A small microwave foaming and post-processing integrated device for foam preparation

Abstract

The utility model relates to melamine bubble cotton production equipment technical field, aims at solving the problem of large equipment floor space, high energy consumption, huge investment in prior art, not suitable for laboratory research and development and small -batch trial production, process parameter can not be accurately controlled, experimental result repeatability is poor, and the problem that operation is complicated and low in efficiency and lacks harmful gas treatment, provide a kind of for bubble cotton preparation Small -size microwave foaming and post -treatment integrated equipment, including microwave foaming module and curing post -treatment module;Automatic material transfer mechanism between microwave foaming module and curing post -treatment module;Outside gas treatment unit, gas treatment unit is connected microwave foaming module and curing post -treatment module by pipeline intercommunication;Outside still have intelligent control system.The utility model has the beneficial effect that floor space is small, energy consumption is low, investment is small, suitable for laboratory research and development and small -batch trial production, process parameter can be accurately controlled, experimental result repeatability is good, operation is simple and efficient, and it is convenient to handle harmful gas.

Description

Technical Field

[0001] This utility model relates to the technical field of melamine foam production equipment, specifically to a small-scale integrated microwave foaming and post-processing equipment for foam preparation. Background Technology

[0002] Melamine foam (also known as melamine foam) is a high-performance three-dimensional network porous material that is widely used in construction, industry and home furnishing due to its excellent flame retardancy, sound absorption and adsorption properties. Its traditional industrial production process mainly includes three stages: batching, microwave foaming and high-temperature post-treatment (curing). The production equipment on the market is all large-scale continuous equipment, which occupies a large area, consumes a lot of energy and requires huge investment, making it completely unsuitable for laboratory research and development and small-batch trial production.

[0003] Currently, laboratories typically use a temporary method combining household microwave ovens and ordinary drying ovens. This method suffers from several core technical problems, including the inability to precisely control process parameters, poor repeatability of experimental results, cumbersome and inefficient operation, and a lack of effective treatment for harmful gases such as formaldehyde. These issues pose serious safety hazards and hinder the research and development process. Utility Model Content

[0004] The present invention aims to provide a small-scale integrated microwave foaming and post-processing device for foam preparation, in order to solve the problems of existing equipment having a large footprint, high energy consumption, huge investment, unsuitability for laboratory research and development and small-batch pilot production, inability to accurately control process parameters, poor repeatability of experimental results, cumbersome operation and low efficiency, and lack of treatment for harmful gases.

[0005] The embodiments of this utility model are implemented as follows: This utility model embodiment provides a small-scale integrated microwave foaming and post-processing device for foam preparation, which includes a device shell; The aforementioned equipment housing contains a microwave foaming module and a curing post-treatment module, which are distributed alternately within the equipment housing. An automatic material transfer mechanism is provided between the microwave foaming module and the curing post-processing module to realize fully automatic material transfer. A gas treatment unit for treating process waste gas is provided on one side of the housing of the above-mentioned equipment. The gas treatment unit is connected to the microwave foaming module and the curing post-treatment module through pipelines. On the other side of the housing of the aforementioned equipment is an intelligent control system for controlling the coordinated operation of the aforementioned microwave foaming module, the aforementioned post-curing processing module, the aforementioned automatic material transfer mechanism, and the aforementioned gas processing unit.

[0006] In operation, the experimenter first places a mold containing melamine foam raw material into the microwave foaming module. The intelligent control system sets and starts the process, initially controlling the microwave foaming module to start, while the gas treatment unit simultaneously collects and purifies the waste gas. After foaming, the intelligent control system stops the microwave foaming module and simultaneously activates the automatic material transfer mechanism, which transports the mold to the curing and post-processing module. The intelligent control system then controls the curing and post-processing module to heat and circulate hot air to cure the material inside the mold. The gas treatment unit continuously collects and treats the waste gas from the curing and post-processing module. After curing, the intelligent control system stops the curing and post-processing module. After cooling, the experimenter removes the finished product from the curing and post-processing module, completing one laboratory preparation operation of melamine foam.

[0007] This embodiment discloses a small-scale integrated microwave foaming and post-processing device for foam preparation. By highly integrating the device shell, microwave foaming module, curing and post-processing module, automatic material transfer mechanism, gas treatment unit, and intelligent control system, it achieves fully automated operation of the entire foam preparation process, from microwave foaming and automatic material transfer to curing and solidification, eliminating the need for manual step-by-step operation. Simultaneously, the gas treatment unit provides real-time purification of waste gas generated during the foaming and curing processes, resolving the safety hazards of waste gas leakage inherent in traditional laboratory methods. Furthermore, the process parameters of each module can be precisely set and stored through the intelligent control system, effectively ensuring the stability of the foam preparation process and the repeatability of experimental results. Therefore, this small-scale integrated microwave foaming and post-processing device for foam preparation offers the advantages of small footprint, low energy consumption, low investment, suitability for laboratory research and development and small-batch pilot production, precise control of process parameters, good repeatability of experimental results, simple and efficient operation, and convenient handling of harmful gases.

[0008] Optionally: The microwave foaming module has a microwave cavity, and at least one microwave generator is provided at the top of the microwave cavity, and the microwave generator is connected to the intelligent control system.

[0009] With this configuration, the microwave cavity of the aforementioned microwave foaming module provides a dedicated foaming space for the laboratory preparation of melamine foam. At least one microwave generator at the top can accurately output microwave energy to meet the foaming requirements. Furthermore, the microwave generator is connected to the aforementioned intelligent control system, which can conveniently control the working status of the microwave generator (such as power, start and stop timing, etc.). This not only ensures the stability and controllability of the melamine foam foaming process and avoids the problem of inaccurate microwave energy control in traditional temporary laboratory methods, but also improves the ease of equipment operation, helping to achieve precision and automation in the laboratory preparation of melamine foam, and providing reliable foaming process conditions for laboratory research and development.

