A foaming forming device for PMI foam structure with adjustable curvature

Abstract

The application discloses a foaming forming equipment with adjustable curvature of PMI foam structure, which is characterized in that two upper roller groups capable of freely rotating are arranged on an upper support frame, each of the upper roller groups clamps one of the two side edges of an upper panel and can adjust the connecting position with the upper panel, two lower roller groups are arranged on a lower support frame, each of the lower roller groups clamps one of the two side edges of a lower panel and can adjust the connecting position with the lower panel, a plurality of upper adjusting members on the upper support frame are connected with the upper panel and can pull the upper panel by changing the connecting position with the upper support frame so as to adjust the curvature of the upper panel, and a plurality of lower adjusting members are connected with the lower support frame, the plurality of lower adjusting members are connected with the lower panel and can pull the lower panel so as to adjust the curvature of the lower panel. The application can adjust the curvature of a foaming forming blank according to the thickness requirement of the bad material, greatly reduces the allowance of post-processing cutting, improves the effective utilization rate of the foaming material, and reduces the time consumption and cost of processing.

Description

Technical Field

[0001] The invention relates to the technical field of PMI foam foaming, and in particular to a foaming molding device with adjustable curvature of a PMI foam structural part. Background Art

[0002] PMI foam, a new polymer structural foam material, boasts low density, high-temperature resistance, excellent wave transmission, and high specific strength. It exhibits promising application prospects in aerospace, medical, military, electronic communications, radar, and other fields. The military industry, in particular, is increasingly favoring the use of PMI foam in the production and manufacture of adapter-type products. Intensifying competition within the industry, coupled with the increasing need for growth and cost reduction and efficiency gains, has led to higher requirements for the material cost, processing costs, and production efficiency of PMI foam-related products.

[0003] PMI foam is expensive, and the shapes of PMI foam workpieces vary across industries. However, traditional flat-sheet PMI foam panels face the following production challenges: The PMI foam blanks cannot be molded to the desired shape; they typically end up in a flat sheet, which is then stacked to form a blank before being processed using processing equipment. Consequently, the effective utilization of the foam material is low, with only approximately 50% of the flat sheet foam used to form the curved adapter body. Furthermore, the large machining margins result in long tool paths, long processing times, high costs, and low efficiency. Furthermore, due to the thickness limitations of the flat sheet foam, the sheets typically need to be bonded and stacked to achieve the desired thickness, impacting the overall integrity of the product. The adhesive used increases the weight and density of the product, and creates the risk of delamination. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the shortcomings of the existing technology and provide a PMI foam structural part foaming molding equipment with adjustable curvature, which can produce blanks foamed from PMI foam raw materials according to the shape, and can adjust the curvature of the foamed blanks by adjusting the equipment. The effective utilization rate of the foaming material is high, the processing efficiency is high, and the cost is low.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0006] A foaming molding device for a PMI foam structural part with adjustable curvature comprises at least one shaping module, each of the shaping modules comprises an upper panel and a lower panel, the lower panel and the upper panel are spaced apart from each other and a conformal foaming space is formed therebetween, the conformal foaming space is used to accommodate the foaming and expansion of the PMI foam raw material, the conformal foaming space is open on all sides and is used to allow the PMI foam raw material to expand to all sides, the upper support frame is provided with two upper roller groups that can rotate freely, each of the upper roller groups is clamped with one of the two sides of the upper panel and can adjust the connection position with the upper panel, the lower The bottom support of the plate is connected to the lower support frame, and the lower support frame is provided with two lower roller groups, each of the lower roller groups clamps one of the two side edges of the lower panel and can adjust the connection position with the lower panel, and the upper support frame is connected to a plurality of upper adjusting parts, and the plurality of upper adjusting parts are connected to the upper panel, and can pull the upper panel by changing the connection position with the upper support frame, thereby adjusting the curvature of the upper panel, and the lower support frame is connected to a plurality of lower adjusting parts, and the plurality of lower adjusting parts are connected to the lower panel, and can pull the lower panel by adjusting the connection position with the lower support frame, thereby adjusting the curvature of the lower panel.

