A large-scale continuous production line for polyurethane elastic pads

Abstract

This application discloses a large-scale continuous production line for polyurethane elastic padding, comprising a foaming machine, a feeder, a track assembly, a cutting mechanism, and a transfer mechanism arranged sequentially. A release paper unwinding frame is located at the front of the feeder, and a release paper winding frame is located between the track assembly and the cutting mechanism. A cross-sweeping frame is provided between the foaming machine and the track assembly, supporting and driving the feeder to reciprocate along the width direction of the track assembly. A geotextile unwinding frame is located at the top of the track assembly. Conveying rollers are horizontally connected through the cutting mechanism and the transfer mechanism. The track assembly consists of an upper track and a lower track arranged parallel to each other. This production line can achieve overall stability during normal continuous (uninterrupted) production of polyurethane continuously foamed elastic padding, achieving adjustable padding width, thickness, and density (pressure), and is suitable for continuous production of track bed vibration damping pads, sleeper pads, and elastic padding under iron pads.

Description

Technical Field

[0001] This application relates to the field of polyurethane elastic pad production technology, and more particularly to a large-scale continuous production line for polyurethane elastic pads. Background Technology

[0002] Currently, the production method for polyurethane sleeper pads and polyurethane elastic pads involves continuously pouring the polyurethane composite material into the casting mold cavity of the sleeper pad or elastic pad after mixing it in a foaming machine. However, because the casting molds for sleeper pads and elastic pads are limited to single-piece, single-mold production, large-scale continuous production of polyurethane sleeper pads and polyurethane elastic pads cannot be achieved, resulting in low production efficiency and poor product consistency. Therefore, it is necessary to improve this single-piece, single-mold production method, as well as the casting equipment and molds, to enable the production of not only track bed vibration damping pads, sleeper pads, and elastic pads under iron base plates, thereby improving production efficiency and reducing production costs. Summary of the Invention

[0003] To address the aforementioned problems, this application aims to provide a large-scale continuous production line for polyurethane elastic pads, which can achieve adjustable pad width, adjustable thickness, and adjustable density (pressure), suitable for producing track bed vibration damping pads, sleeper pads, and elastic pads under iron pads, thereby improving the production efficiency of various pads.

[0004] To achieve the above objectives, the technical solution adopted in this application is as follows: A large-scale continuous production line for polyurethane elastic padding includes a foaming machine, a feeder, a track assembly, a cutting mechanism, and a transfer mechanism arranged sequentially. A release paper unwinding frame is provided on the front side of the feeder, and a release paper winding frame is provided between the track assembly and the cutting mechanism. A cross-sweeping frame is provided between the foaming machine and the track assembly to support and drive the feeder to reciprocate along the width direction of the track assembly. A geotextile unwinding frame is provided on the top of the track assembly. A conveyor roller assembly is horizontally arranged through the cutting mechanism and the transfer mechanism.

[0005] The track assembly consists of an upper track and a lower track arranged in parallel. Both the upper and lower tracks are rotary structures, and their tail ends before the release paper take-up frame. The front end of the lower track extends out of the upper track and forms a receiving part, which is vertically aligned with the feeder. Each drive roller of the upper track is equipped with a lifting mechanism, which adjusts the gap height between the upper and lower tracks.

[0006] The upper track and the lower track are symmetrically provided with blocks on both sides, and the blocks are the same length as the lower track. The upper track, the lower track and the blocks enclose and form a casting cavity. The outer wall of the blocks is provided with drive motors that synchronously drive them to move and adjust along the width direction of the lower track.

[0007] Preferably, a heating and insulation box is provided around the track assembly to cover it, and the geotextile winding frame is located on top of the heating and insulation box.

[0008] Preferably, the conveying roller assembly consists of a front section and a rear section, with a cutting gap between the front section and the rear section corresponding to the cutting head of the cutting mechanism.

[0009] Preferably, the cutting mechanism is a waterjet cutting system.

[0010] Preferably, the release paper unwinding frame is at the same height as the top surface of the lower conveyor belt, and the release paper rewinding frame is lower than the top surface of the lower conveyor belt.

[0011] Preferably, the transfer mechanism includes a robotic arm positioned above the conveyor roller assembly and a transfer vehicle positioned beside the conveyor roller assembly.

