Vacuum defoaming and forming apparatus for slow rebound sponge

Abstract

The utility model discloses a kind of vacuum bubble breaking and forming equipment of slow rebound sponge, including vacuum bubble breaking box, forming die and vacuum system;The top of vacuum bubble breaking box is equipped with the box cover of open-close, forming die is set in the inside of vacuum bubble breaking box, forming die includes upper die, lower die, feed pipe and heating element, lower die is fixed to the bottom in vacuum bubble breaking box by support frame, feed pipe is connected to the upper portion of lower die, and feed pipe is communicated with lower die, the outer end of feed pipe is worn out from vacuum bubble breaking box, and control valve is installed in the worn-out part, first hydraulic cylinder is installed on box cover, upper die is connected with the telescopic end of first hydraulic cylinder, upper die is located directly above lower die, heating element is set in the side wall of lower die;Vacuum system is communicated with the internal cavity of vacuum bubble breaking box by vacuum pipeline.The vacuum bubble breaking cavity and forming die are integrated in a closed box body, avoid the secondary bubble problem caused by material transfer, greatly improve product quality and consistency.

Description

Technical Field

[0001] This utility model relates to the field of sponge molding technology, specifically to a vacuum defoaming and molding device for slow-rebound sponges. Background Technology

[0002] Slow rebound foam, also known as memory foam, produces a large number of air bubbles during the initial stage of raw material mixing and foaming in its production process. Traditional production processes typically involve mixing and casting in an atmospheric environment. If these air bubbles are not eliminated in a timely and effective manner, they will eventually remain inside the finished product, leading to structural defects such as internal pores, uneven density, and decreased physical properties (such as resilience and fatigue resistance). This severely affects product quality and yield.

[0003] At present, although some technologies use vacuum technology to remove bubbles, the following problems usually exist: (1) the bubble breaking process is separated from the molding process, and there is a risk of the material being re-entered into the air during the transfer process; (2) the stability and control precision of the vacuum environment are insufficient, making it difficult to achieve the best bubble breaking effect. Utility Model Content

[0004] To address the shortcomings of existing technologies, this utility model provides a vacuum defoaming and molding device for slow rebound sponges that has a reasonable structure, good sealing performance, significant defoaming effect, and can be directly molded.

[0005] To solve the above-mentioned technical problems, this utility model provides the following technical solution: A vacuum defoaming and molding device for slow-rebound sponge includes a vacuum defoaming chamber, a molding die, and a vacuum system. The top of the vacuum defoaming chamber is equipped with an openable and closable cover. The molding die is disposed inside the vacuum defoaming chamber and includes an upper die, a lower die, a feed pipe, and a heating element. The lower die is fixed to the bottom of the vacuum defoaming chamber by a support frame. The feed pipe is connected to the upper part of the lower die and communicates with the lower die. The outer end of the feed pipe extends out of the vacuum defoaming chamber, and a control valve is installed at the exit. A first hydraulic cylinder is installed on the cover. The upper die is connected to the telescopic end of the first hydraulic cylinder and is located directly above the lower die. The heating element is disposed inside the side wall of the lower die. The vacuum system is connected to the internal cavity of the vacuum defoaming chamber through a vacuum pipeline.

[0006] Preferably, the vacuum system includes a vacuum delivery pipeline, a vacuum breaking pipe, a vacuum buffer tank, a vacuum regulating valve, and a vacuum pump sequentially arranged on the vacuum delivery pipeline. The outlet end of the vacuum delivery pipeline is connected to the vacuum bubble breaking chamber for evacuating the vacuum bubble breaking chamber and the mold. The vacuum breaking pipe is connected to the vacuum bubble breaking chamber and is equipped with a vacuum breaking valve for smoothly introducing air into the chamber after the process is completed.

[0007] Preferably, a temperature sensor is installed on the inner wall of the lower mold to detect the temperature inside the molding die.

[0008] Preferably, the top opening of the lower mold is provided with a first sealing groove, and the bottom of the upper mold is provided with a first sealing ring that matches the first sealing groove. The cooperation of the first sealing groove and the first sealing ring improves the sealing performance after the upper mold and the lower mold are closed.

[0009] The top opening of the vacuum bubble breaking chamber is provided with a second sealing groove, and the bottom of the chamber cover is provided with a second sealing ring that matches the second sealing groove. The cooperation of the second sealing groove and the second sealing ring improves the sealing performance after the chamber cover is connected to the vacuum bubble breaking chamber.

[0010] A third sealing ring is provided at the contact point between the box cover and the piston rod of the first hydraulic cylinder, which improves the sealing performance at the connection between the first hydraulic cylinder and the box cover.

[0011] Preferably, the lower part of both sides of the vacuum bubble-breaking chamber is connected to mounting ears, and a second hydraulic cylinder is mounted on the mounting ears. The telescopic end of the second hydraulic cylinder is connected to the chamber cover. By controlling the operation of the second hydraulic cylinder, the chamber cover can be automatically opened or closed.

