CN112972121A

CN112972121A - Manufacturing device, system and manufacturing method of composite sheet

Info

Publication number: CN112972121A
Application number: CN202110156849.8A
Authority: CN
Inventors: 龚志龙; 许丽芬
Original assignee: Huangshan Futian Precision Manufacturing Co Ltd
Current assignee: Huangshan Futian Precision Manufacturing Co Ltd
Priority date: 2021-02-04
Filing date: 2021-02-04
Publication date: 2021-06-18

Abstract

The invention discloses a manufacturing device, a system and a manufacturing method of a composite sheet, wherein the composite sheet is formed by laminating and compounding a three-dimensional sheet with a plurality of convex parts and a flat sheet without the convex parts; the device comprises: a pair of convex and concave rollers for shaping, an ultrasonic welding mechanism and a negative pressure forming unit which are arranged in parallel; the three-dimensional sheet is formed by passing a fabric between the concave-convex rollers, each of which has a concave-convex shape on the peripheral surface of the convex roller and the concave roller, the concave-convex shapes being engaged with each other at facing positions; the ultrasonic welding mechanism is arranged at the downstream side of the concave roller and is used for compounding a flat sheet with the three-dimensional sheet to form the compound sheet; the negative pressure forming unit is arranged on the concave roller, and the suction range of the negative pressure forming unit is set to be at least between the concave-convex roller and the ultrasonic wave composite area in the circumferential direction of the concave roller. The roller body can form the composite sheet with the three-dimensional convex part without heating, and the joint part is soft; the three-dimensional flower shape is even and full.

Description

Manufacturing device, system and manufacturing method of composite sheet

Technical Field

The invention relates to the technical field of production of hygienic products, in particular to a device and a system for manufacturing a composite sheet and a manufacturing method thereof.

Background

At present, in the field of disposable sanitary products, a three-dimensional surface layer material is manufactured by hot-pressing and bonding two materials through a concave-convex roller, so that the materials form a three-dimensional packet effect; the hot pressing point all around rolls the material through the heating compression roller and forms, but the material that rolls the position through the heating feels harder, leads to liquid infiltration speed slowly, and the wearing comfort level urgently needs to be improved. In addition, when the existing device is used for high-speed production, the convex hull forming effect is not full, the upper layer material and the lower layer material are compounded with wrinkles, and the adhesive force cannot meet the product requirement; the requirement of the market on the production speed of sanitary product equipment is continuously improved, and the existing device cannot meet the requirement of higher production speed.

As disclosed in chinese patent application CN104039528A, a sheet forming apparatus is provided with at least a pair of forming rollers arranged in parallel to each other, each forming roller having a concavo-convex shape on a roller peripheral surface and engaging with each other at facing positions, so that a sheet passes between the forming rollers to form a predetermined three-dimensional shape on the sheet, wherein a rotation shaft of at least one of the forming rollers is linked and connected to a rotation driving unit via a joint having a different axial center; be equipped with the heating unit in the figuration roller, adsorb the sheet through the unit of breathing in on the roller surface through heating extrusion and carry out the complex, it is harder through the material that the heating rolled the position, influence and dress the travelling comfort.

Further, as disclosed in chinese patent application CN104822353A, a composite sheet, a disposable wearing article using the composite sheet, and a method and an apparatus for manufacturing the composite sheet, when a three-dimensional sheet and a flat sheet stacked on each other reach the first pressing position, a portion separated from the convex portion is pressed by the tip of the pressure-bonding projection, and the pressing force is received by the pressing roller to be pressed. Then, the two sheets are guided to the second pressing position in one step, and are also pressed by the tip of the pressure contact protrusion at the second pressing position. The pressing rollers are sufficiently heated, and therefore, two sheets of material are welded to each other at the pressed portion; this forms a joint, and the two sheets are joined to each other at the joint to form a composite sheet, and the material of the heat-rolled portion is hard, which affects wearing comfort.

In the two existing structures, the forming roller is internally provided with the heating unit and the air suction structure, so that the heat of the roller can be taken away when the air distribution and air suction device works during operation, the consumed heat is uncontrollable, the forming roller is heated unevenly and welded infirm, the overall dimension of the heat-seal roller can be changed after long-term use, the material compounding is uneven, and the material compounding quality is influenced; if the materials are thermally laminated together in a short time, the surface temperature of the heat sealing roller must be increased to be high, but the materials are wrapped by the heat sealing roller during the conveying process, and the high surface temperature of the heat sealing roller directly causes the hardening of the materials and influences the softness of the materials.

