A sponge foaming machine

Abstract

The present invention discloses a sponge foaming machine, which includes a foaming box. A camera is installed above the foaming box. A temperature sensor 1 is installed on the inner wall of the foaming box. One side of the foaming box is connected to an integrated high-pressure pump through a pipeline. Adding bottles are fixed on both sides of the foaming box. A temperature sensor 2 is installed inside the foaming box. An installation box is riveted on one side of the foaming box. A pushing component is installed inside the installation box. A positioning component is arranged above the foaming box. A stirring component is fixedly connected inside the positioning component. This device solves the problems of unstable current sponge foaming and poor quality of the obtained sponge.

Description

Technical Field

[0001] The present invention belongs to the technical field of sponge production, and particularly relates to a sponge foaming machine. Background Art

[0002] A sponge foaming machine is a machine used to prepare porous sponge materials. Through a specific chemical process, it mixes foaming resin, foaming aids, and binder resin, and then undergoes foaming processing to produce porous materials. The sponges foamed in the industrial field can be used as sound-absorbing and sound-insulating materials for automobiles, airplanes, buildings, etc., to provide a more comfortable environment; in the production of household items, it is often used for cleaning supplies such as dishwashing sponges and bath balls to improve cleaning efficiency; in the medical field, it is used as wound dressings, surgical suture materials, etc. Its water absorption and permeability contribute to the treatment and healing of wounds. Thus, it can be seen that the sponge foaming machine plays a crucial role in the production process of sponge products.

[0003] Currently, most sponge foaming machines are box-type foaming machines, which are suitable for large-scale sponge production and can achieve efficient and uniform foaming. In the process of sponge processing and production, there are certain requirements for the height of sponge foaming in order to effectively control the quality of sponge foaming. However, sponge foaming often has instability, so adjustments need to be made according to the actual situation. This phenomenon has become an urgent problem for those in this field to solve. Summary of the Invention

[0004] The purpose of the present invention is to provide a sponge foaming machine for the existing device to solve the problems raised in the above background art.

[0005] To solve the above technical problems, the present invention provides the following technical solution: A sponge foaming machine includes a foaming box. A camera is installed above the foaming box, a temperature sensor I is installed on the inner wall of the foaming box, an integrated high-pressure pump is connected to one side of the foaming box through a pipeline, adding bottles are fixed on both sides of the foaming box, and a temperature sensor II is installed inside the foaming box;

[0006] Connection rings are welded on both sides of the foaming box, and adding bottles are installed inside the connection rings on both sides of the foaming box. A first adding pipe is connected to the pipeline below one of the adding bottles, and a second adding pipe is connected to the pipeline below the other adding bottle. Both the first adding pipe and the second adding pipe are connected to the inside of the foaming box through valves;

[0007] An installation box is riveted on one side of the foaming box. A pushing component is installed inside the installation box. A positioning component is arranged above the foaming box, and a stirring component is fixedly connected inside the positioning component.

[0008] The present invention further illustrates that connecting rings are welded on both sides of the foaming box. The pushing component includes a fixing piece, which is riveted above the inner wall of the installation box. A first cylinder is riveted below the fixing piece. A connecting piece is arranged on one side of the first cylinder. A push rod is riveted on one side of the connecting piece. A push plate is welded on one side of the push rod. A first pressure sensor is installed on the side of the push plate that contacts the sponge.

[0009] The present invention further illustrates that the feeding device includes a first feeding barrel, a first feeding pipe is installed above the first feeding barrel. A second feeding barrel is arranged on one side of the first feeding barrel. A second feeding pipe is installed above the second feeding barrel. A third feeding barrel is arranged on the other side of the first feeding barrel. A third feeding pipe is installed above the third feeding barrel.

[0010] The present invention further illustrates that the positioning component includes a positioning rod, which is riveted above the foaming box. A positioning sleeve is welded on one side of the positioning rod. A stirring component is arranged inside the positioning sleeve.

[0011] The present invention further illustrates that the stirring component includes a stirring barrel and a support rod. The stirring barrel is installed inside the positioning sleeve. A discharge port is arranged at the bottom of the stirring barrel. An electric control valve is installed on the discharge port. The support rod is welded on the positioning sleeve. A connecting rod is welded on the top of the support rod. An electric push rod is installed at one end of the connecting rod. A driving piece is fixedly connected below the electric push rod.

[0012] The present invention further illustrates that the driving piece includes a first positioning ring. A driving rod passes through the center of the first positioning ring. One end of the driving rod is connected to a motor. A driving gear is sleeved on the other end of the driving rod. A second positioning ring is fixed to the connecting rod above the first positioning ring. A first stirring rod passes through the center of the second positioning ring. A first driven gear is sleeved on one end of the first stirring rod. A third positioning ring is fixed to the connecting rod below the first positioning ring. A second stirring rod passes through the center of the third positioning ring. A second driven gear is sleeved on one end of the second stirring rod;

[0013] The driving gear is respectively meshed and connected with the first driven gear and the second driven gear. The first stirring rod passes through the center of the second stirring rod. First stirring blades are welded on the part of the first stirring rod that extends out of the second stirring rod. A telescopic stirring blade is connected to a micro electric push rod installed inside the first stirring blade. A telescopic rod is installed inside the first stirring rod. A second pressure sensor is installed inside the telescopic rod. A telescopic spring is welded on the top of the telescopic rod;

[0014] A second stirring blade is welded to the outside of the second stirring rod. Cylinder-driven extension parts are arranged inside both the first stirring blade and the second stirring blade. The extension parts are movably connected to the scraping plates at the outer ends of the first stirring blade and the second stirring blade.

