CA1245817A - Apparatus for manufacturing polyurethane foam slabs in a batch - Google Patents
Apparatus for manufacturing polyurethane foam slabs in a batchInfo
- Publication number
- CA1245817A CA1245817A CA000511328A CA511328A CA1245817A CA 1245817 A CA1245817 A CA 1245817A CA 000511328 A CA000511328 A CA 000511328A CA 511328 A CA511328 A CA 511328A CA 1245817 A CA1245817 A CA 1245817A
- Authority
- CA
- Canada
- Prior art keywords
- tank
- foam
- feed solution
- stirring tank
- stirring
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Abstract of the Disclosure An apparatus for continuously manufacturing poly-urethane foam slabs in a batch, which comprises a cylind-rical tank for developing polyurethane foam, having an inlet at the side wall thereof for introducing therein polyurethane feed solution; a stirring tank for forming polyurethane foam feed solution, which is mounted on a carriage movably placed in proximity to the cylindrical tank; stirring blades mounted within the stirring tank;
a discharge pipe extending from a lower side of the stirring tank to discharge the feed solution through the inlet into the cylindrical tank; pipes for intro-ducing raw materials into the stirring tank; and a pipe for introducing a washing solvent for removing the raw materials. The cylindrical tank is interchangeably con-nected with the stirring tank through the discharge pipe.
a discharge pipe extending from a lower side of the stirring tank to discharge the feed solution through the inlet into the cylindrical tank; pipes for intro-ducing raw materials into the stirring tank; and a pipe for introducing a washing solvent for removing the raw materials. The cylindrical tank is interchangeably con-nected with the stirring tank through the discharge pipe.
Description
This invention relates to an apparatus for manufac-turing polyurethane foam slabs in a batch and, in partic-ular, an apparatus for manufacturing them in a continuous fashion.
Polyurethane foam slabs are usually of a large-sized block type and are cut into slices of a desired thickness or configuration. Conventionally, such slices have found a wider application to an interior design and cushioning material for vehicles.
In the most common method, slabs around 30 to 40 m in length have been manufactured by continuously dis-charging a polyurethane foam feed solution into a re-cessed conveyor belt and expanding it therein. This method has a greater advantage of assuring a higher production efficiency.
A batch-type manufacturing method has also partly been adopted which introduces a foam feed solution into a large-sized tank where it is expanded and raised.
This method is inferior to the aforementioned continuous ~0 method with respect to its reproductivity and, in addi-tion, can be implemented at a relatively narrow loca-tion. According to the method~ slabs of a desired size can be manufactured by using a foam tank of a corre-sponding size. For a cylindrical slab a long sheet can effectively been obtained by peeling off or slicing ~he cylindrical slabj while the latter is rotated.
These known methods have, however, the following
Polyurethane foam slabs are usually of a large-sized block type and are cut into slices of a desired thickness or configuration. Conventionally, such slices have found a wider application to an interior design and cushioning material for vehicles.
In the most common method, slabs around 30 to 40 m in length have been manufactured by continuously dis-charging a polyurethane foam feed solution into a re-cessed conveyor belt and expanding it therein. This method has a greater advantage of assuring a higher production efficiency.
A batch-type manufacturing method has also partly been adopted which introduces a foam feed solution into a large-sized tank where it is expanded and raised.
This method is inferior to the aforementioned continuous ~0 method with respect to its reproductivity and, in addi-tion, can be implemented at a relatively narrow loca-tion. According to the method~ slabs of a desired size can be manufactured by using a foam tank of a corre-sponding size. For a cylindrical slab a long sheet can effectively been obtained by peeling off or slicing ~he cylindrical slabj while the latter is rotated.
These known methods have, however, the following
- 2 ~ 7 disadvantages:
In the continuous manufacturing method using the recessed conveyor belt, a 30 to 60 m production line is needed, requiring a wider spacing and thus a relatively large workshop. Since a slab of a substantially rec-tangular cross-section is obtained according to this method, a slicing machine has to be reciprocated many times to obtain a sheet of a desired thickness. It is, therefore, difficult to improve a quantity produc-tion in high yield. Furthermore, the slab which is sub-stantially rectangular in cross-section is irregularly formed at its top face and has a rough surface and a hardened layer. It is, therefore, necessary to cut off the top surface portion of the slab a few centimeters from its top face, offering a material loss problem.