[0012] The beneficial effects of this application are: the production line can achieve overall stability during normal continuous (uninterrupted) production of polyurethane continuous foam elastic pads, and the pad width, thickness, and density (pressure) are adjustable. It is suitable for producing track bed vibration damping pads, sleeper pads, and elastic pads under iron base plates.

[0013] There is a gap between the upper and lower tracks to accommodate foamed material. The width, thickness and pressure are adjustable. There is a certain pressure between the upper and lower tracks. Foaming is continuous in the constantly moving cavity, which can produce foamed elastic pads with high closed-cell rate and good waterproof performance. The upper and lower track plates of the double track laminator are equipped with heaters and heat preservation systems to provide sufficient temperature for the foamed material to facilitate full foaming.

[0014] Stacking allows the cut subfloor layers to be transferred off the production line to a secondary curing area for storage, enabling continuous production of subfloor layers. Attached Figure Description

[0015] Figure 1 This is an overall diagram of the continuous production line for the elastic padding layer of this application.

[0016] Figure 2 This is a top view of the structure of the block and track assembly in this application.

[0017] Figure 3 For this application Figure 1 Enlarged view of the structure at point A in the middle.

[0018] Figure 4 A diagram showing the transfer vehicle set up next to the transfer agency in this application.

[0019] In the diagram: 1-Foaming machine; 2-Feeder; 3-Sweeping frame; 41-Upper track; 411-Lifting mechanism; 42-Lower track; 421-Receiving section; 4a-Gap; 51-Release paper unwinding frame; 52-Release paper winding frame; 6-Geotextile unwinding frame; 7-Stop block; 8-Drive motor; 9-Heating and insulation box; 10-Conveying roller group; 10a-Front section; 10b-Rear section; 10c-Cutting gap; 11-Cutting mechanism; 12-Transfer mechanism; 13-Transfer vehicle. Detailed Implementation

[0020] To enable those skilled in the art to better understand the technical solutions of this application, the technical solutions of this application will be further described below in conjunction with the accompanying drawings and embodiments.

[0021] See attached document Figures 1-4 The large-scale polyurethane elastic pad continuous production line shown includes a foaming machine 1, a feeder 2, a track assembly, a cutting mechanism 11, and a transfer mechanism 12 arranged in sequence. A release paper unwinding frame 51 is provided on the front side of the feeder 2, and a release paper winding frame 52 is provided between the track assembly and the cutting mechanism 11. A cross-sweeping frame 3 is provided between the foaming machine 1 and the track assembly to support and drive the feeder 2 to swing back and forth along the width direction of the track assembly. A geotextile unwinding frame 6 is provided on the top of the track assembly.

[0022] Among them, the foaming machine 1 is preferably a conventional high-pressure foaming machine 1, which consists of a feeding device, a storage tank, a cleaning tank, a hydraulic tank, a plunger pump, a mass flow meter, a circulation pipeline, a mixing head, a control cabinet, etc. The foaming machine 1 is a known foaming machine 1, and its specific structure is not shown in detail in the figure. The foaming machine 1 is mainly used to foam polyurethane raw materials.

[0023] The feeder 2 is a known product that connects to the foaming machine 1, and its main function is to output the foamed polyurethane. The sweeper 3 is also preferably a known product, used to drive the feeder 2 to swing back and forth along the width of the track assembly, so as to evenly output the foamed material onto the track assembly.

[0024] like Figure 1As shown, the track assembly consists of an upper track 41 and a lower track 42 arranged parallel to each other. Both the upper track 41 and the lower track 42 are rotary structures, and their tail ends before the release paper take-up frame 52. The front end of the lower track 42 extends out of the upper track 41 and forms a receiving part 421. The receiving part 421 is vertically corresponding to the feeder 2. Under the reciprocating drive of the sweeper 3, the feeder 2 continuously outputs the foaming material to the receiving part 421 at the front end of the lower track 42. Each of the drive rollers of the upper track 41 is equipped with a lifting mechanism 411. This lifting mechanism can use known products, such as a combination of a vertical guide rail and a motor. By adjusting the height of the gap 4a between the upper track 41 and the lower track 42 to form the polyurethane elastic pad, the forming thickness of the polyurethane foaming material entering the gap 4a can be adjusted.

