Parallel working type synthetic resin in-mold expansion foaming batch forming device and method

Abstract

According to the parallel working type synthetic resin in-mold expansion foaming batch forming device and method, the three procedures of mold filling of raw materials, steam foaming work and product cooling and taking out are independent of one another, work in parallel and do not interfere with one another, continuous production is achieved, the time fault tolerance is greatly improved, the single-piece production period is effectively shortened, and the production efficiency is improved. The overall production efficiency is improved; after the steam tank is started to work, the steam tank is continuously used and continuously keeps a hot state, so that the consumption of steam can be effectively reduced, and the carbon reduction performance of energy is outstanding; the surface of the upper mold and the surface of the lower mold are additionally provided with air holes which are widely and comprehensively covered, venting plugs which stop raw material foaming particles from passing but can allow water vapor to pass are additionally arranged in the air holes, the radiating surface of the water vapor in a mold cavity is increased, each raw material foaming particle is considered, and the water vapor penetrates through each particle gap, so that heating is more uniform; the foaming particle size is consistent, the density is uniform, the mechanical property is greatly improved, and the appearance quality is excellent.

Description

Technical Field

[0001] The present invention relates to the technical field of manufacturing foamed molded products, and more particularly to a parallel working synthetic resin in-mold expansion foaming batch molding device and method. Background Art

[0002] Patent application number 200710161513.0 discloses an apparatus and method for in-mold expansion foam molding of synthetic resins. The mold comprises an upper mold and a lower mold. The upper mold is sealed by a sealing device and movably supported on the lower shell of a steam tank, hermetically separating the interior of the steam tank into an upper cavity and a lower cavity. Steam in the upper cavity can only enter the mold cavity through a contact air gap that allows steam from the upper cavity to enter the mold cavity. Steam entering the mold cavity can only enter the lower cavity through a contact air gap that allows steam from the mold cavity to enter the lower cavity. Compared with existing in-mold expansion foam molding apparatuses for synthetic resins, this apparatus has a simple structure, low manufacturing cost, easy operation, and can significantly save energy.

[0003] The above patent is a patented technology that the applicant had developed several years ago. In daily production practice, some production bottlenecks have gradually been discovered, such as (1) low production efficiency and long single-piece production cycle, especially in the rigid linear relationship between raw material filling into the mold, steam foaming work and cooling to remove the product; (2) cooling is carried out directly in the steam tank, and each foaming work starts over, and the steam tank needs to be reheated, which consumes a lot of water vapor and wastes energy seriously; (3) water vapor penetrates the mold through the contact gap at the connection between the upper mold and the lower mold to foam, and the coverage area is small, which cannot take care of all the raw material foaming particles in the mold cavity, resulting in uneven heating, inconsistent foaming particle size, uneven density, decreased mechanical properties, and poor appearance quality. Summary of the Invention

[0004] The purpose of the present invention is to overcome the above-mentioned defects of the prior art and provide a parallel working synthetic resin in-mold expansion foaming batch molding device and method with high production efficiency, short single-piece production cycle, outstanding energy and carbon reduction performance, consistent foaming particle size, uniform density, greatly improved mechanical properties and superior appearance quality.

[0005] In order to achieve the above purpose, the present invention is realized through the following technical solutions: a parallel working synthetic resin in-mold expansion foaming batch molding device, comprising a steam tank and a mold placed therein, the steam tank comprising an upper tank body and a lower tank body, an upper tank cavity is formed in the upper tank body, the top of the upper tank cavity is connected to an upper air inlet pipe, a lower tank cavity is formed in the lower tank body, the bottom of the lower tank cavity is connected to a lower air inlet pipe, the mold comprises an upper mold and a lower mold, the upper mold and the lower mold are buckled together to form a mold cavity, an upper connecting flange is provided on the side edge of the upper mold, and a lower mold is provided on the side edge of the lower mold. The lower connecting flange, the upper connecting flange and the lower connecting flange are tightly fitted and connected, characterized in that a supporting flange is provided at the upper opening of the lower tank cavity, the supporting flange and the lower connecting flange are tightly fitted and connected, a first sealing rubber gasket is provided between the supporting flange and the lower connecting flange to seal and isolate the upper tank cavity and the lower tank cavity, a clamping flange is provided at the lower opening of the upper tank cavity, the clamping flange and the upper connecting flange are tightly fitted and connected; a feed pipe is provided on the upper mold, and a plurality of air holes passing through the mold cavity are respectively provided on the upper mold and the lower mold, and each of the air holes is respectively provided with an exhaust plug.

