A production process and production apparatus for fiber-reinforced polyurethane foam material

Abstract

This invention discloses a production process and apparatus for fiber-reinforced polyurethane foam materials, relating to the field of foaming material technology. The process includes the following steps: S1: Laying the base paper onto a conveyor belt; S2: Preparing the fiber cloth, arranging the required fiber cloth at intervals, adjusting the unwinding angle of the fiber cloth to ensure that the width direction of the fiber cloth coincides with and / or intersects with the thickness direction of the material; S3: Preparing the spraying material, setting the parameters of the foaming machine and setting the width of the foam material spraying area, as well as the spraying time; S4: Foaming and molding. The production process of this invention is characterized by wide applicability and simple operation. It can be applied to different fibers, and while the production process is simple, it can significantly enhance the overall strength of the foam material. It can be used to produce foam materials of different densities and heights, and the spacing and arrangement angle of the fiber layers within the foam material can be arbitrarily adjusted as needed to suit different application environments.

Description

Technical Field

[0001] This invention relates to the field of foam materials technology, specifically to a production process and production apparatus for fiber-reinforced polyurethane foam materials. Background Technology

[0002] Existing fiber-reinforced polyurethane foams can be broadly classified into short fiber-reinforced foams and continuous fiber-reinforced foams.

[0003] Studies have shown that adding a certain amount of short fibers to materials can enhance their mechanical properties. However, the addition of short fibers increases the viscosity of the matrix material, and the better the fiber dispersion in the matrix, the greater the viscosity of the material. Therefore, for industrialization, this has the disadvantage of requiring high-level equipment.

[0004] Currently, the fiber-reinforced foam materials used in the market are mainly continuous glass fiber reinforced foam. The production process of continuous glass fiber reinforced foam involves laying a glass fiber cloth at the bottom and then pouring the foaming raw material onto the glass fiber cloth. This production process has high requirements for the selection of glass fiber cloth. There must be sufficient gaps between the fibers of the cloth to allow the raw material to permeate through. Moreover, the viscosity of the foaming raw material cannot be too high, otherwise it will affect the permeability of the glass fiber cloth. Finally, the laying process of the fiber cloth is also very demanding. When laying multiple layers, if one layer is not laid properly, the entire foam will be ruined. Therefore, we provide a production process and production equipment for a longitudinally arranged fiber-reinforced polyurethane foam material. Summary of the Invention

[0005] The purpose of this invention is to provide a production process and apparatus for fiber-reinforced polyurethane foam materials to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a production process for fiber-reinforced polyurethane foam material, comprising the following steps:

[0007] S1: Laying the base paper, laying the base paper onto the conveyor belt.

[0008] S2: Fiber cloth preparation. Arrange the fiber cloth required for production at intervals and adjust the unwinding angle of the fiber cloth. Ensure that the width direction of the fiber cloth coincides with and / or intersects with the thickness direction of the material.

[0009] S3: Spray material preparation. Set the foaming machine parameters and the width and spraying time of the foam material spraying area according to the density, length, height and width required for material molding.

[0010] S4: Foaming and molding. The conveyor belt in step S1 drives the continuous laying of the base paper. The fiber cloth in step S2 is unwound at the same speed as the conveyor belt. When the end of the fiber cloth in step S2 moves to the spraying area in step S3, the foaming machine supplies foam material to spray out and achieve foaming and molding, so as to fix the fiber cloth to overlap in the width direction and / or intersect in the thickness direction of the material.

[0011] Preferably, the foaming process in step S4 is either continuous or intermittent.

[0012] Preferably, the fiber cloth in step S2 includes, but is not limited to, glass fiber, carbon fiber, polyamide fiber, polyphenylene sulfide fiber, poly(p-phenylenebenzobisoxazole) fiber, continuous basalt fiber, and ultra-high molecular weight polyethylene fiber.

[0013] Preferably, the material density in step S3 is 30-500 kg / m³. 3 The material height is 200-600mm.