[0010] Optionally, the bottom of the microwave cavity is provided with a rotatable or tiltable tray. The tray is made of a material that is resistant to high temperatures and has low microwave loss characteristics. The bottom of the tray is connected to a tilting mechanism that switches the tray between a horizontal rotation state and a tilting state. The tray is signal-connected to the intelligent control system.

[0011] This design ensures that the material is heated evenly through horizontal rotation, preventing uneven foaming and guaranteeing the consistency of melamine foam samples prepared in the laboratory. It also addresses the poor repeatability of experimental results caused by uneven heating of materials in traditional laboratory methods. Furthermore, the tray is made of a high-temperature resistant material with low microwave loss, adapting to the high-temperature environment of the foaming process and reducing microwave energy waste, thus ensuring foaming efficiency and equipment lifespan. Simultaneously, the tilting mechanism at the bottom of the tray allows for switching between horizontal rotation and tilting states. Combined with its signal connection to the intelligent control system, the tray's state can be automatically switched via intelligent control. This eliminates the tedious manual material transfer, improving efficiency, and avoids the safety hazards associated with manual operation, further contributing to the automation, safety, and precision of melamine foam laboratory preparation.

[0012] Optionally, the surface of the tray described above has a polytetrafluoroethylene coating.

[0013] This design, due to the excellent low-friction properties of the aforementioned polytetrafluoroethylene (PTFE) coating, reduces the frictional resistance between the material (or the material-holding mold) and the tray surface when the tray is tilted for material transfer, ensuring that the material slides smoothly to the subsequent transfer mechanism and avoiding experimental failures caused by material jamming or tipping. In addition, the aforementioned PTFE coating has good high-temperature resistance and corrosion resistance, which can adapt to the high-temperature environment and possible trace amounts of corrosive gases generated during the microwave foaming process, preventing damage to the tray surface and extending the service life of the tray. At the same time, its chemical stability prevents the coating from reacting with the material and contaminating the sample, ensuring the purity of the melamine foam sample prepared in the laboratory, and further improving the reliability and practicality of the equipment in laboratory research and development scenarios.

[0014] Optionally: the above-mentioned post-curing processing module has a curing chamber, the outer wall of the curing chamber is fitted with a heating jacket, the interior of the curing chamber is equipped with a hot air circulation fan, and the hot air circulation fan is signal-connected to the above-mentioned intelligent control system.

[0015] With this configuration, the curing chamber provides a dedicated curing space for melamine foam. The heating jacket on its outer wall can stably provide the heat required for curing, while the internal hot air circulation fan can evenly distribute heat to all areas within the chamber, avoiding uneven sample solidification caused by local temperature differences during curing. This ensures the consistency of the performance of melamine foam prepared in the laboratory and solves the problem of uneven temperature distribution during curing in traditional laboratory ovens. At the same time, the hot air circulation fan is connected to the intelligent control system, allowing for precise adjustment of the fan's operation to match the curing process requirements. This improves the controllability of the curing process, reduces manual intervention, and further facilitates the automation and precision of melamine foam laboratory preparation, providing stable and reliable curing process conditions for research and development.

[0016] Optionally: The above-mentioned automatic material transfer mechanism has a material transfer channel connecting the microwave foaming module and the curing post-processing module. A polytetrafluoroethylene (PTFE) conveyor belt is provided in the material transfer channel. The running plane of the PTFE conveyor belt is precisely matched with the upper surface of the tray. The PTFE conveyor belt is signal-connected to the intelligent control system.

[0017] With this configuration, the PTFE conveyor belt, thanks to its high-temperature resistance, low friction, and corrosion resistance, can adapt to the process environment in laboratory preparation, preventing damage from high temperatures or trace amounts of corrosive gases, while reducing resistance and wear during material (or material container) transport. Furthermore, the precise matching between the PTFE conveyor belt's running plane and the upper surface of the tray ensures a smooth transition of materials from the tray to the conveyor belt, preventing experimental failures due to material tipping or jamming. Moreover, the PTFE conveyor belt is connected to the intelligent control system, enabling precise control of its start / stop and speed without manual intervention in material transfer. This improves operational efficiency, avoids safety hazards associated with manual transfer, and further ensures the automation, stability, and safety of the entire melamine foam laboratory preparation process.

[0018] Optionally, the microwave foaming module and the curing post-processing module corresponding to the polytetrafluoroethylene conveyor belt are respectively provided with a first insulation valve and a second insulation valve, and both the first insulation valve and the second insulation valve are signal connected to the intelligent control system.

[0019] This configuration allows for independent sealing of the two module cavities during non-material transfer, preventing microwave leakage from the microwave cavity and heat loss from the curing cavity, ensuring microwave foaming efficiency and curing temperature stability, while also preventing cross-flow of process waste gas between the microwave cavity and the curing cavity. Furthermore, both the first and second insulating valves are connected to the intelligent control system, enabling automatic opening and closing in conjunction with the material transfer process, eliminating the need for manual operation. This avoids the tediousness and safety hazards of manual valve operation, while ensuring smooth flow during material transfer and cavity sealing during non-transfer operations, further enhancing the sealing performance, energy utilization, and automation of the entire melamine foam laboratory preparation process.

[0020] Optionally: The gas treatment unit has an exhaust gas treatment box, and the exhaust gas treatment box has a first-stage spray neutralization chamber and a second-stage activated carbon adsorption chamber arranged in parallel inside. The exhaust gas treatment box is equipped with a vortex fan that provides negative pressure to the equipment, and the vortex fan signal is connected to the intelligent control system.

