Multifunctional production device for sinter plate production

Abstract

The invention relates to the technical field of sinter board production, and discloses a multifunctional production device for sinter board production, which comprises a raw material pretreatment unit for stirring and homogenizing raw materials and injecting the uniformly mixed raw materials into a mold; the forming unit comprises a mold preheating cabin and a forming cabin, the mold preheating cabin is used for preheating a mold, and after the mold is preheated in the mold preheating cabin, the uniformly mixed raw materials are injected into the mold and moved to the forming cabin for hot press forming; the mold output by the forming cabin enters the cooling unit to be cooled; and the sintering unit comprises a drying cabin and a sintering furnace. Through the arrangement of the waste heat utilization unit, waste gas of the sintering furnace heats the mold through the heat conduction oil circulation system and then is sequentially used for preheating the drying cabin, the mold preheating cabin and raw materials, multi-stage waste heat recovery and waste heat gradient utilization are achieved, on one hand, the heat efficiency is greatly improved, and on the other hand, energy loss in production is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of plastic-sintered board production, in particular to a multifunctional production device for plastic-sintered board production. Background Art

[0002] The sintered plate is the primary component of the sintered plate dust collector, performing both gas-solid and gas-liquid separation. Vertically mounted for easy maintenance, it boasts a large filter area and strong dust removal capabilities. It is widely used in industries such as steel rolling, metallurgy, chemicals, flue gas, pharmaceuticals, electronics, food processing, welding, and precious metal recovery. Its unique, wave-shaped sintered plate filter element replaces traditional bag filters. The rigid structure of the sintered plate prevents deformation and wear, resulting in a long service life that, under certain operating conditions, can exceed 10 times that of a bag. The sintered plate's surface is deeply treated, resulting in fine, uniform pores and hydrophobic properties that resist adhesion to moisture-rich dust. This makes the sintered plate dust collector the optimal choice for handling moisture-rich and fibrous dust.

[0003] However, the traditional plastic-fired board production process has the following technical bottlenecks: Energy consumption and thermal efficiency are insufficient. The existing sintering furnace exhaust gas (80-150℃) is directly discharged, resulting in heat energy waste. In addition, mold preheating relies on electric heating, and energy consumption accounts for more than 30% of the total production cost.

[0004] The raw materials are unevenly dispersed, and the traditional stirring process is difficult to break up the agglomerated particles of the polymer material, resulting in large fluctuations in the porosity of the plastic-sintered board (±15%), affecting the filtration accuracy and strength.

[0005] Defects in mold cooling and water quenching process can easily cause thermal deformation of the plastic-fired board (warpage ≥ 3%). Summary of the Invention

[0006] In view of the shortcomings of the existing technology, the present invention provides a multifunctional production device for the production of plastic-fired boards, which solves the problems of low energy efficiency, large porosity fluctuations and thermal deformation of plastic-fired boards in traditional plastic-fired board production processes.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solutions: A multifunctional production device for producing plastic-sintered boards, comprising: A raw material pretreatment unit, which is used to stir and homogenize the raw materials and inject the evenly mixed raw materials into the mold; The molding unit includes a mold preheating chamber and a molding chamber. The mold preheating chamber is used to preheat the mold. After the mold is preheated in the mold preheating chamber, the mixed raw materials are injected into the mold and moved to the molding chamber for hot pressing. Cooling unit: the mold output from the molding cabin enters the cooling unit for cooling; The sintering unit includes a drying chamber and a sintering furnace. The cooled mold is demoulded, and the formed plastic sintered plate is taken out and sent to the drying chamber for drying before being sent to the sintering furnace for sintering. The waste heat utilization unit includes a waste gas extraction device, which extracts the waste heat gas discharged from the sintering furnace through the waste gas extraction device and injects it into the heat exchanger of the thermal oil circulation device. After the heat transfer oil in the thermal oil circulation device exchanges heat with the waste heat gas in the heat exchanger, the mold inside the molding chamber is heated. The waste gas output by the heat exchanger is passed into the drying chamber to dry the plastic-sintered plate in the drying chamber. The waste gas discharged from the drying chamber then enters the mold preheating chamber and the raw material pretreatment unit respectively to preheat the mold in the mold preheating chamber and preheat the raw materials in the raw material pretreatment unit. The waste gas discharged from the mold preheating chamber and the raw material pretreatment unit is injected into the cooling unit to air-cool the mold and the plastic-sintered plate in the cooling unit.