[0015] The present invention further explains that the foaming process of the sponge foaming machine includes:

[0016] Raw materials are respectively input into the stirring assembly through the first feed pipe, the second feed pipe, and the third feed pipe from the first feed barrel, the second feed barrel, and the third feed barrel for sufficient stirring. After setting the required stirring time to enable the raw materials for sponge foaming to be fully fused, the discharge port is opened after receiving the signal that the stirring time ends. The raw materials are put into the foaming box and heated by the heating coil at the bottom of the foaming box. At the same time, a high-pressure pump is integrated for pressurization to promote the chemical reaction required for sponge foaming and ensure the distribution of the raw materials, so that the raw materials foam and solidify. The foaming situation inside the foaming box is reflected by a camera. After observing that the foaming situation is qualified, the operator opens the box door on one side of the foaming box and starts the pushing-out assembly to push the sponge out of the foaming box through the push plate, achieving the effect of rapid demoulding, thereby obtaining the foamed sponge.

[0017] The present invention further explains that the process control of the sponge foaming includes the following steps:

[0018] Set the height of the sponge foaming to a fixed value H. Detect the height h of the sponge foaming through a camera. Define the height specifically by making marks on the inner wall of the foaming box, etc., and at the same time use it as a comparison reference for H and h. The height of the push plate is higher than H;

[0019] When h is equal to H and there are no obvious cracks on the surface of the foamed sponge observed through the camera, it indicates that the foaming height of the sponge is qualified at this time and the sponge quality is qualified. The pushing-out assembly can be continued to be started, and the driving cylinder drives the connecting piece to displace. At the same time, the connecting piece drives the push rod and the push plate to displace to one side, and the foamed sponge in the foaming box is pushed out for demoulding operation, thereby obtaining the processed sponge.

[0020] The present invention further explains that the process control of the sponge foaming further includes the following steps:

[0021] When h is less than H, it indicates that the foaming height of the sponge is insufficient at this time. At the same time, it is observed through the camera that the sponge foaming situation has a tendency to stop. When this situation occurs, the temperature inside the foaming box reflected by the temperature sensor one can be detected. If the temperature is too low, it means that the temperature of the heating coil in the foaming box is insufficient, and the temperature needs to be increased to maintain foaming;

[0022] When it is detected that the reason is not the low temperature, the pressure value reflected by the integrated high-pressure pump is detected. When the pressure is too low, it will also cause the problem of insufficient foaming height of the sponge. If the pressure is too low, the pressure of the integrated high-pressure pump needs to be increased to maintain the foaming of the sponge;

[0023] When it is detected that the above parameters are all within the normal values, it is considered that the foaming agent dosage in the raw material is too small or the quality of the foaming agent is too poor, resulting in insufficient foaming height of the sponge detected by the camera. At this time, the electric valve on the first addition pipe is opened to add an appropriate amount of auxiliary foaming agent into the foaming box. At the same time, the electric push rod makes the first stirring blade extend downward out of the discharge port into the foaming box. After the raw material enters the foaming box, foaming will be quickly completed. In order to prevent the sponge in the two states of foamed and unfoamed from being unable to fully promote the heat transfer and gas release between the materials due to the single stirring direction when stirring the sponge after adding the auxiliary foaming agent, resulting in local overheating and a decrease in the quality of the sponge, and the unfoamed part will affect the overall performance of the product. At this time, it is necessary to control the first stirring blade of the stirring assembly to enter the foamed part for stirring, and the second stirring blade stirs the unfoamed raw material part to avoid damaging the formed sponge structure or affecting the performance of the final product;

[0024] Among them, the height of the foamed sponge is set as L1. When the first stirring rod descends, the telescopic rod contacts the foamed sponge. At this time, the pressure sensor two will reflect the change in pressure magnitude and send a signal to the operating system. When L1 is greater than the total length of the first stirring rod and the telescopic rod, when the pressure change is sensed by the pressure sensor two, the operating system starts to calculate the length that the electric push rod pushes the first stirring blade into the foamed sponge part until the upper end of the first stirring blade is at the critical value between the foamed and unfoamed parts of the sponge, and then continues to stir the foaming box to make the auxiliary foaming agent and the raw material fully blend and foam again. Continue to add the foaming auxiliary agent until the foaming height of the sponge meets the set value H;

[0025] When L1 is less than the total length of the first stirring rod and the telescopic rod, the bottom end of the telescopic rod touches the bottom of the foaming box, causing the telescopic spring to contract under force. At this time, when the pressure change is sensed by the pressure sensor two, a signal is sent to the operating system to control the micro electric push rod to retract the telescopic stirring blade synchronously until the upper end of the first stirring blade is at the critical value between the foamed and unfoamed parts of the sponge, and then continue to stir the foaming box to make the auxiliary foaming agent and the raw material fully blend and foam again and the foaming height of the sponge meets the set value H;

[0026] When L1 is less than the telescopic range of the telescopic rod that the telescopic spring can achieve, it means that the foaming quality of the sponge is too poor and it is not suitable for use, and it should be directly recycled and discarded.

[0027] The further description of the present invention is that the process control of the sponge foaming further includes the following steps:

[0028] When h is greater than H, it indicates that the foaming height of the sponge is too high at this time. At this time, observe the outer surface of the foaming sponge through a camera. If small openings appear on the surface of the sponge, it indicates that the heating temperature of the foaming box is too high, then the camera emits an alarm sound to remind the operator to turn off the heating coil;

[0029] Check the taken-out sponge. If the surface opening is small, an adhesive can be used to treat the sponge surface, which does not affect the subsequent use of the sponge; if the surface opening is large, in order not to waste resources, etc., cut the sponge and perform operations such as reprocessing and splicing;

[0030] When observing the outer surface of the foaming sponge through the camera at this time and detecting large cracks on the surface of the sponge, it indicates that the pressure in the foaming box is too high, then the camera also emits an alarm sound to remind the operator to turn off the integrated high-pressure pump and perform the same operations on the sponge as above;

[0031] When the quality of the foamed sponge is too poor in the above situations, the sponge should be recycled;

[0032] When observing the outer surface of the foaming sponge through the camera at this time and there are no obvious cracks, it indicates that the foaming height has nothing to do with the magnitude of the pressure and temperature, but is caused by an excessive dosage of the foaming agent. At this time, open the electric valve of the second addition pipe containing the inhibitor, so that an appropriate amount of inhibitor is added into the foaming box. At the same time, the electric push rod drives the first stirring blade to extend downward out of the discharge port into the foaming box, so that the first stirring blade and the second stirring blade stir the inside of the foaming box in different directions up and down, so that the inhibitor is fully incorporated into the sponge foaming raw material, continue to stir the inside of the foaming box to make the inhibitor and the raw material fully blend and foam again until the foaming height of the sponge meets the set value H.