[0012] Preferably, it also includes a control system, which is a PLC controller, and the PLC controller is electrically connected to the vacuum pump, vacuum regulating valve, first hydraulic cylinder, second hydraulic cylinder, heating element and temperature sensor.

[0013] Compared with the prior art, the present invention has the following beneficial effects: By integrating the vacuum degassing chamber and the molding die into a sealed box, a continuous process of "degassing under vacuum environment - direct mold closing molding" is realized, avoiding the problem of secondary bubbles caused by material transfer and greatly improving product quality and consistency.

[0014] A high-precision vacuum system can quickly provide and maintain a stable high vacuum environment after the liquid is mixed, forcing the bubbles to expand and burst rapidly, thereby achieving the purpose of completely eliminating the bubbles. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the present invention; In the diagram: 1-Vacuum bubble breaking chamber, 2-Chamber cover, 3-Upper mold, 4-Lower mold, 5-Feed pipe, 6-Heating element, 7-First hydraulic cylinder, 8-Vacuum breaking pipe, 9-Vacuum buffer tank, 10-Vacuum regulating valve, 11-Vacuum pump, 12-Vacuum breaking valve, 13-Temperature sensor, 14-First sealing groove, 15-First sealing ring, 16-Second sealing groove, 17-Second sealing ring, 18-Third sealing ring, 19-Mounting ear, 20-Second hydraulic cylinder. Detailed Implementation

[0016] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model. Example 1

[0017] Please see Figure 1 A vacuum defoaming and molding device for slow-rebound sponge includes a vacuum defoaming chamber 1, a molding die, and a vacuum system.

[0018] The vacuum bubble breaking chamber 1 has an openable and closable lid 2 on its top. A second sealing groove 16 is provided at the top opening of the vacuum bubble breaking chamber 1, and a second sealing ring 17 matching the second sealing groove is provided at the bottom of the lid 2. The cooperation of the second sealing groove 16 and the second sealing ring 17 improves the sealing performance after the lid 2 is connected to the vacuum bubble breaking chamber 1.

[0019] The molding die is located inside the vacuum bubble-breaking chamber 1. The molding die includes an upper die 3, a lower die 4, a feed pipe 5, and a heating element 6. The lower die 4 is fixed to the bottom of the vacuum bubble-breaking chamber 1 by a support frame. The feed pipe 5 is connected to the upper part of the lower die 4 and communicates with it. The outer end of the feed pipe 5 extends out of the vacuum bubble-breaking chamber 1, and a control valve is installed at the exit. Sponge liquid is added to the lower die through the feed pipe.

[0020] A first hydraulic cylinder 7 is installed on the cover 2. The upper mold 3 is connected to the telescopic end of the first hydraulic cylinder 7, and the upper mold 3 is located directly above the lower mold 4. A third sealing ring 18 is provided at the contact point between the cover 2 and the piston rod of the first hydraulic cylinder 7. By controlling the extension of the first hydraulic cylinder 7, the upper mold can be driven to descend and lock onto the lower mold. A first sealing groove 14 is provided at the top opening of the lower mold 4, and a first sealing ring 15 matching the first sealing groove is provided at the bottom of the upper mold 3. When the upper mold and the lower mold are closed, the sealing performance between the upper mold and the lower mold can be improved through the cooperation of the first sealing groove and the first sealing ring.

[0021] A temperature sensor 13 is installed on the inner wall of the lower mold 4, and a heating element 6 is located in the side wall of the lower mold 4. The heating element is either an electric heating tube or a circulating oil channel embedded in the lower mold. Both the heating element and the temperature sensor are connected to the control system to form a closed-loop temperature control, which stabilizes the mold cavity temperature at the specific temperature required for the curing of the slow rebound sponge.

[0022] The vacuum system is connected to the internal cavity of the vacuum deflating chamber 1 via a vacuum delivery pipeline. The vacuum system includes a vacuum deflating pipe 8, a vacuum buffer tank 9, a vacuum regulating valve 10, and a vacuum pump 11, sequentially arranged on the vacuum delivery pipeline. The outlet end of the vacuum delivery pipeline is connected to the vacuum deflating chamber 1, and the vacuum deflating pipe 8 is connected to the vacuum deflating chamber 1, with a vacuum deflating valve 12 installed on it. After the vacuum pump 11 is started, it extracts air from the vacuum deflating chamber 1 and the molding cavity. The vacuum regulating valve 10 can precisely control and maintain the required vacuum level (e.g., -0.095MPa to -0.1MPa). The vacuum buffer tank 9 is used to stabilize the vacuum level and reduce pressure fluctuations. The vacuum deflating valve 12 is used to slowly fill the chamber with air after the process is completed, preventing sudden pressure changes from affecting the sponge structure.