[0008] Preferably, the exhaust gas extraction device includes a fan, the air inlet of the fan is connected to the exhaust gas discharge port of the sintering furnace through a pipeline, and the air outlet of the fan is connected to the air inlet of the heat exchanger through a pipeline.

[0009] Preferably, the heat transfer oil circulation device includes an oil storage tank, the heat exchanger is arranged in the oil storage tank and immersed in the heat transfer oil in the oil storage tank, the oil outlet and the oil inlet of the oil storage tank are connected through a circulating oil pipe, and the circulating oil pipe is connected to the mold heating cavity in the molding cabin. A circulating oil pump is also provided on the pipeline of the circulating oil pipe, and the heat transfer oil circulates between the oil storage tank and the mold heating cavity in the molding cabin through the circulating oil pump.

[0010] Preferably, a hanging rack 1 is provided in the drying chamber for hanging and fixing the formed plastic sintering plate, and the air inlet end of the drying chamber is connected to the exhaust port of the heat exchanger through a pipeline.

[0011] Preferably, the cooling unit includes a cooling chamber, in which a second suspension rack is provided, and the second suspension rack is used to suspend and fix the mold and the plastic sintering plate. A vibrator is provided at the bottom of the second suspension rack, and the vibrator drives the second suspension rack to vibrate. The exhaust end of the cooling chamber is connected to the exhaust gas treatment equipment.

[0012] Preferably, the raw material pretreatment unit includes a stirring tank and an injection machine. The raw material enters the stirring tank for stirring and is output to the injection machine, and then is injected into the mold in the mold preheating chamber by the injection machine. The air inlet of the stirring tank is connected to the exhaust end of the drying chamber through a pipe, and the air outlet of the stirring tank is connected to the air inlet end of the cooling chamber through a pipe.

[0013] Preferably, the air inlet end of the mold preheating chamber is connected to the exhaust end of the drying chamber through a pipeline, and the exhaust end of the mold preheating chamber is connected to the air inlet end of the cooling chamber through a pipeline.

[0014] Preferably, an ultrasonic disperser is further provided in the stirring tank, and a 20 kHz ultrasonic field is generated by the ultrasonic disperser to break up agglomerated particles of the raw materials in the stirring tank.

[0015] The present invention provides a multifunctional production device for producing plastic-sintered boards. It has the following beneficial effects: 1. The present invention sets up a waste heat utilization unit. The exhaust gas from the sintering furnace heats the mold through the heat transfer oil circulation system, and then is used in the drying chamber, the mold preheating chamber and the raw material preheating in sequence, realizing multi-stage waste heat recovery and waste heat gradient utilization. On the one hand, it achieves a significant improvement in thermal efficiency and avoids heat energy waste. On the other hand, it reduces energy loss in production and reduces production costs.

[0016] 2. The present invention avoids the agglomeration of raw materials in the stirring tank by combining a 20kHz ultrasonic field with a stirring state, greatly improves the uniformity of raw material mixing, and thus improves the molding quality of subsequent plastic-sintered boards.

[0017] 3. The present invention sets three temperature zones during sintering. The preheating zone causes the polymer matrix to initially soften, enhances the adhesion between particles, and reduces the risk of delamination after molding. At the same time, the lower temperature of the preheating zone is used to promote the full volatilization of residual moisture and organic solvents in the raw materials, and avoids the increase in porosity or cracking of the slurry caused by rapid evaporation of water, thereby reducing the risk of bubble generation in the subsequent high-temperature stage. The cross-linking zone enhances the activity of the polymer molecular chain, promotes the orderly arrangement of the molecular chains along the stress direction through long-term heat preservation, and improves the mechanical properties of the material. The stabilization zone increases the crystallinity of the polymer and improves the temperature resistance and chemical stability.

[0018] 4. By using exhaust gas with a certain temperature for cooling, the thermal stress concentration caused by rapid cooling is avoided and the internal cracks of the material are reduced. At the same time, the slow cooling combined with the vibration can eliminate the residual stress and improve the fatigue life of the material. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a three-dimensional schematic diagram of the present invention; Figure 2 Schematic diagram of the internal structure of the oil storage tank in the present invention; Figure 3 Schematic diagram of the internal structure of the drying cabin in the present invention; Figure 4 Schematic diagram of the internal structure of the cooling cabin in the present invention; Figure 5 Schematic diagram of the system principle of the present invention.

