Preparation process of automobile flame-retardant sponge

Abstract

The invention provides a preparation process of an automobile flame-retardant sponge, and relates to the technical field of flame-retardant sponges, and the preparation process comprises the following steps: step 1, pouring raw materials for producing the automobile flame-retardant sponge into a stirring device for mixing to form a mixture, and inputting the mixture into a constant-temperature tank; 2, the mixture in the constant-temperature tank is added into a foaming device through a mixture injection device to be foamed, and the automobile flame-retardant sponge is generated; the foaming device comprises a mold set, the mold set comprises a plurality of foaming molds, one foaming mold in the mold set is an evaluation mold, the foaming molds in the same mold set are located in the same feeding environment and placed in the same foaming environment for foaming, and a mixture is injected into the foaming molds in the same mold set through the same mixture injection device; a plurality of first temperature sensors are laterally arranged at the inner bottom end and the first depth of the evaluation mold at intervals; the step 2 comprises the step 20 of periodically carrying out material injection evaluation. After material injection in the foaming mold is completed, the temperature distribution state of the mixture is proper, and the foaming effect is ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of flame-retardant sponges, and specifically to a preparation process for automotive flame-retardant sponges. Background Art

[0002] Automotive flame-retardant sponges are mainly used in automotive ornaments, covering all aspects of the interior of the vehicle, such as automotive steering wheel covers, car seat cushions, car floor mats, car perfumes, car pendants, interior ornaments of the car, storage boxes, and so on;

[0003] In the existing preparation process of automotive flame-retardant sponges (such as CN105504208A, a sponge for a highly flame-retardant automotive interior panel), during the process of injecting the mixed raw materials into the foaming box / foaming mold, there is a lack of monitoring of the temperature state of the mixed raw materials in the foaming box / foaming mold. When the temperature state of the mixed raw materials injected into the foaming box / foaming mold is abnormal, it is likely to affect the foaming effect. Summary of the Invention

[0004] The present invention provides a preparation process for automotive flame-retardant sponges to solve the technical problems raised in the above background art.

[0005] To solve the above technical problems, the present invention discloses a preparation process for automotive flame-retardant sponges, including:

[0006] Step 1: Pour the raw materials for producing automotive flame-retardant sponges into a stirring device for mixing to form a mixed material, and input the mixed material into a constant-temperature tank;

[0007] Step 2: Add the mixed material in the constant-temperature tank to a foaming device through a mixed-material injection device for foaming to generate an automotive flame-retardant sponge;

[0008] The foaming device includes: a mold group, the mold group includes a plurality of foaming molds, one foaming mold in the mold group is an evaluation mold, the foaming molds in the same mold group are located in the same feeding environment and are foamed in the same foaming environment, and the foaming molds in the same mold group are injected with the mixed material through the same mixed-material injection device; a number of first temperature sensors are laterally spaced at intervals at the bottom end and the first depth in the evaluation mold; Step 2 includes Step 20: periodically perform feeding evaluation; Step 20 includes:

[0009] Step 201: Obtain the theoretical discharge control parameters of the mixed-material injection device when injecting the current type of mixed material into the foaming molds of the current mold group at the current injection height;

[0010] Step 202: Control the mixed-material injection device to inject the evaluation mold with the mixed material to the first depth according to the theoretical discharge control parameters of the mixed-material injection device obtained in Step 201; and after injecting to the first depth, control the first temperature sensors to detect;

[0011] Step 203: Calculate the actual temperature state coefficient based on the detection value of the first temperature sensor in Step 202. When the actual temperature state coefficient is greater than the preset temperature state coefficient, alarm through the first alarm.

[0012] Preferably, it further includes Step 3: Cut the automotive flame-retardant sponge.

[0013] Preferably, calculate the temperature state coefficient based on the following formula;

[0014] ;

[0015] f is the temperature state coefficient; is the average detection value of the first temperature sensor at the first depth of the evaluation mold; is the average detection value of the first temperature sensor at the bottom end inside the evaluation mold; is the maximum detection value of the first temperature sensor at the first depth of the evaluation mold; is the minimum detection value of the first temperature sensor at the first depth of the evaluation mold; is the maximum detection value of the first temperature sensor at the bottom end inside the evaluation mold; is the minimum detection value of the first temperature sensor at the bottom end inside the evaluation mold; is the evaluation weight of the temperature change in the depth direction; is the evaluation weight of the temperature change in the lateral direction; is the temperature of the current type of mixture in the constant temperature tank.

[0016] Preferably, the lower end of the evaluation mold is arranged on the weighing device;

[0017] Step 201 further includes: Based on the memory, obtain the standard change curve of the detection value of the weighing device in the evaluation mold of the current mold group with time under the current injection height of the current type of mixture and the theoretical discharge control parameter of the mixture injection device;

[0018] Step 202 further includes: Control the mixture injection device to control the weighing device to perform multiple detections during the process of pouring the evaluation mold to the first depth with the theoretical discharge control parameter of the mixture injection device obtained in Step 201;

[0019] Step 20 also includes:

[0020] Step 204: Calculate the actual weight change coefficient based on the detection value of the weighing device. When the actual weight change coefficient is greater than the preset weight change coefficient, alarm through the second alarm;

[0021] Step 205: When the first alarm and the second alarm do not give an alarm, calculate the first discharge control parameter of the mixture injection device based on the actual temperature state coefficient and the actual weight change coefficient. When the first discharge control parameter of the mixture injection device is less than or equal to the maximum allowable discharge control parameter of the mixture injection device, use the first discharge control parameter of the mixture injection device as the target discharge control parameter of the mixture injection device; when the first discharge control parameter of the mixture injection device is greater than the maximum allowable discharge control parameter of the mixture injection device, give an alarm through the third alarm.

