Major foam cutting machines currently in use

Foam cutting machines are used to get the desired thickness of PU foam sheets. The cutting machine is necessary as the blocks of foam formed cannot be used in different applications. The blocks need to be cut into different sizes pieces before using them. The basic structure of foam cutting machine is a stationery part and moving part. The stationery unit is cutting unite and the table, on which is foam for cutting, is put is moving unit. These days Foam Machine Manufacturer in India machines are also coming in automatic and semi automatic version. The automatic versions are coming with touch screen options.

Horizontal cutting foam machines are used to cut PU blocks into sheets. The horizontal cutting machine is controlled by a programmable logic controller. The cutting part of the machines is made of stainless steel. The knife used for cutting comes with automatic grinders. The table moves in front and back movement during the cutting process. The cutting part rises a bit to allow this movement of the table at the end of the cutting process. The automatic versions are generally user friendly and can be operated by one person only.

Vertical cutting machine is used to cut the foam blocks into slices and required thickness pieces. The basic function is to trim the sides of PU blocks. The cutting blade is electrically controlled and the support system can be modified. The smooth upper side of the stainless steel table is used to keep the foam blocks for cutting. The machine has knife with two way guidance system and electrically control grinders. Vertical cutting machines Vertical Foam Cutting Machine Manufacturer in India can be used in cutting units and in packaging departments. 

 

Circular foam cutting machine --Various foam blocks are cut in accuracy and diligence by the circular cutting machine. The name circular machine comes from the circular table of the machine, which is moved by AC motor. The cutting part of the machine is stationery. The foam for cutting is put on the table and when the circular part of the machine moves, the cutting process starts. These machines are used to help a cutting unite to give high yield.

The machine is made of premium the stainless steel block, which is corrosion free. The machine comes with a mechanism to control the speed from 0 to 5 rpm. The machines are coming with various features like blade warning light , touch screen function , vacuum system for holding the blocks on the circular table, electric grinder for knifes and blade adjustment system .

Manufacturing process of polyurethane foam

 

Three main raw materials are used in the production of polyurethane foam . There raw materials are polyol , water and TDI . The use of water allows foam to expand and rise . The three raw materials are accurately conditioned and are carried to the best processing temperature , that is between 20 degree Celsius to 25 degree Celsius . The reaction takes place in one to three minutes . This is the time in which the foam block reaches fixed dimensions . 

The harmful gases for environment such as CFC and methylene chloride are not used in the process now . After coming out of the processing , the foam is cut into blocks for maturation system . After 72 hours of production process , the reaction of the polyurethane ends . At the end of the process the blocks are stored in the warehouses .

The explanation of raw materials used in the production of foam -

Polyol -this is high viscosity oil , which is orderless and colourless . The amount of polyol decides the chemical formulations . This does not pose any danger to the eye etc , but safety glasses are used during its handling .

TOLUENE DI-ISOCYANATE (TDI) is commonly used for flexible foam slab stocks . The raw material is odourless , clear with low viscosity liquid and has pungent smell . However , it is toxic substance and its can be dangerous to health . The reaction of TDI with polyol gives rubber like mixture . The adding of water then gives foaming reaction . The amount of water Foam Machine Manufacturer in India and TDI are used according to the formulations of the manufacturing company .

Blowing agents – the main blowing agent which causes the foam to expand is carbon dioxide . The carbon dioxide is released during the reaction of water with isocymate .

Catalysts used in the foam production is amine . The amine can be toxic to the human beings and can cause skin irritations . The amine has unpleasant smell. Its ingestion is avoided as it may lead to health problems . Tin and stannous are also used as catalysts .

Then foam stabilizers are also in the production . The silicon stabilizer is used for two functions , first, Batch Foaming Machine Manufacturer in India to help the components to form homogeneous liquid , and second , to prevent the collapse before liquid polymerizes phase by stabilizing the bubbles in the forming process .Finally water is added and mixing is done .

Factors that affect the performance of foam

When a foam is selected for its cushioning functions ,the number of physical properties are tested or seen . There are various properties of the foam and each one of them has its importance . These physical properties are measured under controlled situaiions of humidity and temperature .

These physical properties are -

Density – This is the measurement of mass per unit volume . The density is also one of the most important of the properties of the foam . The density in the foam comes as a result of foam making chemistry . It also involves the additives that are used in foam chemistry during its making process . For specifications purposes , it is suggested that the polymer density of the foam should be measured without filters .

Density decides support and durabiity of the foam . If the polymer density is more than the foam can retain its form and provide the suport and comfort it is originally made to offer .

Indentation force deflection is measure of the firmness of the foam . The firmness of the foam is not dependant on the density of the foam , but it is always thought that the higher density of the foam provide firm support . There may be many foams with higher density or low density but they are firm . This property of the foam assures the comfort of the foam and in other words is measurement of the surface of the foam .

Support factor Foam Machine Manufacturer in India of a foam determines the capacity of the foam to provide deep down support . The support factor is measured by indenting the foam 65 percent of its height . The support factor of the foam has to be high to provide better support . The foam with higher support capacity offers number of advantages .

Flex fatigue means the ability of a foam to retain its original position , properties and height . There are several tests to know the foam durability . Some tests are done in the laboratories and other are performed by the different manufacturers at their sites . The all tests are done by pressing or compressing the Batch Foaming Machine Manufacturer in India foam number of times and then measuring the firmness and height of the same foam before the start of the test and after the test . In the flex fatigue testing ,the foam is compressed hundred of times or may be in some cases thousands of times ..

Manufacturing process in rebound plant and vertical cutting machine

Rebounding foam machines are used in the foam plants either in batch foam plant or in continuous foam plant . In Rebounding the foam granules are rebounded with glue brinders and then steam is used to dry it . The pressure from the hydraulic press is given from the top . The manufacturer of the rebounding machines are making the machines with cutting edge technology . They also incorporate all sizes like 6 x 3 , 6 x 4 ,6 x 6 , by adjusting features .

Manufacturing process -

The foam shredding machine is used to shred the scrap foam. These shredding pieces are put directly into the rebound foam machine mixer . At this stage , the 10 percent of the total weight of the foam granuals are added into the mixer as brinder chemical . The mixer wil mix the ingredients for at least 15 minutes . After 15 minutes the mixture is poured in the mould and pressed from the hydraulic press . The steam is Rebonding Machine Manufacturer in India released from the bottom at the same time . This process gives rebounded foam of desired density level .

Foam cutting machines -

These machines are used to cut the foam into desired thickness sheets . The machines have cutting part and stationary part . The cutting part has cutting knifes with automatically grinders . These days manufacturer are making automatic foam cutting machines with touch screen display . The machines can work with minimum human interference .

The cutting machines are coming in various types from horizontal type , to circular type, vertical type , to angular foam cutting machine .

Vertical cutting machines is used to get the desired slices or pieces of the foam blocks after cutting process . The machine Vertical Foam Cutting Machine Manufacturer in India is basically used to trim the sides of the polyurethane foam blocks . The machine has a support system , which can be modified and a motor blade . The machine has aluminum table where the foam blocks are placed for cutting . The machine also comes with manual brake to stop the process .

The sitting section has four balanced wheel blades . As mentioned the machine has electrically controlled knief grinders . The machine can also be used to get the props , Architectural solid modeling, Prototyping and molds for casting concrete and plaster pieces. The makers are also giving machines on the specification of the cutomers .