A full-automatic integrated film-pressing forming device and forming method

Abstract

The application relates to a full-automatic integrated film-pressing forming device and a forming method, and belongs to the technical field of injection molding molds. The device comprises an upper mold plate, a lower mold plate and a filter film pressing assembly. The lower mold plate is provided with a first injection groove and a first placing groove, and the upper mold plate is provided with a second injection groove. The filter film pressing assembly is matched with a pressing block through a bracing block to realize precise bracing of a film body. In addition, the device further comprises a pulling and winding assembly for automatic unwinding and cutting of the film body. The forming method is characterized in that a lower rubber frame is first injected, the lower rubber frame is transferred to cover the film body, and finally, a bracing mechanism is used to brace and secondarily inject an upper rubber frame, so that an integrated rubber frame with the film body is formed. The application significantly improves production efficiency and forming stability.

Description

Technical Field

[0001] This invention belongs to the field of injection mold technology, specifically relating to a fully automatic integrated compression molding equipment and molding method. Background Technology

[0002] Currently, in the production of products involving the combination of plastic frames and filter membranes (or similar membrane bodies), such as seawater filter screens, the molding of the plastic frame and the lamination of the membrane body are usually carried out in separate steps. Traditional production methods often involve first processing the various components of the plastic frame separately using injection molding equipment, then placing the cut membrane body between the plastic frames using manual or semi-automatic equipment, and finally fixing it by methods such as hot pressing, ultrasonic welding, or secondary injection molding.

[0003] However, this traditional processing method has the following significant drawbacks: 1. Low level of automation: The lack of highly integrated automated connection between frame forming, film conveying and film pressing results in limited production efficiency.

[0004] 2. Difficulty in controlling membrane tension: If the membrane cannot be effectively and evenly stretched during the molding process, wrinkles or uneven stress may occur, affecting the quality and filtration effect of the molded product.

[0005] 3. Cumbersome process and poor precision: Due to the need for multiple mold openings and workpiece transfers, not only is the production cycle increased, but secondary pollution or assembly displacement is also likely to occur during the transfer process, making it difficult to guarantee the integrated sealing precision between the glue frame and the membrane.

[0006] In view of this, this solution was developed. Summary of the Invention

[0007] In view of the shortcomings of the prior art, the technical problem to be solved by the present invention is to provide a fully automatic integrated molding equipment and molding method, which can realize the process from frame molding to film conveying, tensioning, and finally integrated molding.

[0008] To solve the above technical problems, the technical solution adopted by the present invention is: a fully automatic integrated pressing and forming equipment, including an upper template, a lower template and a filter membrane pressing assembly, wherein the lower template has a first injection groove and a first placement groove, the first injection groove is a hollow closed-loop frame shape, the first placement groove has the same shape as the first injection groove, and the first placement groove is used to place the lower glue frame formed by the first injection groove. The upper mold has a second injection groove, the shape of which is the same as and corresponds to the shape of the first placement groove; after the upper mold and the lower mold are closed, a first injection cavity is formed between the first injection groove and the upper mold, and a second injection cavity is formed after the first placement groove and the second injection groove are closed. The filter membrane pressing assembly includes two sets of adjustable tensioning modules and two sets of pressing modules. The adjustable tensioning modules are mounted on the upper template, and the two sets of pressing modules are mounted on the upper template and the lower template, respectively. The adjustable tensioning module includes at least four tensioning blocks, which are arranged in a rectangular pattern along the second injection groove. A pressure groove corresponding to the tensioning block is formed on the lower template. The pressing module includes at least four pressure blocks, which are arranged in a rectangular pattern along the first placement groove or the second injection groove and located on the outer side of the tensioning blocks. A reset spring is provided between the lower surface of the pressure block located on the first placement groove side and the lower template. The height of the pressure block on the lower template is higher than the height of the tensioning block.

