Foamed polymer preparation device and method

Abstract

The invention belongs to the field of foamed plastic molding, and provides a foamed polymer preparation device which comprises a mold, a pipeline is connected to the mold, the pipeline is configured to introduce foamed particles, steam and a cooling medium into the mold and discharge gas / condensate water from the mold, and a valve is arranged in the pipeline; wherein the foaming particles are formed by pre-foaming a raw material containing a physical foaming agent; the temperature sensor is configured to measure the temperature of more than one position in the mold and / or the pipeline; the pressure sensor is configured to measure the pressure of more than one position in the mold and / or the pipeline; the image acquisition mechanism is configured to shoot the interior of the mold to judge the fusion state of the foaming particles; and the controller is configured to receive data of the temperature sensor, the pressure sensor and the image acquisition mechanism and generate an instruction for opening / closing the valve, and a calculation unit is further arranged in the controller. The invention also provides a corresponding preparation method of the foamed polymer. And the technological process can be controlled more accurately and automatically.

Description

Technical Field

[0001] This invention belongs to the field of foam plastic molding, and in particular relates to an apparatus and method for preparing foamed polymers. Background Technology

[0002] Food delivery boxes, cold chain turnover boxes, and similar products are typically manufactured using a thermal fusion technology for foamed particles. This process involves heating the foamed particles to melt their surfaces and bond them together, ultimately forming a lightweight insulation material. The foamed particles are typically made from EPP (expanded polypropylene), EPS (expanded polystyrene), EPO (expanded polyethylene / styrene polymer), EPE (expanded polyethylene), PLA (polylactic acid), or ETPU (expanded elastic polyurethane) containing physical foaming agents.

[0003] Existing foamed plastic molding machines, such as Chinese patent CN101511561A, typically only use a thermocouple at one location within the mold cavity to monitor temperature. However, relying solely on temperature at a single location cannot accurately reflect whether process conditions are met, and since temperature is only an indirect parameter, it cannot accurately determine the fusion state of the foamed particles. Controlling the process flow and judging the fusion state of foamed particles based on temperature largely depends on experience, which is prone to misjudgment. Summary of the Invention

[0004] The purpose of this invention is to provide a foaming polymer preparation apparatus and method, which solves the problem of how to more accurately control the process flow.

[0005] In order to achieve the above object, the technical solution adopted by the present invention is: This invention provides a foaming polymer preparation apparatus, comprising: A mold having a pipe connected to it, the pipe being configured to introduce foaming particles, steam, and cooling medium into the mold and to discharge gas / condensate from the mold, the pipe having a valve installed therein, wherein the foaming particles are formed by pre-foaming raw materials containing a physical foaming agent; A temperature sensor is configured to measure the temperature at one or more locations within the mold and / or the pipe; A pressure sensor is configured to measure pressure at one or more locations within the mold and / or the pipe; The image acquisition mechanism is configured to acquire images of foamed particles to determine the fusion status of the foamed particles; The controller is configured to receive data from the temperature sensor, the pressure sensor, and the image acquisition mechanism and generate instructions to open / close the valve. The controller also includes a calculation unit configured to calculate analytical data, including differences and rates of change, for pressure and / or temperature values ​​at different locations.

[0006] Preferably, the temperature sensor and the pressure sensor are integrated into a single component.

[0007] Preferably, the mold includes a concave mold and a convex mold, which form a mold cavity between them when the mold is closed. Both the concave mold and the convex mold are provided with heat exchange chambers for introducing steam and cooling medium. There is a channel for exchanging heat between the heat exchange chamber and the mold cavity. The mold cavity and the heat exchange chamber are connected to the channel.

[0008] Furthermore, the temperature sensor and / or the pressure sensor are disposed within the mold cavity, and at least two are distributed in the mold closing direction.

[0009] Furthermore, the steam pipe and the exhaust / drainage pipe are located upstream and downstream of the opening of the heat exchange cavity, respectively, and the temperature sensor and / or the pressure sensor are installed at both the upstream and downstream positions inside the mold cavity.

[0010] Preferably, the system further includes a production management system configured to send process parameters to the controller and receive processing files from the controller, wherein the controller is configured to compare temperature and pressure with the process parameters and generate the instructions based on the comparison.

