Wet pu sheet opening method

Abstract

The present application provides a kind of wet PU sheet opening method, it can realize small aperture and large density opening to the PU sheet of smaller density, and can be suitable for PU sheet of different thickness, degree of automation and operation efficiency are high, and avoid dust pollution.The steps include: a, the sheet is placed between the upper and lower relative support plate and upper pressing plate, and the sheet is pressed by the relative movement of support plate and upper pressing plate;B, the needle plate with multiple needles moves to the direction close to the sheet, so that the needle passes through the upper pressing plate, support plate, sheet;C, then the needle plate moves reversely, and the needle is pulled out from the upper pressing plate, support plate and sheet;D, the sheet is loosened by the opposite movement of support plate and upper pressing plate;F, take out the sheet.

Description

Technical Field

[0001] This invention belongs to the field of polyurethane (PU) sheet opening technology, specifically a wet-process PU sheet opening method. Background Technology

[0002] Polyurethane (PU) is a polymer material with excellent mechanical properties, formed by the polymerization reaction of polyols and isocyanates. Wet-process PU sheets are cut from the polyurethane foam after polymerization. Wet-process PU has a low open-cell ratio and an air permeability of less than 1.0. When used in ceiling molding, it is prone to sticking to the adhesive rollers, causing the gas in the sheet to form closed cells. When heated, this can easily lead to bulging, delamination, and deformation. Therefore, it is necessary to open the PU sheets. However, the pore size cannot be too large, otherwise it will affect the performance of the PU sheet. This requires small pore size and small pore spacing (high pore density). Given the low density of PU sheets themselves, how to efficiently open pores in PU sheets is a challenge. Summary of the Invention

[0003] The purpose of this invention is to provide a wet-process PU sheet opening method that can achieve small-diameter and high-density openings in PU sheets with low density, and is applicable to PU sheets of different thicknesses. It has a high degree of automation and operation efficiency, and avoids dust pollution.

[0004] To achieve the above-mentioned technical objectives, the technical solution adopted by the present invention is as follows:

[0005] The wet-process PU sheet perforation method includes the following steps: a) placing the sheet between an upper and lower opposing support plate and an upper pressure plate, and pressing the sheet by the relative movement of the support plate and the upper pressure plate; b) moving a needle plate with multiple needles toward the sheet, so that the needles pass through the upper pressure plate, the support plate, and the sheet; c) then moving the needle plate in the opposite direction, and pulling the needles out from the upper pressure plate, the support plate, and the sheet; d) loosening the sheet by the opposite movement of the support plate and the upper pressure plate; f) removing the sheet.

[0006] The above-mentioned wet-process PU sheet perforation method includes the following steps: a) feeding the sheet so that a portion of the sheet is placed between an upper and lower opposing support plate and an upper pressure plate, and pressing the portion of the sheet located between the support plate and the upper pressure plate by the relative movement of the support plate and the upper pressure plate; b) moving a needle plate with multiple needles toward the sheet so that the needles pass through the upper pressure plate, the support plate, and the portion of the sheet located between the support plate and the upper pressure plate; c) then moving the needle plate in the opposite direction, and pulling the needles out from the upper pressure plate, the support plate, and the sheet; d) releasing the sheet by the opposite movement of the support plate and the upper pressure plate.

[0007] Repeat steps a, b, c, and d until the entire sheet is perforated, then proceed to step f and remove the sheet.

[0008] The above-mentioned wet PU sheet opening method uses equipment for improving wet PU opening. The equipment for improving wet PU opening includes a frame, a clamping device for pressing the PU sheet, a conveying device for conveying the PU sheet, and a needle punching device for needle punching the PU sheet.

[0009] A support plate is installed on the frame;

[0010] The pressing device includes a pressing frame that moves up and down, and an upper pressure plate that is set on the pressing frame and is opposite to the support plate. The pressing frame moves up and down relative to the frame under the drive of the pressing power mechanism, thereby changing the distance between the upper pressure plate and the support plate to press the sheet material located between the support plate and the upper pressure plate.

[0011] The needle-punching device is mounted on the frame and includes a needle plate, multiple downward-extending needles connected to the needle plate, and a needle-punching power device that drives the needle plate to move up and down relative to the support plate and the upper pressure plate. When the needle-punching power device drives the needle plate to move up and down, each needle passes through the upper pressure plate, the support plate, and the sheet material located between the support plate and the upper pressure plate, thereby puncturing the sheet material.

