Sponge production process

A Wood Pulp Cotton Cloth Manufacturer Discusses Sponge Production Process
What raw materials are needed for the production of wood pulp cotton cloths? What kind of process is used for wood pulp cotton cloths? These are questions many buyers of wood pulp cotton cloths want to know. Today, a compressed wood pulp cotton manufacturer has arranged for me to introduce the raw materials and production process of sponge production.
The production of sponges is highly automated. The entire process consists of an automatic control feeding system, a foaming machine, a cutting machine, and a computer-controlled molding system. The key processes are the batching and foaming stages. Professional technicians batch the materials according to the manufacturer's requirements for density, hardness, and other parameters; different foaming times are determined based on the characteristics (density, hardness) of each type of sponge. Manual operation is limited, and the quality of the sponge depends on the quality of the batching.
I. Sponge Production Raw Materials
1. Process Control of Fast-Acting and Standard Materials
Fast-Acting Materials: Low molecular weight and volatile content, mainly used in automatic machines, but also usable in manual machines. It contains less foaming agent and has a shorter curing time. During operation, the heating time is short, the cooling time is short, the molding cycle is short, energy consumption is saved, and production efficiency is improved.
Generally, due to the small amount of foaming agent, heating must be carried out in a short time to fully utilize the small amount of foaming agent to bind the foam particles. This short heating time saves time. High pressure and short-time heating are used.
This saves energy by using high-temperature demolding. The difference between the molding mold temperature and the demolding temperature is small, thus saving steam. The mold molding temperature is 115-130℃, followed by water cooling at 90℃. After vacuuming, the surface expansion rate of the product is reduced to a certain value of 85℃ before demolding.
Standard material: High molecular weight and volatile content, mainly used in clay-making machines. From an energy consumption control perspective, it is less commonly used in self-made machines.
2. Fast-setting material – fast molding and steam saving.
Types of fast-setting materials: BASF CP303, Longwang B-SB, Xingda 303, Chengda PK303, etc.
Characteristics: Fast cooling speed results in a faster molding cycle, generally 20-30% faster than conventional materials. Fast-setting materials have a higher demolding temperature, reaching 80-85°C, while conventional materials have a lower demolding temperature, at 60-65°C.
Therefore, fast-setting materials can save up to 30% of steam. The bonding strength of products molded with fast-setting materials should be controlled at 60-80% to better reflect its speed.
Fast-setting material control technology: High-pressure, short-time heating.
Conventional material types: BASF CP203, Longwang E-SB, Xingda 302, Chengda PK302, etc.
Conventional material control technology: Due to their large molecular weight and high volatile content, they are prone to swelling during production. Low-pressure, longer-time heating is recommended.
3. Sponge Ingredients: Polyether polyol, Toluene diisocyanate/TDI, Dichloromethane/MC, Silicone oil, Dimethylethanolamine/P12, and Stannous octoate/T9.
II. Sponge Production Process: Ingredient Formulation → Foaming → Drying → Cutting
III. Main Technical Parameters of Sponge:
Density: Kg/m3
Hardness: Pressure required for indentation percentage (e.g., 40% indentation hardness 25N)
Resilience: Expressed as a percentage