain angle, that is, the second
  • the included angle ⁇ between the line connecting the centers of the first concave roller 2 and the convex roller 3 and the line connecting the centers of the second concave roller 4 and the mirror roller 5 is greater than 90° and less than 180°.
  • the substrate 100 is on the convex roller 3
  • the central angle ⁇ of the wrapped arc 104 is greater than 180° and less than 270°, and the arc length L is greater than ⁇ r and less than 1.5 ⁇ r.
  • the central angle of the wrapped arc 104 is further increased, and the arc length is further lengthened, which is more conducive to the hollow convex on the substrate 100.
  • the stage 101 is kept on the bumps 31 on the convex roller 3 as long as possible to avoid shrinkage after premature detachment, which is beneficial to improve the molding stability and strength of the substrate 100 .
  • the second extruder head 25 is based on the second concave roller 4 and the mirror roller 5 where the mirror roller 5 meets and deviates from the horizontal distance d to the mirror roller 5, and the range of d is 50-200mm.
  • the mirror roller 5 is offset, and the extruded waterproof layer 200 first flows to the surface of the mirror roller 5 to crystallize, and then follows the rotation of the mirror roller 5 and enters the intersection for compounding.
  • the waterproof layer 200 obtains a certain degree of Crystallization time, thermal compounding with the substrate 100 after initial crystallization, higher flatness.
  • Example 1 of integrated waterproof and drainage board is
  • the waterproof and drainage integrally formed board formed by the above-mentioned equipment includes the drainage layer of the substrate 100 and the boss 101 and the waterproof layer 200 are integrally fused, and the top surface of the waterproof layer 200 is fused with the bottom surface of the substrate 100. And the bottom opening of the boss 101 is sealed.
  • a fused flat layer 400 is formed between the bosses 101.
  • the thickness t of the fused flat layer 400 is the thickness t of the substrate 100 and the thickness of the waterproof layer 200.
  • t is the sum of the thicknesses ; since the boss 101 is hollow and has an opening at the bottom, when the substrate 100 and the waterproof layer 200 are combined, there is an extrusion force between the two rollers.
  • each part of the molded waterproof and drainage integrated panel is cut, and then a caliper is used to measure the thickness t of the fused flat plate layer 400, the thickness t 1 of the substrate 100, and a plurality of randomly selected press-fit parts 201.
  • the thickness T n of the points (five points are taken in this embodiment) are detected respectively, and the thickness t2 of the waterproof layer 200 and the average thickness T of the press-fit part 201 are calculated according to the detection data.
  • the maximum thickness Tmax of the indentation part 201 is greater than the thickness t of the fused flat plate layer 400, and the minimum thickness Tmin of the indentation part 201 is greater than or equal to the thickness t of the waterproof layer 200.
  • the average thickness of the indentation part 201 T is greater than the thickness t 2 of the waterproof layer 200.
  • the press-in part 201 bulges into the boss 101 of the waterproof layer 200, which not only closes the bottom surface of the boss 101, but also improves the life and reliability of the waterproof board.
  • an effective support is formed for the boss 101 at the corner of the opening, which can improve the support strength of the boss 101, reinforce the boss 101, prevent the boss 101 from deforming, and be more conducive to improving the compression resistance of the waterproof board performance, longevity and reliability.
  • Example two of waterproof and drainage integrated board is
  • the integrated waterproof and drainage forming board formed by the equipment adding the hot-melt adhesive layer film is also bonded with a layer of hot-melt adhesive film 300 between the drainage layer and the waterproof layer 200, which improves the peel strength of the forming board. It also improves the life and reliability of the waterproof board.