[0009] Furthermore, the molding equipment also includes a needle plate, a lifting drive body, an upper mounting plate and an upper mold base. The upper mounting plate is installed on the lower surface of the upper mold base, and a fixing post is formed on the upper mounting plate. The upper surface of the upper template has a fixing hole, and the fixing post extends into the fixing hole and is fixedly connected. There is a gap between the upper template and the upper mounting plate. The needle plate is located between the upper mounting plate and the upper mold base. The needle plate has clearance holes corresponding to the fixed posts. The lower surface of the needle plate is equipped with ejector pins. The upper template has needle holes adapted to the ejector pins. The lifting drive body is used to drive the needle plate to move up and down.

[0010] Furthermore, the lifting drive body includes two lifting cylinders, which are respectively fixedly installed on both sides of the lower surface of the upper mold base; The upper mounting plate and the needle plate have first notches on both sides for the output end of the lifting cylinder to extend through. The upper surface of the first notch of the upper mounting plate has a second notch, and the lower surface of the needle plate has a boss that extends into the second notch. The output end of the lifting cylinder is connected to the boss in the second notch through a clip.

[0011] Furthermore, the output end of the lifting cylinder has an annular groove formed on its circumferential surface. The clamping component includes a U-shaped part and an extension part. The two ends of the U-shaped part away from the opening are connected to the extension part. The opening of the U-shaped part is adapted to the annular groove. The extension part is detachably connected to the boss.

[0012] Furthermore, a strip groove is provided on the lower template, the connecting piece passes through the pressure block and connects to the lower template, and the reset spring is sleeved on the outer circumferential surface of the connecting piece.

[0013] Furthermore, the forming equipment also includes a winding assembly, which includes an unwinding roller, a rear mold fixing seat, a rear mold floating block, a front mold clamping block, and a cutting blade. The upper surface of the rear mold fixing seat has a long strip groove. The rear mold floating block is connected to the long strip groove by a connector. A spring is sleeved on the circumference of the connector. The spring is located between the rear mold floating block and the bottom of the long strip groove. The surface of the rear mold floating block has a strip through hole. The cutting blade is installed in the long strip groove of the rear mold fixing seat and extends out of the strip through hole. In its natural state, the rear mold floating block extends out of the upper surface of the rear mold fixing seat, and the cutting surface of the cutting blade is flush with the upper surface of the rear mold fixing seat. The front mold clamping block is used to fit against or move away from the rear mold floating block. The lower surface of the front mold clamping block forms a clearance channel corresponding to the cutting blade. The unwinding roller is used to wind the film roll and pull the film between the front mold clamping block and the rear mold floating block.

[0014] Furthermore, the winding assembly also includes two clamping rollers, which are located between the unwinding roller and the rear die fixing seat, and are arranged vertically at intervals and in contact with each other.

[0015] Furthermore, the adjustable tensioning module also includes an adjustment screw, and the tensioning block is connected to the upper template through the adjustment screw.

[0016] A fully automated integrated molding method, employing a fully automated integrated molding equipment, includes the following steps: S1. The upper and lower mold plates are closed, and the lower plastic frame is injected into the first injection cavity; S2. The upper and lower templates are opened, and the lower plastic frame is transferred into the first placement slot; S3. The pulling and winding assembly pulls the membrane through the first placement groove and covers the first placement groove; S4. The upper and lower templates are closed, and the tensioning block and the pressure block work together to tighten the membrane located in the first placement groove. S5. Inject the upper glue frame into the second injection cavity. The upper glue frame, the film body and the lower glue frame are injection molded to form an integrated glue frame with film body.

[0017] Furthermore, the specific working steps of the support block and the pressure block in step S4 are as follows: During the mold closing process of the upper and lower mold plates, the height of the pressure block on the lower mold plate is higher than the height of the support block. The upper and lower mold plates gradually approach each other. At the same time, the pressure block on the upper and lower mold plates first clamps the film body, and then the support block pushes the film body into the pressure groove of the lower mold plate to tighten the film body; until the upper and lower mold plates are completely closed.

[0018] Compared with the prior art, the present invention has the following beneficial effects: 1. By setting a first injection groove, a first placement groove, and a second injection groove, the present invention enables the completion of lower frame forming, transfer, film laying, tensioning, and secondary injection molding within the same equipment.

