Molding unit and molding equipment of foam molding product and use method

Abstract

The invention discloses a forming unit and forming equipment of a foam forming product and a using method, the forming unit comprises a plurality of forming units of the foam forming product, and the forming units are arranged side by side at intervals and operate independently; a release agent nozzle is arranged at the end part of the first mechanical arm, and a release agent is sprayed into the forming mold through the release agent nozzle; a polyurethane mixture nozzle is arranged at the end of the second mechanical arm, and a polyurethane mixture is injected into the forming mold through the polyurethane mixture nozzle; and the negative pressure dust removal cover is arranged above the spraying working area and used for treating dust floating in the spraying working area. According to the forming unit, the space is divided into the filling working area and the spraying working area through the lifting partition curtain, the position of the forming mold is switched between the filling working area and the spraying working area through the ground rail assembly, workers only need to work in the filling working area with the good environment, and the problem that in a foaming workshop, the working efficiency is high is solved. And the physical and psychological health of workers is influenced by the bad working area environment of the workers.

Description

Technical Field

[0001] The present invention relates to the technical field of foaming molding equipment, and in particular to a molding unit, molding equipment and a use method of a foamed molded product. Background Art

[0002] Foam molding primarily involves injecting a molten polyurethane mixture into a mold cavity and then cooling it to create a molded product in the shape of the cavity. Foam molded products using elastic polyurethane, such as seat cushions, consist of a foaming body made of a foamable resin material and a supporting insert that reinforces the foaming body. With the supporting insert positioned within the mold cavity, liquid foaming resin is injected and foamed, forming a single piece.

[0003] The traditional foam molding process involves cleaning the mold, spraying a release agent, drying the mold, adding support inserts, filling the polyurethane mixture, and finally removing the mold material. These steps, such as mold cleaning and spraying a release agent, generate significant amounts of dust. Currently, these processes are typically performed manually within the same workshop, resulting in a harsh workshop environment and significantly impacting worker health. Therefore, the development of environmentally friendly and safe foam molding equipment is urgently needed. Summary of the Invention

[0004] The purpose of the present invention is to provide a foam molding unit, a molding device and a method of use to solve the problem that the current foam molding workshop environment is harsh and affects the physical and mental health of workers.

[0005] To solve the above technical problems, the present invention provides a molding unit for foamed molded products, comprising a floor rail assembly, wherein a lifting curtain is provided in the middle of the floor rail assembly to separate the space above the floor rail assembly into a filling work area and a spraying work area; A forming die is run on the ground rail assembly so that the forming die switches positions between the filling work area and the spraying work area.

[0006] Preferably, the forming mold is mounted on a carrying trolley and moves back and forth along the ground rail assembly under the action of a driving mechanism.

[0007] Preferably, the forming mold is rotatably connected to the carrying trolley on one side through a rotating shaft, and a lifting cylinder is provided on the other side. The forming mold is lifted by the lifting cylinder to adjust the angle of the forming mold.

[0008] The present invention also provides a molding device, comprising a plurality of the above-mentioned molding units for foam molding, wherein the plurality of molding units are arranged side by side and spaced apart and operate independently; and further comprising: a first robotic arm, wherein a release agent nozzle is provided at an end of the first robotic arm, and a release agent is sprayed into the forming mold through the release agent nozzle; a second robotic arm, wherein a polyurethane mixture nozzle is provided at an end of the second robotic arm, and polyurethane mixture is injected into the forming mold through the polyurethane mixture nozzle; The negative pressure dust hood is installed above the spraying work area to deal with the dust floating in the spraying work area.

[0009] Preferably, the lifting curtains in the multiple molding units operate independently but are arranged in a straight line, so that the multiple filling work areas are interconnected into a whole, and the multiple spraying work areas are interconnected into a whole.

[0010] Preferably, the molding units are grouped in pairs, and the molding dies of the two molding units in the group operate alternately.

[0011] Preferably, the first robotic arm is a multi-axis robotic arm, which can drive the release agent nozzle at the end to spray the release agent on the molding cavity of the molding mold at multiple angles; and the first robotic arm is installed on the first overhead rail, which is located above the spraying work area and spans multiple molding units, so that the first robotic arm can spray the release agent on the molding molds on different molding units.

[0012] Preferably, the second robotic arm is a suspended robotic arm, which is lifted up and down by an electric lifter; when it is lowered to the filling port of the forming mold, the polyurethane mixture is filled into the forming cavity of the forming mold through the polyurethane mixture nozzle; and the second robotic arm is installed on the second rail, which is located above the filling work area and spans multiple molding units, so that the second robotic arm can fill the molding molds on different molding units with polyurethane mixture.