[0020] Among them, 1. Mold preheating chamber; 2. Molding chamber; 3. Drying chamber; 4. Sintering furnace; 5. Heat exchanger; 6. Fan; 7. Oil storage tank; 8. Circulating oil pipe; 9. Circulating oil pump; 10. Suspension rack 1; 11. Cooling chamber; 12. Suspension rack 2; 13. Vibrator; 14. Mixing tank; 15. Injection machine. DETAILED DESCRIPTION

[0021] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0022] Please see the attached Figure 1 -Attached Figure 5 The embodiment of the present invention provides a multifunctional production device for producing plastic-sintered boards, comprising: A raw material pretreatment unit is used to stir and homogenize the raw materials and inject the uniformly mixed raw materials into the mold. Before the raw materials are injected into the mold, the mold can be vacuumed in advance to ensure uniform injection of the raw materials and reduce filling density errors; The molding unit includes a mold preheating chamber 1 and a molding chamber 2. The mold preheating chamber 1 is used to preheat the mold. After the mold is preheated in the mold preheating chamber 1, the uniformly mixed raw materials are injected into the mold and moved to the molding chamber 2 for hot pressing. The hot pressing adopts a two-stage pressurization method. The initial stage is 0.5MPa holding pressure for 30 seconds to promote the flow of slurry to fill the mold. The final stage is 1.5MPa holding pressure for 120 seconds to compact the pore structure to reduce porosity and improve mechanical strength. Cooling unit: the mold output from the molding cabin 2 enters the cooling unit for cooling; The sintering unit includes a drying chamber 3 and a sintering furnace 4. The cooled mold is demoulded, and the formed plastic sintered plate is taken out and sent to the drying chamber 3 for drying, and then sent to the sintering furnace 4 for sintering. The sintering furnace 4 is provided with three temperature zones, which are: The preheating stage (180°C / 30min) is used to eliminate residual moisture after drying; the cross-linking stage (220°C / 60min) is used to promote the directional arrangement of polymer molecular chains; and the stabilization stage (190°C / 40min) is used to achieve gradient cooling to reduce thermal stress. By setting three temperature zones during sintering, the preheating section allows the polymer matrix to initially soften, enhancing the adhesion between particles and reducing the risk of delamination after molding. At the same time, the lower temperature of the preheating section is used to fully volatilize the residual moisture and organic solvent in the raw materials, and avoid the increase in porosity or cracking of the slurry caused by rapid evaporation of water, thereby reducing the risk of bubble generation in the subsequent high-temperature stage. The cross-linking section enhances the activity of the polymer molecular chain, and through long-term heat preservation, promotes the orderly arrangement of the molecular chains along the stress direction, thereby improving the mechanical properties of the material. The stabilization section increases the crystallinity of the polymer, improving the temperature resistance and chemical stability.

[0023] The waste heat utilization unit includes an exhaust gas extraction device, which extracts the waste heat gas discharged from the sintering furnace 4 and injects it into the heat exchanger 5 of the thermal oil circulation device. After the thermal oil in the thermal oil circulation device exchanges heat with the waste heat gas in the heat exchanger 5, the mold inside the molding chamber 2 is heated. The exhaust gas output by the heat exchanger 5 is passed into the drying chamber 3 to dry the plastic sintered plate in the drying chamber 3. The exhaust gas discharged from the drying chamber 3 then enters the mold preheating chamber 1 and the raw material pretreatment unit respectively to preheat the mold in the mold preheating chamber 1 and the raw material pretreatment unit. The exhaust gas discharged from the mold preheating chamber 1 and the raw material pretreatment unit is injected into the cooling unit to air-cool the mold and plastic sintered plate in the cooling unit. The air inlet end of the mold preheating chamber 1 is connected to the exhaust end of the drying chamber 3 through a pipeline, and the exhaust end of the mold preheating chamber 1 is connected to the air inlet end of the cooling chamber 11 through a pipeline.

[0024] By setting up the waste heat utilization unit, the exhaust gas from the sintering furnace 4 heats the mold through the thermal oil circulation system, and is then used in the drying chamber 3, the mold preheating chamber 1 and the raw material preheating in sequence, realizing multi-stage waste heat recovery and waste heat gradient utilization. On the one hand, it achieves a significant improvement in thermal efficiency and avoids heat energy waste. On the other hand, it reduces energy loss in production and reduces production costs.

[0025] For the mold, a modular magnetic interface (nickel-plated for corrosion protection) is used. Specifically, the mold is divided into an outer shell and an inner core. The outer shell is fixed, while the inner core can be quickly replaced according to actual production needs to improve the universality of the mold. At the same time, a super-hydrophobic graphene coating (contact angle > 160°) is applied to the contact surface between the mold and the raw material, and zero-residue demolding can be achieved without a release agent. The mold change time is ≤5 minutes.

