An oil float vulcanization foaming device and method

Abstract

This invention discloses an oil float vulcanization foaming device and method, comprising a base and a covering chamber, wherein the covering chamber is fixedly connected to the top outer wall of the base, and further comprising: an ultrasonic array, fixedly installed around the covering chamber; a top sealing mechanism, fixedly installed on the inner wall of the covering chamber; a lead screw guide rail, fixedly installed on the top outer wall of the base; a partition, the outer wall of which is fixedly connected to a slider, and the slider is movably engaged with the lead screw guide rail, the partition being slidably connected to the lead screw guide rail via the slider; a heating foaming chamber, fixedly connected to the top outer wall of the partition, and the bottom inner wall of the heating foaming chamber is fixedly connected to a discharge port, the discharge port passing through the partition, and an electromagnetic valve installed at the connection between the discharge port and the heating foaming chamber, the heating foaming chamber being filled with an inert fluid, and the bottom of the heating foaming chamber having a funnel structure. The oil float vulcanization foaming device and method disclosed in this invention has the effects of enhanced buoyancy accuracy and effectively extending the wear resistance life of the bottom.

Description

Technical Field

[0001] This invention relates to the field of oil float production technology, and in particular to an oil float vulcanization and foaming equipment and method. Background Technology

[0002] The fuel float is a key component of the fuel system level sensor. It is usually made of closed-cell foam material (such as nitrile rubber foam), and its density distribution directly affects the buoyancy accuracy and sensor reliability.

[0003] Currently, the mainstream manufacturing method for oil floats is the compression molding foaming method: rubber blanks mixed with foaming agents and vulcanizing agents are placed into a metal mold, heated and pressurized in a flat vulcanizing machine, so that the material completes vulcanization and foaming under the constraint of the mold cavity.

[0004] The existing technology has the following problems: First, uneven heating. Compression molding relies on heat conduction through the mold, resulting in a high surface temperature and a low center temperature, with a temperature difference of 10-15℃ between the inside and outside of the blank. This uneven temperature leads to inconsistent decomposition rates of the foaming agent, resulting in a wide distribution of cell sizes and poor product consistency.

[0005] Second, the density distribution is uncontrollable. In a static mold, bubble growth is mainly affected by gravity, and the foam naturally forms a unidirectional density gradient with a denser bottom and a sparser top. This passively formed density distribution cannot be designed according to the functional requirements of different parts of the float, resulting in low buoyancy accuracy and insufficient impact resistance at the bottom. Summary of the Invention

[0006] This invention discloses an oil float vulcanization foaming equipment and method, aiming to solve the technical problems of uneven heating and uncontrollable density distribution.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: An oil float vulcanizing foaming device and method includes a base and a cover chamber, with the cover chamber fixedly connected to the top outer wall of the base. It further includes: an ultrasonic array, fixedly installed around the cover chamber; a top sealing mechanism, fixedly installed on the inner wall of the cover chamber; a lead screw guide rail, fixedly installed on the top outer wall of the base; a partition, with a slider fixedly connected to its outer wall, the slider movably engaging with the lead screw guide rail, the partition being slidably connected to the lead screw guide rail via the slider; a heating foaming chamber, fixedly connected to the top outer wall of the partition, with a discharge port fixedly connected to the bottom inner wall of the heating foaming chamber, the discharge port passing through the partition, and a solenoid valve installed at the connection between the discharge port and the heating foaming chamber; the heating foaming chamber being filled with an inert fluid, and the bottom of the heating foaming chamber having a funnel structure; and a cleaning mechanism, fixedly connected to the bottom outer wall of the partition and located directly below the discharge port.

[0008] By incorporating an ultrasonic array, a heated foaming chamber, and an inert fluid, the billet is enveloped and heated by the inert fluid in a heated environment, achieving three-dimensional uniform heating and eliminating temperature gradients. Based on the ultrasonic array, the power and start-stop sequence of probes in different orientations can be controlled in a time-division manner to generate directional acoustic flow in the fluid, applying selective pressure to specific areas of the billet. As a result, a programmable three-dimensional density gradient of "dense at the bottom and sparse at the top" can be achieved inside the billet, enhancing buoyancy accuracy and effectively extending the wear resistance life of the bottom.