Therefore, in the prior art, the material of the heating and rolling part is hard, so that the wearing comfort is influenced; the effect of the three-dimensional small bag can be influenced by hot pressing, and the effects of the convex hull which is not full and the wrinkles which are influenced can be caused; and the forming roller is heated, and the temperature is higher because of standing still after shutting down, causes very easily that the material that attaches on the shaping concave roller is carbonized, causes the accumulation of leaving over the carbon thing in the shaping concave roller shaping hole, and difficult clearance.

Disclosure of Invention

The invention provides a device and a system for manufacturing a composite sheet and a method for manufacturing the composite sheet, aiming at the defects of the prior art, the composite sheet with a three-dimensional bulge can be formed on a roller body without heating, and the joint part is soft.

In order to solve the technical problems, the technical scheme adopted by the invention is as follows:

a composite sheet manufacturing apparatus which is configured by laminating and compounding a three-dimensional sheet having a plurality of projections formed thereon and a flat sheet having no projections, comprising: a pair of convex and concave rollers for shaping arranged in parallel with each other, each of the convex and concave rollers having a concave-convex shape on the circumferential surface thereof, the concave-convex shapes being engaged with each other at facing positions; an ultrasonic welding mechanism arranged at the downstream side of the concave roller and used for compounding a flat sheet with the three-dimensional sheet to form the compound sheet; a negative pressure forming unit arranged on the concave roller, wherein the negative pressure range of the negative pressure forming unit is set to be at least between the concave roller and the convex roller in the circumferential direction of the concave roller and the ultrasonic wave composite area; the concave-convex shape of the negative pressure forming unit and the concave-convex roller periphery enables the fabric to pass through the concave-convex roller and form between the ultrasonic wave composite regions, so that a specified convex part is formed on the fabric. The concave-convex roller of the invention can form a plurality of convex parts on the fabric only by the concave-convex shape of the peripheral surface of the roller and the negative pressure forming unit arranged on the concave roller under the condition of heating or not heating, and does not depend on heating the concave-convex roller to form a three-dimensional sheet.

The three advantages are that firstly, the technical route of 'material shaping needs a heating unit' in the past industry is overturned, the concave roller is improved, the negative pressure forming unit is arranged at a specific position, specifically, the negative pressure range is set to be at least between the concave roller and the convex roller in the circumferential direction and the ultrasonic wave composite area, so that the forming of the three-dimensional sheet material is further stable, and particularly, the advantages are more obvious and outstanding during high-speed production, so that the problems of wrinkles, uneven forming, incompleteness and unsatisfied existing during high-speed production in the past are fundamentally solved. Secondly, because the fabric can not be heated to generate the problem of material hardening carbonization, the original property of the material is kept and not damaged, and especially the traditional heat seal shaping has the problems that the temperature of a concave-convex roller can not be instantly reduced after the machine is stopped, the material attached to the concave roller is easy to carbonize, and the accumulation of the left carbon in the shaping hole of the shaping concave roller is caused and the cleaning is difficult. Thirdly, the problems that the roller body is deformed due to thermal expansion caused by long-term thermal energy are avoided, welding is not uniform, the service life of the concave-convex roller is short, and the like. In addition, the link of preheating in advance is reduced in the production process of the equipment, the production preparation time is greatly shortened, the production time cost is reduced, and the energy consumption of the equipment is reduced.

Preferably, the concave roller and the convex roller are not provided with a heating unit for heating the roller body so as to give heat to the fabric. Considering that there is a possibility of simple changes in the above-mentioned solutions, such as providing a heating function on the device but not using it, or providing a heating unit on the device but not achieving the above-mentioned purpose of providing heat to the fabric, etc., it should be considered that the simple changes made to the technical solutions by using the principle of the present invention should be within the protection scope of the present invention.

Further, the ultrasonic welding mechanism is a material composite flat ultrasonic structure or a material composite circular ultrasonic structure. The material composite flat ultrasonic structure can be referred to CN110978529A, and the material composite circular ultrasonic structure can be referred to CN210792123U, which is not described herein; of course, the form of the ultrasonic welding mechanism is not limited thereto, and other common structures than the above two common ultrasonic forms may also be adopted.