[0026] At the same time, heat dissipation fins can be set on the outer wall of the mold to improve the efficiency of mold preheating and heat dissipation.

[0027] The heat transfer oil circulation device includes an oil storage tank 7, a heat exchanger 5 is arranged in the oil storage tank 7 and immersed in the heat transfer oil in the oil storage tank 7, the oil outlet and the oil inlet of the oil storage tank 7 are connected through a circulating oil pipe 8, and the circulating oil pipe 8 is connected to the mold heating cavity in the molding cabin 2. A circulating oil pump 9 is also arranged on the circulating oil pipe 8, and the heat transfer oil circulates between the oil storage tank 7 and the mold heating cavity in the molding cabin 2 through the circulating oil pump 9.

[0028] The exhaust gas extraction device includes a fan 6, an air inlet of the fan 6 is connected to the exhaust gas discharge port of the sintering furnace 4 through a pipeline, and an air outlet of the fan 6 is connected to the air inlet of the heat exchanger 5 through a pipeline.

[0029] The exhaust gas from the sintering furnace 4 heats the thermal oil through the heat exchanger 5, providing a stable heat source for the molding chamber 2. Furthermore, a PID temperature control algorithm can be used for the thermal oil circulation system to ensure the heating accuracy of the mold in the molding chamber 2.

[0030] A hanging frame 10 is provided in the drying chamber 3 for hanging and fixing the formed sintered plate. The air inlet end of the drying chamber 3 is connected to the exhaust port of the heat exchanger 5 through a pipeline.

[0031] The exhaust gas enters the drying chamber 3 after passing through the heat exchanger 5, and is evenly distributed through the hanging rack 10 to achieve rapid drying of the plastic sintered board; the dry exhaust gas is then divided into two paths, entering the mold preheating chamber 1 to preheat the mold and the mixing tank to preheat the raw materials.

[0032] It should be noted that during production, multiple molds are placed in the mold preheating chamber 1 for unified preheating to reduce the time wasted in the mold preheating step.

[0033] The cooling unit includes a cooling chamber 11, in which a second hanging frame 12 is provided. The second hanging frame 12 is used to suspend and fix the mold and the sintering plate. A vibrator 13 is provided at the bottom of the second hanging frame 12, which drives the second hanging frame 12 to vibrate. The exhaust end of the cooling chamber 11 is connected to the exhaust gas treatment equipment.

[0034] Finally, the exhaust gas enters the cooling chamber 11, where it combines with the vibrator 13 to drive the high-frequency vibration of the second suspension frame 12, accelerating cooling and reducing stress within the sintered board. It should be noted that the exhaust gas still has a certain temperature at this point, which has been verified to be 40-50°C. Using exhaust gas in this temperature range to cool the mold and sintered board in the cooling chamber 11 can solve the problem of sudden shrinkage caused by excessive cooling, thereby improving the molding quality of the sintered board.

[0035] The cooling step uses exhaust gas with a certain temperature to avoid thermal stress concentration caused by rapid cooling and reduce internal cracks in the material. At the same time, slow cooling combined with vibration can eliminate residual stress and improve the fatigue life of the material.

[0036] The raw material pretreatment unit includes a mixing tank 14 and an injector 15. The raw materials enter the mixing tank 14, where they are stirred and then output to the injector 15. The injector 15 then injects the raw materials into the mold within the mold preheating chamber 1. The air inlet of the mixing tank 14 is connected to the exhaust port of the drying chamber 3 via a pipe, while the air outlet of the mixing tank 14 is connected to the air inlet of the cooling chamber 11 via a pipe. An ultrasonic disperser is also installed within the mixing tank 14, generating a 20kHz ultrasonic field to break up agglomerated raw material particles within the mixing tank 14.

[0037] After the raw materials are screened to remove impurities, they are dried in an air flow dryer until the moisture content is ≤0.5%; Silane coupling agent is used to modify the raw material particles to enhance their bonding strength and reduce the risk of high-temperature stratification.

[0038] By combining the 20kHz ultrasonic field with the stirring state, the agglomeration of raw materials in the mixing tank is avoided, the uniformity of raw material mixing is greatly improved, and the molding quality of subsequent plastic-sintered boards is improved.