[0023] This embodiment also includes a control system, employing a PLC controller. The PLC controller is electrically connected to the vacuum pump 10, vacuum regulating valve 11, first hydraulic cylinder 7, second hydraulic cylinder 20, heating element 6, vacuum breaking valve 12, and temperature sensor 13. The PLC controller integrates a touchscreen human-machine interface. Operators can set parameters such as vacuuming time, target vacuum level, holding time, heating temperature, and curing time on the screen. The PLC automatically controls the coordinated operation of the vacuum pump, vacuum regulating valve, vacuum breaking valve, hydraulic cylinder, and heating element to achieve fully automatic or semi-automatic production.

[0024] The working principle of this embodiment is as follows: Close and seal the lid → Start the vacuum pump to evacuate the vacuum defoaming chamber and the inner cavity of the molding die to the target high vacuum → Control the extension of the first hydraulic cylinder to drive the upper mold down and lock it onto the lower mold, thus sealing the molding die → Inject the mixed slow rebound sponge liquid into the lower mold cavity under vacuum through the feed pipe → Let the liquid stand in vacuum for a period of time (e.g., 1-3 minutes), and the internal bubbles will rapidly expand and burst → Start the heating system to heat and solidify the liquid in the mold cavity → After solidification, turn off the heating and open the vacuum defoaming valve to restore normal pressure inside the vacuum defoaming chamber → Open the lid, lift the upper mold, and take out the molded slow rebound sponge product.

[0025] This embodiment also requires the installation of a hydraulic pump, hydraulic actuators, hydraulic pipelines, etc., to provide power to the hydraulic cylinder. Example 2

[0026] The lower parts of both sides of the vacuum bubble-breaking chamber 1 are connected to mounting ears 19, and a second hydraulic cylinder 20 is mounted on the mounting ears 19. The telescopic end of the second hydraulic cylinder 20 is connected to the chamber cover 2. By controlling the operation of the second hydraulic cylinder, the chamber cover can be opened or closed automatically.

[0027] It should be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0028] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A vacuum defoaming and molding device for slow-rebound sponge, characterized in that: Includes a vacuum debubbling chamber (1), a molding die, and a vacuum system; The top of the vacuum bubble breaking chamber (1) is provided with an openable and closable cover (2). The molding die is set inside the vacuum bubble breaking chamber (1). The molding die includes an upper mold (3), a lower mold (4), a feed pipe (5), and a heating element (6). The lower mold (4) is fixed to the bottom of the vacuum bubble breaking chamber (1) by a support frame. The feed pipe (5) is connected to the upper part of the lower mold (4) and communicates with the lower mold (4). The outer end of the feed pipe (5) passes through the vacuum bubble breaking chamber (1), and a control valve is installed at the protruding part. A first hydraulic cylinder (7) is installed on the cover (2). The upper mold (3) is connected to the telescopic end of the first hydraulic cylinder (7). The upper mold (3) is located directly above the lower mold (4). The heating element (6) is set inside the side wall of the lower mold (4). The vacuum system is connected to the internal cavity of the vacuum bubble breaking box (1) through a vacuum delivery pipeline.

2. The vacuum defoaming and molding equipment for slow-rebound sponge according to claim 1, characterized in that: The vacuum system includes a vacuum breaking tube (8), a vacuum buffer tank (9), a vacuum regulating valve (10), and a vacuum pump (11) arranged sequentially on the vacuum delivery pipeline. The outlet end of the vacuum delivery pipeline is connected to the vacuum bubble breaking box (1). The vacuum breaking tube (8) is connected to the vacuum bubble breaking box (1), and a vacuum breaking valve (12) is installed on the vacuum breaking tube (8).

3. The vacuum defoaming and molding equipment for slow-rebound sponge according to claim 2, characterized in that: A temperature sensor (13) is installed on the inner wall of the lower mold (4).

4. The vacuum defoaming and molding equipment for slow-rebound sponge according to claim 3, characterized in that: The lower mold (4) has a first sealing groove (14) at the top opening, and the upper mold (3) has a first sealing ring (15) at the bottom that matches the first sealing groove; the vacuum bubble breaking box (1) has a second sealing groove (16) at the top opening, and the box cover (2) has a second sealing ring (17) at the bottom that matches the second sealing groove; the box cover (2) has a third sealing ring (18) at the contact point between the piston rod of the first hydraulic cylinder (7).

5. The vacuum defoaming and molding equipment for slow-rebound sponge according to claim 4, characterized in that: The lower part of both sides of the vacuum bubble breaking box (1) is connected to mounting ears (19), and a second hydraulic cylinder (20) is installed on the mounting ears (19). The telescopic end of the second hydraulic cylinder (20) is connected to the box cover (2).

6. The vacuum defoaming and molding equipment for slow-rebound sponge according to claim 5, characterized in that: It also includes a control system, which is electrically connected to the vacuum pump (11), vacuum regulating valve (10), first hydraulic cylinder (7), second hydraulic cylinder (20), heating element (6) and temperature sensor (13).

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