[0021] This setup allows for two-stage deep purification of waste gases generated during microwave foaming and curing: chemical neutralization and physical adsorption. It efficiently removes harmful gases such as formaldehyde and odors, addressing the safety hazards of traditional laboratory methods that lack effective waste gas treatment and ensuring a safe experimental environment. Simultaneously, the aforementioned vortex fan inside the chamber provides negative pressure, ensuring that harmful gases within the process chamber are captured in real-time and introduced into the waste gas treatment chamber, preventing gas leakage. Furthermore, the vortex fan is signal-connected to the intelligent control system, allowing for precise matching of the fan's operating status with the process progress through intelligent control, eliminating the need for manual adjustment. This enhances the stability and efficiency of waste gas treatment and further improves the automated control of the entire equipment process, meeting the safety, environmental protection, and convenient operation requirements of laboratory research and development.

[0022] Optionally: The microwave cavity and the curing cavity are respectively provided with a plurality of microwave gas collection ports and a plurality of curing gas collection ports on the side near the exhaust gas treatment box. The plurality of microwave gas collection ports are all connected to the first gas collection area through the first pipe, and the plurality of curing gas collection ports are all connected to the second gas collection area through the second pipe. The first gas collection zone and the second gas collection zone are connected to the first-stage spray neutralization chamber of the waste gas treatment box via a third pipe.

[0023] This configuration allows for the independent collection and orderly transport of waste gases from the microwave cavity and the curing cavity, preventing cross-flow or diffusion of waste gases from different process stages within the equipment and ensuring that harmful gases generated at each location are accurately captured. Furthermore, the zoned gas collection and centralized transport structure ensures that waste gases enter the spray neutralization chamber stably and efficiently for initial purification, laying a solid foundation for subsequent deep treatment in the activated carbon adsorption chamber. This further enhances the comprehensiveness and reliability of waste gas treatment, effectively solving the problem of waste gas leakage in the laboratory preparation of melamine foam and ensuring a safe experimental environment.

[0024] Optionally, the intelligent control system has a control panel and a touch screen integrated on the housing of the device, and a program logic controller is provided between the control panel and the touch screen. The control panel, the touch screen and the program logic controller are electrically connected to each other.

[0025] This setup allows researchers to intuitively operate the aforementioned touchscreen and conveniently set and store process parameters for melamine foam preparation using the control panel, solving the problems of cumbersome parameter setting and storage difficulties in traditional laboratory methods. Furthermore, the programmable logic controller (PLC) enables precise control of the entire process, including microwave foaming, tray tilting, insulation valve opening and closing, conveyor belt operation, curing, and waste gas treatment, eliminating the need for manual step-by-step operation. This avoids process deviations caused by human intervention, improves the repeatability of experimental results, and reduces operational complexity and safety hazards. It effectively automates, precisely targets, and facilitates the entire laboratory preparation process of melamine foam, providing efficient and reliable control for laboratory research and development.

[0026] Optionally, the microwave cavity and the curing cavity are respectively provided with a material inlet / outlet valve and a finished product transfer valve.

[0027] This configuration allows for the independent opening and closing of the microwave cavity and the curing cavity. Materials enter the microwave cavity only through the material inlet / outlet valve, and finished products are removed only through the finished product transfer valve. This avoids microwave leakage, heat loss, or cross-contamination of waste gas caused by communication between the microwave cavity and the curing cavity during non-material transfer stages, ensuring the independent stability of the foaming and curing processes. In addition, the independent valve design ensures that material input and finished product removal operations do not interfere with each other, simplifying laboratory operation procedures and reducing the risk of harmful gas leakage during operation. This further enhances the practicality, safety, and process controllability of the equipment in laboratory settings.

[0028] In summary, the small-scale integrated microwave foaming and post-processing equipment for foam preparation disclosed in this utility model has the advantages of small footprint, low energy consumption, low investment, suitability for laboratory research and development and small-batch pilot production, precise control of process parameters, good repeatability of experimental results, simple operation and high efficiency, and convenient treatment of harmful gases. Attached Figure Description

[0029] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a top view of a small microwave foaming and post-processing integrated device for foam preparation according to an embodiment of the present invention. Figure 2 This is a three-dimensional structural schematic diagram of a small microwave foaming and post-processing integrated device for foam preparation according to an embodiment of the present invention.

[0031] Icons: 1-Equipment housing, 2-Microwave foaming module, 3-Curing post-processing module, 4-Automatic material transfer mechanism, 5-Gas treatment unit, 6-Intelligent control system, 7-Microwave cavity, 8-Microwave generator, 9-Tray, 10-PTFE coating, 11-Curing cavity, 12-Heating jacket, 13-Hot air circulation fan, 14-Material transfer channel, 15-PTFE conveyor belt, 16-First insulating valve, 17-Second insulating valve, 18-Waste gas treatment box, 19-First-stage spray neutralization chamber, 20-Second-stage activated carbon adsorption chamber, 21-Vortex fan, 22-Microwave gas collection port, 23-Curing gas collection port, 24-First pipeline, 25-First gas collection area, 26-Second pipeline, 27-Second gas collection area, 28-Third pipeline, 29-Control panel, 30-Touch screen, 31-Programmable logic controller, 32-Material inlet / outlet valve, 33-Finished product transfer valve. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0033] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0034] Example See Figure 1 and Figure 2 This embodiment proposes a small-scale integrated microwave foaming and post-processing device for foam preparation, including a device housing 1; The equipment housing 1 is equipped with a microwave foaming module 2 and a curing post-treatment module 3, which are distributed alternately inside the equipment housing 1. An automatic material transfer mechanism 4 is provided between the microwave foaming module 2 and the curing post-processing module 3 to realize fully automatic material transfer; A gas treatment unit 5 for treating process waste gas is provided on one side of the equipment housing 1. The gas treatment unit 5 is connected to the microwave foaming module 2 and the curing post-treatment module 3 through pipelines. On the other side of the equipment housing 1, there is an intelligent control system 6 for controlling the coordinated operation of the microwave foaming module 2, the curing post-processing module 3, the automatic material transfer mechanism 4, and the gas processing unit 5.