[0013] The present invention also provides a method for using the foam molding device, comprising the following steps: Step A: First, all the lifting curtains are in the down state to separate the filling work area from the spraying work area; Step B: The first robotic arm then moves along the first ground rail to the top of the first molding unit, and sprays a release agent into the molding mold running on the first ground rail assembly through a release agent nozzle, and then sprays paint into the molding mold; Step C: After spraying the release agent, the lifting curtain on the first floor rail assembly rises, and the molding die moves toward the spraying work area under the action of the drive mechanism. At the same time, the first robotic arm moves along the first floor rail to the top of the second molding unit and sprays the release agent into the molding die running on the second molding unit. Step D: After the forming mold reaches the spraying work area, an insert is manually placed in the forming mold, while the second robotic arm moves along the second rail to above the first forming unit. At the same time, the second robotic arm is driven down by an electric lift until the polyurethane mixture nozzle descends to the filling port of the forming mold and stops. The polyurethane mixture is then added to the forming cavity of the forming mold through the polyurethane mixture nozzle. Step E: When the molding die on the first molding unit is in the foaming reaction, the second robotic arm moves along the second rail to the top of the second molding unit and injects the polyurethane mixture into the molding cavity of the molding die running on the second molding unit; Step F: After the foaming reaction, open the molding die, take out the foamed product, and clean the molding die. After cleaning, return the mold along the floor rail assembly to the spraying work area for recycling.

[0014] Compared with the prior art, the present invention has the following beneficial effects: 1. The foam molding unit of the present invention uses a lifting curtain to separate the space into a filling work area and a spraying work area. A floor rail assembly allows the molding mold to switch between the filling and spraying work areas. Workers only need to work in the filling work area, which has a better environment. This solves the problem of poor working environment in foaming workshops that affects workers' physical and mental health. 2. The two molding units in the foaming molded product molding equipment of the present invention share the first robotic arm and the second robotic arm, thereby forming alternating operations. By utilizing the different times of foaming cooling and spraying, multiple groups of molding units can share one or several first robotic arms and second robotic arms. Through reasonable sharing design, the number of robotic arms in the molding equipment can be reduced, thereby reducing the cost of the molding equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a structural schematic diagram of a molding unit of a foamed molded product provided by the present invention; Figure 2 is a side view of a molding unit of a foam molded product provided by the present invention; Figure 3 This is a schematic structural diagram of the molding device provided by the present invention from a first perspective; Figure 4 This is a structural schematic diagram of the molding device provided by the present invention from a second perspective; Figure 5 is a side view of the molding device provided by the present invention; Figure 6 is a front view of the molding device provided by the present invention; Figure 7 It is a rear view of the molding equipment provided by the present invention.

[0016] In the figure: 1. Ground rail assembly; 2. Lifting curtain; 3. Molding mold; 4. Carrying trolley; 5. Driving mechanism; 100. Filling work area; 200. Spraying work area; 10. First robotic arm; 20. Release agent nozzle; 30. Second robotic arm; 40. Polyurethane mixture nozzle; 50. Negative pressure dust hood; 60. First rail; 70. Second rail. DETAILED DESCRIPTION

[0017] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments. The advantages and features of the present invention will become more apparent from the following description and claims. It should be noted that the drawings are greatly simplified and not to exact scale, and are intended solely to facilitate and clearly illustrate the embodiments of the present invention.

[0018] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0019] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0020] In addition, the features, operations, and characteristics described in this specification may be combined in any appropriate manner to form various embodiments. Similarly, the steps or actions described in the method may be reordered in a manner readily apparent to those skilled in the art. Therefore, the various sequences in the specification and drawings are provided for clarity of description of a particular embodiment and are not mandatory unless otherwise specified. Example

[0021] The present invention provides a molding unit for a foamed molded product. Figure 1 and Figure 2 , including a floor rail assembly 1, a lifting curtain 2 is provided in the middle of the floor rail assembly 1, which separates the space above the floor rail assembly 1 into a filling work area 100 and a spraying work area 200; a forming mold 3 runs on the floor rail assembly 1, so that the forming mold 3 switches its position between the filling work area 100 and the spraying work area 200.

[0022] Specifically, the forming mold 3 is installed on a carrying trolley 4 and moves back and forth along the ground rail assembly 1 under the action of a driving mechanism 5 .

[0023] In this embodiment, the driving mechanism 5 includes a driving motor, a driving gear and a running rack. The running rack is installed on the side wall of the ground rail assembly 1 and arranged along the length direction. The driving motor is installed on one side of the transport trolley 4. The driving gear is driven by the motor shaft to rotate, thereby driving the transport trolley 4 and the forming mold 3 above it to move back and forth along the ground rail assembly 1.