[0014] A production apparatus for fiber-reinforced polyurethane foam includes a conveyor belt and a fiber roll. Fiber cloth is wound around the outer side of the fiber roll, and a base paper covers the outer side of the conveyor belt. A spraying seat is provided above the conveyor belt, and a spraying plate is rotatably connected to the bottom of the spraying seat. The bottom of the spraying plate is provided with nozzles arranged at equal intervals facing the conveyor belt. When the setting angle of the spraying plate is adjusted, it is used to adjust the spraying width of the spraying plate.

[0015] It also includes an unwinding assembly, which includes a base installed at the front end of the conveyor belt. The base has a drive belt arranged horizontally in a racetrack shape inside. The base has a support sleeve for installing the drive belt inside. The base has two rows of equally spaced unwinding seats, which are located on the same side of the parallel sides of the drive belt. The drive belt has teeth on both its inner and outer sides, and the bottom of each unwinding seat has a driven wheel that meshes with the teeth. A drive motor is installed on one side inside the base, and the output end of the drive motor has a drive gear that meshes with the teeth.

[0016] A connecting column is provided at the axial center of the fiber roll. The bottom end of the connecting column is detachably installed on the top of the unwinding seat. An adjusting arm is vertically installed on the top of the connecting column via a bearing. The adjusting arm is arranged along the diameter direction of the fiber roll, and a pair of guide rollers are movably installed at the front end of the adjusting arm.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: The production process of fiber-reinforced polyurethane foam provided by this application has the characteristics of wide applicability and simple operation. It can be applied to different fibers, and the production process is simple, but it can significantly enhance the overall strength of the foam material. It can be used to produce foam materials with different densities and heights. The spacing and arrangement angle of the fiber layers in the foam material can be adjusted arbitrarily as needed to suit different application environments. Moreover, the overall process is simple and easy to produce. Furthermore, the production device provided by this application can realize automatic feeding, including the linkage unwinding of the fiber cloth and the automatic spraying of the foam material. It also includes an array-arranged unwinding seat, adjusting arm and guide roller to make the spacing and angle of the fiber cloth easy to adjust and suitable, meeting the adjustable requirements of the process production, and the adjustment is simple. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the cross-sectional structure of the foam material of the present invention;

[0019] Figure 2 This is a schematic diagram of the internal structure of a partial side view of the production device of the present invention;

[0020] Figure 3 This is a partial top view of the production apparatus of the present invention;

[0021] Figure 4 This is an enlarged internal structural diagram of the base portion of the present invention.

[0022] In the diagram: 1. Adjusting arm; 2. Unwinding seat; 3. Drive motor; 4. Guide roller; 5. Nozzle; 6. Spraying seat; 7. Spraying plate; 8. Fiber cloth; 9. Base paper; 10. Conveyor belt; 11. Drive belt; 12. Support sleeve; 13. Driven wheel; 14. Base; 15. Fiber roll; 16. Connecting column. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. 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.

[0024] Please see Figure 1 The present invention provides an embodiment of a production process for fiber-reinforced polyurethane foam material, comprising the following steps:

[0025] S1: Laying the base paper, laying the base paper onto the conveyor belt.

[0026] The conveyor belt should have sidewalls for lateral restraint to limit material overflow during subsequent foaming. The sidewalls can be integrally formed on the conveyor belt. Understandably, the cross-section of the conveyor belt can be U-shaped. Mainly, the backing paper is used to support the foam material and keep it in contact with the conveyor belt during subsequent foaming. The backing paper can be laid continuously or in one go. Continuous laying can be achieved by rolling the backing paper around the outside of a metal roller and unwinding it simultaneously with subsequent processing at the same speed. One-time laying can be achieved by selecting a suitable length of backing paper based on the circumference of the conveyor belt, wrapping it around the conveyor belt and connecting the ends. In this embodiment, we use a one-time laying method for small-batch, low-cost production.

