1. Foaming equipment

PU foam cushions for seats generally use a foaming machine molding process. Foaming machines can be divided into low-pressure foaming machines and high-pressure foaming machines. The low-pressure foaming machine transfers the A component (isocyanate) and B component (polyol + blowing agent + catalyst + other auxiliary materials) to the mixing chamber of the pouring head through a metering pump, and then is injected into the foaming mold after stirring forming. The disadvantage is that the mixing chamber must be cleaned with solvent after each pouring, which wastes solvent and pollutes the environment. The high-pressure foaming machine is a two-component AB that is sent into the mixing chamber of the high-pressure pouring head through a high-pressure pump, and is instantly mixed under a high pressure of 15~18MPa and then poured into the mold for foaming. The advantage is that the mixture is uniform and does not need to be cleaned with solvents. Foaming is a key component of the seat. Foaming provides the shape and contour of the seat. The characteristics of foaming affect the comfort and H point of the seat. Therefore, choosing a good foaming machine determines the key to the seat. Guangdong FULEITE Electromechanical Technology Co., Ltd. is a polyurethane machinery automated production enterprise focusing on the research and development, production, sales and after-sales service of automobile seat foaming equipment. It has been in the industry for more than 20 years and is a senior electrical engineer and mechanical engineer with experience in polyurethane research and development. , Absorbing the technical characteristics of Conlon of Italy and Hennecke of Germany, integrating the great achievements of polyurethane technology from various manufacturers, possessing strong technical force and strong scientific research and development capabilities; the company has a technical R&D department, test center and other technical supporting teams to build Special core technology, cultivate independent innovation ability, and successfully obtained dozens of national patents; professional production team can meet the production and transformation of different polyurethane series equipment; brand new modern factory buildings and independent office buildings, complete departmental configuration, clear division of labor, to ensure Efficient and systematic tracking management of product design, procurement, manufacturing, installation and commissioning, after-sales service, etc., and the comprehensive introduction of the ISO9001 quality management system, fully guarantees the product quality and technical services of enterprise users.

2. Foaming mold

The foam mold directly affects whether the quality of the foam product can meet our design requirements. Understanding the manufacturing process and manufacturing quality of the foam mold will help the design of the foam structure.

According to the requirements of foam part design and foam production process, the mould used to produce foam parts is called foam mould. According to the manufacturing method of the parting surface, it can be divided into epoxy parting surface mold and EDM parting surface mold. According to the manufacturing material of the mold cavity, the foaming mold can be divided into epoxy mold and aluminum alloy mold.

The design and manufacturing process of the foam mold is divided into the following main steps:

Arrangement and analysis of design input information: design input information includes vehicle model, seat configuration, development progress, project budget, development basis (three-dimensional, two-dimensional, sample), etc.;

Data processing (main model, aluminum mold, inspection card), the main model is an enlarged model with comprehensive shrinkage, and aluminum molds are generally used. The aluminum mold is a forming mold for the comprehensive shrinkage rate-the shrinkage rate of the aluminum alloy material. The inspection card is used to inspect the size of foam products;

Output the technical and process requirements of mold development;

Sand-finding mold production and inspection: The sand-finding mold is a model made on the basis of the main model to prepare for aluminum alloy sand-finding. It will determine all aspects including cavity angle, parting surface, installation size, water pipe distribution, wall thickness, etc. The mold structure provides a guarantee for the final structure of the mold in the future. Its quality will directly affect the quality of the foundry casting;

Sand-finding and casting: On the basis of the sand-finding mold, a sand box is used for modeling to prepare for pouring aluminum alloy. This process is sand-finding. After the sand foundry is completed, the liquid aluminum alloy that reaches the casting standard after various process controls is poured into the sand box. The cooling forming process is casting. Sand foundry and casting will directly affect the internal quality of the mold and the quality of the mold post-processing in the future;

Aluminum mold processing, assembly and inspection: including cavity, outer dimensions, parting surface processing and inspection, as well as component assembly (positioning device, cylinder, pipe joints, etc.);

Test mold verification: After mold base installation, component positioning, automatic exhaust cylinder installation, process parameter preparation and other related preparations, the online trial production will begin, and size and performance testing will be carried out after maturation.

After the mold is completed, it is injected into the mold according to a certain trajectory, a certain flow rate and a certain pouring time, and the temperature of the raw materials, the temperature and the pressure of the mold are controlled, and the raw materials react at a certain temperature. The molding time is about a few minutes. After the foam is out of the mold, the foam is broken, otherwise the foam is easy to shrink and crack, and finally mature. This process takes a few hours to get our final product.

When designing the foaming mold, first confirm the structure of the mold, whether it is a two-piece, three-piece, or one-mold with multiple configurations; secondly, choose the parting surface, whether it is epoxy or electric spark, and determine it according to the appearance and function of the product Mold manufacturing process and foaming process, determine the distribution of the parting surface; again for the fixation and positioning of the parts, select the skeleton positioning datum and control the tolerance; also need to consider the shrinkage rate, the comprehensive shrinkage rate is also mentioned above, and its influence There are many factors, such as the shrinkage of polyurethane foaming raw materials, the shrinkage of aluminum alloy materials during the casting process, the influence of the shape and position of the parts in the foam, the influence of the size and structure of the foam, and the shrinkage rate obtained by the above various shrinkage factors. , Called the comprehensive shrinkage rate.

Design factors that affect the quality of foam mold manufacturing: data design directly affects the quality of the foam mold, so before data is released, it needs to go through a strict review to ensure that the data conforms to the STO shape and other design inputs such as H-point, skeleton, and body While meeting the requirements of environment and function, it also meets the requirements of mold making.