[0009] In a preferred embodiment, the top sealing mechanism includes: a sealing ring, fixedly attached to the top outer wall of the heated foaming chamber; a crossbar, fixedly connected to the inner wall of the covering chamber; a hydraulic cylinder, fixedly connected to the top outer wall of the crossbar, and its output end is fixedly connected to a sealing cover through the crossbar, the sealing cover being attached to the sealing ring, and the top inner wall of the sealing cover being provided with an air injection hole and a pressure relief valve, and the air injection hole being connected to an external nitrogen supply system; The top sealing mechanism further includes: a second hydraulic cylinder, fixedly connected to the sealing cover; a frustum-shaped push plate, the output end of the second hydraulic cylinder passing through the sealing cover and fixedly connected to the frustum-shaped push plate, and the inner wall of the frustum-shaped push plate being provided with multiple leakage holes.

[0010] With a top sealing mechanism, the billet can be pushed by the hydraulic cylinder to the frustum-shaped push plate during unloading, ensuring that it falls smoothly into the cleaning mechanism for cleaning and avoiding blockage that would affect production. The vent hole allows inert fluid to pass through, reducing the downward resistance of the frustum-shaped push plate.

[0011] In a preferred embodiment, the cleaning mechanism includes: a plurality of connecting columns, which are simultaneously fixedly connected to the bottom outer wall of the partition; and an outer cylinder, which is fixedly connected to the bottom outer wall of the plurality of connecting columns. The cleaning mechanism further includes: a drain basket, movably connected to the outer cylinder, with a rotating sealing ring embedded in the inner wall of the bottom end of the outer cylinder; a rotating shaft, fixedly connected to the outer wall of the bottom end of the drain basket and rotatably connected to the rotating sealing ring; and a motor, fixedly installed on the outer wall of the bottom end of the outer cylinder, with its output end fixedly connected to the rotating shaft. The cleaning mechanism further includes: a conveying pipe, one end of which is fixedly connected to the lower part of the inner wall of the outer cylinder, and the other end of which is fixedly connected to the upper part of the inner wall of the heating foaming chamber; and a circulating pump, which is installed on the top outer wall of the partition and connected to the middle section of the conveying pipe.

[0012] By incorporating a cleaning mechanism, the inert fluid on the billet can be completely removed under centrifugal force, achieving self-cleaning of the billet and preventing inert fluid residue from affecting subsequent production. Moreover, the structure is simple and, compared to cleaning, it does not cause loss of inert fluid, thus reducing costs.

[0013] A method for vulcanizing and foaming an oil float includes the following specific steps: S1: Raw material preparation: The nitrile rubber compound is pre-pressed into a round cake-shaped raw material. The diameter and thickness of the raw material are reserved for foaming expansion according to the final size of the oil float; S2: Open-top loading: The inert fluid and raw material are added into the heating and foaming chamber; S3: Sealing and pressurization: The sealing cover is lowered and locked, and high-pressure nitrogen is injected from the top. The pressure in the heating and foaming chamber increases, inhibiting the foaming agent and preventing the raw material from foaming; S4: Uniform heating: The heating and foaming chamber is started, the fluid temperature rises, and heat is conducted to the raw material; S5: Rapid pressure relief triggering foaming: The pressure relief valve is opened to rapidly release pressure, triggering the foaming agent to explode and decompose into foam; S6: Ultrasonic field directional induction gradient foaming: The ultrasonic array is started to form a directional acoustic flow, which forms micro-impacts on the surface of the raw material, achieving selective suppression of bubble growth in different areas; S7: Unloading and cleaning: The solenoid valve is opened, pushing the raw material down into the cleaning mechanism, and then the inert fluid is separated by centrifugal force; S2 includes the following specific steps: S21: filling the heating foaming chamber with high-temperature inert fluid; S22: pushing the heating foaming chamber out of the cover chamber along the screw guide; S23: placing the billet in the heating foaming chamber and pushing it back into the cover chamber, so that the billet is completely immersed in the fluid.