[0027] S2: Fiber cloth preparation. Arrange the fiber cloth required for production at intervals and adjust the unwinding angle of the fiber cloth. Ensure that the width direction of the fiber cloth coincides with and / or intersects with the thickness direction of the material.

[0028] In step S2, the fiber cloth can be any material, including but not limited to glass fiber, carbon fiber, polyamide fiber, polyphenylene sulfide fiber, poly(p-phenylenebenzobisoxazole) fiber, continuous basalt fiber, and ultra-high molecular weight polyethylene fiber. Crucially, it is necessary to ensure that the width direction of the fiber cloth coincides with and / or intersects with the thickness direction of the material. (See [link to relevant documentation]). Figure 1 The fiber cloth shown in the diagram is arranged to completely overlap with the thickness direction of the material, meaning the fiber cloth is parallel to the thickness direction of the foam material. However, according to actual production needs, the fiber cloth is arranged in... Figure 1 In the state shown, it is also possible to rotate the positive and negative sides within 90 degrees so that they are arranged in the direction of the material thickness. It can be understood that the rotation can be a whole rotation or a partial rotation combined with a parallel thickness arrangement. These will not be elaborated on here.

[0029] S3: Spray material preparation. Based on the required density, length, height, and width for material molding, set the foaming machine parameters and the width and spraying time for the foam material to be sprayed. The material density can be set to 30-500 kg / m³. 3 Any value within the range, the material height can be any value within the range of 200-600mm.

[0030] S4: Foaming and molding. The conveyor belt in step S1 drives the continuous laying of the base paper. The fiber cloth in step S2 is unwound at the same speed as the conveyor belt. When the end of the fiber cloth in step S2 moves to the spraying area in step S3, the foaming machine supplies foam material to spray out and achieve foaming and molding, so as to fix the fiber cloth to overlap in the width direction and / or intersect in the thickness direction of the material.

[0031] Furthermore, the foaming process in step S4 above can be either continuous or intermittent. The difference between continuous and intermittent molding is that intermittent molding requires setting a shorter spraying time and cutting the fiber cloth to a fixed length according to the spraying time. In addition, the foaming process in intermittent molding can also include the use of a robotic arm to hold and pull the fiber cloth, while continuous molding only requires the fiber cloth and the conveyor belt to be fixed by a fixture for the first time and then pulled by the conveyor belt. These details will not be elaborated here.

[0032] Please see Figure 2-4 This embodiment also provides a production apparatus for fiber-reinforced polyurethane foam material, including a conveyor belt 10 and a fiber roll 15. Fiber cloth 8 is wound around the outer side of the fiber roll 15, and a base paper 9 is covered on the outer side of the conveyor belt 10. A spraying seat 6 is provided above the conveyor belt 10, and a spraying plate 7 is rotatably connected to the bottom of the spraying seat 6. The bottom of the spraying plate 7 is provided with nozzles 5 arranged at equal intervals facing the conveyor belt 10. When the setting angle of the spraying plate 7 is adjusted, it is used to adjust the spraying width of the spraying plate 7.

[0033] It also includes an unwinding assembly, which includes a base 14 installed at the front end of the conveyor belt 10. The base 14 has a drive belt 11 arranged horizontally in a racetrack shape inside. The base 14 has a support sleeve 12 for mounting the drive belt 11 inside. The base 14 has two rows of equally spaced unwinding seats 2. The two rows of unwinding seats 2 are respectively located on the same side of the two parallel sides of the drive belt 11, so that the two rows of unwinding seats 2 can rotate in the same direction and at the same speed. The spacing between two adjacent fiber cloths 8 can be adjusted by fixing the fiber roll 15 on the unwinding seats 2 at different positions. The inner and outer sides of the drive belt 11 are provided with gear teeth, and the bottom of the unwinding seats 2 is provided with driven wheels 13 that mesh with the gear teeth. A drive motor 3 is installed on one side inside the base 14, and the output end of the drive motor 3 is provided with a drive gear that meshes with the gear teeth.