[0024] Furthermore, the forming mold 3 is rotatably connected to the carrying trolley 4 on one side via a rotating shaft, and a lifting cylinder is provided on the other side. The lifting cylinder is used to lift the forming mold 3, thereby adjusting the angle of the forming mold 3. When the internal structure of the forming cavity of the forming mold is complex or the space difference between the two sides is large, it is necessary to tilt the forming mold 3 at a certain angle to allow the polyurethane mixture to flow faster, thereby improving the forming effect.

[0025] The present invention also provides a foam molding equipment, please refer to Figure 3 and Figure 4 , including the above-mentioned molding unit, multiple molding units are arranged side by side and operate independently; and also include: A first robotic arm 10, wherein a release agent nozzle 20 is provided at an end of the first robotic arm 10, and a release agent is sprayed into the forming mold 3 through the release agent nozzle 20; A second robotic arm 30 , wherein a polyurethane mixture nozzle 40 is provided at the end of the second robotic arm 30 , and polyurethane mixture is injected into the forming mold 3 through the polyurethane mixture nozzle 40 ; The negative pressure dust removal hood 50 is disposed above the spraying work area 200 and is used to process the dust floating in the spraying work area 200 .

[0026] Specifically, the lifting curtains 2 in the multiple molding units operate independently, but are arranged in a straight line, so that the multiple filling work areas 100 are interconnected into a whole, and the multiple spraying work areas 200 are interconnected into a whole.

[0027] The molding units are grouped in pairs, and the molding molds 3 of the two molding units in the group operate alternately. The two molding units share the first robotic arm 10 and the second robotic arm 30, thereby achieving alternating operation. Taking advantage of the different times for foaming, cooling, and spraying, multiple groups of molding units can share one or more first robotic arms 10 and second robotic arms 30. Through a reasonable sharing design, the number of robotic arms in the molding equipment can be reduced, thereby reducing the cost of the molding equipment.

[0028] For details, please refer to Figure 5 and Figure 6 The first robotic arm 10 is a multi-axis robotic arm that can drive the release agent nozzle 20 at the end to spray the release agent on the molding cavity of the molding mold 3 at multiple angles; and the first robotic arm 10 is installed on the first overhead rail 60, which is located above the spraying work area 200 and spans multiple molding units, so that the first robotic arm 10 can spray the release agent on the molding molds 3 on different molding units.

[0029] For details, please refer to Figure 5 and Figure 7 The second robotic arm 30 is a suspended robotic arm, which is lifted up and down by an electric lifter; when it is lowered to the filling port of the forming mold 3, the polyurethane mixture is filled into the forming cavity of the forming mold 3 through the polyurethane mixture nozzle 40; and the second robotic arm 30 is installed on the second rail 70, which is located above the filling work area 100 and spans multiple molding units, so that the second robotic arm 30 can fill the molding molds 3 on different molding units with polyurethane mixture.

[0030] The present invention also provides a method for using the foam molding device, comprising the following steps: Step A: First, all the lifting curtains 2 are in the down state, separating the filling work area 100 from the spraying work area 200; Step B: The first robot arm 10 then moves along the first ground rail 60 to the top of the first molding unit, and uses the release agent nozzle 20 to spray a release agent into the molding mold 3 running on the first ground rail assembly 1, and then sprays paint into the molding mold 3; It should be noted here that the coating is a colored protective film, similar to the effect of paint; and the nozzle used to spray the coating is independently set and is also driven by the first robotic arm 10. The first robotic arm 10 is a multi-axis robotic arm that can achieve multi-angle switching.

[0031] Step C: After spraying the release agent, the lifting curtain 2 on the first floor rail assembly 1 is raised, and the molding die 3 moves toward the spraying work area 200 under the action of the driving mechanism 5. At the same time, the first robotic arm 10 moves along the first floor rail 60 to the top of the second molding unit and sprays the release agent into the molding die 3 running on the second molding unit; Step D: After the forming mold 3 reaches the spraying work area 200, an insert is manually placed in the forming mold 3, while the second robotic arm 30 moves along the second rail 70 to above the first forming unit. At the same time, the second robotic arm 30 is driven downward by the electric lifter until the polyurethane mixture nozzle 40 descends to the filling port of the forming mold 3 and stops. Then, the polyurethane mixture is filled into the forming cavity of the forming mold 3 through the polyurethane mixture nozzle 40. Step E: When the forming mold 3 on the first forming unit is in the foaming reaction, the second robot arm 30 moves along the second rail 70 to the top of the second forming unit and injects the polyurethane mixture into the forming cavity of the forming mold 3 running on the second forming unit; Step F: After the foaming reaction is completed, the forming mold 3 is opened, the foamed product therein is taken out, and the forming mold 3 is cleaned; after cleaning, it is returned to the spraying work area 200 along the ground rail assembly 1 for recycling.

[0032] The above description is only a description of the preferred embodiments of the present invention and does not limit the scope of the present invention. Any changes and modifications made by ordinary technicians in the field of the present invention based on the above disclosure shall fall within the scope of protection of the claims.