[0007] As a further improvement of the above technical solution:

[0008] Each of the upper adjusting parts and each of the lower adjusting parts is a screw rod, the bottom end of each of the upper adjusting parts is connected to the upper panel, the upper section of each of the upper adjusting parts passes through the adjusting hole on the upper support frame and can be fastened by a nut, the top end of each of the lower adjusting parts is connected to the upper panel, the lower section of each of the lower adjusting parts passes through the adjusting hole on the lower support frame and can be fastened by a nut.

[0009] The upper panel and the lower panel are both rectangular, the multiple upper adjustment members are arranged along a center line direction of the upper panel, and the upper panel forms a cylinder, and the multiple lower adjustment members are arranged along the same center line direction of the upper panel, and the lower panel forms a cylinder.

[0010] The upper support frame is provided with two upper roller groups that can rotate freely, each of the upper roller groups is clamped on one of the two side edges of the upper panel and can rotate with the deformation of the upper panel, and the lower support frame is provided with two lower roller groups, each of the lower roller groups is clamped on one of the two side edges of the lower panel and can rotate with the deformation of the lower panel.

[0011] Each of the upper roller group and the lower roller group includes two freely rotating roller bodies, a support and a bearing seat. The two roller bodies are arranged at intervals and have both ends movably connected to the support. The support is provided with a retaining ring connected to the end of each roller body and preventing each roller body from falling out of the support. The support is connected to the bearing seat roller support, and the bearing seat is fixedly connected to the upper support frame and the lower support frame.

[0012] The top surface of the lower panel and the bottom surface of the upper panel are any one of a flat surface, an inclined surface, an arc surface and a curved surface.

[0013] The lower panel and the upper panel are both provided with a plurality of through ventilation slots, and each of the ventilation slots is any one of a circular hole, a rectangular hole, a diamond hole, a polygonal hole, a long slot and a special-shaped hole.

[0014] The lower panel and the upper panel are both woven steel mesh or grating plates, and the grating plates are provided with a plurality of parallel and spaced bars, each of which is any one of a round rod, a round tube, a rectangular tube, a polygonal bar, an L-shaped bar and a special-shaped bar. The upper support frame and the lower support frame are both connected by any one of a rectangular tube, an L-shaped bar, a round tube, a channel steel and a U-shaped steel.

[0015] The lower support frame is provided with casters which are supported and connected to the ground.

[0016] The upper support frame is placed in the lower support frame and can move up and down with the upper panel. A plurality of limit blocks are provided at the four corners of the lower support frame. Each limit block is located above the upper support frame and can abut against the upper support frame to limit the moving position of the upper panel, thereby limiting the thickness of the PMI foam raw material foaming molding.

[0017] Compared with the prior art, the advantages of the present invention are:

[0018] The present invention can produce a blank formed by foaming PMI raw materials by forming a conformable foaming space by setting the upper panel and the lower panel at intervals; through the different shapes of the bottom surface of the upper panel and the top surface of the lower panel, blanks with different shapes and specifications can be produced, such as a curved plate, the curvature of which can be set according to product requirements; thereby greatly reducing the allowance for later processing and cutting, improving the effective utilization rate of the foaming material, reducing the time and cost of processing, and improving processing efficiency; through the upper panel that can move up and down, the upper panel is moved on the PMI foam raw material When not foamed, it is in a static state placed on the PMI foam raw material. During the foaming process of the PMI foam raw material, its foam expands and pushes the upper panel upward; according to the curvature requirements of the upper and lower surfaces of the blank, the curvature of the upper panel can be changed through multiple upper adjusting parts, and the curvature of the lower panel can be changed through multiple lower adjusting parts, so that the foamed blank has the upper and lower surfaces with the required curvature; the use of this foaming molding equipment can greatly reduce the cost of processing materials for adapter-type products, improve the integrity and production efficiency of the adapter, and has a wide range of applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic diagram of the structure of a foam molding device with adjustable curvature for PMI foam structural parts.

[0020] Figure 2This is a side view structural diagram of a foaming molding device with adjustable curvature for PMI foam structural parts.