[0033] Compared with the prior art, the beneficial effects achieved by the present invention are: In the present invention,

[0034] (1) By providing two addition bottles containing different additives and being able to control the dosing, the foaming degree in the sponge foaming process can be effectively controlled, largely preventing the situation of insufficient or excessive foaming of the sponge, and the ratio optimization of subsequent sponge production can be made according to the real-time situation;

[0035] (2) By providing a pushing-out component to quickly demold the foamed sponge, and at the same time, the foaming quality of the sponge can be reflected according to the demolding situation of the sponge, and subsequent foaming parameter optimization can be made;

[0036] (3) By arranging a stirring assembly to fully stir the sponge foaming raw materials in the stirring barrel in different directions, the interfacial tension between the raw materials and the foaming agent can be effectively broken, promoting their full mixing. This helps to reduce the local concentration difference and improve the uniformity of foaming. The outer scraper can avoid the situation of raw material residue causing waste, and can also perform layered stirring on the raw materials in the foaming box when necessary to prevent the insufficient mixing of additives and the damage of the sponge structure. Description of the Drawings

[0037] The drawings are used to provide a further understanding of the present invention and constitute a part of the specification. They are used together with the embodiments of the present invention to explain the present invention and do not constitute a limitation to the present invention. In the drawings:

[0038] Figure 1 is the overall structural schematic diagram of the present invention;

[0039] Figure 2 is the structural schematic diagram inside the installation box of the present invention;

[0040] Figure 3 is the structural schematic diagram of the pushing component of the present invention;

[0041] Figure 4 is the structural schematic diagram of the feeding device of the present invention;

[0042] Figure 5 is the structural schematic diagram of the stirring assembly of the present invention;

[0043] Figure 6 is the structural schematic diagram after the stirring rod extends out;

[0044] Figure 7 is the structural schematic diagram of the driving part of the present invention;

[0045] Figure 8 is the specific structural schematic diagram of the stirring blade of the present invention;

[0046] Figure 9 is the pipeline diagram before the optimized ratio of the present invention;

[0047] Figure 10 is the pipeline diagram after the optimized ratio of the present invention;

[0048] In the figure: 1, foam box; 2, camera; 3, first temperature sensor; 4, integrated high-pressure pump; 5, additive bottle; 51, first addition pipe; 52, second addition pipe; 6, installation box; 7, pushing-out component; 71, fixing piece; 72, first cylinder; 73, connecting piece; 74, push rod; 75, push plate; 8, feeding device; 81, first feeding barrel; 811, first feeding pipe; 82, second feeding barrel; 821, second feeding pipe; 83, third feeding barrel; 831, third feeding pipe; 9, positioning component; 91, positioning rod; 92, positioning sleeve;

[0049] 10, stirring component; 101, stirring barrel; 1011, discharge port; 102, support rod; 103, connecting rod; 104, electric push rod; 105, driving piece; 1051, first positioning ring; 1052, driving rod; 1053, driving gear; 1054, second positioning ring; 1055, first driven gear; 1056, third positioning ring; 1057, second driven gear; 106, first stirring rod; 1061, telescopic rod; 1062, telescopic spring; 107, first stirring blade; 1071, telescopic stirring blade; 108, second stirring rod; 109, second stirring blade. Detailed implementation mode

[0050] The technical solution of the present invention will be further described in detail below in conjunction with the preferred embodiments and their accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0051] Please refer to Figure 1-8 , the present invention provides a technical solution: a sponge foaming machine, including a foam box 1, a camera 2 is installed above the foam box 1, a first temperature sensor 3 is installed on the inner wall of the foam box 1, and the first temperature sensor 3 is used to monitor the temperature of the foamed sponge in real time. One side of the foam box 1 is connected by a pipeline to an integrated high-pressure pump 4. While the integrated high-pressure pump 4 pressurizes the sponge foaming raw material in the foam box 1, it also monitors the pressure. Additive bottles 5 are fixed on both sides of the foam box 1, and a second temperature sensor is installed inside the foam box 1;

[0052] An installation box 6 is riveted on one side of the foam box 1, a pushing-out component 7 is installed inside the installation box 6, a feeding device 8 is arranged above the installation box 6, a positioning component 9 is arranged above the foam box 1, and a stirring component 10 is fixedly connected inside the positioning component 9.