[0006] The three working steps of the present invention, namely, filling the mold with raw materials, steam foaming and cooling and taking out the products, are independent of each other, work in parallel, do not interfere with each other, and are continuously produced. The time tolerance is greatly improved, the single-piece production cycle is effectively shortened, and the overall production efficiency is improved; the steam tank is used continuously after it is turned on, and is continuously kept in a hot state, without the need to repeatedly heat from low temperature to high temperature, which can effectively reduce water vapor consumption and has outstanding performance in energy carbon reduction; widely covered pores are added on the surfaces of the upper mold and the lower mold, and exhaust plugs are added in the pores to block the passage of raw material foaming particles but allow water vapor to pass through, thereby increasing the radiation surface of water vapor in the mold cavity, taking care of each raw material foaming particle, and water vapor penetrates each particle gap, so that the heating is more uniform, and many advantages such as consistent foaming particle size, uniform density, greatly improved mechanical properties and superior appearance quality are achieved.

[0007] The natural feed port can also be set on the lower mold. It can be arranged as conveniently as possible. There is no specific requirement. It can be convenient for filling.

[0008] Preferably, a pipe plug is provided in the pipe mouth of the feed pipe, and the pipe plug is connected to the feed pipe in a threaded manner.

[0009] The feed pipe of the present invention needs to be plugged after being opened to load the raw foam particles to prevent the raw foam particles from being blown out or bulging out during water vapor penetration or subsequent foaming. In addition to the above-mentioned threaded connection, the pipe plug can also be fixed by other connection methods such as snap-fit.

[0010] Preferably, a second sealing rubber gasket is provided at the connection between the upper tank body and the lower tank body and is arranged circumferentially around their fastening edge surfaces.

[0011] The sealing plug of the steam tank of the present invention is the same as that of the prior art, and both need to be sealed to ensure that water vapor can penetrate the mold during transfer from the upper and lower tank bodies.

[0012] Preferably, an upper integrated temperature and pressure sensor is provided on the outer wall of the upper tank body, and a lower integrated temperature and pressure sensor is provided on the outer wall of the lower tank body.

[0013] The present invention uses an integrated upper temperature and pressure sensor to monitor the pressure and temperature inside the upper tank in real time, while a lower temperature and pressure sensor monitors the pressure and temperature inside the lower tank in real time. Both sensors are connected to a control terminal. The upper and lower air intake pipes are also equipped with electronically controlled air valves. The control terminal uses data transmitted by the sensors and, based on set requirements, opens and closes the electronically controlled air valves to replenish air. Designs like these are not innovations of the present invention; they are mature technologies already available on the market, and the present invention leverages these technologies to enhance their effectiveness.

[0014] A method for a parallel working synthetic resin in-mold expansion foaming batch molding device, characterized by comprising the following steps: Step 1: Take multiple molds, close the upper mold and the lower mold one by one through the upper connecting flange and the lower connecting flange, then fill the mold cavity with raw material foam particles through the feed pipe or the lower feed pipe. After filling, seal the pipe opening of the feed pipe with a pipe plug; Step 2: Take a mold filled with raw material foam particles and place it into the lower tank body of the steam tank, and then cover the upper tank body; first, ensure that the second sealing gasket seals the upper tank body and the lower tank body; second, ensure that the lower connecting flange and the supporting flange are tightly connected, and the pressing flange and the upper connecting flange are tightly connected, so that the first sealing gasket seals and isolates the upper tank cavity and the lower tank cavity; Step 3: First, water vapor is introduced from the upper air inlet pipe. The water vapor sequentially penetrates the upper tank cavity, the exhaust plug of the upper mold, the gap between the raw material foam particles in the mold cavity, the exhaust plug of the lower mold, the lower tank cavity, and finally is discharged from the lower air inlet pipe; Step 4: Water vapor is introduced from the lower air inlet pipe, and the water vapor sequentially penetrates the lower tank cavity, the exhaust plug of the lower mold, the gap between the raw material foam particles in the mold cavity, the exhaust plug of the upper mold, the upper tank cavity, and finally discharged from the upper air inlet pipe; Step 5: Finally, water vapor is introduced into the upper and lower air inlet pipes simultaneously to keep the mold warm and pressurized; the upper temperature and pressure integrated sensor monitors the pressure and temperature of the upper tank body, and the lower temperature and pressure integrated sensor monitors the pressure and temperature of the lower tank body, respectively controlling and replenishing water vapor in real time; Step 6: When the foaming temperature and duration in the steam tank reach the preset value, the upper tank is opened, the foamed mold is taken out and placed in the cooling water tank for cooling. After the temperature reaches the preset cooling state, the mold is opened and the product is taken out, completing one production link. Step seven, synchronously with step six, put another mold filled with raw material foam particles into the lower tank body of the steam tank, repeat the above steps two to five to enter the next production cycle.

