(1) Base Fabric Weaving
The first step is the weaving of the base fabric. Fiberglass yarns are woven into various mesh shapes and densities according to different usage requirements. Common weaving methods include plain weave, twill weave, and satin weave. Plain weave is the simplest weaving method; its structure is tight, the mesh is uniform, and it has high strength and stability, making it suitable for general material conveying. Twill weave produces a mesh belt with a diagonal pattern on the surface, offering better flexibility and adaptability to curved conveying paths. Satin weave makes the mesh belt surface smoother, reducing material adhesion, and is often used in applications requiring high surface flatness. During the weaving process, the weaving tension and density must be strictly controlled to ensure the quality and performance of the base fabric meet requirements.
(2) Coating Treatment
After the base fabric weaving is completed, the coating treatment stage begins. The base fabric must first be pre-treated to remove surface impurities and oil stains, ensuring the coating adheres firmly to the base fabric. Pre-treatment typically involves chemical cleaning and high-temperature baking. Then, the Teflon emulsion is evenly coated onto the surface of the base fabric. There are several coating methods, the most common being immersion, spraying, and blade coating. Immersion involves soaking the base fabric in the Teflon emulsion, allowing the emulsion to fully penetrate the fiber gaps. This method ensures the uniformity and thickness of the coating. Spraying uses a spray gun to apply the Teflon emulsion to the base fabric surface; its advantage is its flexibility, adaptable to base fabrics of different shapes and sizes. Blade coating uses a scraper to evenly apply the Teflon emulsion to the base fabric surface; this method allows for precise control of the coating thickness.
After coating, the conveyor belt needs to be sintered at high temperature. The purpose of high-temperature sintering is to evaporate the solvent in the Teflon emulsion and simultaneously induce a cross-linking reaction between Teflon molecules, forming a strong coating. The sintering temperature and time need to be precisely controlled according to the type of Teflon and the coating thickness. Generally, the sintering temperature is between 300℃ and 400℃, and the sintering time varies from a few minutes to tens of minutes.
(3) Post-processing
The conveyor belt after high-temperature sintering requires post-processing. Post-processing mainly includes inspection and repair. Inspection involves a comprehensive check of the conveyor belt's appearance, dimensions, coating quality, etc., to ensure that the conveyor belt meets relevant quality standards. For some defective conveyor belts, repair is required, such as repairing damaged areas of the coating and adjusting the dimensions of the conveyor belt. The Teflon conveyor belt after post-processing can then be put into use.