[0053] On both sides of the foam box 1, connection rings are welded. Inside the connection rings on both sides of the foam box 1, additive bottles 5 are installed. A first addition pipe 51 is connected to the pipeline below one of the additive bottles 5, and a second addition pipe 52 is connected to the pipeline below the other additive bottle 5. Both the first addition pipe 51 and the second addition pipe 52 are connected to the inside of the foam box 1 through valves. The first addition pipe 51 is used to dispense auxiliary foaming agent, and the second addition pipe 52 is used to dispense inhibitor;

[0054] The pushing-out component 7 includes a fixing piece 71, which is riveted above the inner wall of the installation box 6. Below the fixing piece 71, a first cylinder 72 is riveted. On one side of the first cylinder 72, there is a connecting piece 73. On one side of the connecting piece 73, a push rod 74 is riveted. On one side of the push rod 74, a push plate 75 is welded. A first pressure sensor is installed on the side of the push plate 75 that contacts the sponge. After the sponge foaming is completed, open the box door on one side of the foam box 1 and start the pushing-out component 7, so that the first cylinder 72 drives the connecting piece 73 to push out to one side. Thus, the push rod 74 will drive the push plate 75 to push the sponge out of the foam box 1, realizing the demoulding of the sponge;

[0055] The feeding device 8 includes a first feeding bucket 81. Above the first feeding bucket 81, a first feeding pipe 811 is installed. On one side of the first feeding bucket 81, there is a second feeding bucket 82. Above the second feeding bucket 82, a second feeding pipe 821 is installed. On the other side of the first feeding bucket 81, there is a third feeding bucket 83. Above the third feeding bucket 83, a third feeding pipe 831 is installed. The first feeding bucket 81 feeds the sponge foaming raw materials into the stirring component 10. The necessary water for sponge foaming is put into the second feeding bucket 82, and the required additives are put into the third feeding bucket 83. Through the arrangement of the first feeding pipe 811, the second feeding pipe 821, and the third feeding pipe 831, the additives are added slightly later after other main raw materials to ensure the stability and controllability of the foaming process;

[0056] The positioning component 9 includes a positioning rod 91, which is riveted above the foam box 1. On one side of the positioning rod 91, a positioning sleeve 92 is welded. Inside the positioning sleeve 92, a stirring component 10 is installed;

[0057] The stirring component 10 includes a stirring bucket 101 and a support rod 102. The stirring bucket 101 is installed inside the positioning sleeve 92. At the bottom of the stirring bucket 101, there is a discharge port 1011. An electric control valve is installed on the discharge port 1011. The support rod 102 is welded on the positioning sleeve 92. At the top of the support rod 102, a connecting rod 103 is welded. At one end of the connecting rod 103, an electric push rod 104 is installed. Below the electric push rod 104, a driving piece 105 is fixedly connected;

[0058] As Figure 7, the driving member 105 includes a first positioning ring 1051. A driving rod 1052 passes through the center of the first positioning ring 1051. One end of the driving rod 1052 is connected to a motor, and the other end of the driving rod 1052 is sleeved with a driving gear 1053. Above the first positioning ring 1051, a second positioning ring 1054 is fixed to the connecting rod. A first stirring rod 106 passes through the center of the second positioning ring 1054. One end of the first stirring rod 106 is sleeved with a first driven gear 1055. Below the first positioning ring 1051, a third positioning ring 1056 is fixed to the connecting rod. A second stirring rod 108 passes through the center of the third positioning ring 1056. One end of the second stirring rod 108 is sleeved with a second driven gear 1057;

[0059] The driving gear 1053 is respectively meshed and connected with the first driven gear 1055 and the second driven gear 1057. The first stirring rod 106 passes through the center of the second stirring rod 108. A first stirring blade 107 is welded on the part of the first stirring rod 106 extending out of the second stirring rod 108. A micro electric push rod is installed inside the first stirring blade 107 and connected with a telescopic stirring blade 1071. A telescopic rod 1061 is installed inside the first stirring rod 106. A second pressure sensor is installed inside the telescopic rod 1061 for sensing and transmitting pressure signals. A telescopic spring 1062 is welded on the top of the telescopic rod 1061;

[0060] A second stirring blade 109 is welded on the outer side of the second stirring rod 108. Extension parts driven by cylinders are arranged inside both the first stirring blade 107 and the second stirring blade 109. The extension parts are movably connected with the scraping plates at the outer ends of the first stirring blade 107 and the second stirring blade 109. By the driving member 105, the motor drives the driving gear 1053 to rotate. The driving gear 1053 makes the first driven gear 1055 and the second driven gear 1057 rotate in opposite directions, so as to realize the reverse rotation of the first stirring rod 106 and the second stirring rod 108 respectively driving the first stirring blade 107 and the second stirring blade 109, and realize the stirring effect in different directions up and down in the stirring barrel 101. Through the stirring in different directions of the upper and lower parts in the barrel, the interfacial tension between the raw materials and the foaming agent can be broken more effectively, promoting their full mixing. This helps to reduce the local concentration difference, improve the uniformity of foaming, and at the same time helps the bubbles to be evenly distributed in the sponge foaming material.

[0061] During the foaming process, if the foaming height is not enough or too high, an auxiliary foaming agent or inhibitor needs to be added to neutralize the sponge raw materials. The foaming agent or inhibitor is injected into the foaming box 1 from the adding bottle 5. At the same time, the discharge port 1011 is in an open state. The electric push rod 104 controls the first stirring blade 107 to enter the foaming box 1 for stirring, and extends the outer part of the first stirring blade 107 to directly stir and mix the raw materials with the additives.

[0062] Among them, the camera 2, the first temperature sensor 3, the second temperature sensor, the integrated high-pressure pump 4, the heating coil, the electric valve, the first cylinder 72, the first pressure sensor, the electric push rod 104, the micro electric push rod, the second pressure sensor, the cylinder and the electric control valve are all signal-connected to the operating system.