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Abstract

本发明公开了一种防排水一体板、成型机与成型工艺，机架上设置有第一凹辊、凸辊、第二凹辊及镜面辊，凸辊分别与第一凹辊、第二凹辊相对滚动，镜面辊与第二凹辊相对滚动。本发明的排水层基板从第一挤出机头挤出，定型后随即跟随第二凹辊转至底部，与第二挤出机头刚挤出成型的防水层直接融合，通过调整第二凹辊与镜面辊之间的间隙以施加一定的压力进行压合且压光，从而使得排水层与防水层合二为一，空心凸台既具有良好的强度，而且其底面开口被防水层所封闭，即使凸台破裂漏水，也仍有防水层防止渗漏；基板与融合的防水层具有双层厚度，更加增加了其强度与防水性。

Description

防排水一体板成型机、防排水一体板及其成型工艺 技术领域
本发明涉及建筑工程部件成型设备技术领域，尤其是一种防排水一体板成型机、防排水一体板及其成型工艺。
背景技术
排水工程广泛应用于建筑工程、交通工程、园林工程及市政工程等。其中广泛使用塑料排水板。塑料排水板是在塑胶基板经过吸塑制成凸台，相邻凸台之间的空间构成排水通道，铺设地面、土壤或岩层等基面上以防止水分下渗。本发明人的中国发明专利2011103758741公开了一种排水板成型机，所成型的排水板为常见的单层结构，但由于排水板的成型厚度(例如为了省料厚度较薄)、材质(例如为了降低成本使用混料)、工作环境(例如使用在砂岩地区容易割破塑料层)以及塑料老化等影响，所以会发生破裂，尤其容易出现在凸台部，因为凸台部凸出在外且需要承载受力，故更容易受到破坏；一旦破坏后就会发生渗水漏水，出现漏点。实际施工时还需要在土壤等基底表面铺设沥青防水层，以达到防水效果。
中国实用新型专利2019213530377---一种自粘式防水层一体化排水板尝试将沥青材质的防水卷材熔融在排水板底部形成一体，在铺设时再采用喷灯燃具热熔排水板最下方的防水卷材，热熔时的温度应控制使防水卷材表面融化但不流淌为宜，然后一边热熔一边向前滚铺。这种方式实际上仅仅是简单复合了排水板与沥青层，但施工时同样工作量巨大，且难以控制喷灯燃烧效果，同时排水板上的凸台也会软化变形丧失承载力，严重时甚至会烧穿排水板，因此仍然具有一定缺陷。
发明内容
本申请人针对现有排水板成型存在的上述缺点，提供一种结构合理的防排水一体板成型机、防排水一体板及其成型工艺，同时具备良好的排水与防水效果，降低产线投入成本及库存成本。
本发明所采用的技术方案如下：
一种防排水一体板成型机，机架上设置有第一凹辊、凸辊、第二凹辊及镜面辊，凸辊分别与第一凹辊、第二凹辊相对滚动，镜面辊与第二凹辊相对滚动；
第一凹辊的辊面上开设若干第一凹腔，第二凹辊的辊面上开设若干第二凹腔，凸辊的辊面上对应布置若干凸粒，凸粒分别与第一凹腔及第二凹腔对应配合；镜面辊的辊面为光滑面。
作为上述技术方案的进一步改进：
凸辊与第一凹辊相汇处位于第一挤出机头一侧；凸辊、第二凹辊与镜面辊依次布置，第二凹辊与镜面辊的相汇处位于第二挤出机头一侧。
凸辊、第一凹辊的中心连线，与凸辊、第二凹辊、镜面辊的中心连线呈正交设置，凸辊、第二凹辊、镜面辊上下并排布置。
第一凹辊、凸辊、第二凹辊及镜面辊的中心轴处于同一水平面；或第二凹辊及镜面辊的中心轴处于同一水平面，第一凹辊及凸辊的中心连线与第二凹辊及镜面辊的中心连线之间的夹角β大于90°、小于180°。
凸辊上基板的包裹弧的圆心角α大于等于180°，包裹弧的弧长大于等于πr。
第二挤出机头正对第二凹辊与镜面辊相汇处；或者第二挤出机头基于相汇处朝镜面辊偏移水平距离d。
第二凹辊或镜面辊内设置有加热结构，加热温度范围为30-80℃。
第二凹辊的外侧设置有热风枪，并对基板底面加热，加热温度范围为200-400℃。
第二凹辊与镜面辊相汇处的外侧设置有热熔胶膜卷的卷膜辊。
第二凹辊外侧设置有加热板，距第二凹辊一定距离，工作时加热区域部分覆盖工作时绕卷的排水层；所述加热板为弧形，布置于第二凹辊外靠近凸辊的上半侧。