Indeed, the conventional batch type method has the advantage of requiring a bulky apparatus and a larger installation spacing, but it is far inferior to the con-tinuous method with respect to its productivity, thus ~20 posing a critical problem.
It is accordingly the object of this invention to provide an apparatus for manufacturing polyurethane slabs in a continuous fashion, while adopting a batch-type method. According to this invention, polyurethane slabs can be mass produced in high yield, while retaining the advantage obtained from a conventional batch system.
According to this invention there is provided
In the continuous manufacturing method using the recessed conveyor belt, a 30 to 60 m production line is needed, requiring a wider spacing and thus a relatively large workshop. Since a slab of a substantially rec-tangular cross-section is obtained according to this method, a slicing machine has to be reciprocated many times to obtain a sheet of a desired thickness. It is, therefore, difficult to improve a quantity produc-tion in high yield. Furthermore, the slab which is sub-stantially rectangular in cross-section is irregularly formed at its top face and has a rough surface and a hardened layer. It is, therefore, necessary to cut off the top surface portion of the slab a few centimeters from its top face, offering a material loss problem.
Indeed, the conventional batch type method has the advantage of requiring a bulky apparatus and a larger installation spacing, but it is far inferior to the con-tinuous method with respect to its productivity, thus ~20 posing a critical problem.
It is accordingly the object of this invention to provide an apparatus for manufacturing polyurethane slabs in a continuous fashion, while adopting a batch-type method. According to this invention, polyurethane slabs can be mass produced in high yield, while retaining the advantage obtained from a conventional batch system.
According to this invention there is provided
- 3 ~
an apparatus for continuously manufacturing polyurethane slabs in a batch, comprising:
a cylindrical foam tank having a flat bottom and an upper end opened;
an inlet openable at a side wall of the foam tank and through which a polyurethane foam feed solution is introduced into the tank;
a carrier placed in proximity to the foam tank such that it is movable;
a stirring tank for mixture which is fixed on the carrier;
stirring blades mounted within the stirring tank;
a discharge pipe diagonally extending downward from a side of a lower end portion of the stirring tank to permit the feed solution to be discharged therethrough;
a pipe for introducing a polyurethane oam feed solution component into the stirring tank;
a pipe for introducing a washing solvent for the Eoam feed solution into the stirring tank;
an electromagnetic valve mounted in the discharge pipe; and a drive device for moving the carrier in which the polyurethane foam feed solution lS supplied through a corresponding pipe lnto the stirring tank to cause it to be homogeneously stirred; the carrier is moved, causing the forward end portion of the aforementioned pipe to be introduced into the foam tank to permit the .
`
an apparatus for continuously manufacturing polyurethane slabs in a batch, comprising:
a cylindrical foam tank having a flat bottom and an upper end opened;
an inlet openable at a side wall of the foam tank and through which a polyurethane foam feed solution is introduced into the tank;
a carrier placed in proximity to the foam tank such that it is movable;
a stirring tank for mixture which is fixed on the carrier;
stirring blades mounted within the stirring tank;
a discharge pipe diagonally extending downward from a side of a lower end portion of the stirring tank to permit the feed solution to be discharged therethrough;
a pipe for introducing a polyurethane oam feed solution component into the stirring tank;
a pipe for introducing a washing solvent for the Eoam feed solution into the stirring tank;
an electromagnetic valve mounted in the discharge pipe; and a drive device for moving the carrier in which the polyurethane foam feed solution lS supplied through a corresponding pipe lnto the stirring tank to cause it to be homogeneously stirred; the carrier is moved, causing the forward end portion of the aforementioned pipe to be introduced into the foam tank to permit the .
`
- 4 -electromagnetic valve to be opened to flow the foam Eeed solution from the stirring tank into the Eoam tank; and while the solution is expanded and raised with the car-rier retracted and thus the feed solution inlet of the foam tank closed, the washing solvent is introduced through the corresponding pipe into the stirring tank, washing away the polyurethane foam feed solution which is left deposited onto the inner wall of the stirring tank.
According to this invention, it is possible to per-form the automatic, continuous manufacturing of polyure-thane foam slabs in a batch, i.e., an operation including the preparing of the feed solution through its measure-ment and mixing, discharging of the feed solution into the foam tank, and washing away of the stirring tank.
The automatic, continuous operation can be performed in high yield according to this invention in comparison with a conventional batch-type method by which a greater amount of human intervention is necessary in the con-tinuous manufacture of polyurethane foam slabs.