[0011] Furthermore, the controller is configured to record the time, pressure, and temperature of each process, and combine them with process parameters to form a processing record.

[0012] Furthermore, the production management system stores a standard image of the fusion state of foamed particles, and the controller is configured to upload the image of the fusion state of foamed particles acquired by the image acquisition mechanism to the production management system and compare it with the standard image of the fusion state of foamed particles.

[0013] A method for preparing a foamed polymer is also provided, in which pre-foamed particles are collected in a mold cavity of a predetermined shape, steam is introduced into the mold cavity to heat the foamed particles, causing the foamed particles to thermoplastically fuse to obtain a foamed polymer, and the foamed polymer is cooled to reduce the heat in the foamed polymer. During the thermoplastic fusion and cooling process, the temperature at more than one location in the mold cavity is measured, and analytical data including the difference and rate of change of pressure and / or temperature values ​​at different locations are calculated. The measured values ​​are compared with process parameters. During the thermoplastic fusion process, the internal structure of the foamed polymer is photographed to determine the fusion state of the foamed particles. Based on the comparison and the determination, it is decided whether to proceed to the next process.

[0014] Preferably, the time, pressure, and temperature of each step in the preparation process are recorded, and a processing record is formed in combination with the process parameters.

[0015] Due to the application of the above technical solution, the present invention has the following advantages compared with the prior art: The foamed polymer preparation apparatus and method of the present invention, by collecting temperature and pressure data from more than one location, can more accurately control the process flow based on the differences and rates of change between these temperatures and pressures. Furthermore, by acquiring images of the foamed particles through an image acquisition mechanism, the fusion status of the foamed particles can be understood more directly, resulting in more reliable foamed polymer quality. Additionally, the supply of energy such as steam and cooling media can be stopped in a timely manner to save production costs. The process flow control is more precise. Attached Figure Description

[0016] The following sections will describe some specific embodiments of the invention in detail by way of example and not limitation, with reference to the accompanying drawings. The same reference numerals in the drawings denote the same or similar parts or portions. Those skilled in the art should understand that these drawings are not necessarily drawn to scale. In the drawings: Figure 1 This is a partial structural schematic diagram of a preferred embodiment of a foaming polymer preparation apparatus according to the present invention; Figure 2 yes Figure 1 Enlarged view of the intermediate mold; Figure 3 This is a partial structural schematic diagram of a preferred embodiment of a foaming polymer preparation apparatus according to the present invention; Figure 4 It is a schematic diagram of the process flow; The reference numerals in the attached figures are explained as follows: 1. Material tank; 2. Mold; 21. Punch; 22. Die; 23. Mold cavity; 24. Heat exchange chamber; 3. Injector; 4. Steam pipe; 5. Cooling pipe; 6. Exhaust / drainage pipe; 7. Valve; 8. Feeding pipe; 9. Temperature and pressure integrated sensor; 10. X-ray camera mechanism; 11. Steam generator; 12. Cooling mechanism; 13. Mold opening mechanism; 14. Controller; 15. Production management system; 16. Nozzle; 17. Foaming polymer; 18. Feeding mechanism. Detailed Implementation

[0017] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] like Figure 1As shown, the foamed polymer preparation apparatus of the present invention includes a material tank 1 and a mold 2. The material tank 1 stores pre-foamed foamed particles. The foamed particles are made from raw materials (such as EPS beads) containing a physical foaming agent (such as pentane) through heating and pre-foaming. After pre-foaming, the volume increases by approximately 50 times, and the multiple can be adjusted according to the density of the final product.

[0019] The foamed particles in the material tank 1 can be pressurized, causing them to enter the feeding pipe 8 and then the syringe 3. The syringe 3 then injects the foamed particles into the mold cavity 23 of the mold 2. By introducing compressed air (compressed air pipe not shown in the figure) into the syringe 3, the foamed particles are blown into the mold cavity 23. When the mold cavity 23 is full of foamed particles, back pressure is generated, and the airflow blows the foamed particles back into the material tank 1. The syringe 3 is also equipped with a valve (not shown in the figure) to control the connection between the feeding pipe 8 and the mold cavity 23.