第一凹辊、凸辊、镜面辊两端部的支座上分别设有滑块，机架上对应设置滑轨，滑块可滑移地设置在第二滑轨上；第一凹辊、凸辊、镜面辊可以由直线驱动机构带动滑移，实现两辊间间隙的调整；第一凹腔与第二凹腔的孔径相当、均大于凸粒的外径；凸粒外表面与第一凹腔/第二凹腔内表面之间的径向间距与基板的厚度相当、或大于基板的厚度；镜面辊与第二凹辊之间的间隙小于基板与防水层厚度之和。
第一凹辊通过传动机构与电机联接；第一凹辊、凸辊、第二凹辊及镜面辊分别通过齿轮配合传递扭矩；机架上设置有导向辊，导向辊通过传动机构与电机联接。
机架底部相对的两侧设置有若干滚轮，滚轮通过传动机构与电机联接，滚轮的外周具有轮齿；车间的地面上对应设置有轨道，轨道的开设若干滚齿；滚轮的轮齿与轨道的滚齿配合。
一种使用上述防排水一体板成型机进行的防排水一体板的成型工艺，包括以下步骤：
I、第一挤塑机挤塑成型平面基板；
II、基板进入第一凹辊与凸辊之间，成型出空心凸台；
III、基板与凸台构成排水层，从凸辊转移至第二凹辊；
IV、第二挤塑机挤塑成型平面防水层，与排水层一起进入第二凹辊与镜面辊之间，防水层与排水层的基板底面在一定压力下相融合，形成防排水一体板。
作为上述技术方案的进一步改进：
在防水层与基板底面融合前对基板底面进行加热。
一种使用上述防排水一体板成型机生产的防排水一体板，排水层包括基板与空心凸台，防水层与基板底面熔融为一体并封闭凸台的底部开口，排水层与防水层在挤塑成型时一体融合。
作为上述技术方案的进一步改进：
凸台内具有外围高中间低的“火山口”状的压入部，各凸台之间为排水层与防水层的熔合平板层。
压入部的最大厚度T max大于熔合平板层厚度t。
压入部的最小厚度T min大于等于防水层厚度t 2。
压入部的平均厚度T大于熔合平板层的厚度t。
排水层与防水层之间粘接有热熔胶层。
本发明的有益效果如下：
本发明的排水层基板从第一挤出机头挤出，真空吸附成型出凸台冷却定型后随即跟随第二凹辊转至底部，与第二挤出机头刚挤出成型的防水层直接融合，此时基板及防水层均处于温度较高的软化状态下、二者顺利熔合，更通过调整第二凹辊与镜面辊之间的间隙以施加一定的压力进行压合且压光，从而使得排水层与防水层合二为一，空心凸台既具有良好的强度，而且其底面开口被防水层所封闭，即使凸台破裂漏水，也仍有防水层防止渗漏；基板与融合的防水层具有双层厚度，更加增加了其强度与防水性。本发明的防排水一体板在施工时可以无需再铺设沥青层或防水卷材，防水层已经能充分保证了与沥青层等同的防水效果，因此可以直接铺设在基面上。
本发明的基板与防水层熔接前、跟随第二凹辊转动经历了一定的冷却时间，加热板仅对基板的底面加热，同时基板的凸台保留在在第二凹腔内逐渐冷却，即此期间兼顾了基板底面的加热保温及凸台冷却，既保证底面保持在较高温度水平的情况下与防水层顺利熔合，也使得凸台有时间与空间进行冷却，避免凸台发生变形，保证了凸台的成型稳定性与强度。
本发明防水层直接挤出成型即进行熔合，不需要再单独生产、收卷，节省了单独生产所需的生产、收卷等设备，节约了设备成本，也节约了产线空间，降低了对生产车间的空 间要求，进而降低了产线的投入成本；而且防水层不需要再成卷备用，也不需要再预留相应的库存空间，降低了库存成本。
本发明的第一凹辊、凸辊、镜面辊通过支座的滑移运动调整径向距离，从而实现与不同厚度的基板、防水层相匹配，灵活适用于各种规格的排水板，适用范围广；通过调整径向距离还可以调整基板与防水层的压合力，提高熔合的牢固度，提高排水板的可靠性。可调整底座也使成型机与挤塑机之间的距离可调，保证产品的生产质量，有利于设备的维护。
附图说明
图1为本发明第一实施例的立体图。
图2为图1中A部的放大图。
图3为本发明第一实施例的前视图。
图4为图3的B-B截面剖视图，图中箭头所示为各辊的转动方向。
图5为图4中C部的放大图。
图6为图4中D部的放大图。
图7为图4中E部的放大图。
图8为图3的左视图。