Furthermore, the apparatus of this invention canbe installed in a relatively narrow spacing and cylin-drical polyurethane foam slabs can be manufactured in a continuous fashion which can assure a high level of productivity at the slicing of the cylindrical poly-urethane foam slab~ Therefore, the apparatus of this invention is very advantageous over the conventional , ~ 5 ~ ~2~
counterpart using the recessed conveyor belt.
This invention can be more fuly understood Erom the following detailed description when taken in conjunction with the accompanying drawings, in which:
Fig. 1 schematically shows an apparatus according to this invention which manufactures polyurethane foam slabs in a batch;
Fig. 2 is a cross-section showing a modified form of a foam tank in an apparatus of this invention;
Fig. 3 is a perspective view showing a cylindrical member held in the foam tank of Fig. 2; and Figs. 4A to 4C are cross-sectional views showing the steps of manufacturing polyurethane foam slabs with the use of the foam tank of Fig. 2.
An apparatus for manufacturing polyurethane foam slabs in a batch according to this invention will be explained below with reference to the accompanying drawings.
In Fig. 1, foam tank 10 i5 formed as a cylindrical unit having an open upper end and a flat base end. Foam tank 10 has an inlet 11, at the side wall, with openable door 12 attached to inlet 11. A feed solution for foam-ing is fed into foam tank 10 through inlet 11. The tank is placed on a turntable, not shown, and can be moved sequentially, while being rotated.
Rails 20 are located in the neighborhood of foam tank 10, and carrivr 21 is placed on the ralls with , :
-' ~ "
, 1. :
- 6 - ~ ~5~
casters 22 attached to the legs of carrier 21. Car-rier 21 is moved toward and away from foam tank 10 by actuating extrusion cylinder 23. Rotation shaft 30 is horizontally mounted on carrier 30 with cylindrical stirring tank 31 pivotally mounted on rotation shaft 30.
Rotation shaft 30 is driven by a motor and speed change gear, not shown, to permit the stirring tank to be swung through a tilting angle in a direction indicated by an arrow in Fig. 1~ In this connection it is to be noted that stirring tank 31 may be mounted directly on car-rier 21. Within tank 31, stirring blades 32 are mounted in the axial direction of tank 31 and rotated by motor 33 which is located below the stirring tank. Discharge pipe 34 is fixed to the lower side wall of stirring tank 31 and diagonally extends downward to permit the feed solution to be supplied to tank 10. Discharge pipe 34 communicates with stirring tank 31 through electro-magnetic valve 35 which is located at a boundary area between pipe 34 and tank 31. Measuring tank 36 for an isocyanate component is positioned above the stirring tank and connected through pipe 41 to a supply source for an organic isocyanate. Feed supply tube 37 is plac-ed at the lower end of measuring tank 36 with electro-magnetic valve 38 located at an area therebetween. To the side wall of feed supply pipe 37 is connected feed supply pipe 42 which supplies polyurethane foam com-ponents, such as polyol and catalyst, into tank 31 to , ~5~7 the exclusion of the isocyanate component.
Furthermore, supply pipe 43 for a washing solvent for the feed solution is attached to organic isocyanate component measuring tank 36 and connected to solvent tank 44. Tray 45 for a spent solvent is connected to solvent tank 44 through pump 46.
The operation of the aforementioned apparatus will be explained below:
With pushing cylinder 23 retracted and thus stir-ring tank 31 retracted, a polyurethane foam feed solu-tion is prepared. Stated in more detail, the organic isocyanate component is supplied through pipe 41 into measuring tank 36 and measured there. Then, electro-magnetic valve 38 is opened, introducing a predetermined amount of isocyanate component through supply pipe 37 into stirring tank 31. At the same time, the other materials, such as polyol component and catalyst, are introduced through pipe 42 into stirring tank 31. Then stirring blades 32 are rotated to cause these materials to be homogeneously mixed through a stirring motion.
When pushing cylinder 23 is extended, stirring tank 31 is moved forward to a position shown in Fig. 1 to permit the forward end of discharge pipe 34 to be in-serted through inlet 11 into foam tank 10. At this time, door 12 is pushed by the discharge pipe, causing the door to be readily opened. Then electromagnetic valve 35 is opened, permitting the foam feed solution , - . . ., " ~.,,: , . :
~2~513~7 which has been prepared within stirring tank 31 to be poured into foam tank 10 through discharge pipe 34. At this time, stirring tank 10 is tilted ahead, permitting a ready flow of the foam feed solution into tank 10.
