A secondary foaming device for processing foamed materials

Abstract

This application relates to a secondary foaming device for processing foamed materials, comprising several pre-pressurization tanks, a pipeline switching system, a heated foaming chamber, and an extraction and bagging system. The several pre-pressurization tanks are arranged side-by-side, each with a discharge pipe at its bottom. The pipeline switching system includes a slide rail frame, a slider, a telescopic rod assembly, and a quick-connect assembly. The slide rail frame is positioned above the discharge pipe and extends along the direction of the discharge pipe's arrangement. The slider is slidably mounted on the slide rail frame. The telescopic rod assembly is positioned below the slide rail frame. The heated foaming chamber includes a conveying pipe that passes through the slider and has its opening facing the discharge pipe. The conveying pipe is connected to the discharge pipe via the quick-connect assembly. A discharge port is located at the bottom of the heated foaming chamber. A screening device is positioned below the discharge port. The extraction and bagging system is connected to the qualified product outlet of the screening device for extracting and bagging the screened qualified foamed material. This application improves production efficiency during secondary foaming.

Description

Technical Field

[0001] This application relates to the field of foaming technology, and in particular to a secondary foaming device for processing foamed materials. Background Technology

[0002] A foaming device is a specialized process and mechanical equipment assembly that introduces uniform air bubbles into a material matrix through physical foaming, chemical foaming, or gas mixing and pressurization, causing the material to expand in volume and form a porous structure, thus completing the entire process of plasticizing, mixing, gas injection, temperature control, pressure relief, and curing.

[0003] In existing technologies, the expansion degree of materials after primary foaming is uneven, and the overall density is relatively high, with small and unevenly distributed cell sizes. This cannot directly meet the requirements of subsequent product manufacturing for low density, large volume, and uniform cell size in foamed materials. Therefore, a secondary foaming treatment is needed to further reduce the internal density, increase the volume, and make the cell distribution more uniform. However, existing secondary foaming devices have multiple pre-pressurization tanks but only one heating chamber. When switching the pre-pressurization tank for material supply, operators must manually disassemble the pipe connection on the discharge pipe of the current pre-pressurization tank and then install the pipe on the discharge pipe of the next pre-pressurization tank to be discharged. The entire process is time-consuming and labor-intensive, the pipe replacement speed is slow, and frequent disassembly and reassembly can easily lead to poor joint sealing, affecting production efficiency and safety.

[0004] Therefore, how to solve the problem of low production efficiency during secondary foaming has become an urgent problem to be solved in this field. Summary of the Invention

[0005] To address the issue of low production efficiency during secondary foaming, this application provides a secondary foaming apparatus for processing foamed materials, which can improve production efficiency during secondary foaming.

[0006] In a first aspect, this application provides a secondary foaming apparatus for processing foamed materials.

[0007] The secondary foaming device for processing foamed materials provided in this application adopts the following technical solution: A secondary foaming device for processing foamed materials includes several pre-pressurization tanks, a pipeline switching system, a heated foaming chamber, and an extraction and bagging system. The several pre-pressurization tanks are arranged side-by-side, each with a discharge pipe at its bottom. The pipeline switching system includes a slide rail frame, a slider, a telescopic rod assembly, and a quick-connect assembly. The slide rail frame is positioned above the discharge pipe and extends along the arrangement direction of the discharge pipe. The slider is slidably mounted on the slide rail frame. The telescopic rod assembly is positioned below the slide rail frame. The heated foaming chamber includes a conveying pipe that passes through the slider and has its opening facing the discharge pipe. The conveying pipe is connected to the discharge pipe via the quick-connect assembly. The bottom of the heated foaming chamber has a discharge port. A screening device is positioned below the discharge port. The extraction and bagging system is connected to the qualified product outlet of the screening device for extracting and bagging the screened qualified foamed material.

[0008] By adopting the above technical solution and utilizing a mechanical pipeline switching system, operators can quickly complete the physical connection and switching between the feed pipe and the discharge pipe of different pre-pressure tanks by loosening the quick-connect assembly, raising the telescopic rod assembly, moving the slider along the slide rail to the top of the target pre-pressure tank, lowering the telescopic rod assembly, and locking the quick-connect assembly. The entire switching process is achieved through a mechanical structure, making operation intuitive, reliable, and easy to maintain. At the same time, by integrating the pre-pressure tank, pipeline switching system, heating foaming chamber, screening device, and extraction and bagging system into a single secondary foaming production line, continuous operation of the entire process from pressurized permeation, pipeline switching, heating foaming, screening and grading to extraction and bagging is achieved, reducing manual transfer links between processes and improving the overall production efficiency of the production line.

[0009] Preferably, the telescopic rod assembly includes a fixed sleeve and a telescopic rod; the fixed sleeve is fixed below the slide rail frame; the telescopic rod is slidably inserted into the fixed sleeve; the fixed sleeve is provided with a locking member, which is used to lock the telescopic rod at a set height position.

[0010] By adopting the above technical solution, the telescopic rod assembly adopts a sleeve structure of fixed sleeve and telescopic rod. The operator can adjust the height of the feed pipe by raising or lowering the telescopic rod. When switching pre-pressure tanks, the telescopic rod is first raised to make the feed pipe separate from the current discharge pipe. The slider is moved to the top of the target pre-pressure tank and then the telescopic rod is lowered to make the feed pipe connect with the target discharge pipe. The locking part can lock the telescopic rod at the required height to ensure the stability of the pipeline connection and prevent the feed pipe from loosening due to vibration or pipeline pressure during the conveying process.

[0011] Preferably, the quick-connect assembly includes an upper retaining sleeve disposed at the inlet of the feed pipe and a lower retaining sleeve disposed at the inlet of the discharge pipe, with a sealing ring provided between the upper retaining sleeve and the lower retaining sleeve; a first valve is provided at the end of the discharge pipe near the lower retaining sleeve, and a second valve is provided at the end of the feed pipe near the upper retaining sleeve; a venting valve is provided between the second valve and the upper retaining sleeve.