[0035] In operation, the experimenter first places the mold containing the melamine foam raw material into the microwave foaming module 2. The intelligent control system 6 sets and starts the process program, initially controlling the microwave foaming module 2 to start, while the gas treatment unit 5 simultaneously starts collecting and purifying the waste gas. After foaming is complete, the intelligent control system 6 stops the microwave foaming module 2 and simultaneously starts the automatic material transfer mechanism 4, which transports the mold to the curing and post-processing module 3. The intelligent control system 6 then controls the curing and post-processing module 3 to heat and circulate hot air to cure the material inside the mold. The gas treatment unit 5 continuously collects and treats the waste gas inside the curing and post-processing module 3. After curing is complete, the intelligent control system 6 stops the curing and post-processing module 3. After cooling, the experimenter removes the finished product from the curing and post-processing module 3, completing one laboratory preparation operation of melamine foam.

[0036] This embodiment discloses a small-scale integrated microwave foaming and post-processing device for foam preparation. By highly integrating the device housing 1, microwave foaming module 2, curing and post-processing module 3, automatic material transfer mechanism 4, gas treatment unit 5, and intelligent control system 6, it achieves fully automated operation of the entire foam preparation process, from microwave foaming and automatic material transfer to curing and solidification, eliminating the need for manual step-by-step operation. Simultaneously, the gas treatment unit 5 purifies the waste gas generated during the foaming and curing processes in real time, solving the safety hazards of waste gas leakage inherent in traditional laboratory methods. Furthermore, the process parameters of each module can be precisely set and stored through the intelligent control system 6, effectively ensuring the stability of the foam preparation process and the repeatability of experimental results. Therefore, this small-scale integrated microwave foaming and post-processing device for foam preparation offers the advantages of small footprint, low energy consumption, low investment, suitability for laboratory research and development and small-batch pilot production, precise control of process parameters, good repeatability of experimental results, simple and efficient operation, and convenient handling of harmful gases.

[0037] See Figure 1 and Figure 2 The microwave foaming module 2 has a microwave cavity 7, and at least one microwave generator 8 is provided at the top of the microwave cavity 7. The microwave generator 8 is connected to the intelligent control system 6. The microwave cavity 7 of the microwave foaming module 2 provides a dedicated foaming space for the laboratory preparation of melamine foam. The at least one microwave generator 8 at the top can accurately output microwave energy to meet the foaming requirements. The microwave generator 8 is connected to the intelligent control system 6, which can conveniently control the working status of the microwave generator 8 (such as power, start and stop timing, etc.) through the intelligent control system 6. This not only ensures the stability and controllability of the melamine foam foaming process and avoids the problem of inaccurate microwave energy control in traditional temporary laboratory methods, but also improves the convenience of equipment operation, helps to realize the precision and automation of laboratory preparation of melamine foam, and provides reliable foaming process conditions for laboratory research and development.

[0038] The bottom of the microwave cavity 7 is equipped with a rotatable or tiltable tray 9. The tray 9 is made of a high-temperature resistant material with low microwave loss characteristics. The bottom of the tray 9 is connected to a tilting mechanism (not shown in the figure) that switches the tray 9 between a horizontal rotation state and a 15° to 20° tilt state. The tray 9 is connected to the intelligent control system 6. In this way, the horizontal rotation can drive the material to be heated evenly, avoiding uneven foaming in some areas, ensuring the consistency of samples prepared by laboratory melamine foam, and solving the problem of poor repeatability of experimental results caused by uneven heating of materials in traditional laboratory methods. In addition, the tray 9 is made of a high-temperature resistant material with low microwave loss, which can adapt to the high-temperature environment of the foaming process and reduce microwave energy waste, ensuring foaming efficiency and equipment lifespan. At the same time, the tilting mechanism at the bottom of the tray 9 can realize the switching between horizontal rotation and tilting states. With its signal connection with the intelligent control system 6, the state of the tray 9 can be automatically switched by intelligent control. This not only saves the tedious operation of manually transferring materials and improves efficiency, but also avoids the safety hazards caused by manual operation, further contributing to the automation, safety and precision of laboratory preparation of melamine foam.

[0039] See Figure 1 and Figure 2 The surface of tray 9 has a polytetrafluoroethylene (PTFE) coating 10 or an inlaid smooth ceramic plate. Due to the excellent low-friction properties of the PTFE coating 10, it can reduce the frictional resistance between the material (or the material-holding mold) and the surface of tray 9 when the tray 9 is tilted to transfer materials, ensuring that the material slides smoothly to the subsequent transfer mechanism and avoiding experimental failures caused by material jamming or tipping. In addition, the PTFE coating 10 has good high-temperature resistance and corrosion resistance, which can adapt to the high-temperature environment and possible trace corrosive gases generated during the microwave foaming process, prevent damage to the surface of tray 9, extend the service life of tray 9, and at the same time, its chemical stability prevents the coating from reacting with the material and contaminating the sample, ensuring the purity of the melamine foam sample prepared in the laboratory, and further improving the reliability and practicality of the equipment in laboratory research and development scenarios.