[0022] Step 206: Control the mixture injection device to inject and foam other foaming molds in the current mold set except the evaluation mold with the target discharge control parameter of the mixture injection device until the next injection evaluation is performed.

[0023] Preferably, calculate the actual weight change coefficient based on the following formula;

[0024] ;

[0025] W is the actual weight change coefficient; M is the total number of detections of the weighing device in the current Step 202 process; is the i-th detection value of the weighing device in the current Step 202 process; is the (i - 1)-th detection value of the weighing device in the current Step 202 process; is the ordinate in the standard change curve of the detection value of the weighing device over time corresponding to the moment corresponding to the i-th detection value of the weighing device in the current Step 202 process; is the ordinate in the standard change curve of the detection value of the weighing device over time corresponding to the moment corresponding to the (i - 1)-th detection value of the weighing device in the current Step 202 process; is the first weight evaluation weight; is the second weight evaluation weight;

[0026] Calculate the first discharge control parameter of the mixture injection device based on the following formula;

[0027] ;

[0028] is the first discharge control parameter of the mixture injection device; is the theoretical discharge control parameter of the mixture injection device obtained in the current Step 201; ln is the natural logarithm, and e is the natural constant.

[0029] Preferably, the mixture injection device includes an injection pump, and the discharge control parameter is the power of the injection pump.

[0030] Preferably, step 2 further includes: Step 21: The foaming mold after injecting the mixture is placed in a temperature control box for foaming; an ambient temperature adjusting device is provided in the temperature control box;

[0031] Before batch foaming the current type of mixture in the current temperature control box for the first time, obtain the required ambient temperature range for foaming the current type of mixture in the current temperature control box, divide the required ambient temperature range into several sub-required ambient temperature ranges, and construct a preset mapping table of ambient temperature range - power adjustment amount per unit temperature increase;

[0032] When batch foaming the current type of mixture in the current temperature control box for the first time, it includes the following steps:

[0033] Step S211: Obtain the standard ambient temperature adjusting device control parameter curve during the foaming process of the current type of mixture in the current temperature control box, and divide the standard ambient temperature adjusting device control parameter curve into several first sub-curve segments; in the standard ambient temperature adjusting device control parameter curve, the abscissa is the foaming time, and the ordinate is the standard ambient temperature adjusting device control parameter; the time of the first sub-curve segments is continuous and the difference in the ordinates of each first sub-curve segment is not greater than the first preset difference;

[0034] During the process of obtaining the standard ambient temperature adjusting device control parameter curve during the foaming process of the current type of mixture in the current temperature control box, obtain the average temperature change curve of the ambient temperature monitoring points in the current temperature control box during the foaming process when the current type of mixture is foamed qualified. In the average temperature change curve, the abscissa is the foaming time, and the ordinate is the average temperature of all ambient monitoring points in the current temperature control box;

[0035] Step 213: Control the ambient temperature adjusting device to work according to the standard ambient temperature adjusting device control parameter curve during the foaming process of the current type of mixture in the current temperature control box, so that the current type of mixture in the foaming mold placed in the current temperature control box for the current time foams, and calculate several first temperature difference coefficients during the time period corresponding to each first sub-curve segment. When the first temperature difference coefficient is less than the first preset value, alarm through the fourth alarm, and calculate the target control parameter of the ambient temperature adjusting device corresponding to the time period after the current calculation of the current first sub-curve segment based on the first temperature difference coefficient, and control the foaming in the time period corresponding to the current first sub-curve segment to continue with the target control parameter of the ambient temperature adjusting device calculated after the current calculation of the current first sub-curve segment.

[0036] Preferably, the first temperature difference coefficient is calculated based on the following formula:

[0037] ;

[0038] H is the first temperature difference coefficient calculated for the current period corresponding to the current first sub-curve segment. is the average temperature of all environmental monitoring points in the current temperature control box during the current calculation for the period corresponding to the current first sub-curve segment. is the total number of average temperature change curves obtained in step 212. is the average value of the ordinates of the h-th average temperature change curve obtained in step 212. is the minimum value of the ordinates of the h-th average temperature change curve obtained in step 212.

[0039] The target control parameter of the environmental temperature regulation device is calculated based on the following formula:

[0040] ;

[0041] ;

[0042] is the heat efficiency decay coefficient of the environmental temperature regulation device. is the duration from the current calculation for the period corresponding to the current first sub-curve segment to the end of the current first sub-curve. is the correction coefficient of the target control parameter calculated for the current period corresponding to the current first sub-curve segment.

[0043] is the target control parameter of the environmental temperature regulation device corresponding to after the current calculation for the period corresponding to the current first sub-curve segment. is the actual control parameter of the environmental temperature regulation device during the current calculation for the period corresponding to the current first sub-curve segment. is obtained based on the preset mapping table of temperature range - power adjustment amount per unit temperature increase for heating The power adjustment amount per unit temperature increase for the temperature range where it is located.

[0044] Next, through the accompanying drawings and embodiments, the technical solutions of the present invention will be further described in detail.

[0045] Compared with the prior art, the present invention has the following beneficial effects:

[0046] In the present invention, the mold set includes a plurality of foaming molds. One foaming mold in the mold set is an evaluation mold. The foaming molds in the same mold set are located in the same feeding environment and foamed in the same foaming environment. The foaming molds in the same mold set are injected with the mixture through the same mixture injection device. In this way, only the first temperature sensor needs to be set in the evaluation mold to determine that, under the current feeding environment, due to the change in the heat dissipation state of the feeding environment and the change in the performance of the mixture injection device itself, after the injection of the mixture in the evaluation mold is completed, the temperature distribution state of the mixture is different (the temperature state coefficient is different). When the temperature state coefficient is abnormal, the first alarm will alarm in time to remind to repair or adjust the mixture injection device (the discharge control parameters of the mixture injection device can be adjusted. For example, a suitable discharge control parameter of the mixture injection device can be determined based on the evaluation mold, and the discharge control parameter of the mixture injection device is used to control the injection of the mixture into other foaming molds in the mold set to ensure the injection effect of the plurality of foaming molds in the mold set), so as to ensure that after the injection of the mixture in the foaming mold is completed, the temperature distribution state of the mixture is appropriate and the foaming effect is ensured.