[0012] By adopting the above technical solution, the quick-connect assembly uses an upper and lower clamp docking structure. After aligning the pipe ends, simply fastening and tightening the clamps completes the pipe connection. During disassembly, loosening the clamps separates the two pipe ends. Both connection and disassembly are quick and easy, further improving production efficiency. Pipeline valves are installed on both pipelines to ensure that materials do not leak during switching. At the same time, when inspecting pipelines or joints, the valves can be closed nearby to cut off the fluid. The vent valve is used to depressurize the closed section of the pipeline during replacement to prevent residual gas from carrying materials out.

[0013] Preferably, the top of the heating foaming chamber is provided with a heating inlet connected to the conveying pipe, the outer wall of the heating foaming chamber is provided with a heating component, the top of the heating foaming chamber is also provided with an air inlet for introducing high-pressure gas into the chamber, and the chamber body of the heating foaming chamber is also provided with a pressure relief valve for rapidly releasing pressure after the material is heated to a set temperature to cause the material to foam and expand.

[0014] By adopting the above technical solution, the air inlet set on the heating foaming chamber can replenish high-pressure gas into the chamber during the heating process, maintain the pressure environment required for foaming inside the chamber, and, in conjunction with the rapid pressure relief function of the pressure relief valve, allow the gas inside the material to expand instantly, achieving a full and uniform secondary foaming effect, effectively reducing the density of the foamed material and increasing the material volume.

[0015] Preferably, the pre-pressurization tank includes a tank body, the top of the tank body is provided with a pre-pressurization inlet and a pressurization port, the pressurization port is used to connect to a high-pressure air source, the bottom of the tank body is a conical contraction section, the discharge pipe is located at the bottom end of the conical contraction section, and a pressure sensor and a safety valve are also installed on the tank body.

[0016] By adopting the above technical solution, the pre-pressure tank adopts a vertical cylindrical tank body with a conical contraction section at the bottom, which facilitates the material to converge towards the bottom discharge pipe under the action of gravity, achieving smooth discharge and avoiding residue in the tank; the pressure port at the top is connected to a high-pressure air source, which can uniformly pressurize and permeate the material in the tank; the pressure sensor can monitor the pressure in the tank in real time, making it easy for operators to judge whether the pressurization and permeation is completed; the safety valve automatically releases pressure when the pressure in the tank exceeds the standard, ensuring the safe operation of the equipment.

[0017] Preferably, the heating component consists of several heating bands disposed on the outer wall of the chamber. The heating bands are spaced apart along the height direction of the chamber, and each heating band is independently temperature-controlled, so that three temperature zones are formed in the chamber along the height direction: a preheating zone, a foaming zone, and a heat preservation and shaping zone. The chamber body of the heated foaming chamber is also equipped with several temperature sensors, each of which is disposed in its respective temperature zone, and all temperature sensors are electrically connected to the controller.

[0018] By adopting the above technical solution, the heating component uses several heating bands spaced apart along the height of the chamber, and each heating band is independently temperature-controlled, forming three temperature zones inside the chamber: a preheating zone, a foaming zone, and a heat preservation and shaping zone. During the descent of the material, it sequentially undergoes three stages: preheating and heating, high-temperature foaming, and heat preservation and shaping. The temperature of each stage can be independently adjusted according to the different material characteristics. This ensures that the material in the foaming zone is fully softened and foamed, and that the foamed material is slowly cooled and shaped in the heat preservation and shaping zone. This avoids the problem of cell collapse or surface cracking caused by rapid cooling, and improves the quality and consistency of the secondary foamed product.

[0019] Preferably, the heating foaming chamber is further provided with a stirring mechanism, which includes a stirring shaft arranged along the central axis of the chamber and several sets of stirring blades installed on the stirring shaft. The top end of the stirring shaft extends out of the chamber and is connected to a stirring motor.

[0020] By adopting the above technical solution, the stirring mechanism drives the stirring shaft to rotate through the stirring motor, which in turn drives the stirring blades to stir and disperse the materials in the chamber, so that the materials are heated evenly during the heating process, avoiding local overheating or underheating, and preventing the material particles from sticking together and clumping during the heating process.

[0021] Preferably, the screening device includes a screening box, with at least one layer of screen horizontally arranged inside the screening box. A vibration motor is installed on the screening box, and a scraper mechanism is provided above the screen. The scraper mechanism includes a scraper and a scraper drive component that drives the scraper to reciprocate along the surface of the screen. A screening outlet is provided at the bottom of the screening box.

[0022] By adopting the above technical solution, the screening device uses a combination of a vibrating motor and a scraper mechanism for screening. The vibrating motor drives the screening box and screen to vibrate, causing the material particles after secondary foaming to disperse rapidly on the screen. Material with qualified particle size passes smoothly through the screen holes and is discharged from the screening outlet. The scraper moves back and forth along the screen surface under the drive of the scraper drive component, pushing away the material accumulated on the screen and assisting small-diameter particles to pass through the screen. At the same time, it scrapes away the particles blocking the screen holes, effectively preventing screen blockage and improving screening efficiency and screening quality.

[0023] Preferably, the extraction and bagging system includes a negative pressure fan, a conveying pipe, a bagging cylinder, and a weighing sensor. The negative pressure fan is connected to the screening outlet of the screening device through the conveying pipe. The bagging cylinder is located at the end of the conveying pipe, and the weighing sensor is located below the bagging cylinder.

[0024] By adopting the above technical solution, the extraction and bagging system uses the negative pressure generated by the negative pressure fan to extract the qualified materials after screening through the conveying pipeline to the bagging cylinder, realizing the closed conveying of materials and avoiding material loss and environmental dust pollution caused by the scattering of foamed materials during the conveying process; the weighing sensor monitors the bag weight in real time to ensure that the weight of each bag of product is consistent, realizing quantitative bagging and reducing the workload and error of manual weighing.