[0020] like Figure 1 and Figure 2 The mold 2 includes a punch 21 and a die 22, one of which is fixed and the other is movable. Figure 1 The mold is closed or opened in the horizontal direction. When the mold is closed, a closed mold cavity 23 is formed. Both the punch 21 and the die 22 are provided with heat exchange cavities 24 formed by the mold wall plates. The mold wall plates between the heat exchange cavity 24 and the mold cavity 23 are provided with channels, and steam plugs are provided in the channels. Steam, air or water can pass through the steam plugs, but foaming particles cannot pass through the steam plugs, so that mass exchange or heat exchange can occur between the heat exchange cavity 24 and the mold cavity 23.

[0021] Although this example uses a structure such as a punch 21 and a die 22, which is typically used for processing container-type foamed polymers, the concept of the present invention is applicable to virtually any mold used for processing foamed polymers.

[0022] like Figure 1 and Figure 2 A steam pipe 4 is connected to the heat exchange chamber 24. The steam pipe 4 has a valve 7. The steam pipe 4 is connected to the heat exchange chamber 24 and is used to introduce steam into the heat exchange chamber 24. The steam passes through the steam plug and heats the foamed particles in the mold cavity 23, causing the foamed particles to fuse and stick together to form a foamed polymer 17.

[0023] The bottom of the heat exchange chamber 24 is connected to an exhaust / drain pipe 6, which is equipped with a valve. Condensate, steam, or air can be discharged through the exhaust / drain pipe 6.

[0024] A cooling pipe 5 is also provided inside the heat exchange chamber 24. The cooling pipe 5 extends from the outside of the heat exchange chamber 24 to the inside of the heat exchange chamber 24, and a nozzle 16 is provided at the end inside the heat exchange chamber 24. Cooling medium, such as cooling water, is sprayed onto the wall plate surrounding the mold cavity 23 through the cooling pipe 5. After cooling, air can be sprayed through the cooling pipe 5 to remove excess moisture. The cooling pipe 5 can also be used to evacuate the heat exchange chamber 24 to accelerate moisture evaporation.

[0025] Multiple integrated temperature and pressure sensors 9 are installed at various locations within the mold cavity 23. These sensors can simultaneously measure temperature and pressure. The signal lines of the integrated temperature and pressure sensors 9 are connected to an external controller 14 within the heat exchange cavity 24 (see reference). Figure 3 All integrated temperature and pressure sensors 9 use industrial-grade shielded cables to connect to the data acquisition module (not shown) of the controller 14, ensuring signal stability and anti-interference capabilities. The integrated temperature and pressure sensor 9 integrates a temperature sensor and a pressure sensor into one component, effectively performing the individual temperature and pressure measurement functions of the sensors. Alternatively, the integrated temperature and pressure sensor 9 can be replaced with separate temperature and pressure sensors, and the temperature and pressure sensors do not necessarily need to be placed together. Generally, the temperature sensor is placed where temperature measurement is required, and the pressure sensor is placed where pressure measurement is required.

[0026] At least one integrated temperature and pressure sensor 9 can be installed inside the mold cavity 23.

[0027] Figure 2 The display shows that there are three integrated temperature and pressure sensors 9 in the direction of mold closing of the punch 21 and the die 22, which are also distributed along the feeding direction of the syringe 3, and are set on the wall plate of the die 22 or the punch 21 facing the mold cavity 23.

[0028] Since the openings of the steam pipe 4 and the exhaust / drainage pipe 6 on the heat exchange chamber 24 are located at the upstream and downstream positions respectively, integrated temperature and pressure sensors 9 are also installed at the upstream and downstream positions of the mold cavity 23 to facilitate a more precise understanding of the pressure and temperature inside the mold cavity 23.

[0029] A temperature and pressure sensor 9 is also installed near the valve 7 of the exhaust / drainage pipe 6 to know the temperature and pressure of the condensate, and can also know the pressure inside the heat exchange chamber 24.

