Common Problems and Operation Guide for Cyclopentane Polyurethane High-Pressure Foaming Injection Machines

Common Problems and Solutions for Cyclopentane Polyurethane High-Pressure Foaming Injection Machines

1. Uneven Mixing (Striations, Bubbles, Inconsistent Density)

Possible Causes:

Unstable Raw Material Temperature (Cyclopentane or Composite Polyether Outside ±1°C Range)

Injection Pressure Fluctuation (A/B Material Pressure Differential > 5 bar)

Clogged or Worn Mixing Head

Solutions:

Temperature Control:

Maintain the Cyclopentane Tank Temperature at 20-25°C (Prevent Volatility)

Control the Composite Polyether Material Temperature at 22±1°C (Stable Viscosity)

Pressure Calibration:

Check the A/B Material Pressure Daily to Ensure the Pressure Differential is < 3 bar. Use a Pressure Sensor for Real-Time Monitoring

Mixing Head Maintenance:

Flush with a Special Cleaning Agent at the End of Each Shift

Inspect the Mixing Chamber Monthly for Wear (Replacement Standard: Clearance > 0.2mm)

2. Inaccurate injection volume (overfill or underfill)

Possible causes:

Metering pump wear (volumetric efficiency <90%)

Raw material contains bubbles (density fluctuations)

Injection valve response delay

Solution:

Metering pump inspection:

Monthly calibration with a flow meter (error >5% requires pump element replacement)

Use a high-precision gear pump (repeatability ±0.5%)

Degassing treatment:

Install a vacuum degassing device on the raw material tank (vacuum level ≥ -0.095 MPa)

Let the raw material tank sit for 10 minutes before injection

Valve maintenance:

Replace the sealing ring (material: PTFE) quarterly

Solenoid valve response time should be <50 ms

3. Equipment leak (raw material or cyclopentane volatilization)

Possible causes:

High-pressure pipeline seal failure

Cyclopentane tank pressure exceeds specified limit (safety valve trip pressure 0.3 MPa)

Solution:

Leak detection:

Use a combustible gas detector (immediately shut down if LEL alarm > 10%)

Check all joints with soapy water

Safety measures:

Install a rupture disk on the tank (burst pressure 0.35 MPa)

Forced ventilation in the work area (wind speed ≥ 0.5 m/s)

Function of a Cyclopentane Polyurethane High-Pressure Foaming Injection Machine

• Production of High-Efficiency Thermal Insulation Materials

Mechanism of Action: Under high pressure of 150-200 bar, a dynamic mixing head achieves nanoscale mixing of raw materials, uniformly dispersing cyclopentane (boiling point 49°C) in polyether. After foaming, a closed-cell foam structure with a pore size of ≥92% is formed. Performance Indicators:

Thermal conductivity as low as 0.022 W/(m·K) (30% better than traditional CFC foam)

Density range 30-45 kg/m³ (accurately controlled to ±1 kg/m³)

• Precision Filling and Complex Molding

Micropore Control Technology: Utilizing a PID closed-loop control system, achieves:

Injection speed accuracy of ±0.5 g/s

Mold cavity fill rate ≥98% (avoiding cold welds/cavitation)

Typical Applications:

One-time filling of irregular-shaped cavities in refrigerator doors

Continuous production line for building insulation boards (speeds up to 6 m/min)

• Maximized Raw Material Utilization

High-Pressure, No-Loss System:

Metering pump volumetric efficiency ≥97% (compared to 85% for standard low-pressure machines)

Closed-loop recovery device reduces raw material waste to <0.3%

Economic Comparison: 12% less material consumption per 1 m³ of foam produced compared to low-pressure machines

• Structural Enhancement

Fiber-Reinforced Foam: Optional online glass fiber addition module (5-15%) increases foam compressive strength to ≥250kPa and dimensional stability (-30°C to 80°C) to <1%.