[0012] The conveying device includes two pairs of conveying rollers arranged on both sides of the upper and lower opposing support plates and upper pressure plates. Each pair of conveying rollers includes an upper pressure roller and a lower pressure roller. When the upper pressure plate moves away from the support plate, the conveying device drives the sheet to feed the sheet between the support plate and the upper pressure plate, or drives the sheet away from the support plate and the upper pressure plate.

[0013] The above-mentioned wet-process PU sheet opening method, the equipment for improving the opening of wet-process PU also includes a dust collection device, which includes a dust suction pipe, a fan, and a filter bag; one end of the dust suction pipe is connected to the dust channel in the frame, and the other end is connected to the filter bag; the lower part of the support plate is connected to the dust channel, and the lower periphery of the support plate is sealed to the frame, and the fan is set in the dust channel or the dust suction pipe.

[0014] In the aforementioned wet-process PU sheet perforation method, the needle plate is slidably mounted on the frame, and the needle power unit includes a motor mounted on the frame. The motor drives the needle plate to move up and down relative to the upper pressure plate and the support plate through the needle transmission mechanism.

[0015] In the above-mentioned wet-process PU sheet perforation method, the needle transmission mechanism is a crank-slider mechanism or a gear-rack mechanism.

[0016] In the above-mentioned wet-process PU sheet perforation method, the needle transmission mechanism is a crank-slider mechanism, with a turntable fixed on the output shaft of the motor, one end of the connecting rod being eccentrically hinged to the turntable, and the other end being hinged to the needle plate.

[0017] The above-mentioned wet-process PU sheet perforation method uses a gear and rack mechanism for the needle transmission. A drive gear is fixed on the output shaft of the motor. The drive gear directly meshes with the rack or indirectly meshes with the rack through an intermediate gear. The rack is fixedly connected to the needle plate.

[0018] In the above-mentioned wet-process PU sheet perforation method, the needle power device is a cylinder, the cylinder body is fixed on the frame, and the piston rod of the cylinder is fixedly connected to the needle plate.

[0019] The above-mentioned wet PU sheet opening method includes a conveyor belt conveyor located on both sides of each pair of conveyor rollers. The sheet conveyed by one conveyor belt conveyor enters a pair of conveyor rollers and is then fed between the support plate and the upper pressure plate. The sheet leaving the support plate and the upper pressure plate enters a pair of conveyor rollers and is then sent to another conveyor belt conveyor.

[0020] In the above-mentioned wet-process PU sheet perforation method, each conveyor belt conveying device includes a conveyor belt and at least two tension rollers for tensioning the conveyor belt; one tension roller in a conveyor belt conveying device is one of the pressure rollers in a pair of conveyor rollers.

[0021] The above-mentioned wet-process PU sheet perforation method requires 2-4 needles per cm. 2 The diameter of the needle is 1-2 mm.

[0022] The beneficial effects of this invention are as follows:

[0023] This wet-process PU sheet punching method involves pressing, piercing, and needle removal, which is quick and efficient, preventing the sheet from sticking to the needle due to friction and other factors, resulting in good punching effect.

[0024] The cyclical action of feeding, pressing, needle punching, needle removal, and loosening makes the operation fast and more efficient.

[0025] When using the equipment for improving the opening of wet-process PU, the sheet is placed between the upper and lower opposing support plates and the upper pressure plate. The clamping power mechanism drives the clamping frame to move downward, and the upper pressure plate, which is set on the clamping frame, moves downward, approaching the support plate and pressing the sheet between the support plate and the upper pressure plate. Then, the needle power device drives the needle plate with multiple needles to move towards the sheet, so that the needles pass through the upper pressure plate, the support plate, and the sheet. Next, the needle power device drives the needle plate to move in the opposite direction, and the needles are pulled out from the upper pressure plate, the support plate, and the sheet. Then, the clamping power mechanism drives the clamping frame to move upward, and the upper pressure plate moves away from the support plate, releasing the sheet. The sheet can then be removed.

[0026] The sheet is pressed tightly by the upper pressure plate and the support plate. Even if the sheet has low density, light weight, and many needles, the friction between the sheet and the needles is large, and the sheet will not move with the needles. The needles can pierce the sheet, which can effectively open small-diameter and high-density holes in PU sheets with low density. It can also be applied to PU sheets of different thicknesses, resulting in high work efficiency.