[0019] 2. With the automatic unwinding and cutting functions of the winding assembly, the entire process is closely connected, reducing manual intervention and significantly improving the production efficiency of the film frame.

[0020] 3. The equipment is equipped with a special adjustable tensioning module and a film pressing module. During the mold closing process, the pressure block first clamps the film, and then the tensioning block pushes the film into the pressing groove for tension. This clamping and tensioning method ensures that the film is in a flat and tight state before injection molding, effectively avoiding wrinkles, displacement or uneven stress during the molding process, and significantly improving the product qualification rate. Attached Figure Description

[0021] Figure 1 This is a cross-sectional view of a fully automatic integrated molding equipment according to the present invention; Figure 2 This is a three-dimensional structural diagram of the injection-molded finished product of the present invention; Figure 3 This is a cross-sectional view of the injection-molded finished product of the present invention; Figure 4 This is a bottom view of the upper template structure in this invention; Figure 5 This is a three-dimensional structural diagram of the filter membrane pressing assembly in this invention; Figure 6 This is a three-dimensional structural diagram of the needle plate in this invention; Figure 7 This is a schematic diagram of the split structure of the lifting cylinder installation position in this invention; Figure 8 This is a three-dimensional structural diagram of the roll-up assembly in this invention; Figure 9 This is a cross-sectional view of the coiling assembly in this invention.

[0022] The markings in the diagram are as follows: 1. Upper mold base; 11. Lifting cylinder; 111. Annular groove; 112. Clamping piece; 12. Needle plate; 121. Ejector pin; 13. Upper mounting plate; 2. Upper template; 3. Lower template; 31. Pressing groove; 4. Lower mold base; 41. Lower mounting plate; 5. Filter membrane pressing assembly; 51. Support block; 52. Pressing block; 53. Return spring; 6. Connecting piece; 7. Winding assembly; 71. Unwinding roller; 72. Rear mold fixing base; 721. Rebound spring; 73. Rear mold floating block; 731. Strip-shaped through hole; 74. Front mold pressing block; 741. Clearance channel; 75. Cutting knife; 76. Clamping wheel; 8. Upper glue frame; 81. Membrane body; 82. Lower glue frame. Detailed Implementation

[0023] To make the above features and advantages of the present invention more apparent and understandable, specific embodiments are described below in conjunction with the accompanying drawings for detailed explanation.

[0024] like Figures 1-9 As shown, this embodiment provides a fully automatic integrated film pressing and forming equipment, including an upper mold base 1, a lifting drive body, a needle plate 12, an upper mounting plate 13, an upper template 2, a lower template 3, a lower mold base 4, a lower mounting plate 41, a filter membrane pressing assembly 5, and a winding assembly 7.

[0025] The lower template 3, lower mounting plate 41, and lower mold base 4 are arranged sequentially from top to bottom. The lower template 3 has a first injection groove and a first placement groove. The first injection groove is designed as a hollow closed-loop frame shape and is mainly used for injection molding the lower plastic frame 82. The first placement groove has the same shape as the first injection groove and is specifically used to place the molded lower plastic frame 82.

[0026] The upper mold base 1, upper mounting plate 13, needle plate 12, and upper template 2 are arranged in order from top to bottom. The upper template 2 has a second injection groove, the shape of which corresponds to the first placement groove.

[0027] After the two are molded together, the first injection groove and the first injection corresponding groove on the upper template 2 form the first injection cavity, and the first placement groove and the second injection groove form the second injection cavity after being molded together.

[0028] The filter membrane pressing assembly 5 consists of an adjustable tensioning module and two pressing modules. The adjustable tensioning module is mounted on the upper template 2 and includes at least four tensioning blocks 51. These four tensioning blocks 51 are arranged in a rectangular pattern along the second injection groove. In this embodiment, there are eight tensioning blocks 51, with two blocks forming a continuous strip. The tensioning blocks 51 are connected to the upper template 2 by adjusting screws to allow for gap adjustment according to process requirements. Correspondingly, the lower template 3 has a pressing groove 31 for inserting the membrane body 81 into the tensioning block 51.