[0025] Secondly, this application provides a pipeline switching method for a secondary foaming device used in foam material processing.

[0026] A method for switching pipelines in a secondary foaming device for processing foamed materials includes the following steps: S1. Cut off the flow and seal the pipe. Close the first valve and the second valve to form a closed pipe section between the valve on the discharge pipe and the valve on the conveying pipe. S2. Residual pressure relief: Slowly open the relief valve to discharge the residual high-pressure gas in the closed pipe section through the relief branch pipe until the pressure in the closed pipe section drops to atmospheric pressure. S3. Disconnect the pipeline. After confirming that the pressure in the closed section has dropped to atmospheric pressure, loosen the quick-connect assembly and lift the telescopic rod assembly to disconnect the conveying pipe from the current discharge pipe. S4. Pipeline connection: Move the slider along the slide rail to the corresponding position of the target pre-pressure tank, lower the telescopic rod assembly to connect and lock the material conveying pipe with the discharge pipe of the target pre-pressure tank through the quick-connect assembly, and close the relief valve; S5. Pipeline pre-pressurization: Open the first valve of the target pre-pressurization tank to a small opening, so that the high-pressure gas in the target pre-pressurization tank can be injected into the closed pipe section through the discharge pipe at a controlled flow rate, and the closed pipe section can be slowly pre-pressurized; when the pressure in the closed pipe section rises to 60%-80% of the internal pressure of the target pre-pressurization tank, fully open the first valve on the discharge pipe and the second valve on the conveying pipe, so that the material enters the heating foaming chamber in a stable flow state.

[0027] By adopting the above technical solution, the residual high-pressure gas in the closed pipe section is discharged through the vent valve before the pipeline switching, which effectively avoids the waste of materials and the safety risks to operators caused by the instantaneous ejection of residual gas along with materials when disassembling quick-connect components under pressure. At the same time, after the pipeline connection is completed, a pre-pressurization step is adopted. The pressure in the closed pipe section is gradually built up by slowly opening the valve with a small opening. When the pressure difference between the inside and outside of the pipe section is reduced to a safe range, the valve is fully opened to supply materials. This effectively avoids the problem of instantaneous impact and ejection of materials due to the huge pressure difference between the high pressure in the target pre-pressurization tank and the normal pressure in the pipe section. It ensures that the materials enter the heating and foaming chamber in a stable flow state after the material supply switch, which improves the safety of the switching operation and the material utilization rate.

[0028] In summary, this application includes at least one of the following beneficial technical effects: 1. By setting up a mechanical switching structure for the pipeline switching system, operators can quickly complete the physical connection and switching between the feed pipe and the discharge pipe of different pre-pressure tanks by loosening the quick-connect assembly, raising the telescopic rod assembly, moving the slider along the slide rail to the top of the target pre-pressure tank, lowering the telescopic rod assembly and locking the quick-connect assembly. The entire switching process is achieved through a mechanical structure, which is intuitive and reliable to operate, easy to maintain, and greatly improves production efficiency. 2. By integrating the pre-pressurization tank, pipeline switching system, heating foaming chamber, screening device and extraction and bagging system into a single secondary foaming production line, continuous operation of the entire process from pressurized permeation, pipeline switching, heating foaming, screening and grading to extraction and bagging is realized, reducing manual transfer links between processes and improving the overall automation level and production efficiency of the production line. 3. The heating component uses several heating bands spaced apart along the height of the chamber, and each heating band is independently temperature-controlled, forming three temperature zones inside the chamber: a preheating zone, a foaming zone, and a heat preservation and shaping zone. As the material descends, it sequentially undergoes three stages: preheating, high-temperature foaming, and heat preservation and shaping. The temperature of each stage can be independently adjusted according to the different material characteristics. This ensures that the material in the foaming zone is fully softened and foamed, while the heat preservation and shaping zone allows the foamed material to cool and shape slowly, avoiding cell collapse or surface cracking caused by rapid cooling, thus improving the quality and consistency of the secondary foamed product. 4. A vent valve is installed between the second valve of the conveying pipe and the quick-connect assembly. This not only prevents residual high-pressure air from spraying out material instantly, but also allows for pre-pressurization after the pipeline connection is completed, thus improving the safety of the switching operation. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of a secondary foaming device for processing foamed materials according to this application; Figure 2 This is a structural diagram of the tank in the device; Figure 3This is a schematic diagram of the pipeline switching system in the device; Figure 4 This is a schematic diagram of the structure of the heated foaming chamber in the device; Figure 5 This is a schematic diagram of the screening device in the apparatus; Figure 6 This is a schematic diagram of the extraction and bagging system in the device.

[0030] Explanation of reference numerals in the attached figures: 1. Pre-compression tank; 11. Discharge pipe; 12. Tank body; 13. Pre-compression inlet; 14. Pressurization port; 15. Conical contraction section; 16. Pressure sensor; 17. Safety valve; 18. Inspection hole; 19. Support leg; 2. Pipeline switching system; 21. Slide rail bracket; 22. Slider; 23. Telescopic rod assembly; 231. Fixed sleeve; 232. Telescopic rod; 233. Locking element; 24. Quick-connect assembly; 241. Upper clamping sleeve; 242. Lower clamping sleeve; 25. First valve; 26. Second valve; 27. Relief valve; 3. Heated foaming chamber; 31. Heated feed inlet; 32. Heating assembly; 33. Air inlet; 34. Pressure relief valve; 35. Discharge outlet; 36. Stirring mechanism; 361. Stirring shaft; 362. Stirring blades; 363. Stirring motor; 37. Temperature sensor; 38. Feeding pipe; 301. Preheating zone; 302. Foaming zone; 303. Insulation and shaping zone; 4. Screening device; 41. Screening box; 42. Screen; 43. Vibrating motor; 44. Scraper mechanism; 441. Scraper; 442. Scraper drive component; 45. Screening outlet; 5. Bagging and filling system; 51. Negative pressure fan; 52. Conveying pipeline; 53. Bagging cylinder; 54. Weighing sensor. Detailed Implementation

[0031] The following is in conjunction with the appendix Figure 1-6 This application will be described in further detail.