Then pushing cylinder 23 is retracted and thus stirring tank 31 is moved backward to allow door 12 to be closed. The expanding and rising of the polyurethane foam feed solution progress within foam tank 10, thus obtaining a desired polyurethane foam slab.
During the time in which the polyurethane foam slab is prepared within tank 10, some of the feed solution belt deposited on the inner wall of stirring tank 31 and measuring tank 36 is washed away with the stirring tank at the withdrawn position. That is, pump 46 is driven and thus the washing solvent is supplied from tank 36 through pipe 43 into measuring tank 36 and thence into stirring tank 31 so that the tank is filled with the solvent. Then stirring vanes 32 are rotated, dissolv-ing the feed solution left deposited on the inner wall of stirring tank 31. If this is done, electromagnetic valve 3S is opened to allow the solvent to the discharg-ed through discharge pipe 34 so that the feed solution left deposited on the inner wall thereof is also washed away. The spent solvent, after being stored in tray 2S 45, is circulated by pump 46 into solvent tank 44 for recycling~
At the completion ol such a washing cycle, the foam -~' ,:
9 ~l5~
feed solution is again prepared as in the same operation as before. Foam tank 10 held with the feed solution is shifted on a rotating turntable, not shown, and another foam tank is located instead in the indicated position on the turntable. In this way, polyurethane foam slabs can be manufactured in the same continuous process as set forth above.
According to this invention, the apparatus for the manufacture of polyurethane foam slabs can be installed at a relatively narrow location and cylindrical foam slabs can be continuously manufactured in a batch, thus prominently improving a quantity production in com-parison with a conventional batch system.
Although in the aforementioned embodiment the foam tank has been explained as having a cylindrical config-uration, it may take any proper form, for example, a cubic configuration.
As the foam tank, use may be made of a structure in which in the expansion process of the feed solution the expansion level is permitted to be raised together with the corresponding inner wall thereof.
Fig. 2 is a cross-section showing a foam tank for the manufacture of the poIyurethane foam slab in a batch process in accordance with this invention. In Fig. 2 large-sized cylindrical tank Sl has an upper open end and a flat bottom, as in the case of a conventional structure. Cylindrical member 52 with both ends opened - 1 0 - ~ L7 as shown in Fig. 3 is placed within the cylindrical tank such i~ can slide along the inner side wall of the cyl-indrical tank. Wire 53 is connected to the upper end of cylindrical member 52, and cylindrical member 52 can be freely raised or lowered by winding or rewinding the wire around rollers 54 by means of a motor, not shown.
In this connection it is to be noted that the height, H, of cylindrical member 52 is usually of the order of, properly, 20 to 60 cm.
In the manufacture of polyurethane foam slabs in a batch on the apparatus of this invention, a sheet re-lease agent is covered on the inner surface of cylindri-cal tank 51 as in the conventional foam tank. A release agent or release sheet if also covered on the inner sur-face of cylindrical member 52.
When a polyurethane foam feed solution is charged into the foam tank, while under a stirring action, it is expanded and raised under a forming action. As shown in Fig. 4A, cylindrical member 52 in contact with a surface portion of feed solution 55 now being raised is lifted up with the same velocity as the rise velocity as shown in Fig. 4B. After the rise in the level of the feed solution under the expanding action is completed, the cylindrical member is lifted up as shown ln Fig. 4C.
As a result, even if the level of the feed solution is moved up due to the expansion of the feed solution, a portion of the foam tank contacting cylinder member 52 .. , ~. :
,' ~' . .
in the neighborhood of the level suffers no Erictional resistance. There is no possibility that an expansion of the feed solution will be prevented at the marginal edge of a resultant slab and the level is lowered. Ac-cording to this invention no such a defect is encoun-tered so that it is possible to manufacture cylindrical polyurethane foam slabs each with a flat top surface as shown in Fig. 4C.
Although this invention has been explained as manufacturing cylindrical polyurethane foam slabs in a batch, it may be applied to the manufacture of prismatic polyurethane foam slabs in a foam tank of a correspond-ing configuration.
Although, in the aforementioned embodiment, use has been made of the means for lifting up cylindrical member 52, it may be replaced by any other proper means.