Furthermore, a group of forming bulges are arranged on the outer edge of the convex roller, and a group of forming pits matched with the forming bulges are arranged on the outer edge of the concave roller.

The ultrasonic welding device further comprises two inlet guide rollers and a guide-out roller, wherein one inlet guide roller is used for introducing a fabric between the concave roller and the convex roller, and the other inlet guide roller is used for introducing a flat sheet material formed by another fabric to the upstream side of the ultrasonic welding mechanism; the delivery roll is disposed downstream of the ultrasonic welding mechanism. Preferably, the fabric is fed between the female and male rollers at an angle that ensures that the fabric is fed under constant tension to a particular shaping and compounding station.

Furthermore, the negative pressure forming unit comprises a gas distribution disc for forming negative pressure, and gas distribution holes are communicated with the forming pits in the concave roller and communicated with the gas distribution disc. The air distribution plate is connected with an air suction pipeline through a pipeline joint, and the air suction pipeline is connected with an external negative pressure fan.

Furthermore, a first adjusting component for adjusting the radial position between the convex roller and the concave roller is arranged on the convex roller. As one of the structural forms of the first regulation member, it may be a cylinder, and the spur roller is provided on a spur roller regulation cylinder. Of course, the first adjusting member may also take other forms such as a motor, a link mechanism, etc.

Furthermore, a second adjusting component for adjusting the radial position and pressure between the ultrasonic welding mechanism and the concave roller is further arranged on the ultrasonic welding mechanism. As one of the structural forms of the second adjusting member, it may be a cylinder, and the ultrasonic welding mechanism is provided on the ultrasonic welding mechanism adjusting cylinder. Of course, the second adjusting member may also take other forms such as a motor, a link mechanism, etc.

A manufacturing system of the composite sheet comprises a manufacturing device of the composite sheet and a feeding device, and a fabric is stably conveyed towards the manufacturing device of the composite sheet under constant tension.

Furthermore, the feeding device comprises a material storage mechanism, a tension control mechanism and a deviation correcting mechanism; the storage mechanism is used for arranging the fabric conveyed to the direction of the composite sheet manufacturing device, the tension control mechanism is used for conveying the fabric with constant tension, and the deviation correcting mechanism is used for adjusting the lateral displacement of the fabric perpendicular to the flow direction.

Furthermore, the feeding device consists of a first feeding device and a second feeding device; the first feeder device is used to introduce the fabric between the female and male rollers and the second feeder device is used to introduce the flat sheet to the upstream side of the ultrasonic welding mechanism.

A method of manufacturing a composite sheet comprising the steps of: forming a three-dimensional sheet having a plurality of convex portions by guiding a fabric between a convex roller for forming having a convex-concave shape in a circumferential direction and a concave roller; conveying the three-dimensional sheet in a downstream direction while adsorbing the three-dimensional sheet on the surface of the concave roller; superposing a flat sheet made of another fabric with the three-dimensional sheet, and compounding the two sheets by an ultrasonic welding mechanism to form the composite sheet; the fabric is shaped between the ultrasonic wave composite areas through the concave-convex shape of the concave-convex roller and the negative pressure forming unit, so that a specified convex part is formed on the fabric.

Preferably, the fabric is not subjected to the shaping heat transferred from the embossing roll while passing through the embossing roll.

Further, the radial position between the male and female rollers is adjustable.

Further, the radial position and pressure between the ultrasonic welding mechanism and the female roller is adjustable.

Compared with the prior art, the invention has the following advantages:

the manufacturing device, the manufacturing system and the manufacturing method of the composite sheet are reasonable in design, the roller body of the composite sheet can form the composite sheet with the three-dimensional convex parts without heating, the joint part is soft, and the liquid permeability and liquid guiding performance of a three-dimensional surface layer material are better and the composite sheet is more comfortable to wear; in the processing process, the three-dimensional flower shape of the three-dimensional surface layer material is uniformly and fully formed and is not easy to wrinkle through negative pressure adsorption; the mechanical structure is simple, stable and easy to operate, the production requirement of the hygienic products under the high-speed working condition can be met, and the production efficiency is high.

Drawings

The contents of the description and the references in the drawings are briefly described as follows:

fig. 1 is a schematic structural view of a composite sheet manufacturing apparatus according to the present invention.

FIG. 2 is a schematic view of the bonding position of the male and female rollers of the present invention.

FIG. 3 is a schematic view of the sheet pattern of the present invention.