[0027] The conveying device can feed unperforated sheets between the support plate and the upper pressure plate, or drive perforated sheets away from the support plate and the upper pressure plate, further improving the level of automation and efficiency of the operation.

[0028] Dust is inevitably generated when the needle pierces the sheet. To prevent dust from escaping, a dust collection device is installed to reduce dust pollution and improve the air quality of the working environment.

[0029] By simultaneously incorporating one tensioning roller in the conveyor belt system as a pressure roller in a pair of conveyor rollers, the structure is further simplified.

[0030] The number of needles on the lower surface of the needle plate is 2-4 per cm. 2 The needle diameter is 1-2mm. After the needle pierces the sheet, it can form dense small holes on the sheet, effectively increasing the open area ratio of the sheet.

[0031] After opening the sheets using this equipment, the air permeability of the sheets is significantly improved. During the production of automotive headliners using these sheets, consistent adhesive application with rollers is ensured, effectively reducing quality issues such as bulging, delamination, and deformation during headliner molding. During the headliner molding process, the liquid thermosetting polyurethane adhesive penetrates more easily into the PU substrate, forming a strong "anchoring" effect and improving the interlayer adhesion of wet-process headliners. Furthermore, it exhibits excellent sound absorption and insulation performance; sound waves easily enter the foam cells to absorb energy, resulting in better sound absorption and insulation. Attached Figure Description

[0032] Figure 1 This is the main view of the equipment for improving the opening of wet PU (with the barbed needles removed).

[0033] Figure 2 This is the front view of the sheet material when the needle plate and piercing needle are connected.

[0034] Figure 3 yes Figure 2 Side view.

[0035] In the figure, the left side is the conveyor belt conveyor device 1, the right side is the conveyor belt conveyor device 2, the left upper pressure roller 3, the left lower pressure roller 4, the right lower pressure roller 5, the right upper pressure roller 6, the pressing frame 7, the lifting gear 8, the support plate 9, the frame 10, the upper pressure plate 11, the needle plate 12, the motor 14, the needle 17, the sheet 20, the dust suction pipe 21, the dust collection pipe 22, and the filter bag 23. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] Please see Figure 1 The apparatus shown includes a frame 10, a clamping device for pressing PU sheets, a conveying device for conveying PU sheets, and a needle punching device for needle punching PU sheets; a support plate 9 is provided on the frame.

[0038] The clamping device includes a clamping frame 7 that slides vertically on the frame, and an upper pressure plate 11 fixed on the clamping frame and opposite to the support plate. Driven by a clamping power mechanism, the clamping frame moves vertically relative to the frame, thereby changing the distance between the upper pressure plate and the support plate to clamp the sheet 20 located between the support plate and the upper pressure plate. The clamping power mechanism mainly includes a lifting gear 8 rotatably mounted on the frame, a lifting rack meshing with the lifting gear and fixed on the clamping frame, and a lifting motor (not shown) fixed on the frame that drives the lifting gear. Both the support plate 9 and the upper pressure plate 11 have multiple through holes through which needles can pass.

[0039] The needle-piercing device is mounted on a frame and includes a needle plate 12, multiple downwardly extending needles 17 connected to the needle plate, and a needle power unit that drives the needle plate to move up and down relative to a support plate and an upper pressure plate. The needle plate 12 is fixed to a needle plate frame, which is slidably mounted on the frame. The needle power unit includes a motor 14 fixed to the frame, a turntable fixed to the motor's output shaft, one end of a connecting rod eccentrically hinged to the turntable, and the other end hinged to the needle plate frame. The motor 14 drives the needle plate to move up and down relative to the upper pressure plate and support plate via a crank-slider mechanism composed of the turntable, connecting rod, and needle plate frame.

[0040] Of course, the needle power unit may not use motor 14, crank-slider mechanism, etc. Instead, the needle power unit can directly use cylinder. The cylinder body is fixed on the frame, and the cylinder piston rod is fixedly connected to the needle plate or needle plate frame. The needle plate or needle plate frame is moved up and down by the cylinder.

[0041] When the needle power unit drives the needle plate to move up and down, each needle passes through the through hole on the upper pressure plate, the through hole on the support plate, and the sheet material located between the support plate and the upper pressure plate, thereby piercing the sheet material.