Claims

1. A molding unit for a foamed molded product, characterized in that: It comprises a floor rail assembly (1), wherein a lifting curtain (2) is provided in the middle of the floor rail assembly (1) to separate the space above the floor rail assembly (1) into a filling work area (100) and a spraying work area (200); A forming mold (3) is operated on the ground rail assembly (1), so that the forming mold (3) switches positions between the filling work area (100) and the spraying work area (200).

2. A molding unit for a foamed molded product according to claim 1, characterized in that: The forming mold (3) is mounted on a transport trolley (4) and moves back and forth along the ground rail assembly (1) under the action of a driving mechanism (5).

3. A foam molding unit according to claim 2, characterized in that: The forming mold (3) is rotatably connected to the transport trolley (4) on one side via a rotating shaft, and a lifting cylinder is provided on the other side. The forming mold (3) is lifted by the lifting cylinder, thereby adjusting the angle of the forming mold (3).

4. Molding equipment, characterized in that, The invention comprises a plurality of molding units for the foamed molded product according to claim 3, wherein the plurality of molding units are arranged side by side and spaced apart and operate independently; and further comprises: a first robotic arm (10), wherein a release agent nozzle (20) is provided at an end portion of the first robotic arm (10), and a release agent is sprayed into the molding die (3) through the release agent nozzle (20); a second robotic arm (30), wherein a polyurethane mixture nozzle (40) is provided at an end portion of the second robotic arm (30), and polyurethane mixture is injected into the forming mold (3) through the polyurethane mixture nozzle (40); The negative pressure dust removal hood (50) is arranged above the spraying work area (200) and is used to process dust floating in the spraying work area (200).

5. The molding device according to claim 4, characterized in that The lifting curtains (2) in the multiple molding units operate independently but are arranged in a straight line, so that the multiple filling work areas (100) are interconnected to form a whole, and the multiple spraying work areas (200) are interconnected to form a whole.

6. The molding device according to claim 5, characterized in that The molding units are grouped in pairs, and the molding dies (3) of the two molding units in the group operate alternately.

7. The molding device according to claim 6, characterized in that The first robotic arm (10) is a multi-axis robotic arm capable of driving a mold release nozzle (20) at its end to spray a mold release agent on a molding cavity of a molding mold (3) at multiple angles; and the first robotic arm (10) is mounted on a first overhead rail (60), the first overhead rail (60) being located above the spraying work area (200) and spanning across a plurality of molding units, so that the first robotic arm (10) can spray a mold release agent on molding molds (3) on different molding units.

8. The molding device according to claim 4, characterized in that The second robotic arm (30) is a suspended robotic arm and is raised and lowered by an electric lifter; when it is lowered to the filling port of the molding die (3), the polyurethane mixture is filled into the molding cavity of the molding die (3) through the polyurethane mixture nozzle (40); and the second robotic arm (30) is mounted on a second rail (70), which is located above the filling work area (100) and spans across multiple molding units, so that the second robotic arm (30) can fill the molding dies (3) on different molding units with polyurethane mixture.

9. A method for using a foam molding device, characterized in that: The steps include: Step A: First, all the lifting curtains (2) are in the down state, separating the filling work area (100) from the spraying work area (200); Step B: The first robot arm (10) then moves along the first ground rail (60) to the top of the first molding unit, and sprays a release agent into the molding mold (3) running on the first ground rail assembly (1) through a release agent nozzle (20), and then sprays a coating into the molding mold (3); Step C: After spraying the release agent, the lifting curtain (2) on the first ground rail assembly (1) is raised, and the molding mold (3) moves toward the spraying work area (200) under the action of the driving mechanism (5). At the same time, the first robot arm (10) moves along the first ground rail (60) to the top of the second molding unit and sprays the release agent into the molding mold (3) running on the second molding unit; Step D: After the forming mold (3) reaches the spraying work area (200), an insert is manually placed in the forming mold (3), and at the same time, the second robot arm (30) moves along the second rail (70) to the top of the first forming unit, and at the same time, the second robot arm (30) is driven down by the electric lifter; until the polyurethane mixture nozzle (40) descends to the filling port of the forming mold (3) and stops, and then the polyurethane mixture is filled into the forming cavity of the forming mold (3) through the polyurethane mixture nozzle (40); Step E: When the molding die (3) on the first molding unit is in the process of foaming, the second robot arm (30) moves along the second rail (70) to the top of the second molding unit, and injects the polyurethane mixture into the molding cavity of the molding die (3) running on the second molding unit; Step F: After the foaming reaction is completed, the forming mold (3) is opened, the foamed product therein is taken out, and the forming mold (3) is cleaned; after the cleaning is completed, the mold is returned to the spraying work area (200) along the ground rail assembly (1) for recycling.

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