Fig. 4 is an enlarged view of the region i in fig. 3.

Fig. 5 is a perspective view of the sheet of fig. 3.

FIG. 6 is a schematic view of the sheet pattern of the present invention.

Fig. 7 is an enlarged view of area ii in fig. 6.

FIG. 8 is a schematic cross-sectional view of a composite sheet of the present invention.

Fig. 9 is another schematic configuration diagram of the composite sheet manufacturing apparatus of the present invention.

Fig. 10 is a schematic structural view of a composite sheet manufacturing system according to the present invention.

Fig. 11 is a partially enlarged view of fig. 10.

Fig. 12 is a partially enlarged view of fig. 10.

In the figure:

a1 and a2 as feeding devices, b as manufacturing devices

1. Convex roller, 2 concave roller, 3 ultrasonic welding mechanism, 4 air distribution disc, 5 air suction pipeline joint, 6 air suction pipeline, 7 tensioning guide roller I, 8 tensioning guide roller II, 9 tensioning guide roller III, 10 air cylinder I, 11 air cylinder II, 12 fabric I, 13 fabric II, 14 composite sheet material,

15-1 material deviation rectifying structures I and 15-2 material deviation rectifying structures II and 16-1 material tension control structures I and 16-2 material tension control structures II and 17 material rolls and 18 material changing and receiving structures, 19 material storage structures, 20 tension adjusting structures,

The material convex hull three-dimensional flower-shaped parts I and 15B, the absorbing material composite parts I and 16A, the material convex hull three-dimensional flower-shaped parts II and 16B, and the absorbing material composite part II.

Detailed Description

The following description of the embodiments of the present invention will be made in detail with reference to the accompanying drawings.

As shown in fig. 1 to 9, the composite sheet manufactured by the composite sheet manufacturing apparatus is configured by laminating a three-dimensional sheet having a plurality of projections formed thereon and a flat sheet having no projections.

The manufacturing device comprises a pair of convex rollers and concave rollers for shaping, an ultrasonic welding mechanism and a negative pressure forming unit, wherein the convex rollers and the concave rollers are arranged in parallel; a pair of convex and concave rollers for shaping arranged in parallel to each other, each having a concavo-convex shape engaged with each other at facing positions on the roller circumferential surfaces of the convex and concave rollers, and forming the three-dimensional sheet by passing a fabric between the concavo-convex rollers; an ultrasonic welding mechanism arranged at the downstream side of the concave roller and used for compounding a flat sheet with the three-dimensional sheet to form the compound sheet; a negative pressure forming unit provided on the concave roller, the suction range of the negative pressure forming unit being set to be at least between the concave roller and the convex roller in the circumferential direction of the concave roller and the ultrasonic wave composite region; the concave-convex shape of the peripheral surface of the negative pressure forming unit and the concave-convex roller forms the fabric between the ultrasonic wave composite regions by passing through the concave-convex roller to form a predetermined convex part on the fabric.

Preferably, the concave roller and the convex roller are not provided with a heating unit for heating the roller body so as to give heat to the fabric.

Preferably, the manufacturing device of the composite sheet comprises a concave roller 2, a convex roller 1, two inlet guide rollers, an ultrasonic welding mechanism 3, a delivery roller and a gas distribution plate 4 for forming negative pressure.

The forming device comprises a concave roller 2 and a convex roller 1, wherein the concave roller and the convex roller are used for forming a three-dimensional convex part on the surface of a fabric, the forming concave roller and the forming convex roller are arranged oppositely, a group of forming bulges are arranged on the outer edge of the forming convex roller, a group of forming pits matched with the forming bulges are arranged on the outer edge of the forming concave roller, and the fabric forms a specific three-dimensional flower-shaped fabric through the action of the bulges on the forming convex roller and the pits on the forming concave roller.

The two inlet guide rollers are respectively a tensioning guide roller II 8 and a tensioning guide roller III 9, the tensioning guide roller II 8 is used for enabling a fabric to enter a space between the forming concave roller and the forming convex roller, the tensioning guide roller III 9 is used for enabling another fabric to enter and come out from the space between the forming concave roller and the forming convex roller to be compounded together and pasted on the forming concave roller, and the two inlet guide rollers are respectively positioned in front of and behind the forming convex roller according to the production running direction.

