Foam presentation Lear CC

1、PU Seat Foam Technical Presentation 聚氨酯座椅發(fā)泡聚氨酯座椅發(fā)泡技術(shù)介紹技術(shù)介紹 What is foam Basic chemical Machine Process Part I Part II Part III Part IV Polyurethane is one of the biggest market of plastic Mold flexible foam is one kind of polyurethane Comparison between different state of foam The way of mixing insi

2、de of mixhead POLY 聚醚聚醚 ISO 異氰酸酯異氰酸酯 The way of filling in the mold TheThe polyurethane foam is basically polyurethane foam is basically the result of the the result of the reaction between two components:reaction between two components: There are two competing reactions:There are two competing reac

3、tions: Liquid isocyanate Polymerization reaction Gas-producing reaction Liquid polyol The Polymerization reaction The Gas-Producing reaction PolyurethaneISO ISO Water Polyurea Molecule POLY Carbon dioxide Foam BLENDING POLY ISO POLY WATER Silicone Catalyst Additive TDI MDI Basic POLY Graft copolymer

4、 Basic Foam Components POLY WATER Silicone Catalyst Additive ISO ISOThe Gas-Producing reaction Balance and control the above two reaction Colorants/Cell opener Lower bulk surface tension/Emulsifying agent/ The polymerization reaction Basic Foam Components 3 9 8 7 5 6 4 2 1 18 15 10 13 12 11 14 17 16

5、 25.0 24.0 24 I 25.0 24.0 24 I 3 9 8 7 5 6 4 2 1 18 15 10 13 12 11 14 17 16 23 C 23 C 23 C 23 C 23 C23 C Day tank Heat exchange High Pressure Pump Filter Flow rate gauge Mix head Hydraulic unit Temp. Control Unit Day tank Heat exchange Filter High Pressure Pump Mix headHydraulic unit Temp. Control U

6、nit Temp. Control Unit Chemicals direction Water direction Hydraulic oil direction 1.Day tank Level Indicator Agitator Temperature control unit Compressive air 1 .Day tank Store material 1 2Control and stabilize the temperature of chemicals 3Supply the necessary pressure (3.0 bar) Function 2.Heater

7、exchange 3.Filter Control and adjust the temperature by media of water. Temperature is very important parameter to the reaction. For example, higher temp. normally means faster reaction Filter the particles of chemicals before pumping into high pressure pump. If no, those particles will damage the h

8、igh pressure pump during high speed of rotate 4.High pressure pump Rotate group inside Motor Seal liquid tank Hand wheel Delivery line Pressure gauge Suction line 4.High pressure pump 4.High pressure pump Delivery Control plate piston Suction Rotate group inside Drive shaft Drive disc 4. Axial pisto

9、n pump 1Axial piston pump is one kind of metering pump 2 It can supply a stabilized throughput at high pressure 3 It is necessary to do calibration to check the work state of pump 4 Due to the requirement of accurate and pressure, its maintenance frequency is more than others 5Its pressure is normal

10、ly from 80 bar to 200bar Function 5.Mixhead (MQ-06) Six components 1 2 3 4 5 6 5.Mixhead (MQ-06) Cylinder &Plunge Injection Nozzle Slide Throttle Valve Outlet tube 5.Mixhead (MQ-06) Pouring Cleaning 5.Mixhead (MQ-06) Hydraulic for injection open Spring Injector pressure setting screw Chemical inlet

11、Chemical outlet Hydraulic for injection Close In open position In recirculation position 6.Hydraulic unit (MQ-06) 1 2 3 4 6.Hydraulic unit (MQ-06) 1 2 3 4 pump1 Hydraulic oil tank2 Valve block3 filter4 dydaullic cartoon 1Wet side 2Dry side Liquid Solid 1.Wet side Temperature of tank1 Key parameter P

12、ressure of tank2 Pressure in recirculation 3 Temperature of mixhead 4 Flow rate5 Ratio of ISO and polyol 6 Avoid crystallization/Lower the viscosity The necessary energy to delivery chemical to meter pump The necessary energy to mix completely Key point to the rate of reaction Density Hardness Tempe

13、rature of tank1 High Temperature 溫度太高溫度太高Low Temperature 溫度太低溫度太低 Fast reactivity 反應(yīng)速度快反應(yīng)速度快 Ratio Change 比例失控比例失控 Leaks 溢漏溢漏 Poor dimensional stability 尺寸穩(wěn)定性差尺寸穩(wěn)定性差 Poor demolding 脫模性差脫模性差 Loss of blowing agent 發(fā)泡劑遺失發(fā)泡劑遺失 Loss of flow 流動性差流動性差 Slow reactivity 反應(yīng)速度慢反應(yīng)速度慢 Ratio Change 比例失控比例失控 Voids

14、空泡空泡 Increased density 密度提高密度提高 Poor demolding 脫模性差脫模性差 Temperature of mold2 High mold temperature溫度太高溫度太高Low mold temperature 溫度太低溫度太低 Voids 空虛空虛 Poor adhesion 粘性差粘性差 Loss of flow 流動性差流動性差 Thick skin formation 厚表皮厚表皮 Low Core density 芯密度低芯密度低 Poor dimensional stability 尺寸穩(wěn)定性差尺寸穩(wěn)定性差 Poor demolding 脫