As set out above, polyurethane foam slabs can be continuously manufactured in a batch on the apparatus oE this invention, thus offering an advantage inherent in the batch system. It is also possible to improve a ~ass production in high yield in comparison with the conventional batch system. Furthermore, the foam tank used in the manufacture of the polyurethane foam slabs in a batch in accordance with this invention imparts no frictional resistance to the foam feed solution expanded and raised along the inner surface of the foam tank. It is, therefore, possible to manufacture cylindrical polyurethane Eoam slabs having a flat-topped surface.
According to this invention, it is possible to per-form the automatic, continuous manufacturing of polyure-thane foam slabs in a batch, i.e., an operation including the preparing of the feed solution through its measure-ment and mixing, discharging of the feed solution into the foam tank, and washing away of the stirring tank.
The automatic, continuous operation can be performed in high yield according to this invention in comparison with a conventional batch-type method by which a greater amount of human intervention is necessary in the con-tinuous manufacture of polyurethane foam slabs.
Furthermore, the apparatus of this invention canbe installed in a relatively narrow spacing and cylin-drical polyurethane foam slabs can be manufactured in a continuous fashion which can assure a high level of productivity at the slicing of the cylindrical poly-urethane foam slab~ Therefore, the apparatus of this invention is very advantageous over the conventional , ~ 5 ~ ~2~
counterpart using the recessed conveyor belt.
This invention can be more fuly understood Erom the following detailed description when taken in conjunction with the accompanying drawings, in which:
Fig. 1 schematically shows an apparatus according to this invention which manufactures polyurethane foam slabs in a batch;
Fig. 2 is a cross-section showing a modified form of a foam tank in an apparatus of this invention;
Fig. 3 is a perspective view showing a cylindrical member held in the foam tank of Fig. 2; and Figs. 4A to 4C are cross-sectional views showing the steps of manufacturing polyurethane foam slabs with the use of the foam tank of Fig. 2.
An apparatus for manufacturing polyurethane foam slabs in a batch according to this invention will be explained below with reference to the accompanying drawings.
In Fig. 1, foam tank 10 i5 formed as a cylindrical unit having an open upper end and a flat base end. Foam tank 10 has an inlet 11, at the side wall, with openable door 12 attached to inlet 11. A feed solution for foam-ing is fed into foam tank 10 through inlet 11. The tank is placed on a turntable, not shown, and can be moved sequentially, while being rotated.
Rails 20 are located in the neighborhood of foam tank 10, and carrivr 21 is placed on the ralls with , :
-' ~ "
, 1. :
- 6 - ~ ~5~
casters 22 attached to the legs of carrier 21. Car-rier 21 is moved toward and away from foam tank 10 by actuating extrusion cylinder 23. Rotation shaft 30 is horizontally mounted on carrier 30 with cylindrical stirring tank 31 pivotally mounted on rotation shaft 30.
Rotation shaft 30 is driven by a motor and speed change gear, not shown, to permit the stirring tank to be swung through a tilting angle in a direction indicated by an arrow in Fig. 1~ In this connection it is to be noted that stirring tank 31 may be mounted directly on car-rier 21. Within tank 31, stirring blades 32 are mounted in the axial direction of tank 31 and rotated by motor 33 which is located below the stirring tank. Discharge pipe 34 is fixed to the lower side wall of stirring tank 31 and diagonally extends downward to permit the feed solution to be supplied to tank 10. Discharge pipe 34 communicates with stirring tank 31 through electro-magnetic valve 35 which is located at a boundary area between pipe 34 and tank 31. Measuring tank 36 for an isocyanate component is positioned above the stirring tank and connected through pipe 41 to a supply source for an organic isocyanate. Feed supply tube 37 is plac-ed at the lower end of measuring tank 36 with electro-magnetic valve 38 located at an area therebetween. To the side wall of feed supply pipe 37 is connected feed supply pipe 42 which supplies polyurethane foam com-ponents, such as polyol and catalyst, into tank 31 to , ~5~7 the exclusion of the isocyanate component.
Furthermore, supply pipe 43 for a washing solvent for the feed solution is attached to organic isocyanate component measuring tank 36 and connected to solvent tank 44. Tray 45 for a spent solvent is connected to solvent tank 44 through pump 46.