[0040] The post-curing processing module 3 has a curing chamber 11, with a heating jacket 12 fitted on the outer wall of the curing chamber 11. A hot air circulation fan 13 is installed inside the curing chamber 11 and is connected to the intelligent control system 6. The curing chamber 11 provides a dedicated curing space for melamine foam. The heating jacket 12 on its outer wall provides a stable supply of heat required for curing, while the internal hot air circulation fan 13 distributes heat evenly to all areas within the chamber, preventing uneven sample solidification caused by localized temperature differences during curing. This ensures the consistency of the performance of melamine foam prepared in the laboratory and solves the problem of uneven temperature distribution during curing in traditional laboratory ovens. Simultaneously, the hot air circulation fan 13 is connected to the intelligent control system 6, allowing for precise adjustment of its operation to match the curing process requirements. This improves the controllability of the curing process, reduces manual intervention, and further facilitates the automation and precision of melamine foam laboratory preparation, providing stable and reliable curing process conditions for research and development.

[0041] See Figure 1 and Figure 2 The automatic material transfer mechanism 4 has a material transfer channel 14 connecting the microwave foaming module 2 and the curing post-processing module 3. A polytetrafluoroethylene (PTFE) conveyor belt 15 is installed within the material transfer channel 14. The running plane of the PTFE conveyor belt 15 precisely matches the upper surface of the tray 9, with an edge gap of less than 2mm. The PTFE conveyor belt 15 is signal-connected to the intelligent control system 6. Due to its high-temperature resistance, low friction, and corrosion resistance, the PTFE conveyor belt 15 can adapt to the process environment in laboratory preparation, preventing damage from high temperatures or trace amounts of corrosive gases, while also reducing the amount of material (or the amount of material it holds). The resistance and wear during mold conveying; in addition, the running plane of the PTFE conveyor belt 15 is precisely matched with the upper surface of the tray 9, which can ensure that the material is smoothly transferred from the tray 9 to the PTFE conveyor belt 15, preventing experimental failures caused by material tipping or jamming; and the PTFE conveyor belt 15 is connected to the intelligent control system 6, which can realize precise control of the start and stop and speed of the PTFE conveyor belt 15 through intelligent control, without the need for manual intervention in material transfer, which not only improves the operating efficiency, but also avoids the safety hazards caused by manual transfer, further ensuring the automation, stability and safety of the entire process of melamine foam laboratory preparation.

[0042] The microwave foaming module 2 and the curing post-treatment module 3 corresponding to the polytetrafluoroethylene conveyor belt 15 are respectively equipped with a first insulating valve 16 and a second insulating valve 17. Both the first insulating valve 16 and the second insulating valve 17 are signal-connected to the intelligent control system 6. This allows for independent sealing of the two module cavities when the material is not being transferred, preventing microwave leakage from the microwave cavity 7 and heat loss from the curing cavity 11, ensuring microwave foaming efficiency and curing temperature stability, and preventing cross-flow of process waste gas between the microwave cavity 7 and the curing cavity 11. In addition, the first insulating valve 16 and the second insulating valve 17 are both signal-connected to the intelligent control system 6, enabling automatic opening and closing in conjunction with the material transfer process without manual operation. This avoids the cumbersome and safety hazards of manually opening and closing valves, and ensures smooth passage during material transfer and sealed cavity when not being transferred, further improving the sealing performance, energy utilization rate and automation level of the entire melamine foam laboratory preparation process.

[0043] See Figure 1 and Figure 2 The gas treatment unit 5 includes a waste gas treatment box 18. Inside the waste gas treatment box 18, a first-stage spray neutralization chamber 19 and a second-stage activated carbon adsorption chamber 20 are arranged in parallel. The waste gas treatment box 18 is equipped with a vortex fan 21 that provides negative pressure to the equipment. The vortex fan 21 is connected to the intelligent control system 6. This configuration allows for two-stage deep purification of the waste gas generated during microwave foaming and curing, namely "chemical neutralization and physical adsorption," effectively removing harmful gases such as formaldehyde and odors. This solves the safety hazards of traditional laboratory methods that lack effective waste gas treatment and ensures a safe experimental environment. At the same time, the vortex fan 21 inside the box can provide negative pressure to the equipment, ensuring that harmful gases in the process chamber are captured in real time and introduced into the waste gas treatment box 18 to prevent gas leakage. Furthermore, the vortex fan 21 is connected to the intelligent control system 6, which can precisely match the operating status of the vortex fan 21 with the process progress through intelligent control without manual adjustment. This not only improves the stability and efficiency of waste gas treatment but also further improves the full-process automated control of the equipment, meeting the safety, environmental protection, and convenient operation requirements of laboratory research and development.

[0044] The microwave cavity 7 and the curing cavity 11 are respectively provided with a number of microwave gas collection ports 22 and a number of curing gas collection ports 23 on the side near the exhaust gas treatment box 18. The number of microwave gas collection ports 22 are all connected to the first gas collection area 25 through the first pipe 24, and the number of curing gas collection ports 23 are all connected to the second gas collection area 27 through the second pipe 26. The first gas collection zone 25 and the second gas collection zone 27 are connected to the first-stage spray neutralization chamber 19 of the waste gas treatment box 18 via the third pipe 28. This enables the independent collection and orderly transportation of waste gas in the microwave cavity 7 and the curing cavity 11, avoiding cross-flow or diffusion of waste gas from different process stages within the equipment and ensuring that harmful gases generated at each location can be accurately captured. In addition, the structural design of regional gas collection and centralized transportation ensures that waste gas enters the spray neutralization chamber stably and efficiently for preliminary purification, laying a solid foundation for the subsequent deep treatment in the activated carbon adsorption chamber, further improving the comprehensiveness and reliability of waste gas treatment, effectively solving the problem of waste gas leakage in the preparation of melamine foam in the laboratory, and ensuring the safety of the experimental environment.