[0021] Figure 3 This is a front view structural schematic diagram of a foam molding device with adjustable curvature of a PMI foam structural part.

[0022] Figure 4 Schematic diagram of the assembly structure of the lower panel and lower support frame.

[0023] Figure 5 Schematic diagram of the assembly structure of the upper panel and upper support frame.

[0024] Figure 6 It is a structural diagram of the upper roller group.

[0025] Legend:

[0026] 1. Forming module; 2. Upper panel; 21. Upper support frame; 211. Upper adjustment member; 212. Upper roller assembly; 2121. Roller body; 2122. Support; 2123. Bearing seat; 2124. Snap ring; 3. Lower panel; 31. Lower support frame; 311. Lower adjustment member; 312. Lower roller assembly; 4. Conformal foaming space; 5. Casters; 6. Limit block. DETAILED DESCRIPTION

[0027] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0028] like Figures 1-6As shown, the foaming molding equipment of the PMI foam structural part with adjustable curvature of the present embodiment includes at least one shaping module 1, each shaping module 1 includes an upper panel 2 and a lower panel 3, the lower panel 3 and the upper panel 2 are spaced apart from each other and form a conformal foaming space 4 therebetween, the conformal foaming space 4 is used to accommodate the foaming expansion of the PMI foam raw material, the conformal foaming space 4 is open all around and is used to allow the PMI foam raw material to expand all around, the upper support frame 21 is provided with two freely rotatable upper roller groups 212, each upper roller group 212 is clamped with one of the two side edges of the upper panel 2, and can adjust the connection position with the upper panel 2, the bottom support connection of the lower panel 3 It is connected to a lower support frame 31, and two lower roller groups 312 are provided on the lower support frame 31. Each lower roller group 312 clamps one of the two side edges of the lower panel 3 and can adjust the connection position with the lower panel 3. The upper support frame 21 is connected to a plurality of upper adjustment members 211, and the plurality of upper adjustment members 211 are connected to the upper panel 2, and can pull the upper panel 2 by changing the connection position with the upper support frame 21, thereby adjusting the curvature of the upper panel 2. The lower support frame 31 is connected to a plurality of lower adjustment members 311, and the plurality of lower adjustment members 311 are connected to the lower panel 3, and can pull the lower panel 3 by adjusting the connection position with the lower support frame 31, thereby adjusting the curvature of the lower panel 3. The conformable foaming space 4 formed by the interval arrangement of the upper panel 2 and the lower panel 3 can be used to form a blank formed by foaming the PMI foam raw material; through the different shapes of the bottom surface of the upper panel 2 and the top surface of the lower panel 3, blanks of different shapes and specifications can be produced, such as an arc-shaped plate, the curvature of which can be set according to product requirements; thereby greatly reducing the allowance for post-processing cutting, improving the effective utilization rate of the foaming material, reducing the time and cost of processing, and improving processing efficiency; through the upper panel 2 that can move up and down, the upper panel 2 is moved when the PMI foam raw material is not foamed When the foaming process is complete, the upper panel 2 is placed on the PMI foam raw material. During the foaming process of the PMI foam raw material, the foam expands and pushes the upper panel 2 upward. According to the curvature requirements of the upper and lower surfaces of the blank, the curvature of the upper panel 2 can be changed through multiple upper adjustment parts 211, and the curvature of the lower panel 3 can be changed through multiple lower adjustment parts 311, so that the foamed blank has the required curvature of the upper and lower surfaces. The use of this foaming molding equipment can significantly reduce the cost of processing materials for adapter-type products, improve the integrity and production efficiency of the adapter, and has a wide range of applications. The foaming molding equipment has a simple design and is easy to operate. Operators only need simple technical training to operate it, and no special training is required.