[0039] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A multifunctional production device for producing plastic-sintered boards, characterized in that: include: A raw material pretreatment unit, which is used to stir and homogenize the raw materials and inject the evenly mixed raw materials into the mold; A molding unit comprising a mold preheating chamber (1) and a molding chamber (2), wherein the mold preheating chamber (1) is used to preheat the mold, and after the mold is preheated in the mold preheating chamber (1), the uniformly mixed raw materials are injected into the mold and moved to the molding chamber (2) for a hot pressing molding step; A cooling unit, wherein the mold output from the molding chamber (2) enters the cooling unit for cooling; A sintering unit comprises a drying chamber (3) and a sintering furnace (4), wherein the cooled mold is demoulded, the formed plastic sintered plate is taken out, and is sent to the drying chamber (3) for drying, and then sent to the sintering furnace (4) for sintering; The waste heat utilization unit includes a waste gas extraction device, which extracts waste heat gas discharged from the sintering furnace (4) through the waste gas extraction device and injects it into the heat exchanger (5) of the heat transfer oil circulation device. After the heat transfer oil in the heat transfer oil circulation device exchanges heat with the waste heat gas in the heat exchanger (5), the mold inside the molding chamber (2) is heated. The waste gas output by the heat exchanger (5) is passed into the drying chamber (3) to dry the plastic sintering plate in the drying chamber (3). The waste gas discharged from the drying chamber (3) then enters the mold preheating chamber (1) and the raw material pretreatment unit respectively to preheat the mold in the mold preheating chamber (1) and the raw material pretreatment unit. The waste gas discharged from the mold preheating chamber (1) and the raw material pretreatment unit is injected into the cooling unit to air-cool the mold and the plastic sintering plate in the cooling unit.

2. A multifunctional production device for producing plastic-sintered boards according to claim 1, characterized in that: The exhaust gas extraction device comprises a fan (6), the air inlet of the fan (6) is connected to the exhaust gas discharge port of the sintering furnace (4) through a pipeline, and the air outlet of the fan (6) is connected to the air inlet of the heat exchanger (5) through a pipeline.

3. The multifunctional production device for producing plastic-sintered boards according to claim 1, characterized in that: The heat transfer oil circulation device comprises an oil storage tank (7), the heat exchanger (5) is arranged in the oil storage tank (7) and immersed in the heat transfer oil in the oil storage tank (7), the oil outlet and the oil inlet of the oil storage tank (7) are connected through a circulating oil pipe (8), and the circulating oil pipe (8) is connected to the mold heating cavity in the molding chamber (2), and a circulating oil pump (9) is also arranged on the pipeline of the circulating oil pipe (8), and the heat transfer oil circulates between the oil storage tank (7) and the mold heating cavity in the molding chamber (2) through the circulating oil pump (9).

4. The multifunctional production device for producing plastic-sintered boards according to claim 2, characterized in that: A hanging frame (10) is provided in the drying chamber (3) for hanging and fixing the formed plastic sintering plate. The air inlet end of the drying chamber (3) is connected to the exhaust port of the heat exchanger (5) through a pipeline.

5. The multifunctional production device for producing plastic-sintered boards according to claim 4, characterized in that: The cooling unit comprises a cooling chamber (11), wherein a second suspension frame (12) is provided in the cooling chamber (11), wherein the second suspension frame (12) is used to suspend and fix the mold and the plastic sintering plate, and a vibrator (13) is provided at the bottom of the second suspension frame (12), and the second suspension frame (12) is driven to vibrate by the vibrator (13), and an exhaust end of the cooling chamber (11) is connected to an exhaust gas treatment device.

6. The multifunctional production device for producing plastic-sintered boards according to claim 5, characterized in that: The raw material pretreatment unit comprises a stirring tank (14) and an injection machine (15). The raw material enters the stirring tank (14), is stirred, and then output to the injection machine (15). The injection machine (15) injects the raw material into the mold in the mold preheating chamber (1). The air inlet of the stirring tank (14) is connected to the exhaust end of the drying chamber (3) through a pipeline, and the air outlet of the stirring tank (14) is connected to the air inlet end of the cooling chamber (11) through a pipeline.

7. The multifunctional production device for producing plastic-sintered boards according to claim 5, characterized in that: The air inlet end of the mold preheating chamber (1) is connected to the air outlet end of the drying chamber (3) through a pipeline, and the air outlet end of the mold preheating chamber (1) is connected to the air inlet end of the cooling chamber (11) through a pipeline.

8. The multifunctional production device for producing plastic-sintered boards according to claim 6, characterized in that: An ultrasonic disperser is also provided in the stirring tank (14), and a 20 kHz ultrasonic field is generated by the ultrasonic disperser to break up agglomerated particles of the raw materials in the stirring tank (14).

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