[0047] The present invention solves the following problems raised in the background art: In the existing preparation process of flame-retardant sponge for automobiles (such as a sponge for a high-flame-retardant automotive interior trim panel in CN105504208A), during the process of injecting the mixed raw materials into the foaming box / foaming mold, the temperature state of the mixed raw materials in the foaming box / foaming mold is lack of monitoring. When the temperature state of the mixture injected into the foaming box / foaming mold is abnormal, it is easy to affect the foaming effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] 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:

[0049] Figure 1 is the process flow chart of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0050] The following describes the preferred embodiments of the present invention with reference to the drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.

[0051] In addition, in the present invention, descriptions such as "first" and "second" are only for descriptive purposes, and do not particularly refer to the meaning of order or sequence, nor are they used to limit the present invention. They are merely used to distinguish components or operations described with the same technical terms, and should not be construed as indicating or implying their relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include at least one of such features. In addition, the technical solutions and technical features between various embodiments may be combined with each other, but it must be based on the ability of those of ordinary skill in the art to implement. When the combination of technical solutions results in contradictions or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0052] The present invention provides the following embodiments

[0053] Embodiment 1. The embodiment of the present invention provides a preparation process for a flame-retardant sponge for automobiles, as Figure 1 shown, including:

[0054] Step 1: Pour the raw materials for producing the flame-retardant sponge for automobiles into a stirring device for mixing to form a mixed material, and input the mixed material into a constant-temperature tank;

[0055] Step 2: Add the mixed material in the constant-temperature tank to a foaming device through a mixed-material injection device for foaming to generate a flame-retardant sponge for automobiles;

[0056] Step 3: Cut the flame-retardant sponge for automobiles;

[0057] The foaming device includes: a mold group. The mold group includes a plurality of foaming molds (which can be existing foaming molds or existing foaming boxes). One foaming mold in the mold group is an evaluation mold. The foaming molds in the same mold group are located in the same feeding environment and are placed in the same foaming environment for foaming. The foaming molds in the same mold group are injected with the mixed material through the same mixed-material injection device; a number of first temperature sensors are laterally spaced at the inner bottom end and the first depth of the evaluation mold; Step 2 includes Step 20: Periodically conduct feeding evaluation (the above period can be preset, or can be carried out once in Step 20 when the absolute value of the temperature difference between the current feeding environment temperature and the previous feeding environment temperature when Step 20 is executed is greater than the preset temperature difference, or the period can be determined based on the following method); Step 20 includes:

[0058] Step 201: Obtain the theoretical discharge control parameters of the mixture injection device when injecting the mixture of the current type into the foaming mold of the current mold group at the current injection height (obtained through testing before mass-producing the mixture of the current type. The theoretical discharge control parameters of the mixture injection device meet the preset feed flow requirements of the foaming mold. According to experimental tests, the quality of the sponge foamed under the theoretical discharge control parameters of the mixture injection device is more stable, the temperature state coefficient meets the foaming requirements, and it is not easy for bubbles to form between the mixtures, etc.);

[0059] Step 202: Control the mixture injection device to inject the evaluation mold with the mixture to the first depth according to the theoretical discharge control parameters of the mixture injection device obtained in Step 201; and after injecting to the first depth, control the first temperature sensor to detect (it can be that after injecting to the first depth, wait for a duration L to control the first temperature sensor to detect. The duration L is the duration between the moment when the injection of a single foaming mold in the mold group corresponding to the evaluation mold is completed and the moment when it is completely placed in the foaming environment);

[0060] Step 203: Calculate the actual temperature state coefficient based on the detection value of the first temperature sensor in Step 202. When the actual temperature state coefficient is greater than the preset temperature state coefficient (which is a preset reference value and can be obtained based on testing; when the actual temperature state coefficient is greater than the preset temperature state coefficient, the foaming effect is affected due to abnormal temperature distribution), alarm through the first alarm.

[0061] The mixture injection device may include an injection pump. The feed port of the injection pump is connected to the discharge port of the constant temperature tank through a feed pipe, and the discharge port of the injection pump is connected to a discharge pipe.

[0062] The foaming environment can be room temperature or a temperature control box (which can be an existing constant temperature foaming box);

[0063] The feeding environment is at room temperature. Injecting the mixture outside the temperature control box for the foaming mold can facilitate observing and maintaining the foaming mold (such as the foaming mold may leak material or have dirt and residue of the foamed material that needs to be cleaned).

[0064] The first depth is a preset value and can be set to the total depth required for injecting the mixture of the current type into the evaluation mold;

[0065] In the present invention, the raw materials, ratios, mixing temperatures, and foaming temperatures for producing automotive flame-retardant sponges can all be prior arts, such as CN105504208A; the present invention can be applicable to the preparation processes of various existing flame-retardant sponges.