[0034] A connecting post 16 is provided at the axial center of the fiber roll 15. The bottom end of the connecting post 16 is detachably installed on the top of the unwinding seat 2. An adjusting arm 1 is vertically installed on the top of the connecting post 16 via a bearing. Since the diameter of the fiber roll 15 will continuously decrease as it is unwound, and the spacing will change accordingly, the use of the adjusting arm can not only limit the fixed spacing of the fabric exit position, but also be used for high-precision adjustment of the spacing between two adjacent fiber fabrics 8. The adjusting arm 1 is arranged along the diameter direction of the fiber roll 15, and a pair of guide rollers 4 are movably installed at the front end of the adjusting arm 1. The pair of guide rollers 4 can be rotatably connected to the front end of the adjusting arm 1 and fixed with bolts, and are used to adjust the arrangement angle of the fiber fabrics 8 as needed.

[0035] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

Claims

1. A production process for fiber-reinforced polyurethane foam material, characterized in that, Includes the following steps: S1: Laying the base paper, placing the base paper onto the conveyor belt; S2: Fiber cloth preparation: Arrange the fiber cloth required for production at intervals, and adjust the unwinding angle of the fiber cloth to ensure that the width direction of the fiber cloth coincides with and / or intersects with the thickness direction of the material; the fiber cloth includes glass fiber, carbon fiber, polyamide fiber, polyphenylene sulfide fiber, poly(p-phenylene benzobisoxazole) fiber, continuous basalt fiber, and ultra-high molecular weight polyethylene fiber. S3: Spray material preparation. Based on the required density, length, height, and width for material molding, set the foaming machine parameters, the width of the foam material to be sprayed, and the spraying time. The material density should be 30-500 kg / m³. 3 The material height is 200-600mm; S4: Foaming and molding. The conveyor belt in step S1 drives the continuous laying of the base paper. The fiber cloth in step S2 is unwound at the same speed as the conveyor belt. When the end of the fiber cloth moves to the spraying area, the foaming machine supplies foam material to spray out and achieve foaming and molding, so as to fix the arrangement direction of the fiber cloth. The choice between continuous or intermittent molding is adapted to the unwinding and spraying rhythm of the fiber cloth.

2. A production apparatus for the production process of the fiber-reinforced polyurethane foam material according to claim 1, comprising a conveyor belt (10) and a fiber roll (15), wherein a fiber cloth (8) is wound around the outer side of the fiber roll (15), characterized in that, The outer side of the conveyor belt (10) is covered with a base paper (9), and a spraying seat (6) is provided above the conveyor belt (10). A spraying plate (7) is rotatably connected to the bottom of the spraying seat (6), and the bottom of the spraying plate (7) is provided with nozzles (5) arranged at equal intervals facing the conveyor belt (10). When the setting angle of the spraying plate (7) is adjusted, it is used to adjust the spraying width of the spraying plate (7). It also includes an unwinding assembly, which includes a base (14) installed at the front end of the conveyor belt (10). The base (14) has a drive belt (11) arranged horizontally in a racetrack shape inside. The base (14) has a support sleeve (12) for installing the drive belt (11) inside. The base (14) has two rows of unwinding seats (2) arranged at equal intervals. The two rows of unwinding seats (2) are respectively located on the same side of the two parallel sides of the drive belt (11). The inner and outer sides of the drive belt (11) are provided with gear teeth, and the bottom of the unwinding seats (2) is provided with driven wheels (13) that mesh with the gear teeth. A drive motor (3) is installed on one side inside the base (14), and the output end of the drive motor (3) is provided with a drive gear that meshes with the gear teeth. A connecting column (16) is provided at the axial position of the fiber roll (15). The bottom end of the connecting column (16) is detachably installed on the top of the unwinding seat (2). An adjusting arm (1) is vertically installed on the top of the connecting column (16) through a bearing. The adjusting arm (1) is arranged along the diameter direction of the fiber roll (15), and a pair of guide rollers (4) are movably installed at the front end of the adjusting arm (1).

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