[0030] Figure 2The image shows that an X-ray camera mechanism 10 is installed inside the mold 2 to capture images of the internal structure of the foamed polymer 17, providing a more direct understanding of the fusion process of the foamed polymer 17. The X-ray camera mechanism 10 can be embedded in the wall plate facing the mold cavity 23, connected to the ejector plate (not shown) of the demolding push rod, or located inside the heat exchange cavity 24. The demolding push rod passes through the heat exchange cavity 24 from outside the mold 2 and extends into the mold cavity 23. An ejector plate is installed at its end inside the mold cavity 23, embedded in the wall plate facing the mold cavity 23, to eject the foamed polymer 17 out of the mold 2 during mold opening.

[0031] Although an X-ray camera mechanism 10 was used to acquire images of foaming particles in this example, any penetrable detection device can replace the X-ray camera mechanism 10, such as an ultrasonic instrument.

[0032] like Figure 3 As shown, the foamed polymer preparation apparatus of the present invention further includes a production management system 15, a controller 14, a steam generator 11, a cooling mechanism 12, a mold opening mechanism 13, and a feeding mechanism 18.

[0033] The production management system 15 can be a local or remote computer, which can input process parameters and connect to the controller 14 via Ethernet or WIFI.

[0034] The production management system 15 sends basic product information (such as structure, dimensions, materials, and process formulas, with the process formulas including process parameters and procedures) to the controller 14, which serves as the parameter basis for each batch of production. During production, the controller 14 uploads processing files formed from real-time collected key data such as temperature, pressure, and time to the production management system 15, facilitating subsequent quality traceability and process optimization. The system supports anomaly alarms and data analysis functions; when abnormalities are detected in parameters such as temperature, pressure, and time, it automatically alarms and generates maintenance suggestions.

[0035] The controller 14 uses an industrial single-board computer and can connect to a local database (not shown) to temporarily store data in the database and periodically transmit the data to the production management system 15. The integrated temperature and pressure sensor 9 collects data at a high frequency (e.g., 5-10 times per second), and the collected data is stored in the local database in real time and periodically uploaded to the production management system 15.

[0036] Steam generator 11 can generate steam and supply the steam to steam pipe 4.

[0037] The cooling unit 12 can generate cooling water and supply it to the cooling pipe 5. It can also recover and cool the steam condensate or sprayed cooling water recovered from the exhaust / drain pipe 6 and then supply it back to the cooling pipe 5.

[0038] The mold opening mechanism 13 can perform mold opening and closing actions. It can be hydraulic or electric.

[0039] The feeding mechanism 18 includes the aforementioned material tank 1, feeding pipe 8, syringe 3, and a pre-foaming machine (not shown in the figure) for quantitative or non-quantitative pre-foaming.

[0040] The controller 14 is connected to the integrated temperature and pressure sensor 9, X-ray camera mechanism 10, valve 7, steam generator 11, cooling mechanism 12, mold opening mechanism 13, and feeding mechanism 18 via a PLC (not shown). The controller 14 can send commands to the PLC to control these devices, and can also receive feedback information from the devices, such as the timing of actions. It can combine time, temperature, and pressure with process parameters to generate processing files, which are then stored and periodically sent to the production management system 15. The production management system 15 can perform statistical analysis based on the collected historical data, providing decision support for process optimization, equipment maintenance, and quality improvement.

[0041] During the production process, the controller 14 can also perform analysis on the temperature and pressure data of multiple integrated temperature and pressure sensors 9 through the calculation unit (not shown), including the difference and rate of change. Furthermore, it can upload the internal image of the foamed polymer captured by the X-ray camera mechanism 10 to the production management system 15 and compare it with the standard image of the fusion status of the foamed particles in the production management system 15 to determine whether the foamed particles are fully fused. Based on this, it decides whether to proceed to the next process and then controls the valve 7, steam generator 11, cooling mechanism 12 or mold opening mechanism 13, and feeding mechanism 18 to switch to the next process.

[0042] like Figure 4 The process flow diagram shown includes four main processes: filling, steam forming, cooling, and demolding.

[0043] Pre-foamed particles are introduced into the mold cavity 23 as filler, and then steam is introduced into the mold cavity 23 to heat the foamed particles, so that the surfaces of the foamed particles fuse and adhere to form foamed polymer 17. Then the foamed polymer 17 is cooled to reduce its temperature, and finally it is demolded and the foamed polymer 17 is taken out.