[0014] As described above, an oil float vulcanization foaming device and method includes a base and a covering chamber, with the covering chamber fixedly connected to the top outer wall of the base. It further includes: an ultrasonic array, fixedly installed around the covering chamber; a top sealing mechanism, fixedly installed on the inner wall of the covering chamber; a lead screw guide rail, fixedly installed on the top outer wall of the base; a partition, with a slider fixedly connected to its outer wall, the slider movably engaging with the lead screw guide rail, the partition slidably connected to the lead screw guide rail via the slider; a heating foaming chamber, fixedly connected to the top outer wall of the partition, with a discharge port fixedly connected to the bottom inner wall of the heating foaming chamber, the discharge port passing through the partition, and a solenoid valve installed at the connection between the discharge port and the heating foaming chamber; the heating foaming chamber is filled with an inert fluid, and the bottom of the heating foaming chamber has a funnel structure; and a cleaning mechanism, fixedly connected to the bottom outer wall of the partition and located directly below the discharge port. The oil float vulcanization foaming device and method provided by this invention have the technical effects of enhanced buoyancy accuracy and effectively extended bottom wear life. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of an oil float vulcanization foaming device proposed in this invention.

[0016] Figure 2 This is a schematic diagram of the bottom structure of the heating foaming chamber of an oil float vulcanizing foaming device proposed in this invention.

[0017] Figure 3 This is a schematic diagram showing the disassembled cleaning mechanism of an oil float vulcanization foaming device proposed in this invention.

[0018] Figure 4 This is a schematic diagram showing the top sealing mechanism of an oil float vulcanization foaming device proposed in this invention.

[0019] Figure 5 This is a flowchart illustrating the specific process of a vulcanization and foaming method for an oil float proposed in this invention.

[0020] In the diagram: 1. Cover chamber; 2. Ultrasonic array; 3. Cleaning mechanism; 4. Base; 5. Screw guide rail; 6. Heated foaming chamber; 7. Top sealing mechanism; 8. Partition plate; 9. Slider; 10. Solenoid valve; 11. Discharge port; 301. Outer cylinder; 302. Motor; 303. Conveying pipe; 304. Connecting column; 305. Circulating pump; 306. Drain basket; 307. Rotating shaft; 701. Sealing ring; 702. Hydraulic cylinder one; 703. Cross frame; 704. Sealing cover; 705. Hydraulic cylinder two; 706. Frustum-shaped push plate; 707. Drain hole. Detailed Implementation

[0021] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0022] The oil float vulcanization foaming equipment and method disclosed in this invention are mainly applied to the vulcanization foaming of oil floats.

[0023] Reference Figure 1 and Figure 2 An oil float vulcanizing foaming device includes a base 4, a covering chamber 1, an ultrasonic array 2, a top sealing mechanism 7, a lead screw guide rail 5, a partition 8, a heating foaming chamber 6, and a cleaning mechanism 3. The covering chamber 1 is fixedly connected to the top outer wall of the base 4, and the ultrasonic array 2 is fixedly installed around the covering chamber 1. The top sealing mechanism 7 is fixedly installed on the inner wall of the covering chamber 1. The lead screw guide rail 5 is fixedly installed on the top outer wall of the base 4. A slider 9 is fixedly connected to the outer wall of the partition 8, and the slider 9 is movably engaged with the lead screw guide rail 6. On the rail 5, the partition 8 is slidably connected to the lead screw guide rail 5 via the slider 9; the heating foaming chamber 6 is fixedly connected to the top outer wall of the partition 8, and the bottom inner wall of the heating foaming chamber 6 is fixedly connected to the discharge port 11, which passes through the partition 8, and a solenoid valve 10 is installed at the connection between the discharge port 11 and the heating foaming chamber 6. The heating foaming chamber 6 is filled with inert fluid, and the bottom of the heating foaming chamber 6 has a funnel structure; the cleaning mechanism 3 is fixedly connected to the bottom outer wall of the partition 8 and is located directly below the discharge port 11.