图9为本发明第二实施例的结构示意图。
图10为本发明第三实施例的结构示意图。
图11为防排水一体板的结构示意图。
图12为图11中F部的放大图。
图13为防排水一体板另一实施例的结构示意图。
图中：1、机架；2、第一凹辊；21、第一凹腔；3、凸辊；31、凸粒；4、第二凹辊；41、第二凹腔；5、镜面辊；6、导向辊；7、加热板；8、轨道；81、滚齿；9、滚轮；91、轮齿；10、主动轮；11、一级从动轮；12、二级从动轮；13、三级从动轮；14、第一支座；15、第一滑块；16、第一滑轨；17、第二支座；18、第二滑块；19、第二滑轨；20、第三支座；26、第三滑块；22、第三滑轨；23、第四支座；24、第一挤出机头；25、第二挤出机头；27、热风枪；28、卷膜辊；100、基板；101、凸台；102、进入点；103、脱离点；104、包裹弧；200、防水层；201、压入部；300、热熔胶膜；400、熔合平板层。
具体实施方式
下面结合附图，说明本发明的具体实施方式。
第一实施例：
如图1、图3、图4、图8所示，本发明的机架1相对两侧具有竖直的支撑板，两支撑板之间水平设置有相互平行的第一凹辊2、凸辊3、第二凹辊4及镜面辊5(又称光辊)。第一凹辊2位于凸辊3的后侧，两者中心轴位于同一水平面；第二凹辊4、镜面辊5从上至下依次布置在凸辊3的正下方，三者的中心轴位于同一垂直面上；凸辊3、第一凹辊2的中心连线，与凸辊3、第二凹辊4、镜面辊5的中心连线呈正交设置。第一凹辊2的圆周表面上阵列开设若干第一凹腔21，第二凹辊4的圆周表面上阵列开设若干第二凹腔41，凸辊3的圆周表面上对应阵列布置若干凸粒31，凸粒31分别与第一凹腔21及第二凹腔41配合；凸粒31顶面与第一凹腔21/第二凹腔41底面之间的径向间距与基板100的厚度相当、或大于基板100的厚度，确保凸粒31在基板100上冲压出的凸台101高度满足要求；第一凹腔21与第二凹腔41的孔径相当、均大于凸粒31的外径，凸粒31外表面与与第一凹腔21/第二凹腔41内表面之间的径向间距与基板100的厚度相匹配、或大于基板100的厚度，确保基板100被凸粒31顺利压入第一凹腔21/第二凹腔41的同时，具有较小的压入阻力，更利于凸台101的成型。镜面辊5的圆周表面为光滑面，镜面辊5与第二凹辊4之间的间隙小于基板100与防水层200厚度之和，保证基板100与防水层200顺利复合成一体。
如图1所示，第一凹辊2通过传动机构与电机联接，第一凹辊2上套设主动轮10，凸辊3上套设一级从动轮11，第二凹辊4上套设二级从动轮12，镜面辊5上套设三级从动轮13，主动轮10、一级从动轮11、二级从动轮12及三级从动轮13均为齿轮，分别通过齿轮配合传递扭矩；工作时，电机通过传动机构带动第一凹辊2转动，并通过齿轮传动依次带动凸辊3、第二凹辊4、镜面辊5转动，如图4所示，第一凹辊2与凸辊3之间、凸辊3与第二凹辊4之间、第二凹辊4与镜面辊5之间各自分别进行相对滚动。
如图4至图7所示，第一挤塑机(非本专利结构)的第一挤出机头24设置在第一凹辊2与凸辊3的相汇处上方，第一挤塑机通过第一挤出机头24挤出基板100，基板100从第一凹辊2与凸辊3的相汇处连续不断地进入二者的配合部位，凸辊3上的凸粒31将基板100的相应部位压入第一凹辊2的第一凹腔21内，同时利用凸辊3上的真空吸附机构进行吸塑成型，从而在基板100上成型出阵列布置的若干底面开放的空心凸台101；此时即成型出包括基板100与凸台101一体的排水板结构，本专利中定义为排水层。凸辊3带着成型后的排水层一起转动至与第二凹辊4的配合部位，凸粒31与第二凹腔41配合时，将排水层的凸台101转移入第二凹腔41内，并将凸台101保持陷入在第二凹腔41内跟随第二凹辊4一起转动至与镜面辊5的汇合部位；第二凹辊4转动的过程使凸台101获得了一定的冷却时间，有利于提高凸台101的成型稳定性与强度，避免凸台101发生变形。