[0029] In this embodiment, each upper adjustment member 211 and each lower adjustment member 311 is a screw. The bottom end of each upper adjustment member 211 is connected to the upper panel 2. The upper section of each upper adjustment member 211 passes through the adjustment hole on the upper support frame 21 and can be fastened by a nut. The top end of each lower adjustment member 311 is connected to the upper panel 2. The lower section of each lower adjustment member 311 passes through the adjustment hole on the lower support frame 31 and can be fastened by a nut. Screws are easy to purchase, inexpensive, easy to process and manufacture, and convenient to adjust and fasten. Twisting the nuts of each screw can move the middle of the upper panel 2 and the lower panel 3 up and down, thereby changing the curvature size of the arc surface.

[0030] In this embodiment, both the upper panel 2 and the lower panel 3 are rectangular. A plurality of upper adjustment members 211 are arranged along a centerline of the upper panel 2, forming the upper panel 2 into a cylindrical surface. A plurality of lower adjustment members 311 are arranged along the same centerline of the upper panel 2, forming the lower panel 3 into a cylindrical surface. The upper panel 2 and the lower panel 3 can be adjusted to be concentric or non-concentric. The bottom surface of the upper panel 2 can be foam-molded to form the inner arc of the blank, while the top surface of the lower panel 3 can be foam-molded to form the outer arc of the blank.

[0031] In this embodiment, the upper support frame 21 is provided with two freely rotatable upper roller assemblies 212. Each upper roller assembly 212 is clamped to one of the two side edges of the upper panel 2 and can rotate with the deformation of the upper panel 2. The lower support frame 31 is provided with two lower roller assemblies 312. Each lower roller assembly 312 is clamped to one of the two side edges of the lower panel 3 and can rotate with the deformation of the lower panel 3. The two sides of the upper panel 2 and the lower panel 3 are inserted into the gaps of the roller assemblies 212. As the upper panel 2 and the lower panel 3 deform, the upper roller assemblies 212 and the lower roller assemblies 312 are driven to rotate, thereby preventing the two sides of the upper panel 2 and the lower panel 3 from twisting and deformation, thereby maintaining the overall smoothness of the upper panel 2 and the lower panel 3.

[0032] In this embodiment, each upper roller assembly 212 and lower roller assembly 312 includes two freely rotating rollers 2121, a support 2122, and a bearing seat 2123. The two freely rotating rollers 2121 are spaced apart and movably connected to the support 2122 at both ends. The support 2122 is provided with a retaining ring 2124 that connects to the end of each roller 2121 and prevents each roller 2121 from falling out of the support 2122. The support 2122 is connected to the roller support of the bearing seat 2123, and the bearing seat 2123 is fixedly connected to the upper support frame 21 and the lower support frame 31. Through the two freely rotating rollers 2121, the side edges of the upper panel 2 and the lower panel 3 are inserted into the gap between the two rotating rollers 2121, and the two rollers 2121 are connected to the side rolling support.

[0033] In this embodiment, the top surface of the lower panel 3 and the bottom surface of the upper panel 2 are any one of a flat surface, an inclined surface, an arc surface, and a curved surface. By adopting different shapes of the bottom surface of the upper panel 2 and the top surface of the lower panel 3, blanks of different shapes and specifications can be produced, thereby greatly reducing the residual amount of cutting in the later processing, improving the effective utilization rate of the foam material, reducing the time and cost of processing, and improving processing efficiency.

[0034] In this embodiment, both the lower panel 3 and the upper panel 2 are provided with a plurality of through-hole ventilation slots. Each of the ventilation slots can be any of a circular hole, a rectangular hole, a diamond hole, a polygonal hole, an elongated hole, or a special-shaped hole. These multiple ventilation slots provide ventilation during the foaming process, ensuring a uniform temperature distribution across the foam surface, thereby ensuring the quality of the foam formed. This hole-shaped ventilation design ensures uniform temperature distribution across the foaming surface, thereby improving foaming quality.

[0035] In this embodiment, the lower panel 3 and the upper panel 2 are both woven steel mesh or grating plates. The grating plates are provided with a plurality of parallel and spaced bars. Each bar is any one of a round rod, a round tube, a rectangular tube, a polygonal bar, an L-shaped bar, and a special-shaped bar. The upper support frame 21 and the lower support frame 31 are both formed by connecting any one of a rectangular tube, an L-shaped bar, a round tube, a channel steel, and a U-shaped steel. Woven steel mesh or grating plates have excellent ventilation effects and are easy to manufacture or purchase. The upper support frame 21 and the lower support frame 31 can be assembled by welding after simple machining of conventional profiles and plates, and their production cost is low. The materials thereof can be metal, plastic, composite materials, etc.