[0045] See Figure 1 and Figure 2 The intelligent control system 6 has a control panel 29 and a touch screen 30 integrated on the equipment housing 1. A programmable logic controller 31 is provided between the control panel 29 and the touch screen 30. The control panel 29, the touch screen 30 and the programmable logic controller 31 are electrically connected to each other. This allows the experimenters to operate intuitively through the touch screen 30 and adjust it with the assistance of the control panel 29. They can conveniently set and store the process parameters for the preparation of melamine foam, solving the problems of cumbersome parameter setting and difficult storage in traditional laboratory methods. In addition, relying on the programmable logic controller 31, the entire process of microwave foaming, tray 9 tilting, insulation valve opening and closing, conveyor belt operation, curing and solidification and exhaust gas treatment can be precisely controlled without manual step-by-step operation. This avoids process deviations caused by human intervention, improves the repeatability of experimental results, and reduces the cumbersome operation and safety hazards. It truly realizes the automation, precision and convenience of the entire process of melamine foam laboratory preparation, and provides efficient and reliable control guarantee for laboratory research and development.

[0046] The microwave cavity 7 and the curing cavity 11 are respectively equipped with a material inlet valve 32 and a finished product transfer valve 33. This configuration enables the independent opening and closing of the microwave cavity 7 and the curing cavity 11. Materials enter the microwave cavity 7 only through the material inlet valve 32, and finished products are taken out only through the finished product transfer valve 33. This avoids microwave leakage, heat loss, or waste gas crossflow caused by the interconnection between the microwave cavity 7 and the curing cavity 11 during non-material transfer stages, ensuring the independent stability of the foaming and curing processes. In addition, the independent valve design ensures that the material input and finished product removal operations do not interfere with each other, which simplifies the laboratory operation process and reduces the risk of harmful gas leakage during operation, further improving the practicality, safety, and process controllability of the equipment in laboratory settings.

[0047] See Figure 1 and Figure 2 In this embodiment, the tray 9 adopts a circular structure with a diameter of 380mm. Its working surface is treated with low friction and is coated with polytetrafluoroethylene coating 10 or inlaid with a smooth ceramic plate.

[0048] See Figure 1 and Figure 2 In this embodiment, the internal clearance of the microwave cavity 7 is not less than 465mm, which provides clearance for the tilting action of the rotating or tilting tray 9.

[0049] See Figure 1 and Figure 2 In this embodiment, the device housing 1 is a desktop structure with overall dimensions less than 1300mm × 800mm × 700mm.

[0050] See Figure 1 and Figure 2 In this embodiment, the experimenter first opens the material inlet / outlet valve 32 on the outer casing 1 corresponding to the microwave foaming module 2, places the mold containing melamine foam raw material onto the tray 9 inside the microwave cavity 7 of the microwave foaming module 2, and closes the material inlet / outlet valve 32. The intelligent control system 6 sets and starts the process program. The intelligent control system 6 first controls the microwave foaming module 2 to start the microwave generator 8, and simultaneously controls the tray 9 to rotate so that the raw material is evenly heated and foamed. During this period, the gas treatment unit 5 starts synchronously, collecting and purifying the foaming waste gas through the gas collection port of the microwave cavity 7. After foaming is completed, the intelligent control system 6 controls the microwave foaming module 2 to stop working, and simultaneously controls the automatic material transfer... The insulated valve of the transfer mechanism 4 is opened, and the tray 9 is tilted, causing the mold to slide onto the conveyor belt. The conveyor belt transports the mold to the curing chamber 11 of the curing post-processing module 3, and then the insulated valve is closed. The intelligent control system 6 then controls the heating jacket 12 and the hot air circulation fan 13 of the curing post-processing module 3 to start, so as to cure and solidify the material in the mold. The gas treatment unit 5 continuously collects and treats the waste gas in the curing chamber 11. After curing is completed, the intelligent control system 6 controls the curing post-processing module 3 to stop working. After cooling, the experimenter opens the finished product transfer valve 33 on the outer shell 1 corresponding to the curing post-processing module 3, takes out the finished product, and completes one laboratory preparation operation of melamine foam.

[0051] See Figure 1 and Figure 2 In this embodiment, the equipment is designed to meet the needs of laboratory research and development and small-batch trial production of melamine foam. It adopts a compact desktop design with an overall size of 1300mm×800mm×700mm for the outer shell 1. The internal components include a microwave foaming module 2, a curing and post-processing module 3, and an automatic material transfer mechanism 4. A gas treatment unit 5 is located on the back of the equipment, and an intelligent control system 6 is integrated on the front, realizing the integrated operation of the entire process of foaming, transfer, curing, and waste gas treatment.

[0052] See Figure 1 and Figure 2In this embodiment, the microwave foaming module 2 is located on the right side of the device. The core is a 304 stainless steel microwave cavity 7 with an internal volume of approximately 400mm×400mm×465mm. A microwave generator 8 with a continuously adjustable power of 200W to 1000W is installed on the top of the cavity, and a circular rotating / tilting tray 9 with a diameter of 380mm is provided at the bottom. The tray 9 is made of high-purity alumina ceramic with a Teflon coating on the surface, which has both high temperature resistance and low friction characteristics. It also integrates a tilting mechanism, which can switch between horizontal rotation and 15° to 20° tilt to ensure uniform heating of materials and subsequent transfer.