[0044] The steam forming process includes five sub-steps: steam delay, die punching, cross-steaming, double-sided steaming, and fusion stabilization. These sub-steps are primarily achieved by opening and closing the corresponding valves (7) to determine different steam introduction modes. However, not all products undergo these five sub-steps; for products with simple structures, some sub-steps can be omitted.

[0045] Steam delay: For more complex products, the steam introduction is generally delayed to allow the foaming particles in mold 2 to pause briefly and stabilize within mold 2. At this time... Figure 2Valves 7 at points A, B, C, and D are closed. Valves 7 at points E and F are opened, allowing air entering the mold cavity 23 from the syringe 3 to be expelled.

[0046] The controller 14 can read the basic product information in the production management system 15 in advance, including parameters such as product structural complexity, wall thickness, volume, and material type. If the product structure is complex (such as wall thickness greater than a preset threshold, or the presence of multiple cavities or irregular structures), the system will automatically set a longer particle filler stabilization time during the steam delay stage to ensure that the pre-foamed particles are evenly distributed and fully settled in the mold 2.

[0047] At this point, the integrated temperature and pressure sensor 9 detects that the temperature at each point in the mold cavity 23 has reached the set uniformity standard (e.g., the temperature difference between each point is less than 2℃), and determines that the particle distribution is stable, allowing the process to proceed to the next step. If the temperature difference does not meet the standard, the delay continues until the standard is met or the maximum allowable delay time is reached. The calculation unit (not shown in the figure) in the controller 14 calculates the temperature difference value at each point.

[0048] Die: Used to preheat the mold and expel cold air from the heat exchange chamber 24. At this time, Figure 2 Valves 7 at points B, C, E, and F are in the open state, while valves 7 at points A and D are in the closed state. Steam enters the heat exchange chamber 24 to preheat the mold, and then is discharged from the exhaust / drainage pipe 6.

[0049] The controller 14 collects data from the integrated temperature and pressure sensor 9 at different locations in the mold cavity in real time, and the calculation unit analyzes the rate of temperature rise and the change in absolute value. When the temperature at all key locations reaches or exceeds the set mold completion threshold (e.g., 110℃), and the rate of temperature rise decreases significantly (e.g., rises less than 0.5℃ within 30 consecutive seconds), the mold process is automatically determined to be complete.

[0050] If the temperature at certain locations does not meet the standard, the system will automatically extend the die stamping time until the temperature at all monitoring points meets the standard or the maximum safe time is reached.

[0051] Cross-steaming: This process replaces the remaining air between the foamed particles in mold cavity 23 with steam, which heats the surface of the foamed particles, causing slight adhesion between them. The initial heating is done at lower pressure and for shorter duration; subsequent heating is done at higher pressure and for longer duration. Heating the side of the product with the simpler outer surface shape first can blow the foamed particles to the other side. Figure 2First, open valves 7 at points B and F, and close valves 7 at points C and E to heat one side. Steam enters the mold cavity 23 from the heat exchange chamber 24 of the punch 21 to heat the foaming particles. Then, the cooled steam or condensate enters the heat exchange chamber 24 of the die 22 and exits from valve 7 at point F. The foaming particles are pushed by the steam to adhere tightly to the die 22. For complex-shaped products, this allows the corners to be filled with foaming particles. Then, close valves 7 at points B and F, and open valves 7 at points C and E to heat the other side.

[0052] The controller 14 synchronously collects pressure and temperature data at the punch and die, as well as the vent / drain valves. If, during the cross-steaming process, the pressure of the punch and die gradually reaches equilibrium, and the temperature reaches the set standard (e.g., ≥105℃), and the condensate flow rate and temperature change at the vent / drain valves conform to the preset condensation characteristics (e.g., condensate temperature begins to decrease, and flow rate gradually decreases), then the cross-steaming is deemed sufficient. If the pressure and temperature are not balanced, or the condensate condition is abnormal, the cross-steaming duration is automatically extended until the above conditions are met.

[0053] Double-sided steam: Simultaneously open valves B and C 7, and close valves E and F 7. The actual expansion process of the foamed particles begins, reaching the melting temperature, and the foamed particles fuse together.