第二挤塑机(非本 专利结构)的第二挤出机头25设置在第二凹辊4与镜面辊5的相汇处一侧，第二挤塑机通过第二挤出机头25挤出防水层200，防水层200从第二凹辊4与镜面辊5的相汇处连续不断进入汇合部位，与第二凹辊4带下来的排水层的基板100底面进行熔融并复合成一体。第二凹辊4绕带有排水层一侧的外侧、距离第二凹辊4一定距离设置有弧形的加热板7，加热板7布置于第二凹辊4外靠近凸辊3的上半侧，加热板7的加热区域部分覆盖工作时绕卷的排水层，加热板7对排水层的基板100的底面进行保温或加热，利于基板100与防水层200顺利进行熔合，此时排水层的凸台101保留在第二凹腔41内，第二凹腔41对凸台101起到保护的作用，避免凸台101由于加热板7的加热作用进一步升温，利于提高排水层的凸台101的成型稳定性，避免凸台101发生变形。
如图1、图8所示，第一凹辊2的两端部具有第一支座14，第一支座14与电机联接，第一支座14的底面固定有第一滑块15，机架1上对应设置第一滑轨16，第一滑块15可滑移地设置在第一滑轨16上，第一支座14可以由电机带动沿第一滑轨16前后滑移，对第一凹辊2与凸辊3的径向距离径向调整。凸辊3的两端部具有第二支座17，第二支座17与电机连接，第二支座17的侧面固定有第二滑块18，机架1上对应设置第二滑轨19，第二滑块18可滑移地设置在第二滑轨19上，第二支座17可以由电机带动沿第二滑轨19上上下滑移，对凸辊3与第二凹辊4的径向距离径向调整。镜面辊5的两端部具有第三支座20，第三支座20与电机连接，第三支座20的侧面固定有第三滑块26，机架1上对应设置第三滑轨22，第三滑块26可滑移地设置在第三滑轨22上，第三支座20可以由电机带动沿第三滑轨22上下滑移，对镜面辊5与第二凹辊4的径向距离径向调整。第二凹辊4的两端部具有第四支座23，第四支座23通过紧固件固定在机架1上。本实施例的第一凹辊2、凸辊3、镜面辊5通过支座的滑移运动调整径向距离，从而实现与不同厚度的基板100、防水层200相匹配，灵活适用于各种规格的排水板，适用范围广；通过调整径向距离还可以调整基板100与防水层200的压合力，提高熔合的牢固度，提高排水板的可靠性。在其他实施例中，第一凹辊2、凸辊3、镜面辊5也可以通过其他直线驱动机构带动实现滑移，实现径向距离的调整。
如图4所示，机架1上、位于镜面辊5的后下侧设置有导向辊6，导向辊6通过传动机构与电机联接；工作时，电机通过传动机构带动导向辊6转动，将复合成一体的防排水板输送至下一工艺段。
如图1、图2所示，车间的地面上沿排水板的输送方向平行设置有两根轨道8，轨道8的上表面均匀开设若干滚齿81；机架1底部相对的两侧对应轨道8分别设置有若干滚轮 9，滚轮9的外周具有轮齿91，滚轮9的轮齿91与轨道8的滚齿81配合；滚轮9通过传动机构与电机联接，电机通过传动机构可以带动滚轮9转动，实现在轨道8上行走，对设备的位置进行调整。
本发明实际使用时，基板100从第一挤出机头24挤出，经第一凹辊2与凸辊3吸塑成型为排水层后，跟随凸辊3转至与第二凹辊4的配合部位，在凸辊3与第二凹辊4配合时转绕到第二凹辊4上，随第二凹辊4转至第二凹辊4与镜面辊5的汇合部位；防水层200从第二挤出机头25挤出、与排水层于第二凹辊4与镜面辊5的汇合部位熔合；熔接复合成一体的排水板经由导向辊6输送至下一工艺段。
第二实施例：
如图9所示，本实施例中，第一凹辊2、凸辊3、第二凹辊4及镜面辊5水平并排布置，四辊的中心轴处于同一水平面，四辊两两相互之间的相汇处也处于同一水平面上。
第一挤出机头24垂直设置在第一凹辊2与凸辊3的相汇处正上方、竖直向下朝第一凹辊2与凸辊3的相汇处挤出基板100；基板100进入第一凹辊2与凸辊3相汇处的进入点102，在基板100上成型出阵列布置的若干底面开放的空心凸台101；进入点102与脱离凸辊3与第二凹辊4相汇处的脱离点103之间的弧段为包裹在凸辊3上的包裹弧104，此时，包裹弧104的圆心角α为180°，包裹弧104的弧长L为πr(r为凸辊3的半径，弧长L等于凸辊3的半圆周弧长)，相对于第一实施例，本实施例的包裹弧104的圆心角更大，弧长更长，基板100成型后在凸辊3上行进的行程更长，停留的时长更长，即基板100在凸辊3上获得了更长的定型行程与时间，更利于基板100上空心凸台101的定型，降低基板100从凸辊3上脱离后的收缩率，提高基板100的成型稳定性与强度。