The ultrasonic welding mechanism 3 is used for jointing different fabrics attached to the forming concave roller to form a composite sheet with a three-dimensional convex part; preferably, the ultrasonic welding mechanism is a material composite flat ultrasonic structure or a material composite circular ultrasonic structure.

The guide-out roller is tensioning guide roller I, and the guide-out roller is used for leading out the composite sheet. The tension guide roller I and the tension guide roller II are arranged close to each other, so that a fabric is wrapped on the forming concave roller.

The concave roller 2 is communicated with an air distribution hole corresponding to the forming pit, and the air distribution hole is connected with an air distribution disc 4; the air distribution disc is connected with an air suction pipeline 6 through a pipeline joint 5, the air suction pipeline 6 is connected with an external negative pressure fan, and the formed three-dimensional convex part is firmly sucked and covered in the concave pit on the outer edge of the concave roller through a group of negative pressure forming concave pits.

The vacuum suction covering effect not only enables the high-speed conveying of the formed fabric I before being compounded with the fabric II to be more stable, but also has the main function that the three-dimensional convex hull of the formed fabric I in the high-speed conveying process can be fuller on the premise that the concave roller and the convex roller do not need to be heated, and meanwhile, the phenomena of uneven convex hull and wrinkles are not easy to occur.

The invention also comprises an adjusting component for adjusting the radial positions and pressures of the forming convex roller and the ultrasonic welding mechanism, wherein the adjusting component comprises a forming convex roller adjusting cylinder and an ultrasonic welding mechanism adjusting cylinder, the forming convex roller adjusting cylinder is a cylinder I10, and the ultrasonic welding mechanism adjusting cylinder is a cylinder II 11; the forming convex roller is arranged on the forming convex roller adjusting cylinder, and the ultrasonic welding mechanism is arranged on the ultrasonic welding mechanism adjusting cylinder. The forming convex roller and the ultrasonic welding mechanism are oppositely arranged on two sides of the forming concave roller, the working stress is balanced, and the high-speed operation is stable and reliable.

The manufacturing process of the composite sheet with the three-dimensional convex part comprises the following specific steps:

a fabric enters through an inlet guide roller and is coated on the forming concave roller according to a certain angle, and when the fabric passes through the tangent part of the forming concave roller and the forming convex roller, the fabric is pressed into a forming concave pit on the forming concave roller through a forming bulge on the forming convex roller to form a three-dimensional bulge part;

the formed fabric and the three-dimensional convex part are sucked and covered on the outer edge of the forming concave roller through the negative pressure in the forming concave roller;

the other fabric enters through the other entering guide roller and is pressed on the fabric sucked and covered on the forming concave roller, meanwhile, the different fabrics are jointed at a compounding position through the pressing of ultrasonic waves and the forming concave roller, and finally, the formed composite sheet 14 is led out through the leading-out roller.

According to the invention, the roller body can form the composite sheet with the three-dimensional bulge without heating, the joint part is soft, and the liquid permeability and drainage performance of the three-dimensional surface layer material are better and the wearing is more comfortable; in the processing process, the three-dimensional flower shape of the three-dimensional surface layer material is uniformly and fully formed and is not easy to wrinkle through negative pressure suction covering; the mechanical structure is simple, stable and easy to operate, the production equipment of the hygienic products with high linear speed can be met, and the production efficiency is high

Preferred specific examples are:

the invention relates to a manufacturing device which can simultaneously form a three-dimensional flower shape and well joint at least 2 non-woven fabrics overlapped with each other under the condition of conveying the fabrics at a high speed.

The composite sheet 14 comprises a fabric I12, a fabric II 13, an absorbent material composite part I15B, an absorbent material composite part II 16B, a material convex hull three-dimensional flower part I15A and a material convex hull three-dimensional flower part II 16A.

The I12 fabric gets into through tensioning guide roll II, according to certain angle cladding on concave roller 2, has respectively to do pit and the arch of mutually supporting on concave roller 2 and the convex roller 1, when I12 fabric passes through concave roller 2 and the tangent position of convex roller 1, I10 cylinder is with accurate pressure to the effect of shaping convex roller 1, makes it impress the three-dimensional flower shape portion 15A of material convex hull, 16A behind the concave roller 2 to I12 fabric.