[0054] The controller 14 monitors the pressure and temperature change curves upstream and downstream of the mold cavity. When the pressure difference between upstream and downstream is lower than the preset value (e.g., ≤0.05MPa), and the temperature reaches the complete fusion standard (e.g., ≥110℃) and remains there for a period of time (e.g., more than 30 seconds), the foamed particles are determined to be completely fused. If the fusion is insufficient (e.g., abnormal pressure difference or temperature not meeting the standard), the system automatically extends the steam time on both sides until the fusion conditions are met or the maximum safe time limit is reached.

[0055] Stable fusion: Close valves 7 at points B, C, E, and F to allow the edges and corners of the foamed polymer and areas without air pockets to fuse better using the heat from the mold. This is suitable for products with more complex structures.

[0056] The controller 14 combines the product's structural complexity (such as the structural parameters issued by the production management system 15) with the fusion process sensor data to dynamically adjust the stabilization time.

[0057] If the temperature fails to reach the fusion temperature (160℃) within the set time according to the system, an alarm will be issued. If the temperature fluctuates significantly, the system will issue an alarm, and workers will need to intervene.

[0058] At this point, the X-ray camera 10 inside the mold cavity takes pictures of the inside of the product and transmits the images back to the controller 14. The controller 14 then connects to the production management system 15 for comparison to confirm whether the fusion state is stable. After confirming that the fusion is complete, the controller 14 controls the valves 7 at points B and C to close and stop the steam supply, proceeding to the next cooling stage.

[0059] During the cooling process, Figure 2 When valves 7 at points A, D, E, and F are opened, cooling water is sprayed from the cooling pipes 5 through nozzles 16 onto the mold wall panel containing the product, thereby cooling the product.

[0060] The integrated temperature and pressure sensor 9 at the exhaust / drainage pipe 6 monitors the temperature and pressure of the condensate in real time. If the condensate temperature drops below the set safety value (e.g., ≤40℃) and the pressure inside the mold cavity returns to normal, the system determines that the cooling process is complete. If the condensate temperature remains high or the pressure has not recovered, the controller 14 automatically extends the cooling time to ensure safe demolding.

[0061] After cooling is complete, the controller 14 automatically checks that the temperature and pressure inside the mold cavity are within a safe range (e.g., temperature ≤ 40℃, pressure is normal pressure), all valves are in normal condition, and there are no abnormal alarms. The controller 14 then sends a command to the mold opening mechanism 13 to execute the mold opening action.

[0062] This example can be used to manufacture various foamed materials, such as EPP (expanded polypropylene), EPS (expanded polystyrene), EPO (expanded polyethylene / styrene polymer), EPE (expanded polyethylene), PLA (polylactic acid), or ETPU (expanded elastic polyurethane). The molding pressure and temperature range for each product can be found in Table 1. These parameters may vary slightly depending on the specific formulation, equipment, and process, but the following data can be used as a general reference. Generally speaking, a temperature sensor capable of measuring up to 200°C and a pressure sensor capable of measuring 1 MPa are sufficient for the needs of this invention.

[0063] Table 1 Material Pressure (MPa) Molding temperature (°C) Cooling and demolding temperature (°C) EPP 0.6~1 120～180 50~60 EPS 0.4~0.5 90～110 50~60 PLA 0.2~0.25 100~160 50~60 ETPU 0.2~0.7 150~180 50~60 The controller 14 records data such as temperature, pressure, and time from each sensor at each stage of the process, and archives this data along with product information to form a processing file. The data is uploaded to the production management system 15 in real time via the network, facilitating subsequent quality analysis, performance evaluation, and process optimization.

[0064] The system also supports historical data review and statistics, providing a foundation for intelligent functions such as predictive maintenance, process parameter optimization, and anomaly alarms. Utilizing long-term accumulated data, the system identifies abnormal patterns and potential faults in equipment operation through data mining and analysis, issuing early maintenance warnings and reducing equipment failure rates. Furthermore, based on the analysis of processing records, management personnel can adjust process parameters to continuously optimize the molding process, improving product consistency and production efficiency.

[0065] All valve actions, mold opening, and other critical processes are automatically controlled by controller 14, ensuring precise execution and traceability of the process flow. The system supports remote process parameter distribution, process formula switching, and equipment status monitoring, facilitating centralized management and flexible production.