[0066] The present invention can be provided with a feeding environment temperature sensor and a feeding environment wind speed sensor, and calculate the heat dissipation parameter based on a formula , is the heat dissipation parameter calculated currently; V is the detection value of the wind speed sensor in the current feeding environment; is the detection value of the temperature sensor in the current feeding environment; is the heat transfer coefficient of the ambient air; is the area where the current type of mixture contacts the ambient air under the current required injection amount of the current type of mixture for each foaming mold in the current mold set; is the temperature of the current type of mixture in the constant temperature tank;

[0067] When the absolute value of the difference between the currently calculated heat dissipation parameter and the heat dissipation parameter when step 20 was executed in the previous cycle is greater than the preset heat dissipation amount, the sixth alarm is used to remind to execute the next step 20)

[0068] The beneficial effects of the above technical solution are:

[0069] In the present invention, the mold set includes multiple foaming molds. One foaming mold in the mold set is an evaluation mold. The foaming molds in the same mold set are located in the same feeding environment and foam in the same foaming environment. The foaming molds in the same mold set are injected with the mixture through the same mixture injection device. In this way, only the first temperature sensor needs to be set in the evaluation mold to determine the temperature distribution state (temperature state coefficient) of the mixture after the injection is completed in the evaluation mold due to the change of the heat dissipation state of the feeding environment and the change of the performance of the mixture injection device itself when the current mixture injection device is in the current feeding environment. When the temperature state coefficient is abnormal, the first alarm is used to give an alarm in time to remind to repair or adjust the mixture injection device (the discharge control parameters of the mixture injection device can be adjusted. For example, a suitable discharge control parameter of the mixture injection device can be determined based on the evaluation mold, and the discharge control parameter of the mixture injection device is used to control the mixture injection device to inject the mixture into other foaming molds in the mold set to ensure the injection effect of multiple foaming molds in the mold set), so as to ensure that the temperature distribution state of the mixture is appropriate after the injection is completed in the foaming mold and ensure the foaming effect.

[0070] The present invention solves the following problems raised in the background technology: In the existing preparation process of flame-retardant sponge for automobiles (such as a sponge for a high-flame-retardant automotive interior trim panel in CN105504208A), during the process of injecting the mixed raw materials into the foaming box / foaming mold, the temperature state of the mixed raw materials in the foaming box / foaming mold is lacking in monitoring. When the temperature state of the mixture injected into the foaming box / foaming mold is abnormal, it is easy to affect the foaming effect.

[0071] Example 2, on the basis of Example 1, calculate the temperature state coefficient based on the following formula;

[0072] ;

[0073] f is the temperature state coefficient; is the average detected value of the first temperature sensor at the first depth of the evaluation mold; is the average detected value of the first temperature sensor at the bottom end inside the evaluation mold; is the maximum detected value of the first temperature sensor at the first depth of the evaluation mold; is the minimum detected value of the first temperature sensor at the first depth of the evaluation mold; is the maximum detected value of the first temperature sensor at the bottom end inside the evaluation mold; is the minimum detected value of the first temperature sensor at the bottom end inside the evaluation mold; is the evaluation weight for temperature change in the depth direction (the value ranges from greater than 0 to less than 1); is the evaluation weight for temperature change in the lateral direction (the value ranges from greater than 0 to less than 1, 、 set according to the importance of the temperature distribution in the depth direction and the importance / impact degree of the temperature distribution in the lateral direction on the foaming quality, + = 1); is the temperature of the current type of mixture in the constant temperature tank.

[0074] The beneficial effects of the above technical solution are: Based on the evaluation of the temperature difference in the depth direction and the temperature difference state in the lateral direction, the reliability of the actual temperature state evaluation is ensured.

[0075] Example 2, on the basis of Example 1, the lower end of the evaluation mold is arranged on the weighing device;

[0076] Step 201 further includes: Based on the memory, obtain the standard change curve of the detected value of the weighing device in the evaluation mold of the current mold group over time under the current injection height of the current type of mixture and the theoretical discharge control parameter of the mixture injection device (it is the change curve of the detected value of the weighing device in the evaluation mold of the current mold group over time when injecting the current type of mixture into the evaluation mold of the current mold group at the current injection height of the current type of mixture and the theoretical discharge control parameter of the mixture injection device using a currently qualified mixture injection device at the initial use);

[0077] Step 202 further includes: Controlling the mixture injection device to perform multiple detections on the weighing device during the process of pouring the evaluation mold to the first depth with the theoretical discharge control parameter of the mixture injection device obtained in Step 201;

[0078] Step 20 further includes:

[0079] Step 204: Calculate the actual weight change coefficient based on the detected value of the weighing device. When the actual weight change coefficient is greater than the preset weight change coefficient, alarm through the second alarm;

[0080] Step 205: When the first alarm and the second alarm do not give an alarm, calculate the first discharge control parameter of the mixture injection device based on the actual temperature state coefficient and the actual weight change coefficient. When the first discharge control parameter of the mixture injection device is less than or equal to the maximum allowable discharge control parameter of the mixture injection device, use the first discharge control parameter of the mixture injection device as the target discharge control parameter of the mixture injection device; when the first discharge control parameter of the mixture injection device is greater than the maximum allowable discharge control parameter of the mixture injection device, give an alarm through the third alarm.

[0081] Step 206: Control the mixture injection device to inject and foam other foam molds in the current mold set except the evaluation mold with the target discharge control parameter of the mixture injection device until the next injection evaluation is performed.

[0082] Preferably, calculate the actual weight change coefficient based on the following formula;

[0083] ;

[0084] W is the actual weight change coefficient; M is the total number of detections of the weighing device during the current step 202; is the i-th detection value of the weighing device during the current step 202; is the (i - 1)-th detection value of the weighing device during the current step 202; is the ordinate in the standard change curve of the detection value of the weighing device over time corresponding to the moment corresponding to the i-th detection value of the weighing device during the current step 202; is the ordinate in the standard change curve of the detection value of the weighing device over time corresponding to the moment corresponding to the (i - 1)-th detection value of the weighing device during the current step 202; is the first weight evaluation weight; is the second weight evaluation weight; 、 both take values greater than 0 and less than 1, and are set according to the importance of respectively;

[0085] Calculate the first discharge control parameter of the mixture injection device based on the following formula;

[0086] ;

[0087] is the first discharge control parameter of the mixture injection device; is the theoretical discharge control parameter of the mixture injection device obtained in the current step 201; ln is the natural logarithm, and e is the natural constant.