[0063] Embodiment 1: Generally, raw materials are respectively input into the mixing assembly 10 through the first feed pipe 811, the second feed pipe 821, and the third feed pipe 831 from the first feed bucket 81, the second feed bucket 82, and the third feed bucket 83 for sufficient mixing. Set the required mixing time, and mix the raw materials in the mixing bucket 101 in different up and down directions, so as to effectively break the interfacial tension between the raw materials and the foaming agent, promote their full mixing, help reduce the local concentration difference, improve the uniformity of foaming, and further enable the raw materials for sponge foaming to be fully fused. After the electric control valve at the discharge port 1011 receives the signal indicating the end of the mixing time, it opens, and the raw materials are put into the foaming box 1 and heated by the heating coil at the bottom of the foaming box 1. At the same time, the integrated high-pressure pump 4 pressurizes to promote the chemical reaction required for sponge foaming and ensure the distribution of the raw materials, so that the raw materials foam and solidify. The foaming situation inside the foaming box 1 is reflected by the camera 2. After observing that the foaming situation is qualified, after the foaming is completed, the operator can open the door on one side of the foaming box 1 and start the pushing assembly 7 to push the sponge out of the foaming box 1 through the push plate 75, achieving the effect of rapid demoulding, and thus obtaining the foamed sponge.

[0064] Embodiment 2: During the process of sponge foaming, the foaming height of the sponge is affected by the temperature, pressure, and foaming raw material ratio set in the foaming box 1. Since the foaming box 1 adopts the open structure of a box-type foaming machine, the sponge will come into direct contact with the outside world during the foaming process. Therefore, during the foaming process, the set parameters such as temperature and pressure will be affected by the external environment. The level of the external environmental temperature will affect the temperature of sponge foaming, and the level of the external environmental air pressure will also affect the pressure of sponge foaming, etc.

[0065] Specifically, set the foaming height of the sponge to a fixed value H, detect the foaming height h of the sponge through the camera 2, and specifically define the height by making marks on the inner wall of the foaming box 1, etc., and at the same time use it as a comparison reference for H and h, where the height of the push plate 75 is higher than H.

[0066] When h is equal to H, and through the camera 2, it is observed that there are no obvious cracks on the surface of the foamed sponge, etc., it indicates that the foaming height of the sponge is qualified at this time and the sponge quality is qualified. The pushing assembly 7 can be continued to be started to drive the first cylinder 72 to drive the connecting piece 73 to displace, and at the same time the connecting piece 73 drives the push rod 74 and the push plate 75 to displace to one side, and perform the operation of pushing and demoulding the foamed sponge in the foaming box 1, so as to obtain the processed sponge.

[0067] When h is less than H, it indicates that the foaming height of the sponge is insufficient at this time. At the same time, through the camera 2, it is observed that the foaming of the sponge shows a tendency to stop. When this situation occurs, the temperature inside the foaming box 1 reflected by the temperature sensor 1 can be detected. If the temperature is too low, it means that the temperature of the heating coil in the foaming box 1 is insufficient, and the temperature needs to be increased to maintain foaming;

[0068] When it is detected through inspection that it is not due to low temperature, the pressure value reflected by the integrated high-pressure pump 4 is detected. When the pressure is too low, it will also cause the problem of insufficient foaming height of the sponge. If the pressure is too low, the pressure of the integrated high-pressure pump 4 needs to be increased to maintain the foaming of the sponge;

[0069] When it is detected that the above parameters are all within the normal values, it is considered that the foaming height of the sponge detected by the camera 2 is insufficient due to too little foaming agent dosage or too poor quality of the foaming agent in the raw material. At this time, the electric valve on the first addition pipe 51 is opened, so that an appropriate amount of auxiliary foaming agent is added into the foaming box 1. At the same time, the electric push rod 104 makes the first stirring blade 107 extend downward out of the discharge port 1011 into the foaming box 1. After the raw material enters the foaming box 1, foaming will be quickly completed. In order to prevent when stirring the sponge after adding the auxiliary foaming agent, the sponge in the foamed and unfoamed states cannot fully promote the heat transfer and gas release between the materials due to the single stirring direction, resulting in local overheating and a decrease in the quality of the sponge, and the unfoamed part will affect the overall performance of the product. At this time, it is necessary to control the first stirring blade 107 of the stirring assembly 10 to enter the foamed part for stirring, and the second stirring blade 109 stirs the unfoamed raw material part to avoid damaging the formed sponge structure or affecting the performance of the final product;

[0070] Among them, the height of the foamed sponge is set as L1. When the first stirring rod 106 descends, the telescopic rod 1061 contacts the foamed sponge. At this time, the pressure sensor 2 will reflect the change in the magnitude of the pressure and send the signal to the operating system. When L1 is greater than the total length of the first stirring rod 106 and the telescopic rod 1061, when the pressure change is sensed by the pressure sensor 2, the operating system starts to calculate the length that the electric push rod 104 pushes the first stirring blade 107 into the foamed sponge part until the upper end of the first stirring blade 107 is at the critical value between the foamed and unfoamed parts of the sponge, and continue to stir the inside of the foaming box 1 to make the auxiliary foaming agent and the raw material fully blend and foam again, and continue to add the foaming auxiliary agent until the foaming height of the sponge meets the set value H;

[0071] When L1 is less than the total length of the first stirring rod 106 and the telescopic rod 1061, the bottom end of the telescopic rod 1061 touches the bottom of the foaming box 1, causing the telescopic spring 1062 to contract under force. At this time, when the pressure sensor two senses a pressure change, it sends a signal to the operating system to control the micro electric push rod to retract the telescopic stirring blade 1071 synchronously until the upper end of the first stirring blade 107 is at the critical value between the foamed and unfoamed parts of the sponge, and then continue the stirring operation in the foaming box 1 to fully blend the auxiliary foaming agent and the raw materials for re-foaming until the foaming height of the sponge meets the set value H;

[0072] When L1 is less than the contraction range of the telescopic rod 1061 that the telescopic spring 1062 can achieve, it indicates that the foaming quality of the sponge is too poor to be used and should be directly recycled and discarded.

[0073] When h is greater than H, it means that the foaming height of the sponge is too high at this time. Observe the outer surface of the foamed sponge through the camera 2. If small openings are detected on the surface of the sponge, it indicates that the heating temperature of the foaming box 1 is too high, then the camera 2 emits an alarm sound to remind the operator to turn off the heating coil;

[0074] Check the taken-out sponge. If the surface opening is small, an adhesive can be used to treat the sponge surface without affecting the subsequent use of the sponge; if the surface opening is large, in order not to waste resources, etc., the sponge is cut and reprocessed, spliced, etc.