第二挤出机头25垂直设置在第二凹辊4与镜面辊5的相汇处正上方、竖直向下朝向第二凹辊4与镜面辊5的相汇处挤出防水层200；第二凹辊4与镜面辊5水平排布，利于防水层200垂直流延，防水层200垂直流延更利于与基板100交汇与热熔复合，可以提高复合后的平整度，第二挤出机头25正对第二凹辊4与镜面辊5的相汇处，可以使防水层200垂直进入相汇处，更利于基板100与防水层200复合，提高基板100与防水层200的粘合强度。
本实施例中，第二凹辊4及镜面辊5内分别设置有加热结构，分别对第二凹辊4、镜面辊5的辊面进行加热，辊面的加热温度范围控制在30-80℃；对第二凹辊4的辊面加热可以防止基板100的凸台101收缩而滞留在第二凹腔41内、从而造成内卡的现象；对镜面辊5的辊面加热有利于防水层200挤出后与基板100交汇与热熔复合，提高复合后的粘合强 度，复合效果更好。
为了提高复合效果，使基板100与防水层200更好地进行熔合，本实施例在第二凹辊4外侧设置有热风枪27，通过热风枪27对基板100的底面进行加热，加热的温度范围控制在200-400℃，热风枪27的温度根据基板100的线速度决定，线速度慢则热风枪27温度较低，线速度快则热风枪27温度较高；热风枪27的风速也是可控的，通过变频调节风量。
针对厚度较薄的基板100与防水层200，为了进一步提高二者的剥离强度，本实施例还可以在第二凹辊4与镜面辊5相汇处的外侧设置卷膜辊28用于放置热熔胶膜卷，热熔胶膜卷将热熔胶膜300放送至第二凹辊4与镜面辊5相汇处、基板100与防水层200之间，通过热熔后粘接在基板100与防水层200之间，提高粘结强度。
第三实施例：
如图10所示，与第二实施例不同的是，本实施例的第二凹辊4及镜面辊5水平布置，第一凹辊2、凸辊3斜向上偏移一定角度布置，即第一凹辊2及凸辊3的中心连线与第二凹辊4及镜面辊5的中心连线之间的夹角β大于90°、小于180°，此时，基板100在凸辊3上的包裹弧104的圆心角α大于180°、小于270°，弧长L大于πr、小于1.5πr，包裹弧104的圆心角进一步增大，弧长进一步加长，更有利于基板100上的空心凸台101尽可能时间长地保留在凸辊3上的凸粒31上，避免过早脱离后的收缩，有利于提高基板100的成型稳定性与强度。
本实施例中，第二挤出机头25基于第二凹辊4与镜面辊5相汇处朝镜面辊5偏移水平距离d，d的范围50-200mm，第二挤出机头25朝镜面辊5偏移，其挤出的防水层200先流向镜面辊5辊面上结晶后，再紧随镜面辊5的旋转进入相汇处进行复合，防水层200在镜面辊5上获得一定的结晶时间，初步结晶后再与基板100进行热复合，平整度更高。
防排水一体板实施例一：
如图11、图12所示，采用上述设备成型的防排水一体成型板，包括基板100与凸台101的排水层与防水层200一体熔合，防水层200顶面与基板100底面熔融为一体、并对凸台101的底部开口进行封闭，基板100与防水层200熔合后，在各凸台101之间形成熔合平板层400，熔合平板层400厚度t为基板100厚度t 1与防水层200厚度t 2厚度之和；由于凸台101为空心且底部具有开口，而基板100与防水层200进行复合时、二辊之间具有挤压力，在挤压力的作用下，处于温度较高、软化状态下的防水层200的表层被压入凸台101内，冷却后在凸台101的口部形成压入部201；压入部201呈高低不平、且外围高中间低的“火山口”状。