The fabric I12 and the convex hull three-dimensional flower-shaped part after being formed are firmly sucked and covered on the concave roller 2 in the vacuum negative pressure area, air distribution holes are formed in the concave roller 2 and are connected to a negative pressure fan through an air distribution disc 4, a pipeline joint 5 and an air suction pipeline 6, the vacuum sucking and covering effect enables the high-speed conveying of the fabric I12 after being formed before being combined with the fabric II 13 to be more stable, the main function is that the convex hull of the fabric I12 after being formed in the high-speed conveying process can be more full on the premise that the forming concave roller 2 and the forming convex roller 1 do not need to be heated, and meanwhile, the phenomena of unevenness and wrinkling of the convex hull are not easy to occur. And because the concave roller and the convex roller are not heated, the fabric is not hardened, and the absorbing material is softer. The traditional vacuum suction only sucks the material on the surface of a roller to stably convey, and the convex hull cannot be fuller; in addition, most of the traditional technologies are matched with air blowing to separate materials from the roller surface, and the 3D bubbles are blown in the opposite direction by the air blowing, so that the 3D effect is influenced.

The fabric II 13 enters through the tensioning guide roller III 9, is pressed on the fabric sucked and covered on the concave roller 2, is pressed by ultrasonic waves and the concave roller, is provided with composite salient points with the height of 0.5mm and the shapes of 15B and 16B on the forming concave roller, and the ultrasonic waves realize the adhesive force and the precision of the composite points through the pressure of the air cylinder II and the arrangement of an electric control system. When the ultrasonic device is used for compounding, the concave roller has better jointing effect under the unheated state, the adhesive force can completely meet the requirements of products under the condition of high-speed production, and the phenomena of wrinkles and uneven adhesion can not occur when the multi-layer material is compounded.

As shown in fig. 10 to 12, the manufacturing system of the composite sheet includes a manufacturing apparatus b and a feeding apparatus for feeding the fabric toward the manufacturing apparatus under constant tension; the feeding device consists of a first feeding device a2 and a second feeding device a 1; the first feeder a2 was used to introduce the fabric between the concave and convex rollers and the second feeder a1 was used to introduce the flat sheet into the upstream side of the ultrasonic welding mechanism.

The feeding device comprises a material roll frame, a material changing and receiving structure 18, a material storing structure 19 and a tension adjusting structure 20, wherein the material changing and receiving structure is positioned between the material roll frame and the material storing structure; the two material roll frames are oppositely arranged, the material changing and receiving structure is an automatic material changing and receiving structure, and the material can be automatically changed and received after the material supply of one material roll 17 is finished without stopping the machine, so that the production efficiency is improved.

A material deviation rectifying structure and a material tension control structure are arranged in the composite sheet processing mechanism before entering the guide roller; the material deviation rectifying device comprises a tensioning guide roller II, a material deviation rectifying structure I15-1, a material tension control structure I16-1, a material deviation rectifying structure II 15-2, a material tension control structure II 16-2 and a material tension control structure II 16-2.

A method of manufacturing a composite sheet comprising the steps of: forming a three-dimensional sheet having a plurality of convex portions by guiding a fabric between a convex roller for forming having a convex-concave shape in a circumferential direction and a concave roller; conveying the three-dimensional sheet in a downstream direction while adsorbing the three-dimensional sheet on the surface of the concave roller; superposing a flat sheet made of another fabric with the three-dimensional sheet, and compounding the two sheets by an ultrasonic welding mechanism to form the composite sheet; the fabric is shaped between the ultrasonic wave composite areas through the concave-convex shape of the concave-convex roller and the negative pressure forming unit, so that a specified convex part is formed on the fabric. Preferably, the fabric is not subjected to the shaping heat transferred from the embossing roll as it passes over the embossing roll. The radial position between the male and female rollers is adjustable. The radial position and pressure between the ultrasonic welding mechanism and the female roller is adjustable.

The above-mentioned features are merely for describing preferred embodiments of the present invention and may be arbitrarily combined to form a plurality of embodiments of the present invention.

The invention is described above with reference to the accompanying drawings, it is obvious that the specific implementation of the invention is not limited by the above-mentioned manner, and it is within the scope of the invention to adopt various insubstantial modifications of the inventive concept and solution, or to apply the inventive concept and solution directly to other applications without modification.