15、模性差脫模性差 Voids 空虛空虛 Leaks 溢料溢料 Mixing head problem3 Poor mixing of Isocyanate and Polyol 黑料和白料混合不均勻黑料和白料混合不均勻 Contamination with oil 油漬的玷污油漬的玷污 Large, glassy cells 大且呈玻璃狀的泡孔大且呈玻璃狀的泡孔 Streaky foam 泡體有條紋泡體有條紋 Soft spots in foam 泡體里局部柔軟泡體里局部柔軟 Timing of injector opening 注射活塞的開關(guān)時間注射活塞的開關(guān)時間 Pre-foam assem

16、bly3 Contaminated surfaces (oil / dirty) 表面玷污表面玷污 （油（油/骯臟）骯臟） Adhesion loss 粘接性差粘接性差 Poor mold sealing 模具密封差模具密封差 Foam leaks 溢漏溢漏 Calibration 校準校準/Linear Regression 線性回歸線性回歸 4 Procedure 步驟步驟 Select Isocyanate, Polyol or foam 選擇黑料、白料或泡沫體選擇黑料、白料或泡沫體 Set recycle and pour pressure 設(shè)定再循環(huán)和注射壓力設(shè)定再循環(huán)和注射壓力 T

17、ake shots at a minimum of three different shot times and careful record each weight 以三次不同的注射時間灌注，并記錄每一次注射重量以三次不同的注射時間灌注，并記錄每一次注射重量 Compare output,ratio and correlation to specification. 把得到的流量、比例同規(guī)格比較把得到的流量、比例同規(guī)格比較 Foam Testing 泡沫測試泡沫測試 5 Density (kg/m3)密度密度 Density Distribution (kg/m3)密度分布密度分布 Clos

18、ed Cell Content (%) 閉孔率閉孔率ISO 4590 Adhesion (Kpa)粘接性粘接性 ？ Thermal Conductivity ( mw/mk) 熱傳導(dǎo)系數(shù)熱傳導(dǎo)系數(shù) ？ Compressive Strength (Kpa)壓縮強度壓縮強度DIN 53421 Tensile Strength (Kpa) 抗張強度抗張強度DIN 53292 Shear Strength (Kpa) 剪切強度剪切強度DIN 53427 Flamability 可燃性可燃性ISO 3582 Dimensional Stability (%)尺寸穩(wěn)定性尺寸穩(wěn)定性UNI 8069 Trou

19、bleshooting 問題檢查問題檢查 6 Poor Adhesion 粘接性差粘接性差 Poor Demolding 脫模性差脫模性差 Foam Leaks 漏泡漏泡 Voids 空虛空虛 Troubleshooting 問題檢查問題檢查 6 Voids 空虛空虛 Preheat temperature out of spec. 預(yù)熱溫度不符合規(guī)格預(yù)熱溫度不符合規(guī)格 Mold temperature out of spec. 模溫不符合規(guī)格模溫不符合規(guī)格 Venting problem. 透氣問題透氣問題 Ratio of Isocyanate to Polyol is too high.

20、 黑料對白料的比例太高黑料對白料的比例太高 Wrong tilted angle. 錯誤的模具傾斜角度錯誤的模具傾斜角度 Mixhead output tube dirty.混合頭排出管骯臟混合頭排出管骯臟 Mixhead angle incorrect.混合頭角度不正確混合頭角度不正確 Obstruction in flow path. 流道被阻流道被阻 Troubleshooting 問題檢查問題檢查 6 Foam Leaks 漏泡漏泡 Too much foam in cabinet 箱體內(nèi)有太多的泡沫箱體內(nèi)有太多的泡沫 Pre-heat temperature too high 預(yù)熱溫

21、度太高預(yù)熱溫度太高 Mold temperature too high 模具溫度太高模具溫度太高 Low ratio of Isocyanate to Polyol 黑料對白料的比例低黑料對白料的比例低 Chemical Temperature too high 原料溫度太高原料溫度太高 Bad Pre-foam assembly 發(fā)泡前的裝配工作差發(fā)泡前的裝配工作差 Pack level too high 過分充填太高過分充填太高 Troubleshooting 問題檢查問題檢查 6 Poor Demolding 脫模性差脫模性差 Too much foam in cabinet 太多的泡沫

22、體在箱體太多的泡沫體在箱體 Demolding time is shorter than spec.脫模時間比規(guī)格指定低脫模時間比規(guī)格指定低 Pre-heat temperature are too high 模具預(yù)熱溫度太高模具預(yù)熱溫度太高 Mold temperatures are too high 模具溫度太高模具溫度太高 Low ratio of Isocyanate to Polyol 黑料對白料的比例低黑料對白料的比例低 Too low ratio of Polyol to Isocyanate 白料對黑料的比例過低白料對黑料的比例過低 Bad Pre-foam assembly 發(fā)泡前的裝配工作差發(fā)泡前的裝配工作差 Pack level too high 過分充填太高過分充填太高 Troub