[0088] The mixture injection device includes an injection pump, and the discharge control parameter is the power (input power) of the injection pump.

[0089] The beneficial effects of the above technical solution are as follows:

[0090] When the injection pump is used for a long time, due to reasons such as wear, the efficiency of the injection pump may decrease. When injecting the mixture into the evaluation mold of the current mold set at the current injection height of the current type of mixture and under the theoretical discharge control parameter of the mixture injection device, the actual detection value of the weighing device changes. Based on the actual detection value of the weighing device and the standard change curve of the detection value of the corresponding weighing device over time, the actual weight change coefficient is determined. The actual weight change coefficient reflects the difference state of the total material falling amount corresponding to the actual and standard curves. reflects the difference state of the material falling amounts in two consecutive times corresponding to the actual and standard curves. Combining the difference state of the total material falling amount and the difference state of the material falling amounts in two consecutive times, the actual comprehensive material falling difference state when falling into the evaluation mold is obtained (actual weight change coefficient; if the actual comprehensive material falling difference state is normal, the actual material falling flow state is normal). When the actual weight change coefficient is greater than the preset weight change coefficient (the actual comprehensive material falling difference state is abnormal), an alarm is given by the second alarm. When the actual comprehensive material falling state when falling into the evaluation mold is abnormal, an alarm is given in time to remind to adjust the power of the injection pump;

[0091] Each time step 20 is executed, the environmental states during actual material injection of each foaming mold in the current mold set are close and the state of the mixture injection device is close. Based on the actual temperature state coefficient and the actual weight change coefficient of the evaluation mold of the current mold set, the target discharge control parameter of the mixture injection device is determined, and the mixture injection device is controlled with the target discharge control parameter of the mixture injection device to inject and foam other foaming molds in the current mold set except the evaluation mold until the next injection evaluation is executed; ensuring reliable material injection for the foaming molds in the current mold set except the evaluation mold.

[0092] Adjusting the power of the injection pump based on the actual temperature state coefficient and the actual weight change coefficient, on the one hand, ensures normal material falling state (normal material falling flow) into other foaming molds corresponding to the mold set of the evaluation mold, ensures normal material falling accumulation state under a suitable material falling flow, and thus ensures the quality of the finally produced sponge; on the other hand, makes the temperature distribution state of the mixture normal after material falling by adjusting the power of the injection pump, ensuring the quality of the finally produced sponge.

[0093] Embodiment 3, based on Embodiment 1 or 2, step 2 further includes: Step 21: The foaming mold (which can be an existing foaming mold or an existing foaming box) after injecting the mixture is placed in a temperature control box for foaming (foaming and curing); an environmental temperature adjustment device is provided in the temperature control box;

[0094] Before batch foaming the current type of mixture in the current temperature control box for the first time, obtain the required ambient temperature range for foaming the current type of mixture in the current temperature control box, divide the required ambient temperature range into several sub-required ambient temperature ranges, and construct a preset mapping table of ambient temperature range - power adjustment amount per unit temperature increase (obtained by testing the current temperature control box and taking the average value of the power adjustment amount);

[0095] When batch foaming the current type of mixture in the current temperature control box for the first time, it includes the following steps:

[0096] Step S211: Obtain the standard ambient temperature adjustment device control parameter curve during the foaming process of the current type of mixture in the temperature control box, and divide the standard ambient temperature adjustment device control parameter curve into several first sub-curve segments; in the standard ambient temperature adjustment device control parameter curve, the abscissa is the foaming time, and the ordinate is the standard ambient temperature adjustment device control parameter; the time of the first sub-curve segments is continuous and the difference in the ordinate of each first sub-curve segment is not greater than the first preset difference;

[0097] During the process of obtaining the standard ambient temperature adjustment device control parameter curve during the foaming process of the current type of mixture in the temperature control box, obtain the average temperature change curve of the ambient temperature monitoring points in the temperature control box during the foaming process when the current type of mixture is foamed qualified. In the average temperature change curve, the abscissa is the foaming time, and the ordinate is the average temperature of all ambient monitoring points in the temperature control box;

[0098] Step 213: Control the ambient temperature adjustment device to work according to the standard ambient temperature adjustment device control parameter curve during the foaming process of the current type of mixture in the temperature control box, so that the current type of mixture in the foaming mold placed in the temperature control box this time is foamed, and calculate several first temperature difference coefficients during the time period corresponding to each first sub-curve segment. When the first temperature difference coefficient is less than the first preset value, alarm through the fourth alarm, and calculate the target control parameter of the ambient temperature adjustment device corresponding to the time period after the current calculation of the current first sub-curve segment based on the first temperature difference coefficient, and control the foaming in the time period corresponding to the current first sub-curve segment to continue with the target control parameter of the ambient temperature adjustment device calculated after the current calculation of the current first sub-curve segment (until the first temperature difference coefficient calculated next time for the current first sub-curve segment is less than the first preset value, then obtain the target control parameter of the ambient temperature adjustment device corresponding to the time period after the next calculation of the current first sub-curve segment again).

[0099] The first temperature difference coefficient is calculated based on the following formula:

[0100] ;

[0101] H is the first temperature difference coefficient calculated for the current time period corresponding to the current first sub-curve segment. is the average temperature of all environmental monitoring points in the temperature control box during the current calculation for the time period corresponding to the current first sub-curve segment. is the total number of average temperature change curves obtained in step 212. is the average value of the ordinates of the h-th average temperature change curve obtained in step 212. is the minimum value of the ordinates of the h-th average temperature change curve obtained in step 212.

[0102] The target control parameter of the environmental temperature regulation device is calculated based on the following formula:

[0103] ;

[0104] ;

[0105] is the heat efficiency decay coefficient of the environmental temperature regulation device. is the duration from the current calculation (the current calculation of the target control parameter) for the time period corresponding to the current first sub-curve segment to the end of the current first sub-curve. is the correction coefficient of the target control parameter calculated for the current time period corresponding to the current first sub-curve segment.