[0053] See Figure 1 and Figure 2 In this embodiment, the post-curing processing module 3 is located on the left side of the equipment. Its core is a 304 stainless steel curing chamber 11 with an internal volume of 400mm×400mm×465mm. The outer wall of the chamber is surrounded by a composite heat insulation structure heating jacket 12 with a thickness of 25mm. The heating jacket 12 uses a silicone rubber heater and is combined with a micro hot air circulation fan 13 in the chamber to achieve precise temperature control within the range of room temperature to 250℃, with a temperature control accuracy of ±2℃, which meets the requirements of the melamine foam curing process.

[0054] See Figure 1 and Figure 2 In this embodiment, the automatic material transfer mechanism 4 connects the microwave foaming module 2 and the curing post-processing module 3, and is the key to the fully automatic operation of the equipment. It includes a rectangular material transfer channel 14, a first insulating valve 16, a second insulating valve 17, and a polytetrafluoroethylene (PTFE) conveyor belt 15. The inner wall of the material transfer channel 14 is made of PTFE plate, which has corrosion resistance and low friction characteristics. The first insulating valve 16 and the second insulating valve 17 in the middle are made of 316 stainless steel. The running plane of the PTFE conveyor belt 15 in the material transfer channel 14 is precisely matched with the upper surface of the tray 9, with an edge gap of less than 5mm, to ensure smooth material transfer.

[0055] See Figure 1 and Figure 2In this embodiment, the gas treatment unit 5 is the core of the equipment's safe and environmentally friendly operation, including a gas collection system, a waste gas treatment box 18, and a power system. The gas collection system has several microwave gas collection ports 22 and several curing gas collection ports 23 respectively located at the top rear of the microwave cavity 7 and the curing cavity 11, which are connected to the waste gas treatment box 18 through a PTFE gas pipeline with a diameter of 50mm. The waste gas treatment box 18 is divided into two-stage treatment chambers. The first-stage spray neutralization chamber 19 uses a 5% to 10% urea solution to neutralize acidic gases such as formaldehyde. The second-stage activated carbon adsorption chamber 20 is filled with 2kg of coconut shell activated carbon with a particle size of 4mm to 6mm to adsorb residual organic matter and odors. The power system uses a 90W vortex fan 21 to provide a constant air volume of 150m³ / h, so that the two process chambers maintain a slight negative pressure of -10Pa to -20Pa, realizing the real-time capture and treatment of harmful gases.

[0056] See Figure 1 and Figure 2 In this embodiment, the intelligent control system 6 serves as the command center for the fully automated operation of the equipment. The core hardware adopts an industrial-grade programmable logic controller 31 (PLC), paired with a 7-inch color touch screen 30 as the human-machine interface. The system has formula management and process automation control functions, and can store no less than twenty complete process formulas (including parameters such as microwave power, foaming time, curing temperature, and curing time). It supports one-button control of the entire process linkage of microwave foaming, tray 9 tilting, insulation valve opening and closing, conveyor belt operation, curing and solidification, and waste gas treatment, which greatly improves the ease of operation and process stability.

[0057] See Figure 1 and Figure 2 The specific steps for using the small-scale integrated microwave foaming and post-processing equipment for foam preparation in this embodiment are as follows: Step 1: Preparation and foaming stage; The experimenters placed a mold containing melamine foam material on a rotating tray 9 inside the microwave cavity 7 of the microwave foaming module 2, and then closed the material inlet / outlet valve 32 of the microwave cavity 7. The preset foaming program is selected and started by the touch screen 30 of the intelligent control system 6. The intelligent control system 6 then controls the microwave generator 8 to start, and at the same time controls the rotating tray 9 to rotate at a speed of 10 rpm to 15 rpm in a horizontal state to ensure that the material is heated evenly for foaming reaction. The gas treatment unit 5 starts synchronously with the microwave foaming module 2. The vortex fan 21 runs to maintain a slight negative pressure of -10Pa to -20Pa inside the microwave cavity 7. The waste gas generated during the foaming process enters the gas pipeline through several microwave gas collection ports 22 at the top rear of the microwave cavity 7 and is finally transported to the waste gas treatment box 18 for purification. Step two, fully automated gravity transfer stage; After the foaming process is completed, the intelligent control system 6 controls the microwave generator 8 to stop working, the rotating tray 9 to stop rotating, and at the same time controls the first insulating valve 16 in the channel of the automatic material transfer mechanism 4 to open automatically. The intelligent control system 6 controls the tilting mechanism at the bottom of the rotating tray 9 to tilt the rotating tray 9 smoothly to 20° towards the polytetrafluoroethylene conveyor belt 15 of the automatic material transfer mechanism 4. Under the action of gravity, the mold containing the foamed material slides down naturally along the low friction surface of the rotating tray 9, enters the material transfer channel 14 and falls smoothly onto the polytetrafluoroethylene conveyor belt 15. After the mold has completely slid onto the PTFE conveyor belt 15, the tilting mechanism immediately operates under the control of the intelligent control system 6 to restore the rotating tray 9 to a horizontal position and lock it. Subsequently, the first insulating valve 16 closes under the control of the intelligent control system 6. Step 3, Curing and solidification stage; The intelligent control system 6 controls the second insulation valve 17 to open, and the intelligent control system 6 controls the start of the polytetrafluoroethylene conveyor belt 15 of the automatic material transfer mechanism 4. The operation of the polytetrafluoroethylene conveyor belt 15 transports the mold to the predetermined position in the curing cavity 11 of the curing post-processing module 3. After the mold reaches the predetermined position, the intelligent control system 6 controls the polytetrafluoroethylene conveyor belt 15 to stop running and simultaneously controls the second insulation valve 17 to close. Then, the curing program is automatically started, the heating jacket 12 on the outer wall of the curing chamber 11 is heated, and the hot air circulation fan 13 in the chamber is started to stabilize the temperature in the curing chamber 11 at the preset curing temperature (room temperature to 250°C) to cure the material at high temperature. During the curing process, the gas treatment unit 5 operates continuously. The waste gas generated in the curing chamber 11 enters the gas pipeline through several curing gas collection ports 23 at the top rear of the chamber and is transported to the waste gas treatment box 18. After being treated by the first-stage spray neutralization chamber 19 and the second-stage activated carbon adsorption chamber 20, the waste gas is discharged in compliance with standards. Step four: End and sampling phase; After the curing process is completed, the intelligent control system 6 controls the heating jacket 12 and the hot air circulation fan 13 to stop working, and the system enters the cooling stage. After the temperature inside the curing chamber 11 drops to a safe range, the intelligent control system 6 displays a prompt message through the touch screen 30 to inform the experimenters that the curing process is over. After receiving the prompt, the experimenters opened the finished product transfer valve 33 of the curing chamber 11 and took out the cured melamine foam finished product and mold from the curing chamber 11, thus completing the laboratory preparation operation of this melamine foam.