[0075] If at this time, observing the outer surface of the foamed sponge through the camera 2 and detecting large cracks on the surface of the sponge, it indicates that the pressure in the foaming box 1 is too high, then the camera 2 also emits an alarm sound to remind the operator to turn off the integrated high-pressure pump 4 and perform the same operation on the sponge as above;

[0076] When the quality of the foamed sponge is too poor in the above situations, the sponge should be recycled.

[0077] At this time, observing the outer surface of the foamed sponge through the camera 2 and there are no obvious cracks, etc., it means that the foaming height has nothing to do with the pressure and temperature, but is caused by too much dosage of the foaming agent. At this time, open the electric valve of the second adding pipe 52 containing the inhibitor, so that an appropriate amount of inhibitor is added into the foaming box 1. At the same time, the electric push rod 104 drives the first stirring blade 107 to extend downward out of the discharge port 1011 into the foaming box 1, so that the first stirring blade 107 and the second stirring blade 109 stir the inside of the foaming box 1 in different directions up and down, so that the inhibitor is fully integrated into the sponge foaming raw materials, and continue the stirring operation in the foaming box 1 to fully blend the inhibitor and the raw materials for re-foaming until the foaming height of the sponge meets the set value H.

[0078] Example 3. Changing the dosage of the foaming agent from the raw materials requires pre-calculation and adjustment, and there may be waste caused by inaccurate dosage. However, adjusting the dosage of the inhibitor or foaming aid in real time according to the foaming situation can more precisely control the cost. Therefore, based on Example 2, the ratio of the sponge foaming raw materials can be optimized, such as Figures 9-10 , at this time, connect the first addition pipe 51 and the second addition pipe 52 to the stirring barrel 101, so that the additive can be added during the stirring process or during the foaming process;

[0079] Specifically, when the situation of h being less than H occurs, and this situation is caused by too little dosage or poor quality of the foaming agent, on the basis of the raw materials originally put into the stirring barrel 101, open the first addition pipe 51 to put the auxiliary foaming agent into the stirring barrel 101, so as to increase the foaming effect of the raw materials, thereby making the foaming height of the sponge reach the set value H;

[0080] When the situation of h being greater than H occurs, and this situation is caused by too much dosage of the foaming agent, on the basis of the raw materials originally put into the stirring barrel 101, open the second addition pipe 52 to put the inhibitor into the stirring barrel 101, so as to inhibit the foaming effect of the raw materials, thereby making the foaming height of the sponge reach the set value H.

[0081] Example 4. The above situation only judges whether the quality of the sponge foaming is qualified by the height of the sponge foaming. The height of the sponge foaming directly affects the molding stability. If the foaming height is not enough, the filling of the sponge in the foaming box 1 may be incomplete, resulting in easy breakage or deformation during the demolding process. On the contrary, a moderate and uniform foaming height helps to keep the shape of the sponge stable and makes the demolding process smoother;

[0082] Based on Example 3, when the ratio of the sponge foaming raw materials is reconfigured, the raw materials enter the stirring barrel 101 for stirring. After being fully mixed, they are poured into the foaming box 1 for heating and pressurization operations to achieve sponge foaming. After a period of time, when the foaming height of the sponge reaches H and the foaming is completed, the demolding operation is started. The pushing component 7 is used for demolding. The driving cylinder 72 drives the connecting piece 73 to displace. At the same time, the connecting piece 73 drives the push rod 74 and the push plate 75 to displace to one side. The push plate 75 pushes the sponge out of the foaming box 1. When the sponge is pushed out, observe the outer surface of the pushed-out part of the sponge and the inner wall of the foaming box 1. Whether there are more pores on the sponge surface and whether there is more residue on the inner wall of the foaming box 1;

[0083] When there are many foam holes and there are many residues on the inner wall of the foaming box 1, it is necessary to observe the pressure value reflected by the pressure sensor 1 on the push plate 75, and compare the actual pressure with the pressure range required by the process. Insufficient or excessive pressure may lead to incomplete demoulding or damage to the product. The demoulding pressure can be reduced or increased by controlling the cylinder 1 72 to slow down or speed up the pushing speed of the push plate 75, so as to achieve the effect of controlling the demoulding pressure within the required pressure range;

[0084] At the same time, the temperature of the inner wall of the foaming box 1 is detected by the second temperature sensor to determine whether the sponge is rapidly cooled and solidified on the inner surface of the foaming box 1 due to the low temperature inside the foaming box 1, forming a strong adhesion with the inner surface of the foaming box 1, making demoulding difficult. If the temperature reflected by the second temperature sensor is lower than the normal value, the heating coil needs to be started again to heat the inside of the foaming box 1 to promote demoulding of the sponge;

[0085] It should be noted that the order of detecting the above pressure and temperature values is not fixed.

[0086] The above steps can ensure that the foaming height of the sponge reaches the set value, and the sponge can get a complete demoulding process, so that the sponge with the required quality can be obtained through the sponge foaming machine, and the sponges produced under different conditions can be effectively processed to avoid the waste of foaming raw materials. By precisely controlling the foaming process and parameters, the stability and consistency of sponge production can be ensured, thereby improving the overall production efficiency. Stable foaming height and high-quality sponges can reduce the scrap rate and rework rate, making the production line smoother.

[0087] In the description of the present invention, it is necessary to understand that the terms "up", "down", "front", "back", "left", "right", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation on the present invention.