[0032] This application discloses a secondary foaming device for processing foamed materials.

[0033] Reference Figure 1 A secondary foaming device for processing foamed materials includes several pre-pressurization tanks 1 arranged in parallel, a pipeline switching system 2, a heating foaming chamber 3, a screening device 4, and an extraction and bagging system 5. In this embodiment, three pre-pressurization tanks 1 are arranged in parallel. After the material is pressurized and permeated through the pre-pressurization tanks 1 in sequence, it is automatically switched to the heating foaming chamber 3 for heating and secondary foaming through the pipeline switching system 2. The foamed material is screened and graded by the screening device 4, and qualified products are extracted and bagged by the extraction and bagging system 5.

[0034] Reference Figure 2 The pre-pressurization tank 1 is used to receive the material after primary foaming and to perform pressurized permeation treatment on it. The pre-pressurization tank 1 includes a vertical cylindrical tank body 12, which is made of stainless steel and has good pressure resistance and corrosion resistance.

[0035] The top of the tank 12 is equipped with a pre-pressurization inlet 13 and a pressurization inlet 14. The pre-pressurization inlet 13 is funnel-shaped, with its upper port diameter larger than its lower port diameter, facilitating the rapid addition of material particles after primary foaming into the tank. A sealing cap is provided on the pre-pressurization inlet 13; after feeding, the cap is closed to ensure the tank is sealed. The pressurization inlet 14 is used to connect to a high-pressure gas source pipeline, allowing high-pressure gas to be introduced into the tank. This high-pressure gas penetrates into the pore structure inside the material particles under high pressure, providing the gas expansion power for subsequent secondary foaming. A pressure regulating valve is provided on the pressurization inlet 14 to adjust the inlet pressure.

[0036] A pressure sensor 16 and a safety valve 17 are also installed on the tank body 12. The pressure sensor 16 is used to monitor the gas pressure inside the tank in real time, providing a signal basis for the automatic switching control of the pipeline switching system 2. In this embodiment, the working pressure range of the pre-pressurization tank 1 is 2-5 MPa, and the pressurization permeation time is 30-60 minutes. The safety valve 17 is installed on the upper part of the tank body 12. When the pressure inside the tank abnormally exceeds the safety threshold, the safety valve 17 automatically opens to release pressure, preventing the tank from overpressure and causing danger.

[0037] The bottom of the tank 12 is a conical contraction section 15, which causes the material inside the tank to converge towards the bottom center under the action of gravity and air pressure, achieving smooth discharge and reducing residue in the tank. The discharge pipe 11 is located at the bottom end of the conical contraction section 15, and the lower end of the discharge pipe 11 is provided with a flange interface for connecting with the branch pipe 22 of the pipeline switching system 2.

[0038] The side wall of the tank body 12 is provided with an inspection hole 18. Several bolt holes are evenly distributed on the flange of the inspection hole 18, and a seal is achieved by tightening the bolts. Operators can clean, inspect and maintain the inside of the tank by opening the inspection hole 18.

[0039] The tank body 12 has four support legs 19 at its bottom, which are evenly distributed around the circumference of the tank body. The bottom of each support leg 19 has a base plate, which is fixed to the ground foundation with anchor bolts to ensure the tank body stands stably. The support legs 19 provide sufficient operating space between the bottom of the tank body and the ground, facilitating the installation and maintenance of the valve body 23 and pipeline components below the discharge pipe 11.

[0040] Reference Figure 1 and Figure 3The pipeline switching system 2 is used to switch and connect the heated foaming chamber 3 with different pre-pressurization tanks 1, solving the problem of manually disassembling and assembling pipelines one by one in the prior art. The pipeline switching system 2 includes a slide rail frame 21, a slider 22, a telescopic rod assembly 23, and a quick-connect assembly 24.

[0041] The slide rail frame 21 is horizontally set and is mounted above the discharge pipe 11 via the telescopic rod assembly 23. The middle of the slide rail frame 21 has a sliding area for accommodating the slider 22. The middle of the slide rail frame 21 is hollowed out, and the slider 22 is set in the sliding area. The sliding direction of the slider 22 is parallel to the arrangement direction of the discharge pipe 11.

[0042] The heated foaming chamber 3 includes a conveying pipe 38, which passes through the slider and has its opening facing the discharge pipe 11. The conveying pipe 38 can slide along the slide rail frame 21 together with the slider 22. In this embodiment, the slider 22 has an outwardly protruding horizontally at a position perpendicular to the direction of movement, thereby engaging with the slide rail frame 21. In other embodiments of this application, a moving wheel can be added to the engagement between the slider 22 and the slide rail frame 21 to reduce the friction between them. The operator can manually push the slider 22 to slide along the slide rail frame 21, moving the conveying pipe 38 to a position above the discharge pipe 11 of the target pre-pressure tank 1.

[0043] The telescopic rod assembly 23 is located below the slide rail frame 21. The telescopic rod assembly 23 includes a fixed sleeve 231 and a telescopic rod 232. The fixed sleeve 231 is vertically fixed to the lower surface of the slide rail frame 21. The telescopic rod 232 is slidably inserted into the fixed sleeve 231 and can move vertically up and down. The fixed sleeve 231 is equipped with a locking element 233. In this embodiment, the locking element 233 is a locking bolt that penetrates the wall of the fixed sleeve 231. When the locking bolt is tightened, its end presses against the outer surface of the telescopic rod 232, locking the telescopic rod 232 at the current height position. When the locking bolt is loosened, the telescopic rod 232 can move freely up and down. The operator can manually raise or lower the telescopic rod 232 to adjust the height of the conveyor pipe 38.