[0106] is the target control parameter of the environmental temperature regulation device corresponding to after the current calculation for the time period corresponding to the current first sub-curve segment. is the actual control parameter of the environmental temperature regulation device during the current calculation for the time period corresponding to the current first sub-curve segment. is obtained based on a preset mapping table of environmental temperature range - power adjustment amount per unit temperature increase for the power adjustment amount per unit temperature increase within the temperature range where it is located.

[0107] The environmental temperature regulation device of the present invention is an existing environmental temperature regulation device.

[0108] When initially batch foaming the current type of mixture in the current temperature control box, one or a group of foaming molds are used to perform steps S211 - S213 in the current temperature control box for foaming once. Taking the actual control parameter of the temperature regulation device during this process as the standard control parameter of the environmental temperature regulation device for foaming the current batch of the current type of mixture, the remaining current batch of the current type of mixture is foamed.

[0109] The beneficial effects of the above technical solution are:

[0110] Before initially batch - foaming the current type of mixture in the current temperature - controlled box, obtain the required ambient temperature range for foaming the current type of mixture in the current temperature - controlled box, and then conduct several foaming tests on the current type of mixture to provide a basis for batch - foaming the current type of mixture; for each foaming test of the current type of mixture, first adjust the control parameters of the ambient temperature adjustment device so that the actual ambient temperature in the temperature - controlled box is within the required ambient temperature range for foaming the current type of mixture in the current temperature - controlled box. During the foaming process, when the temperature in the temperature - controlled box changes due to the temperature generated by the foaming of the current type of mixture, adjust the control parameters of the ambient temperature adjustment device so that during the process of foaming the current type of mixture in the current temperature - controlled box, the actual ambient temperature in the temperature - controlled box is within the required ambient temperature range for foaming the current type of mixture.

[0111] The standard ambient temperature adjustment device control parameter curve during the foaming process of the current type of mixture in the temperature - controlled box, where the abscissa is the foaming time and the ordinate is the average value of the control parameters of the ambient temperature adjustment device during the foaming test of the current type of mixture.

[0112] During the actual use of the temperature - controlled box, due to possible changes in the thermal efficiency of the ambient temperature adjustment device, when batch - foaming the current type of mixture, controlling the ambient temperature adjustment device to work according to the standard ambient temperature adjustment device control parameter curve during the foaming process of the current type of mixture in the temperature - controlled box may cause the ambient temperature to not meet the required ambient temperature range for foaming the current type of mixture in the current temperature - controlled box. Therefore, during the process of batch - foaming the current type of mixture, divide the foaming process of each mixture into multiple sub - time periods (time periods corresponding to the first sub - curve segment). Calculate several first temperature difference coefficients during the time period corresponding to each first sub - curve segment. When the first temperature difference coefficient is less than the first preset value, alarm through the fourth alarm, and calculate the target control parameter of the ambient temperature adjustment device corresponding to the subsequent calculation of the current time period of the current first sub - curve segment based on the first temperature difference coefficient, and control the foaming of the current time period corresponding to the current first sub - curve segment to continue with the target control parameter of the ambient temperature adjustment device corresponding to the subsequent calculation of the current time period of the current first sub - curve segment, so as to ensure the foaming reliability of batch - foaming each current type of mixture.

[0113] Consider the first temperature difference coefficient calculated during the current time period of the current first sub - curve segment, the thermal efficiency decay coefficient of the ambient temperature adjustment device, and the duration from the current calculation during the current time period of the current first sub - curve segment to the end of the current first sub - curve to obtain the control parameter correction coefficient, ensuring the calculation reliability of the control parameters.

[0114] Example 4, based on Example 3, when not initially batch - foaming the current type of mixture in the current temperature - controlled box, includes the following steps:

[0115] Step S214: Obtain the control parameter curve of the reference ambient temperature regulating device during the foaming process of the previous batch of the current type of mixture in the current temperature control box, and divide the control parameter curve of the reference ambient temperature regulating device into several second sub-curve segments; in the control parameter curve of the reference ambient temperature regulating device, the abscissa is the foaming time, and the ordinate is the average value of the control parameters of the ambient temperature regulating device corresponding to the foaming time during the foaming process of the previous batch of the current type of mixture in the current temperature control box; the time of the second sub-curve segments is continuous and the difference in the ordinates of each second sub-curve segment is not greater than the first preset difference;

[0116] Step 215: Obtain the second average temperature change curve of all ambient temperature monitoring points in the current temperature control box during the foaming process of the previous batch of the current type of mixture in the current temperature control box when the current type of mixture is foamed qualified; in the second average temperature change curve, the abscissa is the foaming time, and the ordinate is the average temperature of all ambient monitoring points in the current temperature control box during the foaming process of the previous batch of the current type of mixture in the current temperature control box when the current type of mixture is foamed qualified;

[0117] Step 216: Control the operation of the ambient temperature regulating device with the control parameter curve of the reference ambient temperature regulating device during the foaming process of the previous batch of the current type of mixture in the current temperature control box, so that the current type of mixture in the foaming mold placed in the current temperature control box this time foams, and calculate several second temperature difference coefficients during the time period corresponding to each second sub-curve segment. When the second temperature difference coefficient is less than the first preset value, alarm through the fifth alarm, and calculate the target control parameter of the ambient temperature regulating device corresponding to the subsequent calculation during the time period corresponding to the current second sub-curve segment based on the second temperature difference coefficient, and control the foaming during the time period corresponding to the current second sub-curve segment to continue with the target control parameter of the ambient temperature regulating device corresponding to the subsequent calculation during the current second sub-curve segment.