[0024] Within the heating and foaming chamber 6, the billet is enveloped and heated by an inert fluid under heating conditions, achieving three-dimensional uniform heating. Compared to traditional molding methods, this eliminates temperature gradients and ensures a consistent decomposition rate of the foaming agent. Simultaneously, based on the ultrasonic array 2, the power and start-stop sequence of probes at different orientations can be controlled in a time-division manner to generate directional acoustic flow in the fluid. This selectively applies pressure to specific areas of the billet. When the bottom probe is at high power, the acoustic flow impacts and inhibits bubble growth, forming a dense layer. When the top probe is at low power or off, the bubbles expand freely, forming a loose layer. Thus, a programmable three-dimensional density gradient of "dense at the bottom and sparse at the top" can be achieved within the billet, enhancing buoyancy accuracy and effectively extending the wear life of the bottom.

[0025] Reference Figure 2 and Figure 3 In a preferred embodiment, the cleaning mechanism 3 includes: a plurality of connecting columns 304, which are fixedly connected to the bottom outer wall of the partition 8; and an outer cylinder 301, which is fixedly connected to the bottom outer wall of the plurality of connecting columns 304.

[0026] The cleaning mechanism 3 also includes: a basket 306, which is movably connected inside the outer cylinder 301, and a rotating sealing ring is embedded in the inner wall of the bottom end of the outer cylinder 301; a rotating shaft 307, which is fixedly connected to the outer wall of the bottom end of the basket 306 and rotatably connected inside the rotating sealing ring; and a motor 302, which is fixedly installed on the outer wall of the bottom end of the outer cylinder 301, and its output end is fixedly connected to the rotating shaft 307.

[0027] The cleaning mechanism 3 also includes: a conveying pipe 303, one end of which is fixedly connected to the lower part of the inner wall of the outer cylinder 301, and the other end of which is fixedly connected to the upper part of the inner wall of the heating foaming chamber 6; and a circulating pump 305, which is installed on the top outer wall of the partition 8 and connected to the middle section of the conveying pipe 303.

[0028] After foaming is complete, the solenoid valve 10 opens, allowing the billet to fall into the basket 306 through the discharge port 11. After all the inert fluid has completely entered the outer cylinder 301, the solenoid valve 10 is closed, and the circulation pump 305 is turned on to extract the inert fluid and return it to the heating and foaming chamber 6. At this time, the motor 302 drives the basket 306 to rotate rapidly through the rotating shaft 307, which can completely remove the inert fluid from the billet under the action of centrifugal force, achieving self-cleaning of the billet and avoiding the impact of inert fluid residue on subsequent production. Moreover, this cleaning method has a simple structure and does not cause loss of inert fluid compared to washing, thus reducing cost expenditure.

[0029] Reference Figure 4In a preferred embodiment, the top sealing mechanism 7 includes: a sealing ring 701, fixedly attached to the top outer wall of the heated foaming chamber 6; a crossbar 703, fixedly connected to the inner wall of the covering chamber 1; a hydraulic cylinder 702, fixedly connected to the top outer wall of the crossbar 703, and its output end is fixedly connected to a sealing cover 704 through the crossbar 703. The sealing cover 704 is attached to the sealing ring 701. The top inner wall of the sealing cover 704 is provided with an air injection hole and a pressure relief valve, and the air injection hole is connected to an external nitrogen supply system.

[0030] The top sealing mechanism 7 also includes: a second hydraulic cylinder 705, which is fixedly connected to the sealing cover 704; a frustum-shaped push plate 706, the output end of the second hydraulic cylinder 705 passes through the sealing cover 704 and is fixedly connected to the frustum-shaped push plate 706, and the inner wall of the frustum-shaped push plate 706 is provided with multiple leakage holes 707.