[0044] In other embodiments of this application, the telescopic rod assembly 23 can be electrically or pneumatically powered, and its height can be controlled by a PLC, eliminating the need for manual height adjustment by operators and making it more convenient.

[0045] The quick-connect assembly 24 is used to achieve a quick and detachable connection between the feed pipe 38 and the discharge pipe 11. The quick-connect assembly 24 includes an upper retaining sleeve 241 located at the port of the feed pipe 38 and a lower retaining sleeve 242 located at the top of each discharge pipe 11. The upper retaining sleeve 241 is fixed to the lower outer wall of the feed pipe 38, and the lower retaining sleeve 242 is fixed to the top outer wall of the discharge pipe 11. The mating surfaces of both the upper retaining sleeve 241 and the lower retaining sleeve 242 are flat flange structures, and their shapes match.

[0046] The quick-connect assembly 24 can use a quick-connect fitting or a ferrule fitting to achieve quick connection; it can also use a locking clamp, such as a V-clamp or a chuck quick clamp, to lock or release the device by turning the handle.

[0047] A sealing ring (not shown in the figure) is provided on the mating surface between the upper ferrule 241 and the lower ferrule 242. The sealing ring is embedded in the sealing groove on the end face of the upper or lower ferrule. After the mating is locked, the sealing ring is compressed to form a reliable seal, preventing high-pressure materials and gases from leaking from the mating point. A first valve 25 is provided at the middle end of the feed pipe 11 near the lower ferrule 242, and a second valve 26 is provided at the middle end of the conveying pipe 38 near the upper ferrule 241. These valves are used to close the opening of the feed pipe 24 when the pipeline is not connected or during switching, to prevent residual materials from leaking from the opening.

[0048] Reference Figure 3 A first valve 25 is installed near the end of the discharge pipe 11, and a second valve 26 is installed near the end of the conveying pipe 38. A sealing pipe is formed between the first valve 25 and the second valve 26. A relief valve 27 is installed on the sealing pipe. Specifically, the relief valve 27 is located between the second valve 26 and the upper clamping sleeve 241. The relief valve 27 can be a manual ball valve or a needle valve. It should be noted that the valves and quick-connect plugs shown in the attached drawings are for illustrative purposes only and do not represent the actual shape of the valves and plugs.

[0049] The specific operation process for the pipeline is as follows: The first step is to shut off the flow and seal the pipes by closing the first valve 25 on the discharge pipe 11 and the second valve 26 on the conveying pipe 38, thus cutting off the material delivery to the heating and foaming chamber 3. At this time, a closed pipe section is formed between the first valve 25 and the second valve 26, and high-pressure gas from the previous material delivery process remains in this closed pipe section. It should be noted that the closing sequence can be to first close the first valve 25 on the upstream side, and then close the second valve 26 on the downstream side. This ensures that all the material in the pipeline is delivered to the heating and foaming chamber 3, avoiding the generation of a large amount of residual material that clogs the sealed pipe section.

[0050] The second step is to release residual pressure. Slowly open the release valve 27 to discharge the residual high-pressure gas in the closed pipe section through the release branch pipe until the pressure in the closed pipe section drops to atmospheric pressure. When opening the release valve 27, it should be filled to avoid excessive airflow impact caused by instantaneous full opening. After the released airflow weakens significantly until it stops and the pressure in the closed pipe section drops to balance with atmospheric pressure, the release step is completed.

[0051] The third step is to disconnect the pipeline. After confirming that the pressure inside the closed pipe section has dropped to atmospheric pressure, loosen the quick-connect assembly 24. The upper clamp 241 and the lower clamp 242 separate. Since there is no residual pressure inside the pipe section, the separation process is smooth and no material is ejected. Then, loosen the locking part 233 of the telescopic rod assembly 23 and lift the telescopic rod 232 upward so that the conveying pipe 38 is disengaged from the current discharge pipe 11.

[0052] Fourth step, pipe connection: Move the slider 22 along the slide rail 21 to the corresponding position directly above the discharge pipe 11 of the target pre-pressure tank 1. Lower the telescopic rod 232 so that the upper clamping sleeve 242 of the conveying pipe 38 is aligned with the end face of the lower clamping sleeve 242 of the discharge pipe 11 of the target pre-pressure tank 1, and lock it. Then tighten the locking part 233 of the telescopic rod assembly 23 to fix the telescopic rod 232 at the current height. Close the relief valve 27 to restore the pipe section to a sealed state.

[0053] The fifth step is to pre-pressurize the pipeline. Open the first valve 25 on the discharge pipe 11 of the target pre-pressurization tank 1 to a small opening, about one-quarter opening, so that the high-pressure gas in the target pre-pressurization tank can be injected into the closed pipe section through the discharge pipe at a controlled flow rate to slowly pre-pressurize the closed pipe section. When the pressure in the closed pipe section rises to 60%-80% of the internal pressure of the target pre-pressurization tank, the pressure difference between the inside and outside of the pipe section has been reduced to a safe range. Then, fully open the first valve 25 on the discharge pipe 11 and the second valve 26 on the conveying pipe 38 so that the material enters the heating foaming chamber 3 in a stable flow state.

[0054] In this embodiment, the working pressure of the pre-pressurization tank is 2-5 MPa. If the valve is fully opened directly without pre-pressurization, there will be a pressure difference of approximately 20-50 times between the atmospheric pressure (approximately 0.1 MPa) in the pipeline section and the high pressure (2-5 MPa) in the tank. Driven by this instantaneous huge pressure difference, the material will impact the pipe wall and the sealing surface of the quick-connect assembly at high speed, potentially causing damage to the sealing ring, material splashing, and pipeline vibration. By pre-pressurizing to reduce the pressure difference to within the range of 20%-40% before fully opening the valve, the material flow rate is smooth and controllable, effectively protecting the service life of the pipeline seals and preventing material waste.