[0066] In summary, this invention addresses the problems of existing foam plastic molding equipment by proposing a molding device and method based on real-time acquisition of multi-point physical quantities, intelligent control of industrial single-board computers, and interconnection with a production management system. This ensures that each batch of products achieves optimal fusion and strength, avoiding quality issues such as under-melting, over-melting, and deformation. The entire process requires no manual intervention, achieving a high degree of automation and intelligent production control. It significantly improves the automation, precision, and intelligence of the production process and has broad industrial application prospects.

[0067] The above embodiments are only for illustrating the technical concept and features of the present invention. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be used to limit the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A foaming polymer preparation apparatus, characterized in that, include: A mold having a pipe connected to it, the pipe being configured to introduce foaming particles, steam, and cooling medium into the mold and to discharge gas / condensate from the mold, the pipe having a valve installed therein, wherein the foaming particles are formed by pre-foaming raw materials containing a physical foaming agent; A temperature sensor is configured to measure the temperature at one or more locations within the mold and / or the pipe; A pressure sensor is configured to measure pressure at one or more locations within the mold and / or the pipe; The image acquisition mechanism is configured to acquire images of foamed particles to determine the fusion status of the foamed particles; The controller is configured to receive data from the temperature sensor, the pressure sensor, and the image acquisition mechanism and generate instructions to open / close the valve. The controller also includes a calculation unit configured to calculate analytical data, including differences and rates of change, for pressure and / or temperature values ​​at different locations.

2. The foaming polymer preparation apparatus according to claim 1, characterized in that, The temperature sensor and the pressure sensor are integrated into one component.

3. The foaming polymer preparation apparatus according to claim 1, characterized in that, The mold includes a concave mold and a convex mold. When the concave mold and the convex mold are closed, they form a mold cavity. Both the concave mold and the convex mold are provided with heat exchange chambers for introducing steam and cooling medium. There are channels for exchanging heat between the heat exchange chambers and the mold cavity. The mold cavity and the heat exchange chambers are connected to the channels.

4. The foaming polymer preparation apparatus according to claim 3, characterized in that, The temperature sensor and / or the pressure sensor are disposed inside the mold cavity, and at least two are distributed in the mold closing direction.

5. The foaming polymer preparation apparatus according to claim 4, characterized in that, The steam pipe and the exhaust / drainage pipe are located upstream and downstream of the opening of the heat exchange cavity, respectively, and the temperature sensor and / or the pressure sensor are installed at both upstream and downstream positions inside the mold cavity.

6. The foaming polymer preparation apparatus according to claim 1, characterized in that, It also includes a production management system configured to send process parameters to the controller and receive production data from the controller, wherein the controller is configured to compare temperature and pressure with the process parameters and generate the instructions based on the comparison.

7. The foaming polymer preparation apparatus according to claim 6, characterized in that, The controller is configured to record the time, pressure, and temperature of each process and combine them with process parameters to form a processing record.

8. The foaming polymer preparation apparatus according to claim 6, characterized in that, The production management system stores a standard image of the fusion state of foamed particles. The controller is configured to upload the image of the fusion state of foamed particles acquired by the image acquisition mechanism to the production management system and compare it with the standard image of the fusion state of foamed particles.

9. A method for preparing a foaming polymer, characterized in that, Pre-foamed particles are collected in a mold cavity of a predetermined shape. Steam is introduced into the mold cavity to heat the particles, causing them to thermoplastically fuse to form a foamed polymer. The foamed polymer is then cooled to reduce its heat content. During the thermoplastic fusion and cooling process, the temperature at more than one location within the mold cavity is measured. Analytical data, including the difference and rate of change, are calculated for the pressure and / or temperature values ​​at different locations. The measured values ​​are compared with process parameters. The internal structure of the foamed polymer is photographed during the thermoplastic fusion process to determine the fusion state of the particles. Based on the comparison and determination, a decision is made on whether to proceed to the next step.

10. The method for preparing the foamed polymer according to claim 9, characterized in that, During the preparation process, the time, pressure, and temperature of each step are recorded, and processing records are formed by combining the process parameters.

Images