[0088] Finally, it should be pointed out that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them. Although the present invention has been described in detail with reference to the above embodiments, a person skilled in the art should understand that the technical solutions described in the above embodiments can still be modified, or some of the technical features can be replaced by equivalents, and these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A sponge foaming machine, comprising a foaming box (1), characterized in that, A camera (2) is installed above the foam box (1), a first temperature sensor (3) is installed on the inner wall of the foam box (1), an integrated high-pressure pump (4) is connected to one side of the foam box (1) through a pipeline, adding bottles (5) are fixed on both sides of the foam box (1), and a second temperature sensor is installed inside the foam box (1). Connection rings are welded on both sides of the foam box (1), the adding bottles (5) are installed in the connection rings on both sides of the foam box (1), a first adding pipe (51) is connected to the pipeline below one of the adding bottles (5), a second adding pipe (52) is connected to the pipeline below the other adding bottle (5), and both the first adding pipe (51) and the second adding pipe (52) are connected to the inside of the foam box (1) through valves. An installation box (6) is riveted on one side of the foam box (1), a pushing component (7) is installed inside the installation box (6), a feeding device (8) is arranged above the installation box (6), a positioning component (9) is arranged above the foam box (1), and a stirring component (10) is fixedly connected inside the positioning component (9). The pushing component (7) includes a fixing part (71), the fixing part (71) is riveted above the inner wall of the installation box (6), a first cylinder (72) is riveted below the fixing part (71), a connecting part (73) is arranged on one side of the first cylinder (72), a push rod (74) is riveted on one side of the connecting part (73), a push plate (75) is welded on one side of the push rod (74), and a first pressure sensor is installed on the side of the push plate (75) in contact with the sponge. The stirring assembly (10) includes a stirring barrel (101) and a support rod (102). The stirring barrel (101) is installed in a positioning sleeve (92). A discharge port (1011) is provided at the bottom of the stirring barrel (101), and an electric control valve is installed on the discharge port (1011). The support rod (102) is welded to the positioning sleeve (92). A connecting rod (103) is welded to the top of the support rod (102). An electric push rod (104) is installed at one end of the connecting rod (103), and a driving member (105) is fixedly connected below the electric push rod (104). The driving member (105) includes a first positioning ring (1051). A driving rod (1052) passes through the center of the first positioning ring (1051). One end of the driving rod (1052) is connected to a motor, and a driving gear (1053) is sleeved on the other end of the driving rod (1052). A second positioning ring (1054) is fixed to the connecting rod above the first positioning ring (1051). A first stirring rod (106) passes through the center of the second positioning ring (1054). A first driven gear (1055) is sleeved on one end of the first stirring rod (106). A third positioning ring (1056) is fixed to the connecting rod below the first positioning ring (1051). A second stirring rod (108) passes through the center of the third positioning ring (1056). A second driven gear (1057) is sleeved on one end of the second stirring rod (108). The driving gear (1053) is respectively meshed and connected with the first driven gear (1055) and the second driven gear (1057). The first stirring rod (106) passes through the center of the second stirring rod (108). A first stirring blade (107) is welded to the part of the first stirring rod (106) extending out of the second stirring rod (108). A telescopic stirring blade (1071) is connected to a micro electric push rod installed inside the first stirring blade (107). A telescopic rod (1061) is installed inside the first stirring rod (106). A second pressure sensor is installed inside the telescopic rod (1061). A telescopic spring (1062) is welded to the top of the telescopic rod (1061). A second stirring blade (109) is welded to the outside of the second stirring rod (108). Cylinder-driven extension parts are provided inside both the first stirring blade (107) and the second stirring blade (109). The extension parts are movably connected to the scraping plates at the outer ends of the first stirring blade (107) and the second stirring blade (109).

2. The sponge foaming machine according to claim 1, characterized in that, The feeding device (8) includes a first feeding barrel (81). A first feeding pipe (811) is installed above the first feeding barrel (81). A second feeding barrel (82) is provided on one side of the first feeding barrel (81). A second feeding pipe (821) is installed above the second feeding barrel (82). A third feeding barrel (83) is provided on the other side of the first feeding barrel (81). A third feeding pipe (831) is installed above the third feeding barrel (83).

3. A sponge foaming machine according to claim 2, characterized in that, The positioning component (9) includes a positioning rod (91), the positioning rod (91) is riveted above the foam box (1), a positioning sleeve (92) is welded to one side of the positioning rod (91), and a stirring component (10) is arranged inside the positioning sleeve (92).

4. A sponge foaming machine according to claim 3, characterized in that, The foaming process of the sponge foaming machine includes: Raw materials are respectively input into the stirring component (10) from the first feed barrel (81), the second feed barrel (82), and the third feed barrel (83) through the first feed pipe (811), the second feed pipe (821), and the third feed pipe (831) for sufficient stirring. After setting the required stirring time to enable the raw materials for sponge foaming to be fully fused, the discharge port (1011) is opened after receiving the signal that the stirring time ends, and the raw materials are put into the foam box (1). Heating is carried out through the heating coil at the bottom of the foam box (1), and at the same time, the integrated high-pressure pump (4) is pressurized to promote the chemical reaction required for sponge foaming and ensure the distribution of the raw materials, so that the raw materials foam and solidify. The foaming situation inside the foam box (1) is reflected by the camera (2). After observing that the foaming situation is qualified, the operator opens the box door on one side of the foam box (1) and starts the pushing-out component (7) to push the sponge out of the foam box (1) through the push plate (75), achieving the effect of rapid demoulding, and thus obtaining foamed sponge.