[0042] Two pairs of conveyor rollers are arranged on both sides of the upper and lower opposing support plates and pressure plates. Each pair of conveyor rollers includes an upper pressure roller and a lower pressure roller. The left conveyor rollers include a left upper pressure roller 3 and a left lower pressure roller 4, and the right conveyor rollers include a right upper pressure roller 6 and a right lower pressure roller 5. Conveyor belt conveying devices are arranged on both sides of each pair of conveyor rollers. Each conveyor belt conveying device includes a conveyor belt and at least two tensioning rollers for tensioning the conveyor belt. The right tensioning roller in the left conveyor belt conveying device 1 is the left lower pressure roller 4 in the left conveyor rollers. When the pressure plate moves away from the support plate, the conveyor device drives the sheet material, feeding the sheet material between the support plate and the upper pressure plate, or driving the sheet material away from the support plate and the upper pressure plate.

[0043] The number of needles on the lower surface of the needle plate is 2-4 per cm. 2 The diameter of the needle is 1-2 mm.

[0044] The dust collection device includes a suction pipe 21, a fan, a dust collection pipe 22, and a filter bag 23. One end of the suction pipe 21 is connected to the dust channel inside the frame, and the other end is connected to the filter bag 23 through the dust collection pipe 22. The lower part of the support plate 9 is connected to the dust channel, and the lower periphery of the support plate is sealed to the frame. The fan is installed inside the dust channel or the suction pipe.

[0045] a. The working process is as follows: A portion of the sheet 20 conveyed by the right-side conveyor belt 2 enters the right-side conveyor roller and is then fed between the support plate and the upper pressure plate, so that a portion of the sheet is placed between the upper and lower opposing support plates and the upper pressure plate. Then the conveyor belt 2 and the right-side conveyor roller stop working.

[0046] b. The clamping power mechanism operates, driving the clamping frame (including the lower pressure plate) to move downward, and the lower pressure plate clamps a portion of the sheet 20 located between the support plate and the upper pressure plate; the clamping power mechanism stops operating.

[0047] c. The needle power unit drives the needle plate frame and needle plate to move downwards, and each needle passes through the through holes in the upper pressure plate, the through holes in the support plate, and the sheet material located between the support plate and the upper pressure plate, thereby piercing the sheet material. The needle power unit then drives the needle plate frame and needle plate to move upwards, and the needles are pulled out from the upper pressure plate, the support plate, and the sheet material.

[0048] d. The clamping power mechanism operates, driving the clamping frame (including the lower pressure plate) to move upward, and the lower pressure plate releases the sheet 20 located between the support plate and the upper pressure plate; the clamping power mechanism stops operating.

[0049] e. Feeding: The right-side conveyor belt 2 operates, feeding the unperforated portion of the sheet 20 into the right-side conveyor roller and then between the support plate and the upper pressure plate, thus placing the unperforated portion of the sheet between the upper and lower opposing support plates and the upper pressure plate. At the same time, the left-side conveyor belt 1 and the left-side conveyor roller operate, feeding the perforated portion of the sheet onto the transmission belt on the left-side conveyor belt 1. Then, the conveyor belts and conveyor rollers on both sides stop operating.

[0050] f. Pressing: The pressing power mechanism operates, driving the pressing frame (including the lower pressing plate) to move downwards, and the lower pressing plate presses the unperforated part of the sheet 20 located between the support plate and the upper pressing plate; the pressing power mechanism stops working.

[0051] g. Needle piercing: The needle power unit drives the needle plate frame and needle plate to move downwards, and each needle passes through the through hole on the upper pressure plate, the through hole on the support plate, and the sheet material located between the support plate and the upper pressure plate, thereby piercing the sheet material. Needle removal: The needle power unit then drives the needle plate frame and needle plate to move upwards, and the needle is pulled out from the upper pressure plate, the support plate, and the sheet material.

[0052] h. Loosening the material: The pressing power mechanism is working, driving the pressing frame (including the lower pressing plate) to move upward, and the lower pressing plate loosens the sheet 20 located between the support plate and the upper pressing plate; the pressing power mechanism stops working.

[0053] Repeat steps e, f, g, and h above until the entire sheet is punched.

[0054] The scope of protection of this invention includes, but is not limited to, the above embodiments. The scope of protection of this invention is defined by the claims. Any substitutions, modifications, or improvements to this technology that are easily conceived by those skilled in the art fall within the scope of protection of this invention.