[0036] In this embodiment, casters 5 connected to the ground are provided on the lower support frame 31. The casters 5 can facilitate the transportation of the device.

[0037] In this embodiment, the upper support frame 21 is placed inside the lower support frame 31 and can move up and down together with the upper panel 2. A plurality of limit blocks 6 are provided at the four corners of the lower support frame 31. Each limit block 6 is located above the upper support frame 21 and can abut against the upper support frame 21 to limit the movement of the upper panel 2, thereby limiting the thickness of the PMI foam raw material foamed and molded. According to the thickness requirements of the blank, the plurality of limit blocks 6 that limit the movement of the upper panel 2 can be adjusted to adjust the distance between the upper panel 2 and the lower panel when it is at its highest position. The foaming and expansion of the PMI foam raw material pushes the upper panel 2, causing the upper support frame 21 to abut against the limit blocks 6, thereby preventing the upper panel 2 from continuing to move upward, thereby playing a positioning role. During this positioning, the height of the bottom surface of the upper panel 2 relative to the top surface of the lower panel 3 determines the thickness of the foamed and molded blank.

[0038] Foam molding operation steps:

[0039] 1. Based on the required thickness of the adapter product, select the appropriate upper and lower panels (2) and (3). Use pre-coated PMI foaming material. Heat and pre-bend the pre-coated panels before foaming. There are no specific requirements for the curvature; a rough bend is sufficient. This ensures that the pre-coated panels have a certain degree of conformability, facilitating better conformal foaming.

[0040] 2. Place the upper support frame 21 on the lower support frame 31.

[0041] 3. Calculate and adjust the installation position of each limit block 6 according to the thickness of the foam blank of the adapter product; adjust each upper adjustment member 211 and each lower adjustment member 311 according to the curvature requirements of the upper and lower surfaces of the blank to adjust the upper panel 2 and the lower panel 3 to the appropriate curvature.

[0042] 4. Place the pre-polymer plate in the conformal foaming space 4 between the upper panel 2 and the lower panel 3, and adjust the position so that the pre-polymer plate is centered; the upper panel 2 is pressed on the top of the pre-polymer plate, and the weight of the upper panel 2 and the upper support frame 21 provides a certain pressure on the pre-polymer plate to reduce its deviation.

[0043] 5. Place the entire set of foaming molding equipment in the oven, adjust the various parameters of the oven, and then start the oven to allow the pre-polymer plate to begin foaming. During the foaming process, the pre-polymer plate continues to expand in all directions, and its bottom surface is completely in line with the top surface of the lower panel 3. Its top surface pushes the upper panel 2, causing the upper panel 2 to move upward. When the upper panel 2 moves to abut against the limit block 6, it stops moving, and the foam continues to expand until the upper surface is completely in line with the bottom surface of the upper panel 2; finally, until the foaming is completed. The above is only a preferred embodiment of the present invention, and the scope of protection of the present invention is not limited to the above embodiments. For those skilled in the art, improvements and changes obtained without departing from the technical concept of the present invention should also be regarded as the scope of protection of the present invention.