[0015] Preferably, the order of step three and step four can be reversed.

[0016] Preferably, step three and step four can be repeated alternately multiple times.

[0017] According to actual experience and in accordance with the requirements of product characteristics for the foaming process, steps three and four can be repeated alternately multiple times to make the foaming work more thorough and more effective.

[0018] Beneficial effects: The three working steps of the present invention, namely, filling the mold with raw materials, steam foaming and cooling and removing the products, are independent of each other, work in parallel, do not interfere with each other, and produce continuously. The time tolerance is greatly improved, the single-piece production cycle is effectively shortened, and the overall production efficiency is improved; the steam tank is used continuously after it is turned on, and it keeps a hot state continuously, without repeatedly switching from low temperature to high temperature, which can effectively reduce water vapor consumption and has outstanding performance in energy carbon reduction; widely covered pores are added to the surfaces of the upper mold and the lower mold, and exhaust plugs are added to the pores to block the passage of raw material foaming particles but allow water vapor to pass through, thereby increasing the radiation surface of water vapor in the mold cavity, taking care of each raw material foaming particle, and water vapor penetrates each particle gap, making the heating more uniform, achieving many advantages such as consistent foaming particle size, uniform density, greatly improved mechanical properties and superior appearance quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a structural schematic diagram of the present invention; Figure 2 It is a cross-sectional view of the structure of the steam tank of the present invention; Figure 3 It is a structural cross-sectional view of the mold of the present invention; Figure 4 This is a diagram showing the state effect of the mold after being filled into the steam tank.

[0020] In the figure: 1-steam tank, 2-mold, 3-upper tank body, 4-lower tank body, 5-second sealing gasket, 6-upper tank cavity, 7-upper air inlet pipe, 8-lower tank cavity, 9-lower air inlet pipe, 10-upper temperature and pressure integrated sensor, 11-lower temperature and pressure integrated sensor, 12-upper mold, 13-lower mold, 14-mold cavity, 15-upper connecting flange, 16-lower connecting flange, 17-supporting flange, 18-first sealing gasket, 19-pressing flange, 20-feed pipe, 21-pipe plug, 22-exhaust plug. DETAILED DESCRIPTION

[0021] In order to make the technical means, creative features and objectives of the present invention easier to understand, the present invention is further described below with reference to specific embodiments.

[0022] Example: Figure 1 As shown, a parallel working synthetic resin in-mold expansion foaming batch molding device includes a steam tank 1 and a mold 2 placed therein, the steam tank 1 includes an upper tank body 3 and a lower tank body 4, and a second sealing gasket 5 is arranged circumferentially around their fastening edge surfaces at the connection between the upper tank body 3 and the lower tank body 4.

[0023] like Figure 2 As shown, an upper tank cavity 6 is formed in the upper tank body 3, and the top of the upper tank cavity 6 is connected to an upper air inlet pipe 7. A lower tank cavity 8 is formed in the lower tank body 4, and the bottom of the lower tank cavity 8 is connected to a lower air inlet pipe 9. An upper temperature and pressure integrated sensor 10 is provided on the outer wall of the upper tank body 3, and a lower temperature and pressure integrated sensor 11 is provided on the outer wall of the lower tank body 4.