The operation of the aforementioned apparatus will be explained below:
With pushing cylinder 23 retracted and thus stir-ring tank 31 retracted, a polyurethane foam feed solu-tion is prepared. Stated in more detail, the organic isocyanate component is supplied through pipe 41 into measuring tank 36 and measured there. Then, electro-magnetic valve 38 is opened, introducing a predetermined amount of isocyanate component through supply pipe 37 into stirring tank 31. At the same time, the other materials, such as polyol component and catalyst, are introduced through pipe 42 into stirring tank 31. Then stirring blades 32 are rotated to cause these materials to be homogeneously mixed through a stirring motion.
When pushing cylinder 23 is extended, stirring tank 31 is moved forward to a position shown in Fig. 1 to permit the forward end of discharge pipe 34 to be in-serted through inlet 11 into foam tank 10. At this time, door 12 is pushed by the discharge pipe, causing the door to be readily opened. Then electromagnetic valve 35 is opened, permitting the foam feed solution , - . . ., " ~.,,: , . :
~2~513~7 which has been prepared within stirring tank 31 to be poured into foam tank 10 through discharge pipe 34. At this time, stirring tank 10 is tilted ahead, permitting a ready flow of the foam feed solution into tank 10.
Then pushing cylinder 23 is retracted and thus stirring tank 31 is moved backward to allow door 12 to be closed. The expanding and rising of the polyurethane foam feed solution progress within foam tank 10, thus obtaining a desired polyurethane foam slab.
During the time in which the polyurethane foam slab is prepared within tank 10, some of the feed solution belt deposited on the inner wall of stirring tank 31 and measuring tank 36 is washed away with the stirring tank at the withdrawn position. That is, pump 46 is driven and thus the washing solvent is supplied from tank 36 through pipe 43 into measuring tank 36 and thence into stirring tank 31 so that the tank is filled with the solvent. Then stirring vanes 32 are rotated, dissolv-ing the feed solution left deposited on the inner wall of stirring tank 31. If this is done, electromagnetic valve 3S is opened to allow the solvent to the discharg-ed through discharge pipe 34 so that the feed solution left deposited on the inner wall thereof is also washed away. The spent solvent, after being stored in tray 2S 45, is circulated by pump 46 into solvent tank 44 for recycling~
At the completion ol such a washing cycle, the foam -~' ,:
9 ~l5~
feed solution is again prepared as in the same operation as before. Foam tank 10 held with the feed solution is shifted on a rotating turntable, not shown, and another foam tank is located instead in the indicated position on the turntable. In this way, polyurethane foam slabs can be manufactured in the same continuous process as set forth above.
According to this invention, the apparatus for the manufacture of polyurethane foam slabs can be installed at a relatively narrow location and cylindrical foam slabs can be continuously manufactured in a batch, thus prominently improving a quantity production in com-parison with a conventional batch system.
Although in the aforementioned embodiment the foam tank has been explained as having a cylindrical config-uration, it may take any proper form, for example, a cubic configuration.
As the foam tank, use may be made of a structure in which in the expansion process of the feed solution the expansion level is permitted to be raised together with the corresponding inner wall thereof.
Fig. 2 is a cross-section showing a foam tank for the manufacture of the poIyurethane foam slab in a batch process in accordance with this invention. In Fig. 2 large-sized cylindrical tank Sl has an upper open end and a flat bottom, as in the case of a conventional structure. Cylindrical member 52 with both ends opened - 1 0 - ~ L7 as shown in Fig. 3 is placed within the cylindrical tank such i~ can slide along the inner side wall of the cyl-indrical tank. Wire 53 is connected to the upper end of cylindrical member 52, and cylindrical member 52 can be freely raised or lowered by winding or rewinding the wire around rollers 54 by means of a motor, not shown.
In this connection it is to be noted that the height, H, of cylindrical member 52 is usually of the order of, properly, 20 to 60 cm.
In the manufacture of polyurethane foam slabs in a batch on the apparatus of this invention, a sheet re-lease agent is covered on the inner surface of cylindri-cal tank 51 as in the conventional foam tank. A release agent or release sheet if also covered on the inner sur-face of cylindrical member 52.
When a polyurethane foam feed solution is charged into the foam tank, while under a stirring action, it is expanded and raised under a forming action. As shown in Fig. 4A, cylindrical member 52 in contact with a surface portion of feed solution 55 now being raised is lifted up with the same velocity as the rise velocity as shown in Fig. 4B. After the rise in the level of the feed solution under the expanding action is completed, the cylindrical member is lifted up as shown ln Fig. 4C.