[0029] The molding modules are respectively installed on the upper template 2 and the lower template 3, and contain at least four pressing blocks 52, which are also arranged in a rectangular pattern and are located on the outer side of the supporting block 51 on the upper template 2. Specifically, in this embodiment, each molding module has eight pressing blocks 52, and every two form a continuous pressing block 52. The pressing block 52 located on one side of the first placement groove of the lower template 3 has a return spring 53 between its lower surface and the lower template 3. The height of the pressing block 52 on the lower template is higher than the height of the supporting block 51. A strip groove is opened on the lower template 3, and the connecting piece 6 passes through the groove to connect with the lower template 3. The return spring 53 is sleeved on the outer peripheral surface of the connecting piece 6. The connecting piece 6 is a long screw with a small diameter part at the lower end, and the external thread is located on the peripheral surface of the small diameter part. Each pressing block 52 must be provided with at least two connecting pieces 6.

[0030] After being pressed, the pressure block 52 extends into the strip groove under the action of the return spring 53, while the tensioning block 51 extends into the pressure groove 31. Thus, a mold closing process is that the mold body located at the position of the pressure block 52 moves from top to bottom, thereby tightening the mold body on the tensioning block 51. At this time, the mold body can be tightened.

[0031] The mounting plate is fixed to the lower surface of the upper mold base 1 and is provided with a fixing post. The upper template 2 is fixedly connected to the fixing post through fixing holes, so that a certain gap is maintained between the upper template 2 and the mounting plate. The needle plate 12 is located between the mounting plate and the upper mold base 1 and is provided with a clearance hole for the fixing post to pass through. The lower surface of the needle plate 12 is equipped with an ejector pin 121, and the upper template 2 is provided with a corresponding needle hole. The lifting drive body drives the needle plate 12 to move up and down to complete the ejection action.

[0032] The lifting drive unit is used to drive the needle plate 12 to move up and down. The lifting drive unit includes two lifting cylinders 11, which are respectively fixed on both sides of the lower surface of the upper mold base 1. The upper mounting plate 13 and the needle plate 12 have first notches on both sides for the output end of the lifting cylinder 11 to extend through. The upper surface of the first notch of the upper mounting plate 13 has a second notch, and the lower surface of the needle plate 12 has a boss that extends into the second notch. The output end of the lifting cylinder 11 is connected to the boss in the second notch through a locking piece 112. The peripheral surface of the output end of the lifting cylinder 11 has an annular groove 111. The locking piece 112 includes a U-shaped part and an extension part. The two ends of the U-shaped part away from the opening are connected to the extension part. The opening of the U-shaped part is adapted to the annular groove 111, and the extension part is connected to the boss with a screw.

[0033] After the lower glue frame 82, the film body 81 and the upper glue frame 8 are formed, the driving cylinder is pushed out, which drives the needle plate 12 to move down. The ejector pin 121 pushes against the film body 81, ensuring that after the upper template 2 and the lower template 3 are opened, the film body 81 and the upper glue frame 8 are separated from the upper template 2.

[0034] To achieve automatic film stretching, this solution is equipped with a film stretching assembly 7, which includes an unwinding roller 71, a clamping roller 76, a rear mold fixing seat 72, a rear mold floating block 73, a front mold clamping block 74, and a cutting blade 75.

[0035] The film roll is wound on the unwinding roller 71. Two spaced-apart clamping rollers 76 pull the film between the front mold clamping block 74 and the rear mold floating block 73. The rear mold fixing seat 72 has a long, narrow groove, and the rear mold floating block 73 is installed in the groove via a connector 6 and a return spring 721. A cutting blade 75 is installed in the groove and passes through the long, narrow hole 731 of the floating block. The connector 6 is a long bolt that extends from below the rear mold fixing seat 72 into the long, narrow groove and is fixedly connected to the rear mold floating block 73. The front mold clamping block 74 is used to fit against or move away from the rear mold floating block 73, and its lower surface has a clearance channel 741 corresponding to the cutting blade 75.