[0024] like Figure 3 As shown, the mold 2 includes an upper mold 12 and a lower mold 13, which form a mold cavity 14 when the upper mold 12 and the lower mold 13 are buckled together. An upper connecting flange 15 is provided on the side edge of the upper mold 12, and a lower connecting flange 16 is provided on the side edge of the lower mold 13. The upper connecting flange 15 and the lower connecting flange 16 are tightly fitted and connected. A supporting flange 17 is provided at the upper opening of the lower tank cavity 8, and the supporting flange 17 and the lower connecting flange 16 are tightly fitted and connected. A first sealing gasket 18 is provided between the supporting flange 17 and the lower connecting flange 16 to seal and isolate the upper tank cavity 6 and the lower tank cavity 7. A clamping flange 19 is provided at the lower opening of the upper tank cavity 6, and the clamping flange 19 and the upper connecting flange 15 are tightly fitted and connected; a feed pipe 20 is provided on the upper mold 12, and a pipe plug 21 is provided in the pipe mouth of the feed pipe 20, and the pipe plug 21 is connected to the feed pipe 20 in a threaded manner.

[0025] The upper mold 12 and the lower mold 13 are respectively provided with a plurality of inner through mold cavities and air holes distributed over their respective width-extending surfaces, and each air hole is respectively provided with an air vent plug 22 .

[0026] like Figure 4 As shown, a method for a parallel working synthetic resin in-mold expansion foaming batch molding device is characterized by comprising the following steps: Step 1: Take multiple molds, close the upper mold and the lower mold one by one through the upper connecting flange and the lower connecting flange, then fill the mold cavity with raw material foam particles through the feed pipe or the lower feed pipe. After filling, seal the pipe opening of the feed pipe with a pipe plug; Step 2: Take a mold filled with raw material foam particles and place it into the lower tank body of the steam tank, and then cover the upper tank body; first, ensure that the second sealing gasket seals the upper tank body and the lower tank body; second, ensure that the lower connecting flange and the supporting flange are tightly connected, and the pressing flange and the upper connecting flange are tightly connected, so that the first sealing gasket seals and isolates the upper tank cavity and the lower tank cavity; Step 3: First, water vapor is introduced from the upper air inlet pipe. The water vapor sequentially penetrates the upper tank cavity, the exhaust plug of the upper mold, the gap between the raw material foam particles in the mold cavity, the exhaust plug of the lower mold, the lower tank cavity, and finally is discharged from the lower air inlet pipe; Step 4: Water vapor is introduced from the lower air inlet pipe, and the water vapor sequentially penetrates the lower tank cavity, the exhaust plug of the lower mold, the gap between the raw material foam particles in the mold cavity, the exhaust plug of the upper mold, the upper tank cavity, and finally discharged from the upper air inlet pipe; Step 5: Finally, water vapor is introduced into the upper and lower air inlet pipes simultaneously to keep the mold warm and pressurized; the upper temperature and pressure integrated sensor monitors the pressure and temperature of the upper tank body, and the lower temperature and pressure integrated sensor monitors the pressure and temperature of the lower tank body, respectively controlling and replenishing water vapor in real time; Step 6: When the foaming temperature and duration in the steam tank reach the preset value, the upper tank is opened, the foamed mold is taken out and placed in the cooling water tank for cooling. After the temperature reaches the preset cooling state, the mold is opened and the product is taken out, completing one production link. Step seven, synchronously with step six, put another mold filled with raw material foam particles into the lower tank body of the steam tank, repeat the above steps two to five to enter the next production cycle.

[0027] The above steps can be adjusted according to actual conditions, product characteristics, etc. For example, the order of step 3 and step 4 can be reversed. For another example, step 3 and step 4 can be repeated multiple times.