如图12所示，在成型后的防排水一体成型板的各部位进行剖切，然后采用卡尺对熔合 平板层400厚度t、基板100厚度t 1、及随机选取的压入部201上的多个点(本实施例取五个点)的厚度T n分别进行检测，根据检测数据计算得出防水层200厚度t 2与压入部201平均厚度T，本实施例对一个防排水一体板样品进行检测，检测数据为：熔合平板层400厚度t＝2.2mm，基板100厚度t 1为t 1＝1.0mm，压入部201五个点的厚度T n分别为3.6mm、4.2mm、2.5mm、3.0mm、4.4mm，通过计算得出防水层200厚度t 2＝2.2-1.0＝1.2mm，压入部201平均厚度T＝(3.6+4.2+2.5+3.0+4.4)/5＝3.54mm。从检测及计算得出的数据可以看出，压入部201的最大厚度T max大于熔合平板层400厚度t，压入部201的最小厚度T min大于等于防水层200厚度t 2压入部201的平均厚度T大于防水层200厚度t 2，在凸台101内径较小时，压入部201被压入凸台101内后被挤压堆积得更高，压入部201的平均厚度T甚至大于熔合平板层400的厚度t。压入部201鼓入防水层200的凸台101内，不仅封闭了凸台101底面，利于提高了防水板的寿命与可靠性，同时压入部201压入凸台101内，压入部201外侧面贴在凸台101内侧面，对凸台101在开口转角处形成有效支撑，可以提高凸台101的支撑强度，对凸台101进行加固，防止凸台101发生变形，更利于提高防水板的抗压性能、寿命与可靠性。
防排水一体板实施例二：
如图13所示，增加热熔胶层膜的设备成型的防排水一体成型板，在排水层与防水层200之间还粘接有一层热熔胶膜300，提高了成型板的剥离强度，也提高了防水板的寿命与可靠性。
以上描述是对本发明的解释，不是对本发明的限定，在不违背本发明精神的情况下，本发明可以作任何形式的修改。例如略微调整四个辊筒的布置位置、角度，或者将本发明横放布置等方式，只要能达到将防水层与排水层复合成一体的目的即可。

Claims (21)

  1. 一种防排水一体板成型机，其特征在于：机架(1)上设置有第一凹辊(2)、凸辊(3)、第二凹辊(4)及镜面辊(5)，凸辊(3)分别与第一凹辊(2)、第二凹辊(4)相对滚动，镜面辊(5)与第二凹辊(4)相对滚动；
    第一凹辊(2)的辊面上开设若干第一凹腔(21)，第二凹辊(4)的辊面上开设若干第二凹腔(41)，凸辊(3)的辊面上对应布置若干凸粒(31)，凸粒(31)分别与第一凹腔(21)及第二凹腔(41)对应配合；镜面辊(5)的辊面为光滑面。
  2. 按照权利要求1所述的防排水一体板成型机，其特征在于：凸辊(3)与第一凹辊(2)相汇处位于第一挤出机头(24)一侧；凸辊(3)、第二凹辊(4)与镜面辊(5)依次布置，第二凹辊(4)与镜面辊(5)的相汇处位于第二挤出机头(25)一侧。
  3. 按照权利要求1所述的防排水一体板成型机，其特征在于：凸辊(3)、第一凹辊(2)的中心连线，与凸辊(3)、第二凹辊(4)、镜面辊(5)的中心连线呈正交设置，凸辊(3)、第二凹辊(4)、镜面辊(5)上下并排布置。
  4. 按照权利要求1所述的防排水一体板成型机，其特征在于：第一凹辊(2)、凸辊(3)、第二凹辊(4)及镜面辊(5)的中心轴处于同一水平面；或第二凹辊(4)及镜面辊(5)的中心轴处于同一水平面，第一凹辊(2)及凸辊(3)的中心连线与第二凹辊(4)及镜面辊(5)的中心连线之间的夹角β大于90°、小于180°。
  5. 按照权利要求1所述的防排水一体板成型机，其特征在于：凸辊(3)上基板(100)的包裹弧(104)的圆心角α大于等于180°，包裹弧(104)的弧长大于等于πr。
  6. 按照权利要求1所述的防排水一体板成型机，其特征在于：第二挤出机头(25)正对第二凹辊(4)与镜面辊(5)相汇处；或者第二挤出机头(25)基于相汇处朝镜面辊(5)偏移水平距离d。
  7. 按照权利要求1所述的防排水一体板成型机，其特征在于：第二凹辊(4)或镜面辊(5)内设置有加热结构，加热温度范围为30-80℃。