[0025] To achieve adjustment of the width of the molded polyurethane elastic pad, such as Figure 2 As shown, symmetrical blocks 7 are arranged on both sides of the upper track 41 and the lower track 42, and the blocks 7 are the same length as the lower track 42, i.e., elongated structures. The upper track 41, the lower track 42, and the blocks 7 enclose and form a casting cavity. Drive motors 8 are spaced on the outer wall of the blocks 7, synchronously driving them to move and adjust along the width direction of the lower track 42. The shaft of the drive motor 8 is preferably threadedly connected to the blocks 7, allowing the blocks 7 to extend or retract when the drive motor 8 rotates. When producing track bed vibration damping pads, sleeper pads, and elastic pads under iron plates, according to the different widths of each product, before production, the drive motors 8 drive the blocks 7 on both sides into the gap between the upper track 41 and the lower track 42, reducing the width of the gap, thus achieving width adjustment of the molded polyurethane pad. Since the finished thicknesses of the track bed vibration damping pads, sleeper pads, and elastic pads under the iron pads are different, it is preferable to replace the blocks 7 of different heights before forming the different pads. After the blocks 7 of different heights are inserted between the upper track 41 and the lower track 42 according to the width of the pad, the gap between the upper track 41 and the lower track 42 is adjusted by the lifting mechanism to be consistent with the height of the current block 7.

[0026] The geotextile unwinding frame 6 can also be used for unwinding adhesive mesh or textured fabric, etc. The unwound geotextile enters the track assembly and is pressed and bonded to the foam layer to produce track bed vibration damping pads; the unwound adhesive mesh enters the track assembly and is pressed and bonded to the foam layer to produce sleeper pads; the unwound textured fabric enters the track assembly and is pressed and bonded to the foam layer to produce the elastic pad layer under the iron pad. Among them, the textured fabric under the iron pad is manually torn off before water jet cutting, forming a textured elastic pad layer under the iron pad; the geotextile of the track bed vibration damping pad is bonded to the foam material; the adhesive mesh of the sleeper pad is also bonded to the foam material.

[0027] A conveyor roller group 10 is horizontally arranged through the cutting mechanism 11 and the transfer mechanism 12. The polyurethane pad layer output from the track assembly is transferred onto the conveyor roller group 10. The continuously formed pad layer is cut according to a set length by the cutting mechanism 11, which is preferably a known water-cutting device. After cutting, the polyurethane pad layer continues to be conveyed to the transfer mechanism 12, which is preferably a suction cup type transfer mechanism 12, to transfer the cut polyurethane pad layer from the conveyor roller group 10 to the outside for stacking.

[0028] The production process of this continuous production line is as follows: Before production, the gap height between the upper track 41 and the lower track 42 is adjusted by the lifting mechanism, and the width of the pad layer is adjusted by the movement of the stop block 7. Then, the release paper unwinding frame 51 unwinds the release paper onto the lower track 42. Next, the foaming machine 1 foams the polyurethane raw material and outputs it to the release paper on the receiving part 421 of the lower track 42 through the feeder 2. The upper track 41 and the lower track 42 start simultaneously, and the geotextile unwinding frame 6 unwinds the geotextile onto the upper side of the foamed layer on the lower track 42, that is, the foamed layer and the lower release paper. Together with the geotextile on the upper side, it enters the gap between the upper track 41 and the lower track 42. The release paper and geotextile are pressed and bonded to the upper and lower surfaces of the foam layer by the upper track 41 and the lower track 42 (the release paper is selected to have a texture; after the foam material comes into contact with the release paper, it forms a self-skin, and the self-skin has a corresponding texture; the geotextile is then bonded to the foam material to form an elastic pad with puncture-proof and tear-proof functions; if a mesh fabric is selected, a fabric texture layer that increases friction is formed on the surface of the pad during the molding process). The foam material undergoes leveling, foaming, and curing. The feeder 2 continuously feeds material onto the release paper of the receiving layer of the lower track 42 via the sweeping frame 3. The formed polyurethane pad is output from the rear end of the track assembly. The release paper at the bottom of the pad is recycled by the release paper winding frame 52. The pad and the top geotextile are conveyed backward to the conveyor roller assembly 10, where a fixed-length cut is achieved by the cutting mechanism 11 (preferably a water jet cutting system with conventional length tracking function). The cut elastic pad is conveyed to the underside of the transfer mechanism 12 and then transferred by the palletizing robot to the transfer car 13 next to the conveyor roller assembly 10. During the cutting process, all mechanisms in front of the cutting device are simultaneously paused. After the transverse cutting is completed, operation resumes.