Claims

1. An apparatus for manufacturing a composite sheet, the composite sheet being formed by laminating and compounding a three-dimensional sheet having a plurality of projections and a flat sheet having no projections, the apparatus comprising:

a pair of convex and concave rollers for shaping arranged in parallel with each other, each of the convex and concave rollers having a concave-convex shape on the circumferential surface thereof, the concave-convex shapes being engaged with each other at facing positions;

an ultrasonic welding mechanism arranged at the downstream side of the concave roller and used for compounding a flat sheet with the three-dimensional sheet to form the compound sheet;

a negative pressure forming unit arranged on the concave roller, wherein the negative pressure range of the negative pressure forming unit is set to be at least between the concave roller and the convex roller in the circumferential direction of the concave roller and the ultrasonic wave composite area;

the concave-convex shape of the negative pressure forming unit and the concave-convex roller periphery enables the fabric to pass through the concave-convex roller and form between the ultrasonic wave composite regions, so that a specified convex part is formed on the fabric.

2. The apparatus for manufacturing a composite sheet according to claim 1, wherein: the concave roller and the convex roller are not provided with heating units for heating the roller body so as to endow the fabric with heat.

3. The apparatus for manufacturing a composite sheet according to claim 1, wherein: the ultrasonic welding mechanism is a material composite flat ultrasonic structure or a material composite circular ultrasonic structure.

4. The apparatus for manufacturing a composite sheet according to claim 1, wherein: the outer edge of the convex roller is provided with a group of forming bulges, and the outer edge of the concave roller is provided with a group of forming pits matched with the forming bulges.

5. The apparatus for manufacturing a composite sheet according to claim 1, wherein: the ultrasonic welding device further comprises two inlet guide rollers and a guide-out roller, wherein one inlet guide roller is used for introducing a fabric between the concave roller and the convex roller, the other inlet guide roller is used for introducing a flat sheet material formed by the other fabric into the upstream side of the ultrasonic welding mechanism, and the guide-out roller is arranged on the downstream side of the ultrasonic welding mechanism.

6. The manufacturing apparatus of the composite sheet according to claim 4, wherein: the negative pressure forming unit comprises a gas distribution disc for forming negative pressure, and gas distribution holes are communicated with the forming pits in the concave roller and communicated with the gas distribution disc.

7. The apparatus for manufacturing a composite sheet according to claim 1, wherein: the convex roller is also provided with a first adjusting component for adjusting the radial position between the convex roller and the concave roller.

8. The apparatus for manufacturing a composite sheet according to claim 1, wherein: and the ultrasonic welding mechanism is also provided with a second adjusting member for adjusting the radial position and pressure between the ultrasonic welding mechanism and the concave roller.

9. A composite sheet manufacturing system, comprising:

the manufacturing apparatus of composite sheet according to any one of claims 1 to 8,

and a feeding device for stably conveying the fabric toward the composite sheet manufacturing device under constant tension.

10. The composite sheet manufacturing system of claim 9, wherein: the feeding device comprises a material storage mechanism, a tension control mechanism and a deviation correcting mechanism; the storage mechanism is used for arranging the fabric conveyed to the direction of the composite sheet manufacturing device, the tension control mechanism is used for conveying the fabric with constant tension, and the deviation correcting mechanism is used for adjusting the lateral displacement of the fabric perpendicular to the flow direction.

11. The composite sheet manufacturing system of claim 9, wherein: the feeding device consists of a first feeding device and a second feeding device; the first feeder device is used to introduce the fabric between the female and male rollers and the second feeder device is used to introduce the flat sheet to the upstream side of the ultrasonic welding mechanism.

12. A method of manufacturing a composite sheet, comprising the steps of:

forming a three-dimensional sheet having a plurality of convex portions by guiding a fabric between a convex roller for forming having a convex-concave shape in a circumferential direction and a concave roller; conveying the three-dimensional sheet in a downstream direction while adsorbing the three-dimensional sheet on the surface of the concave roller; superposing a flat sheet made of another fabric with the three-dimensional sheet, and compounding the two sheets by an ultrasonic welding mechanism to form the composite sheet; the fabric is shaped between the ultrasonic wave composite areas through the concave-convex shape of the concave-convex roller and the negative pressure forming unit, so that a specified convex part is formed on the fabric.

13. The method of manufacturing a composite sheet according to claim 12, wherein: the fabric is not subjected to shaping heat transferred from the concave-convex roller when passing through the concave-convex roller.

14. The method of manufacturing a composite sheet according to claim 12, wherein: the radial position between the male and female rollers is adjustable.

15. The method of manufacturing a composite sheet according to claim 12, wherein: the radial position and pressure between the ultrasonic welding mechanism and the female roller is adjustable.