[0055] Reference Figure 1 and Figure 4 The heated foaming chamber 3 is equipped with a heated feed inlet 31 at the top. The heated feed inlet 31 is connected to the conveying pipe 24 of the pipeline switching system 2 via a bend. The material from the pre-compression tank 1 enters the chamber through the conveying pipe 24 and the heated feed inlet 31. The top of the chamber is also equipped with an air supply port 33, which is connected to a high-pressure gas source pipeline. The pipeline of the air supply port 33 is equipped with a pressure regulating valve. During the heating process, high-pressure CO2 gas is supplied to the chamber through the air supply port 33 to maintain the high-pressure environment inside the chamber.

[0056] The outer wall of the chamber is equipped with a heating component 32, which consists of several electric heating bands spaced apart along the height of the chamber. In this embodiment, the heating bands are divided into three groups along the height direction, and each group of heating bands is independently temperature-controlled, so that the chamber is divided into three temperature zones from top to bottom along the height direction: a preheating zone 301, a foaming zone 302, and a heat preservation and shaping zone 303. The preheating zone 301 is used to preheat the material that has just entered the chamber; the foaming zone 302 is located in the middle of the chamber, where the material undergoes secondary foaming; the heat preservation and shaping zone 303 is located in the lower part of the chamber and is used to slowly cool and shape the foamed material.

[0057] The chamber is equipped with a pressure relief valve 34. The pressure relief valve 34 is installed at the corresponding position in the foaming zone 302 in the middle of the chamber. The pressure relief valve 34 can be a manual or electromagnetically controlled quick-release valve, which is opened by the operator after the temperature inside the chamber reaches the set foaming temperature.

[0058] The heating and foaming chamber 3 is also equipped with a stirring mechanism 36. The stirring mechanism 36 includes a stirring shaft 361 arranged along the central axis of the chamber and several sets of stirring blades 362 mounted on the stirring shaft 361. The stirring shaft 361 is vertically arranged at the center of the chamber, with its top end passing through the top end cap of the chamber and supported by a sealed bearing. The top end of the stirring shaft 361 is connected to a stirring motor 363, which is fixedly installed on the top of the chamber. Several sets of stirring blades 362 are arranged at intervals along the height direction of the stirring shaft 361. In this embodiment, one set of stirring blades 362 is arranged in each of the preheating zone 301, the foaming zone 302, and the heat preservation and shaping zone 303. The stirring motor 363 drives the stirring shaft 361 to rotate, which in turn drives each set of stirring blades 362 to rotate, stirring and dispersing the material in each section of the chamber, so that the material particles are heated evenly, avoiding local overheating or underheating, and preventing the material particles from sticking together and clumping during the heating and softening process.

[0059] The heated foaming chamber 3 is equipped with several temperature sensors 37, which are thermocouples or PT100 temperature probes. Each temperature sensor 37 is inserted into one of the sections of the preheating zone 301, the foaming zone 302, and the heat preservation and shaping zone 303. The temperature sensors 37 display the real-time temperature of each section on a temperature instrument. The operator adjusts the heating power of each heating band according to the display on the temperature instrument to achieve precise and independent temperature control of each temperature section.

[0060] The bottom of the heating foaming chamber 3 is a conical shrinking structure. The bottom of the conical bottom is provided with a discharge port 35. A discharge valve is provided on the discharge port 35. The material that has completed secondary foaming and shaping and cooling is discharged from the discharge port 35 and enters the screening device 4 below.

[0061] Reference Figure 1 and Figure 5The screening device 4 is located below the discharge port 35 of the heating foaming chamber 3. The screening device 4 includes a screening box 41, which is a rectangular box structure. The top is provided with a feed inlet that is connected to the discharge port 35 of the heating foaming chamber 3 or is located directly below the discharge port 35 to receive materials.

[0062] At least one layer of screen 42 is horizontally arranged inside the screening box 41. In this embodiment, one layer of screen 42 is provided. The aperture of the screen 42 is set according to the target particle size range of the qualified foamed material. After secondary foaming, the material particles fall onto the screen 42. Qualified products with a particle size smaller than the aperture of the screen pass through the screen 42 and fall into the space below the screen.

[0063] It should be noted that, in this embodiment, although the qualified foamed material after secondary foaming increases in volume after sufficient expansion, the particle size of the monomer particles formed after physical dispersion falls within the screen mesh size range and can pass through the screen. However, unqualified particles that are insufficiently foamed, agglomerated, or abnormally large are trapped above the screen mesh because their particle size is larger than the screen mesh size. The qualification standard for screening can be adjusted according to the actual product requirements to change the screen mesh size.

[0064] A scraper mechanism 44 is provided above the screen 42. The scraper mechanism 44 includes a scraper 441 and a scraper drive 442. The scraper 441 is a strip-shaped plate structure, extending along the width direction of the screen 42, with its bottom edge close to or lightly touching the upper surface of the screen 42. The scraper drive 442 adopts a motor-driven crank-connecting rod mechanism. The motor drives the crank to rotate, and the rotational motion is converted into the reciprocating linear motion of the scraper 441 along the surface of the screen 42 through the connecting rod. The reciprocating motion of the scraper 441 on the upper surface of the screen 42 disperses and evenly distributes the material accumulated on the screen, assisting particles of the qualified particle size to pass through the screen holes, while scraping and clearing particles stuck in the screen holes, preventing screen blockage and improving screening efficiency.

[0065] A vibrating motor 43 is installed on the screening box 41. The vibrating motor 43 is installed at the bottom or side of the screening box 41. When the vibrating motor 43 operates, it drives the screening box 41 and the screen 42 to generate high-frequency vibration, causing the material particles to jump and disperse on the screen 42, further accelerating the speed at which qualified particles pass through the screen holes and improving screening efficiency. The vibrating motor 43 works in conjunction with the scraper mechanism 44; the scraper pushes the material apart in conjunction with the vibrating screening, achieving efficient screening operations.