[0058] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A small-scale integrated microwave foaming and post-processing device for foam preparation, characterized in that: Includes the equipment casing (1); The device housing (1) is provided with a microwave foaming module (2) and a curing post-processing module (3) inside the housing. The microwave foaming module (2) and the curing post-processing module (3) are distributed at intervals inside the device housing (1). An automatic material transfer mechanism (4) is provided between the microwave foaming module (2) and the curing post-processing module (3) to realize fully automatic material transfer; A gas treatment unit (5) for treating process waste gas is provided on one side of the equipment housing (1). The gas treatment unit (5) is connected to the microwave foaming module (2) and the curing post-treatment module (3) through pipelines. On the other side of the equipment housing (1), there is an intelligent control system (6) for controlling the coordinated operation of the microwave foaming module (2), the curing post-processing module (3), the automatic material transfer mechanism (4), and the gas processing unit (5).

2. The integrated small-scale microwave foaming and post-processing equipment for foam preparation according to claim 1, characterized in that: The microwave foaming module (2) has a microwave cavity (7), and at least one microwave generator (8) is provided at the top of the microwave cavity (7). The microwave generator (8) is connected to the intelligent control system (6).

3. The integrated microwave foaming and post-processing equipment for foam preparation according to claim 2, characterized in that: The bottom of the microwave cavity (7) is provided with a rotatable or tiltable tray (9). The tray (9) is made of a material that is resistant to high temperature and has low loss characteristics to microwaves. The bottom of the tray (9) is connected to a tilting mechanism that switches the tray (9) between a horizontal rotation state and a tilting state. The tray (9) is signal-connected to the intelligent control system (6).

4. The integrated microwave foaming and post-processing equipment for foam preparation according to claim 3, characterized in that: The surface of the tray (9) has a polytetrafluoroethylene coating (10).

5. A small-scale integrated microwave foaming and post-processing device for foam preparation according to claim 2, characterized in that: The post-processing module (3) has a curing chamber (11), the outer wall of which is fitted with a heating jacket (12), and the interior of the curing chamber (11) is equipped with a hot air circulation fan (13), which is signal-connected to the intelligent control system (6).

6. The integrated small-scale microwave foaming and post-processing equipment for foam preparation according to claim 3, characterized in that: The automatic material transfer mechanism (4) has a material transfer channel (14) connecting the microwave foaming module (2) and the curing post-processing module (3). The material transfer channel (14) is equipped with a polytetrafluoroethylene conveyor belt (15). The running plane of the polytetrafluoroethylene conveyor belt (15) is precisely matched with the upper surface of the tray (9). The polytetrafluoroethylene conveyor belt (15) is signal-connected to the intelligent control system (6).

7. A small-scale integrated microwave foaming and post-processing device for foam preparation according to claim 6, characterized in that: The microwave foaming module (2) and the curing post-processing module (3) corresponding to the polytetrafluoroethylene conveyor belt (15) are respectively provided with a first insulating valve (16) and a second insulating valve (17). The first insulating valve (16) and the second insulating valve (17) are both signal connected to the intelligent control system (6).

8. A small-scale integrated microwave foaming and post-processing device for foam preparation according to claim 5, characterized in that: The gas treatment unit (5) has a waste gas treatment box (18), and the waste gas treatment box (18) has a first-stage spray neutralization chamber (19) and a second-stage activated carbon adsorption chamber (20) arranged in parallel inside. The waste gas treatment box (18) is equipped with a vortex fan (21) that provides negative pressure to the equipment, and the vortex fan (21) is connected to the intelligent control system (6).

9. A small-scale integrated microwave foaming and post-processing device for foam preparation according to claim 8, characterized in that: The microwave cavity (7) and the curing cavity (11) are respectively provided with a plurality of microwave gas collection ports (22) and a plurality of curing gas collection ports (23) on the side near the waste gas treatment box (18). The plurality of microwave gas collection ports (22) are all connected to the first gas collection area (25) through the first pipe (24), and the plurality of curing gas collection ports (23) are all connected to the second gas collection area (27) through the second pipe (26). The first gas collection zone (25) and the second gas collection zone (27) are connected to the first-stage spray neutralization chamber (19) of the waste gas treatment box (18) through a third pipe (28).

10. A small-scale integrated microwave foaming and post-processing device for foam preparation according to claim 1, characterized in that: The intelligent control system (6) has a control panel (29) and a touch screen (30) integrated on the device housing (1). A program logic controller (31) is provided between the control panel (29) and the touch screen (30). The control panel (29), the touch screen (30) and the program logic controller (31) are electrically connected to each other.

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