Claims

1. A PMI foam structural part with adjustable curvature foaming molding equipment, characterized in that: The invention comprises at least one shaping module (1), each of the shaping modules (1) comprises an upper panel (2) and a lower panel (3), the lower panel (3) and the upper panel (2) are spaced apart from each other and a conformable foaming space (4) is formed therebetween, the conformable foaming space (4) is used to accommodate the foaming and expansion of a PMI foaming raw material, the conformable foaming space (4) is open on all sides and is used to allow the PMI foaming raw material to expand in all directions, an upper support frame (21) is provided with two freely rotatable upper roller groups (212), each of the upper roller groups (212) is clamped on one of the two sides of the upper panel (2) and can adjust the connection position with the upper panel (2), the bottom support of the lower panel (3) is connected to a lower support frame (31), the lower support frame (3 1) Two lower roller groups (312) are provided on the upper portion, each of the lower roller groups (312) is clamped on one of the two side edges of the lower panel (3) and can adjust the connection position with the lower panel (3); the upper support frame (21) is connected to a plurality of upper adjustment members (211); the plurality of upper adjustment members (211) are connected to the upper panel (2) and can pull the upper panel (2) by changing the connection position with the upper support frame (21), thereby adjusting the curvature of the upper panel (2); the lower support frame (31) is connected to a plurality of lower adjustment members (311); the plurality of lower adjustment members (311) are connected to the lower panel (3) and can pull the lower panel (3) by adjusting the connection position with the lower support frame (31), thereby adjusting the curvature of the lower panel (3); Each of the upper adjusting members (211) and each of the lower adjusting members (311) is a screw rod, the bottom end of each of the upper adjusting members (211) is connected to the upper panel (2), the upper section of each of the upper adjusting members (211) passes through the adjusting hole on the upper support frame (21) and can be fastened by a nut, the top end of each of the lower adjusting members (311) is connected to the lower panel (3), the lower section of each of the lower adjusting members (311) passes through the adjusting hole on the lower support frame (31) and can be fastened by a nut; Each of the upper roller group (212) and the lower roller group (312) comprises two freely rotating roller bodies (2121), a support (2122) and a bearing seat (2123). The two roller bodies (2121) are spaced apart and movably connected to the support (2122) at both ends. A retaining ring (2124) is provided on the support (2122) and is connected to the end of each roller body (2121) and prevents each roller body (2121) from falling off from the support (2122). The support (2122) and the bearing seat (2123) are connected via roller supports, and the bearing seat (2123) is fixedly connected to the upper support frame (21) or the lower support frame (31).

2. The PMI foam structural part radian adjustable foaming molding equipment according to claim 1, characterized in that: The upper panel (2) and the lower panel (3) are both rectangular, the plurality of upper adjustment members (211) are arranged along a center line direction of the upper panel (2), and the upper panel (2) forms a cylindrical surface, and the plurality of lower adjustment members (311) are arranged along the same center line direction of the upper panel (2), and the lower panel (3) forms a cylindrical surface.

3. The PMI foam structural part radian adjustable foaming molding equipment according to claim 1, characterized in that: The top surface of the lower panel (3) and the bottom surface of the upper panel (2) are either a flat surface or a curved surface.

4. The PMI foam structural part radian adjustable foaming molding equipment according to claim 1, characterized in that: The lower panel (3) and the upper panel (2) are both provided with a plurality of through ventilation slots, each of which is any one of a circular hole, a rectangular hole, a diamond hole, a polygonal hole, a long slotted hole and a special-shaped hole.

5. The PMI foam structural part radian adjustable foaming molding equipment according to claim 1, characterized in that: The lower panel (3) and the upper panel (2) are both woven steel wire mesh or grid plates, and the grid plates are provided with a plurality of parallel and spaced bars, each of which is any one of a round bar, a round tube, a rectangular tube, a polygonal bar, an L-shaped bar and a special-shaped bar.

6. The PMI foam structural part radian adjustable foaming molding equipment according to claim 1, characterized in that: The upper support frame (21) and the lower support frame (31) are both formed by connecting any one of rectangular tubes, L-shaped bars, round tubes, channel steels and U-shaped steels.

7. The PMI foam structural part radian adjustable foaming molding equipment according to claim 1, characterized in that: The lower support frame (31) is provided with casters (5) that are supported and connected to the ground.

8. The foaming molding equipment for PMI foam structural parts with adjustable curvature according to any one of claims 1 to 7, characterized in that: The upper support frame (21) is placed in the lower support frame (31) and can move up and down together with the upper panel (2). A plurality of limit blocks (6) are provided at the four corners of the lower support frame (31). Each limit block (6) is located above the upper support frame (21) and can abut against the upper support frame (21) to limit the moving position of the upper panel (2), thereby limiting the thickness of the PMI foaming raw material foamed and molded.

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