[0066] The bottom of the screening box 41 is provided with a screening outlet 45. The screening outlet 45 is located below the screen 42. Qualified foamed material particles that pass through the screen 42 are collected at the bottom of the screening box 41 under the action of gravity and discharged from the screening outlet 45, entering the extraction and bagging system 5. The side of the screening box 41 is provided with a non-conforming product discharge outlet above the screen 42. Non-conforming products remaining above the screen 42 are discharged and collected through the non-conforming product discharge outlet and can be returned for reprocessing.

[0067] Reference Figure 1 and Figure 6 The extraction and bagging system 5 is connected to the screening outlet 45 of the screening device 4. The extraction and bagging system 5 includes a negative pressure fan 51, a conveying pipe 52, a bagging cylinder 53, and a weighing sensor 54.

[0068] The negative pressure fan 51 generates negative pressure suction, drawing qualified foamed material particles discharged from the screening outlet 45 into the conveying pipe 52 and transporting them along the pipe. One end of the conveying pipe 52 is connected to the screening outlet 45, and the other end is connected to the bagging cylinder 53. Under negative pressure, the material is conveyed in a closed manner along the conveying pipe 52 to the bagging cylinder 53. The bagging cylinder 53 is a vertically arranged cylindrical structure, with the bag body fitted onto the outer wall of the bagging cylinder 53. The material falls from the conveying pipe 52 through the inner cavity of the bagging cylinder 53 into the bag body fitted onto its outer wall.

[0069] A load cell 54 is positioned below the bagging cylinder 53, with the bag placed on a support platform above it. The load cell 54 monitors the total weight of the bag and its contents in real time and displays the weight signal on the weighing instrument. When the load cell 54 detects that the weight of the material inside the bag has reached a preset quantitative value, the operator manually shuts off the negative pressure fan 51 or closes the shut-off valve on the conveying pipe 52 to stop the material from being fed into the bag. The operator removes the filled bag from the bagging cylinder 53, seals it, and stores it in the warehouse before replacing it with a new empty bag to continue the bagging operation.

[0070] The implementation principle of the secondary foaming device for processing foamed materials in this application is as follows: The material after primary foaming is fed into each pre-pressurization tank 1, the pre-pressurization inlet 13 is closed, and high-pressure gas is introduced through the pressurization port 14 to pressurize the secondary foaming material. When it is necessary to replace the pre-pressurization tank 1 connected to the heated foaming chamber 3, the operator performs a pipeline switching operation. First, the first valve 25 in the feed pipe 24 and the second valve 26 in the currently connected discharge pipe 11 are closed. The pressure is released by opening the vent valve 27. Then, the upper clamp 241 and the lower clamp 242 are loosened. Next, the locking member 253 is loosened, and the telescopic rod 252 is raised until the feed pipe 24 is completely disengaged from the current discharge pipe 11. Then, the locking member 253 is tightened to fix the height of the telescopic rod 252. Finally, the slider 23 is manually pushed along... The slide rail 22 slides, moving the slider 23 to the position corresponding to the outlet pipe 11 of the target pre-pressure tank 1, so that the center of the inlet pipe 24 is aligned with the center of the outlet pipe 11. Then, the locking member 253 is released, and the telescopic rod 252 is lowered, so that the upper sleeve 261 at the lower end of the inlet pipe 24 and the lower sleeve 262 at the top of the target outlet pipe 11 are aligned and abutted. The locking clamp 263 is fastened to lock the upper sleeve 261 and the lower sleeve 262, and the sealing ring is compressed to form a seal. Finally, the first valve 25 in the outlet pipe 11 and the second valve 26 in the inlet pipe 24 are opened in sequence. Under the combined action of residual air pressure and gravity in the tank, the pressurized and permeated material flows into the conveying pipe 29 through the outlet pipe 11 and the inlet pipe 24, and enters the heating foaming chamber 3 from the heating inlet 31. The material entering the heating foaming chamber 3 passes through three temperature zones from top to bottom in the chamber. In the preheating zone 301, the material is preheated; in the foaming zone 302, the material softens and undergoes secondary foaming; in the heat preservation and shaping zone 303, the material after secondary foaming is shaped and fixed. The stirring mechanism 36 operates continuously throughout the heating and foaming process, and the stirring blades 362 stir and disperse the material to ensure uniform heating. The material that has completed secondary foaming and shaping is discharged from the discharge port 35 and falls into the screening box 41 of the screening device 4. The vibrating motor 43 and the scraper mechanism 44 work simultaneously, and the material is screened after being vibrated and dispersed by the scraper on the screen 42. Qualified material is discharged from the screening outlet 45, while unqualified material remains above the screen 42 and is discharged from the unqualified product outlet for collection and recycling. The qualified foamed material discharged from the screening outlet 45 is drawn and transported to the bagging cylinder 53 by the negative pressure fan 51 through the conveying pipe 52, and falls into the bag body fitted on the outer wall of the bagging cylinder 53. The weighing sensor 54 monitors the weight of the bag in real time. When the weight reaches the set value, the operator stops the extraction, removes the full bag, seals it, and puts it into storage.

[0071] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A secondary foaming device for processing foamed materials, characterized in that: It includes several pre-pressurization tanks (1), a pipeline switching system (2), a heated foaming chamber (3), and an extraction and bagging system (5); Several of the aforementioned pre-pressurization tanks (1) are arranged side by side, and each of the aforementioned pre-pressurization tanks (1) is provided with a discharge pipe (11) at the bottom. The pipeline switching system (2) includes a slide rail frame (21), a slider (22), a telescopic rod assembly (23), and a quick-connect assembly (24); the slide rail frame (21) is disposed above the discharge pipe (11), and the slide rail frame (21) extends along the arrangement direction of the discharge pipe (11); the slider (22) is slidably disposed on the slide rail frame (21); the telescopic rod assembly (23) is disposed below the slide rail frame (21); The heating foaming chamber (3) includes a conveying pipe (38), which passes through the slider (22) and has its opening facing the discharge pipe (11). The conveying pipe (38) is connected to the discharge pipe (11) via a quick-connect assembly (24). The bottom of the heating foaming chamber (3) is provided with a discharge port (35). The screening device (4) is located below the discharge port (35), and the extraction and bagging system (5) is connected to the qualified product outlet of the screening device (4) for extracting and bagging the qualified foamed material after screening.