[0118] ;

[0119] is the second temperature difference coefficient calculated this time during the time period corresponding to the nth second sub-curve segment when the (d + 1)th batch of the current type of mixture is batch-foamed in the current temperature control box, is the average temperature of all ambient monitoring points in the temperature control box during the calculation this time during the time period corresponding to the nth second sub-curve segment when the (d + 1)th batch of the current type of mixture is batch-foamed in the current temperature control box; is the total number of the second average temperature change curves obtained in Step 215 when the (d + 1)th batch of the current type of mixture is batch-foamed in the current temperature control box; is the average value of the ordinate of the nth second sub-curve segment of the ath second average temperature change curve obtained in step 215 when batch foaming the current type of mixture in the current temperature control box for the (d + 1)th batch; is the minimum value of the ordinate of the nth second sub-curve segment of the ath second average temperature change curve obtained in step 215 when batch foaming the current type of mixture in the current temperature control box for the (d + 1)th batch; d is greater than or equal to 1;

[0120] ;

[0121] ;

[0122] is the target control parameter of the environmental temperature adjustment device corresponding to the current calculation after the time period corresponding to the nth second sub-curve segment when batch foaming the current type of mixture in the current temperature control box for the (d + 1)th batch; is the actual control parameter of the environmental temperature adjustment device at the time of the current calculation of the time period corresponding to the nth second sub-curve segment when batch foaming the current type of mixture in the current temperature control box for the (d + 1)th batch; is obtained based on a preset mapping table of environmental temperature range - power adjustment amount per unit temperature increase the power adjustment amount per unit temperature increase within the temperature range where it is located; the correction coefficient of the target control parameter corresponding to the current calculation of the time period corresponding to the nth second sub-curve segment when batch foaming the current type of mixture in the current temperature control box for the (d + 1)th batch; is the duration from the current calculation (current calculation of the target control parameter) to the end of the nth second sub-curve segment corresponding to the time period corresponding to the nth second sub-curve segment when batch foaming the current type of mixture in the current temperature control box for the (d + 1)th batch.

[0123] When batch foaming the current type of mixture in the current temperature control box for each batch, one or a group of foaming molds are used to perform steps S214 - S216 once in the current temperature control box for foaming. Taking the actual control parameter of the temperature adjustment device in this process as the standard control parameter of the environmental temperature adjustment device for foaming the current type of mixture of the current batch, the remaining current type of mixture of the current batch is foamed.

[0124] The beneficial effects of the above technical solution are:

[0125] Based on the control parameter curve of the reference environmental temperature adjustment device in the foaming process of the previous batch of the current type of mixture in the current temperature control box, the control parameters of the temperature adjustment device for foaming the next batch of the current type of mixture in the current temperature control box are adjusted, so that the adjustment of the control parameters of the environmental temperature adjustment device in the current temperature control box is more matched with its current state, ensuring the control effect of the environmental temperature adjustment device.

[0126] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalent technologies, the present invention is also intended to include these changes and modifications.

Claims

1. A process for preparing a flame retardant sponge for an automobile, characterized in that: include: Step 1: Pour the raw materials for producing automotive flame retardant sponge into a stirring device for mixing to form a mixture, and then input the mixture into a constant temperature tank; Step 2: Add the mixed material in the constant temperature tank into the foaming device through the mixed material injection device for foaming to generate automotive flame retardant sponge; The foaming device comprises: a mold group, the mold group comprises a plurality of foaming molds, one foaming mold in the mold group is an evaluation mold, the foaming molds in the same mold group are located in the same feeding environment and placed in the same foaming environment for foaming, and the foaming molds in the same mold group are injected with mixed materials through the same mixed material injection device; a plurality of first temperature sensors are arranged at lateral intervals at the bottom end and the first depth in the evaluation mold; step 2 comprises step 20: periodically performing injection evaluation; step 20 comprises: Step 201: obtaining theoretical discharge control parameters of a mixed material injection device when injecting a current type of mixed material into a foaming mold of a current mold group at a current injection height; Step 202: Control the mixed material injection device to inject the material to the first depth of the evaluation mold using the theoretical discharge control parameters of the mixed material injection device obtained in step 201; and control the first temperature sensor to detect after injecting the material to the first depth; Step 203: Calculate the actual temperature state coefficient based on the detection value of the first temperature sensor in step 202, and when the actual temperature state coefficient is greater than the preset temperature state coefficient, an alarm is issued through the first alarm.

2. The process for preparing a flame retardant sponge for automobile according to claim 1, characterized in that: The invention also includes step 3: cutting the automotive flame retardant sponge.

3. The process for preparing a flame retardant sponge for automobile according to claim 1, characterized in that: The temperature state coefficient is calculated based on the following formula; ； f is the temperature state coefficient; for evaluating an average detection value of a first temperature sensor at a first depth of the mold; To evaluate the average detection value of the first temperature sensor at the bottom end of the mold; for evaluating a maximum detection value of a first temperature sensor at a first depth of the mold; To evaluate a minimum detection value of a first temperature sensor at a first depth of the mold; To evaluate the maximum detection value of the first temperature sensor at the bottom end of the mold; To evaluate the minimum detection value of the first temperature sensor at the bottom end in the mold; Evaluate the weight of temperature variation in depth; Evaluate the weight of temperature change in lateral direction; It is the temperature of the current type of mixed material in the constant temperature tank.