[0031] After the heating and foaming chamber 6 retracts into the covering chamber 1, the output end of the hydraulic cylinder 702 extends to drive the sealing cover 704 to tightly fit onto the sealing ring 701 to complete the seal, preparing for subsequent pressurization. When unloading, since the bottom of the heating and foaming chamber 6 is conical, the billet may get stuck at the discharge port 11 during the unloading process. At this time, the hydraulic cylinder 705 can push the frustum-shaped push plate 706 to push the billet to ensure that it falls smoothly into the cleaning mechanism 3 for cleaning, avoiding blockage and affecting production. The setting of the leakage hole 707 allows inert fluid to pass through the leakage hole 707, reducing the downward pushing resistance of the frustum-shaped push plate 706.

[0032] Reference Figure 5 A method for vulcanizing and foaming an oil float includes the following specific steps: S1: Raw material preparation: Pre-press nitrile rubber compound into a round cake shape, with the diameter and thickness of the raw material reserved for foaming expansion according to the final size of the oil float; S2: Open-top loading: Add inert fluid and raw material into the heating and foaming chamber 6; S3: Sealing and pressurizing: Lower and lock the sealing cap 704, and fill with high-pressure nitrogen from the top, increasing the pressure in the heating and foaming chamber 6, inhibiting the foaming agent, and preventing the raw material from foaming; S4: Uniform heating S5: Start heating the foaming chamber 6 to raise the temperature of the fluid and conduct heat to the billet; S6: Rapid pressure relief triggers foaming: Open the pressure relief valve to rapidly release pressure and trigger the foaming agent to explode and decompose into foam; S7: Ultrasonic field directional induction gradient foaming: Start the ultrasonic array to form a directional acoustic flow, which forms a micro-impact on the surface of the billet and achieves selective suppression of bubble growth in different areas; S8: Discharge and clean: Open the solenoid valve 10 to push the billet down into the cleaning mechanism 3, and then separate the inert fluid through centrifugal force.

[0033] S2 includes the following specific steps: S21: Fill the heating foaming chamber 6 with high-temperature inert fluid; S22: Push the heating foaming chamber 6 out of the cover chamber 1 along the screw guide rail 5; S23: Place the billet in the heating foaming chamber 6 and push it back into the cover chamber 1, so that the billet is completely immersed in the fluid.

[0034] Working principle: The billet is heated and foamed in the heating chamber 6. Under the heating environment, it is enveloped and heated by an inert fluid, achieving three-dimensional uniform heating. Compared with the traditional molding method, it can eliminate temperature gradients and make the decomposition rate of foaming agent consistent. At the same time, based on the setting of the ultrasonic array 2, the power and start-stop sequence of probes in different directions can be controlled in a time-division manner to generate directional acoustic flow in the fluid. This selectively suppresses specific areas of the billet. When the bottom probe is at high power, the acoustic flow impact inhibits bubble growth and forms a dense layer. When the top probe is at low power or turned off, the bubbles expand freely and form a loose layer. Thus, a programmable three-dimensional density gradient of "dense at the bottom and sparse at the top" can be achieved inside the billet, enhancing buoyancy accuracy and effectively extending the wear life of the bottom.

[0035] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An oil float vulcanization foaming device, comprising a base (4) and a covering chamber (1), wherein the covering chamber (1) is fixedly connected to the top outer wall of the base (4), characterized in that, Also includes: An ultrasonic array (2) is fixedly installed around the cover chamber (1); The top sealing mechanism (7) is fixedly installed on the inner wall of the covering chamber (1); The lead screw guide (5) is fixedly installed on the top outer wall of the base (4); The partition (8) has a slider (9) fixedly connected to its outer wall, and the slider (9) is movably engaged with the lead screw guide rail (5). The partition (8) is slidably connected to the lead screw guide rail (5) through the slider (9). The heating foaming chamber (6) is fixedly connected to the top outer wall of the partition (8), and the bottom inner wall of the heating foaming chamber (6) is fixedly connected to the discharge port (11). The discharge port (11) passes through the partition (8), and a solenoid valve (10) is installed at the connection between the discharge port (11) and the heating foaming chamber (6). The heating foaming chamber (6) is filled with inert fluid, and the bottom of the heating foaming chamber (6) has a funnel structure. The cleaning mechanism (3) is fixedly connected to the bottom outer wall of the partition (8) and located directly below the discharge port (11).