  8. 按照权利要求1所述的防排水一体板成型机，其特征在于：第二凹辊(4)的外侧设置有热风枪(27)，并对基板(100)底面加热，加热温度范围为200-400℃。
  9. 按照权利要求1所述的防排水一体板成型机，其特征在于：第二凹辊(4)与镜面辊(5)相汇处的外侧设置有热熔胶膜卷的卷膜辊(28)。
  10. 按照权利要求1所述的防排水一体板成型机，其特征在于：第二凹辊(4)外侧设置有加热板(7)，距第二凹辊(4)一定距离，工作时加热区域部分覆盖工作时绕卷的排水层；所述加热板(7)为弧形，布置于第二凹辊(4)外靠近凸辊(3)的上半侧。
  11. 按照权利要求1所述的防排水一体板成型机，其特征在于：第一凹辊(2)、凸辊(3)、镜面辊(5)两端部的支座上分别设有滑块，机架(1)上对应设置滑轨，滑块可滑移地设置在第二滑轨上；第一凹辊(2)、凸辊(3)、镜面辊(5)可以由直线驱动机构带动滑移，实现两辊间间隙的调整；第一凹腔(21)与第二凹腔(41)的孔径相当、均大于凸粒(31)的外径；凸粒(31)外表面与第一凹腔(21)/第二凹腔(41)内表面之间的径向间距与基板(100)的厚度相当、或大于基板(100)的厚度；镜面辊(5)与第二凹辊(4)之间的间隙小于基板(100)与防水层(200)厚度之和。
  12. 按照权利要求1所述的防排水一体板成型机，其特征在于：第一凹辊(2)通过传动机构与电机联接；第一凹辊(2)、凸辊(3)、第二凹辊(4)及镜面辊(5)分别通过齿轮配合传递扭矩；机架(1)上设置有导向辊(6)，导向辊(6)通过传动机构与电机联接。
  13. 按照权利要求1所述的防排水一体板成型机，其特征在于：机架(1)底部相对的两侧设置有若干滚轮(9)，滚轮(9)通过传动机构与电机联接，滚轮(9)的外周具有轮齿(91)；车间的地面上对应设置有轨道(8)，轨道(8)的开设若干滚齿(81)；滚轮(9)的轮齿(91)与轨道(8)的滚齿(81)配合。
  14. 一种使用如权利要求1所述防排水一体板成型机进行的防排水一体板的成型工艺，其特征在于包括以下步骤：
    I、第一挤塑机挤塑成型平面基板(100)；
    II、基板(100)进入第一凹辊(2)与凸辊(3)之间，成型出空心凸台(101)；
    III、基板(100)与凸台(101)构成排水层，从凸辊(3)转移至第二凹辊(4)；
    IV、第二挤塑机挤塑成型平面防水层(200)，与排水层一起进入第二凹辊(4)与镜面辊(5)之间，防水层(200)与排水层的基板(100)底面在一定压力下相融合，形成防排水一体板。
  15. 按照权利要求14所述的防排水一体板的成型工艺，其特征在于：在防水层(200)与基板(100)底面融合前对基板(100)底面进行加热。
  16. 一种使用如权利要求1所述防排水一体板成型机生产的防排水一体板，其特征在于：排水层包括基板(100)与空心凸台(101)，防水层(200)与基板(100)底面熔融为一体并封闭凸台(101)的底部开口，排水层与防水层(200)在挤塑成型时一体融合。
  17. 按照权利要求16所述的防排水一体板，其特征在于：凸台(101)内具有外围高中间低的“火山口”状的压入部(201)，各凸台(101)之间为排水层与防水层(200)的熔合平板层(400)。
  18. 按照权利要求17所述的防排水一体板，其特征在于：压入部(201)的最大厚度T max大于熔合平板层(400)厚度t。
  19. 按照权利要求17所述的防排水一体板，其特征在于：压入部(201)的最小厚度T min大于等于防水层(200)厚度t 2。
  20. 按照权利要求17所述的防排水一体板，其特征在于：压入部(201)的平均厚度T大于熔合平板层(400)的厚度t。
  21. 按照权利要求16所述的防排水一体板，其特征在于：排水层与防水层(200)之间粘接有热熔胶层。
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