[0029] This production equipment can achieve overall stability during normal continuous production of polyurethane continuous foaming elastic pads, and the pad width (e.g., 1200-1600mm), thickness (e.g., 5-60mm), and density (e.g., 250-950kg / m3) are adjustable. It is suitable for continuous production of track bed vibration damping pads, sleeper pads, and elastic pads under iron pads.

[0030] Furthermore, such as Figure 1As shown, a heated and insulated box 9 is provided around the track assembly to cover it. The heated and insulated box 9 has a heater and an insulation system to provide sufficient temperature for the foaming material to facilitate full foaming. The geotextile roll-up frame is located on top of the heated and insulated box 9.

[0031] like Figure 3 As shown, the conveyor roller assembly 10 consists of a front section 10a and a rear section 10b, with a cutting gap 10c between the front section 10a and the rear section 10b corresponding to the cutting head of the cutting mechanism 11. During waterjet cutting, the pressurized water jet cuts the pad layer and then resides within this cutting gap 10c, preventing damage to the rollers of the conveyor roller assembly 10.

[0032] like Figure 1 As shown, the release paper unwinding rack 51 is at the same height as the top surface of the lower conveyor belt 42, so that the release paper is horizontally attached to the surface of the lower conveyor belt 42 after unwinding, avoiding interference with the self-leveling of the foam layer on the release paper when it enters at an angle. At the same time, the release paper winding rack 52 is lower than the top surface of the lower conveyor belt 42. After the formed pad layer is output from the conveyor belt assembly, the lower part of the release paper is wound downwards to separate the release paper from the pad layer.

[0033] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Various changes and modifications may be made to this utility model without departing from its spirit and scope of protection, and all such changes and modifications fall within the scope of protection claimed by this utility model.

Claims

1. A large scale polyurethane elastomeric cushion continuous production line characterized by, The device includes a foaming machine, a feeder, a track assembly, a cutting mechanism, and a transfer mechanism arranged sequentially. A release paper unwinding frame is provided on the front side of the feeder, and a release paper take-up frame is provided between the track assembly and the cutting mechanism. A cross-sweeping frame is provided between the foaming machine and the track assembly to support and drive the feeder to reciprocate along the width direction of the track assembly. A geotextile unwinding frame is provided on the top of the track assembly. A conveyor roller assembly is horizontally arranged through the cutting mechanism and the transfer mechanism. The track assembly consists of an upper track and a lower track arranged in parallel. Both the upper and lower tracks are rotary structures, and their tail ends before the release paper take-up frame. The front end of the lower track extends out of the upper track and forms a receiving part, which is vertically aligned with the feeder. Each drive roller of the upper track is equipped with a lifting mechanism, which adjusts the gap height between the upper and lower tracks. The upper track and the lower track are symmetrically provided with blocks on both sides, and the blocks are the same length as the lower track. The upper track, the lower track and the blocks enclose and form a casting cavity. The outer wall of the blocks is provided with drive motors that synchronously drive them to move and adjust along the width direction of the lower track.

2. The continuous production line according to claim 1, characterized in that: The track assembly is surrounded by a heating and insulation box that covers it, and the geotextile winding frame is located on top of the heating and insulation box.

3. The continuous production line according to claim 1, characterized in that: The conveying roller assembly consists of a front section and a rear section, with a cutting gap between the front and rear sections corresponding to the cutting head of the cutting mechanism.

4. The continuous production line according to claim 3, characterized in that: The cutting mechanism is a waterjet cutting system.

5. The continuous production line according to claim 1, characterized in that: The release paper unwinding frame is at the same height as the top surface of the lower track, while the release paper rewinding frame is lower than the top surface of the lower track.

6. The continuous production line according to any one of claims 1-5, characterized in that: The transfer mechanism includes a robotic arm positioned above the conveyor roller assembly and a transfer vehicle positioned beside the conveyor roller assembly.

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