As a result, even if the level of the feed solution is moved up due to the expansion of the feed solution, a portion of the foam tank contacting cylinder member 52 .. , ~. :
,' ~' . .
in the neighborhood of the level suffers no Erictional resistance. There is no possibility that an expansion of the feed solution will be prevented at the marginal edge of a resultant slab and the level is lowered. Ac-cording to this invention no such a defect is encoun-tered so that it is possible to manufacture cylindrical polyurethane foam slabs each with a flat top surface as shown in Fig. 4C.
Although this invention has been explained as manufacturing cylindrical polyurethane foam slabs in a batch, it may be applied to the manufacture of prismatic polyurethane foam slabs in a foam tank of a correspond-ing configuration.
Although, in the aforementioned embodiment, use has been made of the means for lifting up cylindrical member 52, it may be replaced by any other proper means.
As set out above, polyurethane foam slabs can be continuously manufactured in a batch on the apparatus oE this invention, thus offering an advantage inherent in the batch system. It is also possible to improve a ~ass production in high yield in comparison with the conventional batch system. Furthermore, the foam tank used in the manufacture of the polyurethane foam slabs in a batch in accordance with this invention imparts no frictional resistance to the foam feed solution expanded and raised along the inner surface of the foam tank. It is, therefore, possible to manufacture cylindrical polyurethane Eoam slabs having a flat-topped surface.
Claims (3)
1. An apparatus for manufacturing polyurethane foam slabs in a batch, comprising:
a cylindrical foam tank having a flat bottom and an upper end opened;
an inlet openable at a side wall of the foam tank and through which a polyurethane foam feed solution is introduced into the tank;
a carrier placed in proximity to the foam tank such that it is movable;
a stirring tank for mixture which is fixed on the carrier;
stirring blades mounted within the stirring tank;
a discharge pipe diagonally extending downward from a side of a lower end portion of the stirring tank to permit the feed solution to be discharged therethrough;
a pipe for introducing a polyurethane foam feed solution component into the stirring tank;
a pipe for introducing a washing solvent for the urethane foam feed solution into the stirring tank;
an electromagnetic valve mounted in the discharge pipe; and a drive device for moving the carrier.
a cylindrical foam tank having a flat bottom and an upper end opened;
an inlet openable at a side wall of the foam tank and through which a polyurethane foam feed solution is introduced into the tank;
a carrier placed in proximity to the foam tank such that it is movable;
a stirring tank for mixture which is fixed on the carrier;
stirring blades mounted within the stirring tank;
a discharge pipe diagonally extending downward from a side of a lower end portion of the stirring tank to permit the feed solution to be discharged therethrough;
a pipe for introducing a polyurethane foam feed solution component into the stirring tank;
a pipe for introducing a washing solvent for the urethane foam feed solution into the stirring tank;
an electromagnetic valve mounted in the discharge pipe; and a drive device for moving the carrier.
2. An apparatus according to claim 1, further including a drive device arranged associated with said stirring tank pivotally mounted on a rotation shaft ex-tending horizontally relative to said carrier, said drive device permitting the stirring tank to swing around said rotation shaft, whereby when said poly-urethane foam feed solution within said stirring tank is flowed into said foam tank said stirring tank is tilted forward to permit the polyurethane foam feed solution to be readily flowed into the foam tank.
3. An apparatus according to claim 1, further including a cylindrical member having upper and lower open ends and placed within said foam tank such that it is liftable along an inner side wall of said foam tank, in which when said urethane foam feed solution intro-duced into said foam tank is expanded said cylindrical member is movable upward with a level of said poly-urethane foam feed solution movable to a corresponding extent.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000511328A CA1245817A (en) | 1986-06-11 | 1986-06-11 | Apparatus for manufacturing polyurethane foam slabs in a batch |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000511328A CA1245817A (en) | 1986-06-11 | 1986-06-11 | Apparatus for manufacturing polyurethane foam slabs in a batch |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1245817A true CA1245817A (en) | 1988-12-06 |
Family
ID=4133325
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000511328A Expired CA1245817A (en) | 1986-06-11 | 1986-06-11 | Apparatus for manufacturing polyurethane foam slabs in a batch |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1245817A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2023108356A1 (en) * | 2021-12-13 | 2023-06-22 | 袁建民 | Full-automatic polyurethane foaming device |
-
1986
- 1986-06-11 CA CA000511328A patent/CA1245817A/en not_active Expired
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2023108356A1 (en) * | 2021-12-13 | 2023-06-22 | 袁建民 | Full-automatic polyurethane foaming device |
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