[0036] In its natural state, the rear mold floating block 73 extends out of the surface of the rear mold fixing seat 72 under the action of the return spring 721, and at this time, the cutting surface of the cutting blade 75 is flush with the upper surface of the rear mold fixing seat 72. During operation, when the front mold clamping block 74 is in contact with the rear mold floating block 73, the rear mold floating block 73 moves downward, so that the film body 81 contacts the cutting blade 75 to achieve cutting. This setting ensures that the film body 81 will not be cut by the cutting blade 75 when it passes through the rear mold fixing seat 72.

[0037] It is worth noting that the automatic film pulling and the transfer of the lower glue frame 82 to the first placement slot are both operated by robotic arms of different specifications. The robotic arms are existing robotic arm structures, which will not be described in detail here.

[0038] This solution also provides a fully automated integrated molding method, which uses a fully automated integrated molding equipment for molding; including the following steps: S1. The upper mold plate 2 and the lower mold plate 3 are closed, and the lower plastic frame 82 is injected into the first injection cavity; S2. The upper template 2 and the lower template 3 are opened, and the lower glue frame 82 is transferred into the first placement groove; S3, the pulling and winding assembly 7 pulls the membrane 81 through the first placement groove and covers the first placement groove; S4. The upper template 2 and the lower template 3 are closed, and the tensioning block 51 and the pressing block 52 work together to tighten the membrane body 81 located in the first placement groove. S5. Inject the upper glue frame 8 into the second injection cavity. The upper glue frame 8, the film body 81 and the lower glue frame 82 are injection molded to form an integrated glue frame with film body 81.

[0039] S6. Take out the integrated membrane frame 81 and cut off any excess membrane 81.

[0040] Specifically, the working steps of the support block 51 and the pressure block 52 in step S4 are as follows: During the mold closing process of the upper mold 2 and the lower mold 3, the height of the pressure block 52 on the lower mold 3 is higher than the height of the support block 51. The upper mold 2 and the lower mold 3 gradually approach each other. At the same time, the pressure block 52 on the upper mold 2 and the lower mold 3 first clamps the film body 81, and then the support block 51 pushes against the film body 81 and presses it into the pressure groove 31 of the lower mold 3 to tighten the film body 81; until the upper mold 2 and the lower mold 3 are completely closed.

[0041] The foregoing has shown and described the basic principles and main features of the present invention, as well as its advantages. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the present invention. Various changes and modifications can be made to the present invention without departing from its spirit and scope. All such changes and modifications fall within the scope of the present invention as claimed, which is defined by the appended claims and their equivalents.

Claims

1. A fully automatic integrated molding and die-cutting equipment, characterized in that: It includes an upper template, a lower template, and a filter membrane pressing assembly. The lower template has a first injection groove and a first placement groove. The first injection groove is a hollow closed-loop frame shape. The first placement groove has the same shape as the first injection groove. The first placement groove is used to place the lower glue frame formed by the first injection groove. The upper mold has a second injection groove, the shape of which is the same as and corresponds to the shape of the first placement groove; after the upper mold and the lower mold are closed, a first injection cavity is formed between the first injection groove and the upper mold, and a second injection cavity is formed after the first placement groove and the second injection groove are closed. The filter membrane pressing assembly includes an adjustable tensioning module and two pressing modules. The adjustable tensioning module is mounted on the upper template, and the two pressing modules are mounted on the upper template and the lower template, respectively. The adjustable tensioning module includes at least four tensioning blocks, which are arranged in a rectangular pattern along the second injection groove. A pressure groove corresponding to the tensioning block is formed on the lower template. The pressing module includes at least four pressure blocks, which are arranged in a rectangular pattern along the first placement groove or the second injection groove and located on the outer side of the tensioning blocks. A return spring is provided between the lower surface of the pressure block located on the first placement groove side and the lower template. The height of the pressure block on the lower template is higher than the height of the tensioning block.