2. The secondary foaming device for processing foamed materials according to claim 1, characterized in that: The telescopic rod assembly (23) includes a fixed sleeve (231) and a telescopic rod (232). The fixing sleeve (231) is fixed below the slide rail frame (21); The telescopic rod (232) is slidably inserted into the fixed sleeve (231); The fixed sleeve (231) is provided with a locking member (233), which is used to lock the telescopic rod (232) at a set height position.

3. The secondary foaming device for processing foamed materials according to claim 1, characterized in that: The quick-connect assembly (24) includes an upper sleeve (241) disposed at the inlet of the feed pipe (38) and a lower sleeve (242) disposed at the inlet of the discharge pipe (11), and a sealing ring is provided between the upper sleeve (241) and the lower sleeve (242); The discharge pipe (11) is provided with a first valve (25) at the end near the lower sleeve (242), and the conveying pipe (38) is provided with a second valve (26) at the end near the upper sleeve (241). A relief valve (27) is provided between the second valve (26) and the upper ferrule (241).

4. The secondary foaming device for processing foamed materials according to claim 1, characterized in that: The top of the heating foaming chamber (3) is provided with a heating inlet (31) connected to the conveying pipe (38). The outer wall of the heating foaming chamber (3) is provided with a heating component (32). The top of the heating foaming chamber (3) is also provided with an air inlet (33). The air inlet (33) is used to introduce high-pressure gas into the chamber. The chamber body of the heating foaming chamber (3) is also provided with a pressure relief valve (34). The pressure relief valve (34) is used to quickly release pressure after the material is heated to a set temperature to cause the material to foam and expand.

5. The secondary foaming device for processing foamed materials according to claim 1, characterized in that: The pre-pressurization tank (1) includes a tank body (12). The top of the tank body (12) is provided with a pre-pressurization inlet (13) and a pressurization port (14). The pressurization port (14) is used to connect to a high-pressure gas source. The bottom of the tank body (12) is a conical contraction section (15). The discharge pipe (11) is located at the bottom end of the conical contraction section (15). The tank body (12) is also equipped with a pressure sensor (16) and a safety valve (17).

6. The secondary foaming device for processing foamed materials according to claim 4, characterized in that: The heating component (32) consists of several heating bands on the outer wall of the chamber. The heating bands are distributed at intervals along the height direction of the chamber, and each heating band is independently temperature controlled, so that the chamber is divided into three temperature zones along the height direction: a preheating zone (301), a foaming zone (302), and a heat preservation and shaping zone (303). The chamber of the heated foaming chamber (3) is also equipped with several temperature sensors (37). Each temperature sensor (37) is set in each temperature zone, and each temperature sensor (37) is electrically connected to the controller (26).

7. The secondary foaming device for processing foamed materials according to claim 1, characterized in that: The heating foaming chamber (3) is also equipped with a stirring mechanism (36). The stirring mechanism (36) includes a stirring shaft (361) arranged along the central axis of the chamber and several sets of stirring blades (362) installed on the stirring shaft (361). The top end of the stirring shaft (361) extends out of the chamber and is connected to a stirring motor (363).

8. The secondary foaming device for processing foamed materials according to claim 1, characterized in that: The screening device (4) includes a screening box (41), in which at least one layer of screen (42) is horizontally arranged. A vibration motor (43) is installed on the screening box (41). A scraper mechanism (44) is provided above the screen (42). The scraper mechanism (44) includes a scraper (441) and a scraper drive (442) that drives the scraper (441) to reciprocate along the surface of the screen (42). A screening outlet (45) is provided at the bottom of the screening box (41).

9. A secondary foaming device for processing foamed materials according to claim 8, characterized in that: The extraction and bagging system (5) includes a negative pressure fan (51), a conveying pipe (52), a bagging cylinder (53), and a weighing sensor (54). The negative pressure fan (51) is connected to the screening outlet (45) of the screening device (4) through the conveying pipe (52). The bagging cylinder (53) is located at the end of the conveying pipe (52), and the weighing sensor (54) is located below the bagging cylinder (53).

10. The pipeline switching method of a secondary foaming device for processing foamed materials according to claim 3, characterized in that, Includes the following steps: S1. Cut off the flow and seal the pipe, close the first valve (25) and the second valve (26) to form a closed pipe section between the valve on the discharge pipe (11) and the valve on the conveying pipe (38); S2. Residual pressure release: Slowly open the release valve (27) to discharge the residual high pressure gas in the closed pipe section through the release branch pipe until the pressure in the closed pipe section drops to atmospheric pressure. S3. After confirming that the pressure in the closed pipe section has dropped to atmospheric pressure, release the quick-connect assembly (24) and lift the telescopic rod assembly (23) to disconnect the conveying pipe (38) from the current discharge pipe (11). S4. Pipeline connection: Move the slider (22) along the slide rail frame (21) to the corresponding position of the target pre-pressure tank (1), lower the telescopic rod assembly (23) so that the conveying pipe (38) and the discharge pipe (11) of the target pre-pressure tank (1) are connected and locked through the quick-connect assembly (24), and close the relief valve (27). S5. Pre-pressurize the pipeline. Open the first valve (25) of the target pre-pressurization tank (1) to a small opening. The high-pressure gas in the target pre-pressurization tank (1) is filled into the closed pipe section through the discharge pipe (11) at a controlled flow rate. The closed pipe section is slowly pre-pressurized. When the pressure in the closed pipe section rises to 60%-80% of the internal pressure of the target pre-pressurization tank (1), the first valve (25) on the discharge pipe (11) and the second valve (26) on the conveying pipe (38) are fully opened so that the material enters the heating foaming chamber (3) in a stable flow state.

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