2. The oil float vulcanization foaming equipment according to claim 1, characterized in that, The cleaning mechanism (3) includes: Multiple connecting columns (304) are simultaneously fixedly connected to the bottom outer wall of the partition (8); The outer cylinder (301) is fixedly connected to the bottom outer wall of multiple connecting columns (304).

3. The oil float vulcanization foaming equipment according to claim 2, characterized in that, The cleaning mechanism (3) also includes: The basket (306) is movably connected inside the outer cylinder (301), and a rotating sealing ring is embedded in the inner wall of the bottom end of the outer cylinder (301); The rotating shaft (307) is fixedly connected to the bottom outer wall of the sieve (306) and rotatably connected to the rotating sealing ring; The motor (302) is fixedly installed on the bottom outer wall of the outer cylinder (301), and its output end is fixedly connected to the rotating shaft (307).

4. The oil float vulcanization foaming equipment according to claim 3, characterized in that, The cleaning mechanism (3) also includes: The conveying pipe (303) has one end fixedly connected to the lower part of the inner wall of the outer cylinder (301), and the other end fixedly connected to the upper part of the inner wall of the heating foaming chamber (6). A circulating pump (305) is installed on the top outer wall of the partition (8) and connected to the middle section of the delivery pipe (303).

5. The oil float vulcanization foaming equipment according to claim 1, characterized in that, The top sealing mechanism (7) includes: A sealing ring (701) is fixedly attached to the top outer wall of the heated foaming chamber (6); A crossbeam (703) is fixedly connected to the inner wall of the covered compartment (1); Hydraulic cylinder 1 (702) is fixedly connected to the top outer wall of the cross frame (703), and its output end is fixedly connected to a sealing cover (704) through the cross frame (703). The sealing cover (704) is attached to the sealing ring (701). The top inner wall of the sealing cover (704) is provided with an air injection hole and a pressure relief valve, and the air injection hole is connected to an external nitrogen supply system.

6. The oil float vulcanization foaming equipment according to claim 5, characterized in that, The top sealing mechanism (7) also includes: Hydraulic cylinder two (705) is fixedly connected to the sealing cover (704); The output end of the second hydraulic cylinder (705) passes through the sealing cover (704) and is fixedly connected to the frustum-shaped push plate (706). The inner wall of the frustum-shaped push plate (706) is provided with multiple leakage holes (707).

7. A method for vulcanizing and foaming an oil float, applied to the vulcanizing and foaming equipment for an oil float as described in claim 6, characterized in that, The specific steps include the following: S1: Blank preparation: Pre-press the nitrile rubber compound into a round cake blank. The diameter and thickness of the blank are reserved for foaming expansion according to the final size of the oil float. S2: Open loading: Inert fluid and billet are added into the heated foaming chamber (6); S3: Sealing and pressurization: The sealing cap (704) falls and locks, high-pressure nitrogen is injected from the top, the pressure inside the heating foaming chamber (6) increases, inhibiting the foaming agent, and the billet does not foam; S4: Uniform heating: Start heating the foaming chamber (6) to heat the fluid and conduct heat to the billet; S5: Rapid pressure relief triggers foaming: Open the pressure relief valve to rapidly relieve pressure, triggering the foaming agent to explode and decompose into foam; S6: Ultrasonic field directional induced gradient foaming: The ultrasonic array is activated to form a directional acoustic flow, which creates micro-impacts on the surface of the billet, thereby achieving selective suppression of bubble growth in different areas; S7: Unloading and cleaning: Open the solenoid valve (10) to push the billet down into the cleaning mechanism (3), and then separate the inert fluid by centrifugal force.

8. The method for vulcanizing and foaming an oil float according to claim 7, characterized in that, S2 includes the following specific steps: S21: Fill the heated foaming chamber (6) with a high-temperature inert fluid; S22: The heated foaming chamber (6) is pushed out of the covering chamber (1) along the lead screw guide (5); S23: Place the billet in the heated foaming chamber (6) and push it back into the covering chamber (1), so that the billet is completely submerged in the fluid.

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