2. The fully automatic integrated molding equipment according to claim 1, characterized in that: The molding equipment also includes a needle plate, a lifting drive body, an upper mounting plate and an upper mold base. The upper mounting plate is installed on the lower surface of the upper mold base. A fixing post is formed on the upper mounting plate. The upper surface of the upper template has a fixing hole. The fixing post extends into the fixing hole and is fixedly connected. There is a gap between the upper template and the upper mounting plate. The needle plate is located between the upper mounting plate and the upper mold base. The needle plate has clearance holes corresponding to the fixed posts. The lower surface of the needle plate is equipped with ejector pins. The upper template has needle holes adapted to the ejector pins. The lifting drive body is used to drive the needle plate to move up and down.

3. The fully automatic integrated molding equipment according to claim 2, characterized in that: The lifting drive body includes two lifting cylinders, which are respectively fixedly installed on both sides of the lower surface of the upper mold base; The upper mounting plate and the needle plate have first notches on both sides for the output end of the lifting cylinder to extend through. The upper surface of the first notch of the upper mounting plate has a second notch, and the lower surface of the needle plate has a boss that extends into the second notch. The output end of the lifting cylinder is connected to the boss in the second notch through a clip.

4. The fully automatic integrated molding equipment according to claim 3, characterized in that: The output end of the lifting cylinder has an annular groove on its circumferential surface. The clamping part includes a U-shaped part and an extension part. The two ends of the U-shaped part away from the opening are connected to the extension part. The opening of the U-shaped part is adapted to the annular groove. The extension part is detachably connected to the boss.

5. The fully automatic integrated molding equipment according to claim 1, characterized in that: The lower template has a slot, the connector passes through the pressure block and connects to the lower template, and the reset spring is sleeved on the outer circumference of the connector.

6. The fully automatic integrated molding equipment according to claim 1, characterized in that: The forming equipment also includes a winding assembly, which includes an unwinding roller, a rear mold fixing seat, a rear mold floating block, a front mold clamping block, and a cutting blade. The upper surface of the rear mold fixing seat has a long strip groove. The rear mold floating block is connected to the long strip groove by a connector. A spring is sleeved on the circumference of the connector. The spring is located between the rear mold floating block and the bottom of the long strip groove. The surface of the rear mold floating block has a strip through hole. The cutting blade is installed in the long strip groove of the rear mold fixing seat and extends out of the strip through hole. In its natural state, the rear mold floating block extends out of the upper surface of the rear mold fixing seat and the cutting surface of the cutting blade is flush with the upper surface of the rear mold fixing seat. The front mold clamping block is used to fit against or move away from the rear mold floating block. The lower surface of the front mold clamping block forms a clearance channel corresponding to the cutting blade. The unwinding roller is used to wind the film roll and pull the film between the front mold clamping block and the rear mold floating block.

7. The fully automatic integrated molding equipment according to claim 6, characterized in that: The winding assembly also includes two clamping rollers, which are located between the unwinding roller and the rear die fixing seat. The two clamping rollers are arranged vertically at intervals and are in contact with each other.

8. The fully automatic integrated molding equipment according to claim 1, characterized in that: The adjustable tensioning module also includes an adjustment screw, and the tensioning block is connected to the upper template through the adjustment screw.

9. A fully automated integrated molding method, characterized in that: The molding process employs a fully automatic integrated molding equipment as described in claim 6, comprising the following steps: S1. The upper and lower mold plates are closed, and the lower plastic frame is injected into the first injection cavity; S2. The upper and lower templates are opened, and the lower plastic frame is transferred into the first placement slot; S3. The pulling and winding assembly pulls the membrane through the first placement groove and covers the first placement groove; S4. The upper and lower templates are closed, and the tensioning block and the pressure block work together to tighten the membrane located in the first placement groove. S5. Inject the upper glue frame into the second injection cavity. The upper glue frame, the film body and the lower glue frame are injection molded to form an integrated glue frame with film body.

10. The fully automated integrated molding method according to claim 9, characterized in that: The specific working steps of the support block and the pressure block in step S4 are as follows: During the mold closing process of the upper and lower mold plates, the height of the pressure block on the lower mold plate is higher than the height of the support block. The upper and lower mold plates gradually approach each other. At the same time, the pressure block on the upper and lower mold plates first clamps the film body, and then the support block pushes the film body into the pressure groove of the lower mold plate to tighten the film body; until the upper and lower mold plates are completely closed.

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