5. A sponge foaming machine according to claim 4, characterized in that, The process control of the sponge foaming includes the following steps: Set the height of the sponge foaming to a fixed value H, detect the height h of the sponge foaming through the camera (2), and specifically define the height by making marks on the inner wall of the foam box (1) etc., and at the same time use it as a comparison reference for H and h, wherein the height of the push plate (75) is higher than H; When h is equal to H, and there are no obvious cracks etc. on the surface of the foamed sponge observed through the camera (2), it indicates that the foaming height of the sponge is qualified at this time and the sponge quality is qualified. The pushing-out component (7) can be continued to be started, and the driving cylinder one (72) is driven to drive the connecting piece (73) to displace. At the same time, the connecting piece (73) drives the push rod (74) and the push plate (75) to displace to one side, and the foamed sponge in the foam box (1) is pushed out and demoulded, thereby obtaining the processed sponge.

6. A sponge foaming machine according to claim 5, characterized in that, The process control of the sponge foaming further includes the following steps: When h is less than H, it indicates that the foaming height of the sponge is insufficient at this time. At the same time, it is observed through the camera (2) that the sponge foaming situation has a tendency to stop. When this situation occurs, the temperature inside the foam box (1) reflected by the temperature sensor one (3) can be detected. If the temperature is too low, it means that the temperature of the heating coil in the foam box (1) is insufficient, and the temperature needs to be increased to maintain foaming; When it is detected that it is not due to low temperature, the pressure value reflected by the integrated high-pressure pump (4) is detected. When the pressure is too low, it will also cause the problem of insufficient foaming height of the sponge. If the pressure is too low, the pressure of the integrated high-pressure pump (4) needs to be increased to maintain sponge foaming; When it is detected that the above parameters are all within normal values, considering that the amount of foaming agent in the raw material is too small or the quality of the foaming agent is too poor, resulting in insufficient foaming height of the sponge detected by the camera (2), the electric valve on the first addition pipe (51) is opened at this time, so that an appropriate amount of auxiliary foaming agent is added into the foaming box (1). At the same time, the electric push rod (104) makes the first stirring blade (107) extend downward out of the discharge port (1011) into the foaming box (1). After the raw material enters the foaming box (1), foaming will be completed quickly. In order to prevent when stirring the sponge after adding the auxiliary foaming agent, the sponge in the foamed and unfoamed states cannot fully promote the heat transfer and gas release between materials due to the single stirring direction, resulting in local overheating and a decrease in the quality of the sponge, and the unfoamed part will affect the overall performance of the product. At this time, it is necessary to control the first stirring blade (107) of the stirring assembly (10) to enter the foamed part for stirring, and the second stirring blade (109) stirs the unfoamed part of the raw material to avoid damaging the formed sponge structure or affecting the performance of the final product; Among them, the height of the foamed sponge is set as L1. When the first stirring rod (106) descends, the telescopic rod (1061) contacts the foamed sponge. At this time, the second pressure sensor will reflect the change in pressure magnitude and send the signal to the operating system. When L1 is greater than the total length of the first stirring rod (106) and the telescopic rod (1061), when the pressure change is sensed by the second pressure sensor, the operating system starts to calculate the length that the electric push rod (104) pushes the first stirring blade (107) into the foamed sponge part until the upper end of the first stirring blade (107) is at the critical value between the foamed and unfoamed parts of the sponge, and continue to perform the stirring operation in the foaming box (1) to make the auxiliary foaming agent and the raw material fully blend and foam again, and continue to add the foaming auxiliary agent until the foaming height of the sponge meets the set value H; When L1 is less than the total length of the first stirring rod (106) and the telescopic rod (1061), the bottom end of the telescopic rod (1061) touches the bottom of the foaming box (1) so that the telescopic spring (1062) is forced to contract. At this time, when the pressure change is sensed by the second pressure sensor, a signal is sent to the operating system to control the micro electric push rod to synchronously retract the telescopic stirring blade (1071) until the upper end of the first stirring blade (107) is at the critical value between the foamed and unfoamed parts of the sponge, and continue to perform the stirring operation in the foaming box (1) to make the auxiliary foaming agent and the raw material fully blend and foam again and the foaming height of the sponge meets the set value H; When L1 is less than the contraction range of the telescopic rod (1061) that the telescopic spring (1062) can achieve, it means that the foaming quality of the sponge is too poor and it is not suitable for use, and it should be directly recycled and discarded.

7. A sponge foaming machine according to claim 6, wherein, The process control of the sponge foaming further includes the following steps: When h is greater than H, it indicates that the foaming height of the sponge is too high at this time. At this time, observe the outer surface of the foamed sponge through the camera (2). If small openings appear on the surface of the sponge, it indicates that the heating temperature of the foaming box (1) is too high. Then the camera (2) emits an alarm sound to remind the operator to turn off the heating coil; Check the taken-out sponge. If the surface opening is small, an adhesive can be used to treat the sponge surface, which does not affect the subsequent use of the sponge; if the surface opening is large, in order not to waste resources, etc., cut the sponge and perform operations such as reprocessing and splicing; At this time, observe the outer surface of the foamed sponge through the camera (2). If large cracks appear on the surface of the sponge, it indicates that the pressure in the foaming box (1) is too high. Then the camera (2) also emits an alarm sound to remind the operator to turn off the integrated high-pressure pump (4), and perform the same operations on the sponge as above; When the quality of the foamed sponge is too poor in the above situations, the sponge should be recycled; If there are no obvious cracks on the outer surface of the foamed sponge observed through the camera (2) at this time, it means that the foaming height has nothing to do with the pressure and temperature, but is caused by too large a dosage of the foaming agent. At this time, open the electric valve of the second addition pipe (52) containing the inhibitor, so that an appropriate amount of inhibitor is added to the foaming box (1). At the same time, the electric push rod (104) drives the first stirring blade (107) to extend downward out of the discharge port (1011) into the foaming box (1), so that the first stirring blade (107) and the second stirring blade (109) stir the inside of the foaming box (1) in different directions up and down, so that the inhibitor is fully incorporated into the sponge foaming raw material. Continue to stir the inside of the foaming box (1) to make the inhibitor and the raw material fully blend and foam again until the foaming height of the sponge meets the set value H.

Images