Claims

1. A method for creating openings in wet-process PU sheets, characterized by the following steps: include: a. Place the sheet between the upper and lower opposing support plates and the upper pressure plate, and press the sheet together by moving the support plates and the upper pressure plate relative to each other; b. Move the needle plate with multiple needles toward the sheet, so that the needles pass through the upper pressure plate, the support plate, and the sheet; c. Then the needle plate moves in the opposite direction, and the needles are pulled out from the upper pressure plate, the support plate, and the sheet; d. Release the sheet by moving the support plates and the upper pressure plate in opposite directions. f. Remove the sheet.

2. The wet-process PU sheet opening method as described in claim 1, characterized in that, step include: a. The sheet is fed so that a portion of the sheet is placed between the upper and lower opposing support plates and the upper pressure plate. The relative movement of the support plates and the upper pressure plate presses the portion of the sheet between them. b. A needle plate with multiple needles moves toward the sheet, so that the needles pass through the upper pressure plate, the support plate, and the portion of the sheet between the support plates and the upper pressure plate. c. Then the needle plate moves in the opposite direction, and the needles are pulled out from the upper pressure plate, the support plate, and the sheet. d. The sheet is released by the opposing movement of the support plates and the upper pressure plate. Repeat steps a, b, c, and d until the entire sheet is perforated, then proceed to step f and remove the sheet.

3. The wet-process PU sheet perforation method as described in claim 2, characterized in that, The device for improving the opening of wet-process PU includes a frame, a clamping device for pressing PU sheets, a conveying device for conveying PU sheets, and a needle punching device for needle punching PU sheets. A support plate is installed on the frame; The pressing device includes a pressing frame that moves up and down, and an upper pressure plate that is set on the pressing frame and is opposite to the support plate. The pressing frame moves up and down relative to the frame under the drive of the pressing power mechanism, thereby changing the distance between the upper pressure plate and the support plate to press the sheet material located between the support plate and the upper pressure plate. The needle-punching device is mounted on the frame and includes a needle plate, multiple downward-extending needles connected to the needle plate, and a needle-punching power device that drives the needle plate to move up and down relative to the support plate and the upper pressure plate. When the needle-punching power device drives the needle plate to move up and down, each needle passes through the upper pressure plate, the support plate, and the sheet material located between the support plate and the upper pressure plate, thereby puncturing the sheet material. The conveying device includes two pairs of conveying rollers arranged on both sides of the upper and lower opposing support plates and upper pressure plates. Each pair of conveying rollers includes an upper pressure roller and a lower pressure roller. When the upper pressure plate moves away from the support plate, the conveying device drives the sheet to feed the sheet between the support plate and the upper pressure plate, or drives the sheet away from the support plate and the upper pressure plate.

4. The wet-process PU sheet perforation method as described in claim 3, characterized in that, The equipment for improving the opening of wet PU also includes a dust collection device, which includes a suction pipe, a fan, and a filter bag. One end of the suction pipe is connected to the dust channel inside the frame, and the other end is connected to the filter bag. The lower part of the support plate is connected to the dust channel, and the lower periphery of the support plate is sealed to the frame. The fan is installed inside the dust channel or the suction pipe.

5. The wet-process PU sheet perforation method as described in claim 3, characterized in that, The needle plate is slidably mounted on the frame. The needle power unit includes a motor mounted on the frame. The motor drives the needle plate to move up and down relative to the upper pressure plate and the support plate through the needle transmission mechanism.

6. The wet-process PU sheet opening method as described in claim 5, characterized in that, The needle transmission mechanism is a crank-slider mechanism or a gear and rack mechanism.

7. The wet-process PU sheet perforation method as described in claim 3, characterized in that, The needle power unit is a cylinder, the cylinder body is fixed on the frame, and the piston rod of the cylinder is fixedly connected to the needle plate.

8. The wet-process PU sheet opening method as described in claim 3, characterized in that, The conveying device also includes a conveyor belt conveyor located on both sides of each pair of conveyor rollers; the sheet conveyed by one conveyor belt conveyor enters a pair of conveyor rollers and is then fed between the support plate and the upper pressure plate. The sheet leaving the support plate and the upper pressure plate enters a pair of conveyor rollers and is then sent to another conveyor belt conveyor.

9. The method for opening holes in wet-process PU sheets according to claim 8, characterized in that, Each conveyor belt conveyor includes a conveyor belt and at least two tension rollers for tensioning the conveyor belt; one tension roller in a conveyor belt conveyor is one of the pressure rollers in a pair of conveyor rollers.

10. The wet-process PU sheet perforation method according to claim 1, characterized in that, The number of needles is 2-4 per cm. 2 The diameter of the needle is 1-2 mm.

Images