Claims

1. A parallel working synthetic resin in-mold expansion foaming batch molding device, comprising a steam tank and a mold placed therein, the steam tank comprising an upper tank body and a lower tank body, an upper tank cavity formed in the upper tank body, the top of the upper tank cavity being connected to an upper air inlet pipe, a lower tank cavity formed in the lower tank body, the bottom of the lower tank cavity being connected to a lower air inlet pipe, the mold comprising an upper mold and a lower mold, the upper mold and the lower mold being buckled together to form a mold cavity, an upper connecting flange being provided on the side edge of the upper mold, a lower connecting flange being provided on the side edge of the lower mold, the upper connecting flange being provided on the side edge of the lower mold, The flange is tightly fitted with the lower connecting flange, and is characterized in that a supporting flange is provided at the upper opening of the lower tank cavity, and the supporting flange and the lower connecting flange are tightly fitted and connected, and a first sealing rubber gasket is provided between the supporting flange and the lower connecting flange to seal and isolate the upper tank cavity and the lower tank cavity, and a clamping flange is provided at the lower opening of the upper tank cavity, and the clamping flange and the upper connecting flange are tightly fitted and connected; a feed pipe is provided on the upper mold, and a plurality of air holes passing through the mold cavity are respectively provided on the upper mold and the lower mold, and each of the air holes is respectively provided with an exhaust plug.

2. The parallel working synthetic resin in-mold expansion foaming batch molding device according to claim 1 is characterized in that a pipe plug is provided in the pipe mouth of the feed pipe, and the pipe plug is connected to the feed pipe in a threaded manner.

3. The parallel working synthetic resin in-mold expansion foaming batch molding device according to claim 1 is characterized in that a second sealing rubber gasket is provided at the connection between the upper tank body and the lower tank body and is arranged circumferentially around their fastening edge surfaces.

4. The parallel working synthetic resin in-mold expansion foaming batch molding device according to claim 1 is characterized in that an upper temperature and pressure integrated sensor is provided on the outer wall of the upper tank body, and a lower temperature and pressure integrated sensor is provided on the outer wall of the lower tank body.

5. The method of the parallel working synthetic resin in-mold expansion foaming batch molding device according to any one of claims 1 to 4, characterized in that it comprises the following steps: Step 1: Take multiple molds, close the upper mold and the lower mold one by one through the upper connecting flange and the lower connecting flange, then fill the mold cavity with raw material foam particles through the feed pipe. After filling, seal the pipe opening of the feed pipe with a pipe plug; Step 2: Take a mold filled with raw material foam particles and place it into the lower tank body of the steam tank, and then cover the upper tank body; first, ensure that the second sealing gasket seals the upper tank body and the lower tank body; second, ensure that the lower connecting flange and the supporting flange are tightly connected, and the pressing flange and the upper connecting flange are tightly connected, so that the first sealing gasket seals and isolates the upper tank cavity and the lower tank cavity; Step 3: First, water vapor is introduced from the upper air inlet pipe. The water vapor sequentially penetrates the upper tank cavity, the exhaust plug of the upper mold, the gap between the raw material foam particles in the mold cavity, the exhaust plug of the lower mold, the lower tank cavity, and finally is discharged from the lower air inlet pipe; Step 4: Water vapor is introduced from the lower air inlet pipe, and the water vapor sequentially penetrates the lower tank cavity, the exhaust plug of the lower mold, the gap between the raw material foam particles in the mold cavity, the exhaust plug of the upper mold, the upper tank cavity, and finally discharged from the upper air inlet pipe; Step 5: Finally, water vapor is introduced into the upper and lower air inlet pipes simultaneously to keep the mold warm and pressurized; the upper temperature and pressure integrated sensor monitors the pressure and temperature of the upper tank body, and the lower temperature and pressure integrated sensor monitors the pressure and temperature of the lower tank body, respectively controlling and replenishing water vapor in real time; Step 6: When the foaming temperature and duration in the steam tank reach the preset value, the upper tank is opened, the foamed mold is taken out and placed in the cooling water tank for cooling. After the temperature reaches the preset cooling state, the mold is opened and the product is taken out, completing one production link. Step seven, synchronously with step six, put another mold filled with raw material foam particles into the lower tank body of the steam tank, repeat the above steps two to five to enter the next production cycle.

6. The method of the parallel working synthetic resin in-mold expansion foaming batch molding device according to claim 5 is characterized in that the order of step three and step four can be reversed.

7. The method of the parallel working synthetic resin in-mold expansion foaming batch molding device according to claim 5 is characterized in that step three and step four can be repeated multiple times and performed alternately.

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