4. The process for preparing a flame retardant sponge for automobile according to claim 3, characterized in that: The lower end of the evaluation mold is set on a weighing device; Step 201 also includes: obtaining, based on the memory, a standard curve of a detection value of a weighing device in an evaluation mold of the current mold group over time under a current injection height and theoretical discharge control parameters of a mixture injection device of the current type of mixture; Step 202 also includes: controlling the mixture injection device to perform multiple tests on the weighing device during the process of evaluating the mold pouring to the first depth using the theoretical discharge control parameters of the mixture injection device obtained in step 201; Step 20 also includes: Step 204: Calculate the actual weight change coefficient based on the detection value of the weighing device, and when the actual weight change coefficient is greater than the preset weight change coefficient, alarm through the second alarm; Step 205: When the first alarm and the second alarm do not sound an alarm, a first discharge control parameter of the mixture injection device is calculated based on the actual temperature state coefficient and the actual weight change coefficient; when the first discharge control parameter of the mixture injection device is less than or equal to the maximum allowable discharge control parameter of the mixture injection device, the first discharge control parameter of the mixture injection device is used as the target discharge control parameter of the mixture injection device; when the first discharge control parameter of the mixture injection device is greater than the maximum allowable discharge control parameter of the mixture injection device, an alarm is sounded through the third alarm; Step 206: Control the mixed material injection device with the target discharge control parameter of the mixed material injection device to perform material injection and foaming on other foaming molds in the current mold group except the evaluation mold until the next injection evaluation is performed.

5. The process for preparing a flame retardant sponge for automobile according to claim 4, characterized in that: The actual weight variation coefficient was calculated based on the following formula; ； W is the actual weight variation coefficient; M is the total number of detections of the weighing device during the current step 202; is the i-th detection value of the weighing device in the current step 202; is the i-1th detection value of the weighing device in the current step 202; is the ordinate of the standard curve of the detection value of the weighing device over time corresponding to the corresponding moment of the i-th detection value of the weighing device in the current step 202; is the ordinate of the standard variation curve of the detection value of the weighing device over time corresponding to the moment corresponding to the i-1th detection value of the weighing device in the current step 202; Evaluate weights for the first weight; Evaluate weights for the second weight; Calculate the first discharge control parameter of the mixed material injection device based on the following formula; ； It is the first discharge control parameter of the mixed material injection device; It is the theoretical discharge control parameter of the mixed material injection device obtained in the current step 201; ln is the natural logarithm, and e is the natural constant.

6. The process for preparing a flame retardant sponge for automobile according to claim 5, characterized in that: The mixed material injection device comprises an injection pump, and the discharge control parameter is the power of the injection pump.

7. The process for preparing a flame retardant sponge for automobile according to claim 1, characterized in that: Step 2 also includes: Step 21: placing the foaming mold after the mixture is injected into a temperature control box for foaming; an environmental temperature regulating device is arranged in the temperature control box; Before the current type of mixed material is foamed in batches in the current temperature control box for the first time, the required ambient temperature range for foaming the current type of mixed material in the current temperature control box is obtained, and the required ambient temperature range is divided into a plurality of sub-required ambient temperature ranges, and a power adjustment amount mapping table of a preset ambient temperature range-temperature rise unit temperature is constructed; When the current type of mixed material is foamed in batches in the current temperature control box for the first time, the following steps are included: Step S211: obtaining a standard ambient temperature control device control parameter curve of the current type of mixed material during the foaming process in the current temperature control box, and dividing the standard ambient temperature control device control parameter curve into a plurality of first sub-curve segments; the abscissa of the standard ambient temperature control device control parameter curve is the foaming time, and the ordinate is the standard ambient temperature control device control parameter; the first sub-curve segments are continuous in time and the difference of the ordinates of each first sub-curve segment is not greater than a first preset difference; Step 212: in the process of obtaining the control parameter curve of the standard ambient temperature regulating device of the current type of mixed material in the foaming process in the current temperature control box, the average temperature change curve of the ambient temperature monitoring points in the current temperature control box during the foaming process corresponding to the qualified foaming of the current type of mixed material, the abscissa of the average temperature change curve is the foaming time, and the ordinate is the average temperature of all the ambient temperature monitoring points in the current temperature control box; Step 213: The ambient temperature regulating device is controlled to work with the standard ambient temperature regulating device control parameter curve of the current type of mixture in the foaming process in the current temperature control box, so that the current type of mixture in the foaming mold currently placed in the current temperature control box is foamed, and the first temperature difference coefficient is calculated several times in the time period corresponding to each first sub-curve segment. When the first temperature difference coefficient is less than the first preset value, an alarm is given through the fourth alarm, and the target control parameter of the ambient temperature regulating device corresponding to the time period corresponding to the current first sub-curve segment after the current calculation is calculated based on the first temperature difference coefficient, and the foaming of the time period corresponding to the current first sub-curve segment is continued with the target control parameter of the ambient temperature regulating device corresponding to the time period corresponding to the current first sub-curve segment.

8. The process for preparing a flame retardant sponge for automobile according to claim 7, characterized in that: The first temperature difference coefficient is calculated based on the following formula: ； H is the first temperature difference coefficient calculated for the current period corresponding to the current first sub-curve segment. The average temperature of all environmental monitoring points in the current temperature control box at the time of the current calculation in the period corresponding to the current first sub-curve segment; The total number of average temperature variation curves obtained in step 212; is the average value of the ordinate of the h-th average temperature variation curve obtained in step 212; is the minimum value of the ordinate of the h-th average temperature variation curve obtained in step 212; The target control parameter of the ambient temperature control device is calculated based on the following formula: ； ； is the thermal efficiency attenuation coefficient of the ambient temperature regulating device; The duration from the last calculation of the time period corresponding to the current first sub-curve segment to the end of the current first sub-curve; The correction coefficient of the target control parameter calculated for the current time period corresponding to the current first sub-curve segment; The target control parameter of the ambient temperature regulating device corresponding to the time period corresponding to the current first sub-curve segment after the current calculation; The actual control parameter of the ambient temperature regulating device calculated at the time period corresponding to the current first sub-curve segment; The power adjustment amount mapping table based on the preset ambient temperature range-heating unit temperature is obtained. The temperature range in which the power is adjusted per unit temperature rise.

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