In December 2021, we received an inquiry from Mr. Hairun in Malaysia. Mr. Hairun is a mattress manufacturer in need of producing rebonded foam. He had limited knowledge about machine usage and selection and had no prior experience with the production process. Therefore, he required guidance from experts who could assist him from the ground up.

We systematically explained the principles of foam production to Mr. Hairun, along with the necessary materials and equipment. We also took him on a tour of our factory to provide a clear understanding of the entire production process.

After understanding Mr. Hairun's preferences for the rebonded foam, including density, softness, and market prices, we offered him the most suitable foam production solution. We also provided him with information on foam production costs and compared raw material prices for his reference.

Based on the client's needs, budget, and existing factory layout, we devised a cost-effective machine configuration and layout plan for his facility, including an assessment of startup costs.

Once the machines were successfully installed, our team of engineers provided Mr. Hairun with one-on-one foam production training. When he successfully produced the foam he desired for the first time, he called us and said, "I am happy with crying, thank you very much!" Afterward, he purchased a batch foam machine from us and continued to reorder foam chemical materials from our company.

The production of block-shaped soft foam typically utilizes the batch foam machine foaming process, a gap-type production method. This method evolved from manual foaming in laboratories. The process involves immediately pouring the mixed reaction materials into an open mold resembling a wooden or metal box, hence the name "boxed foam." The molds (boxes) for boxed foam can be rectangular or cylindrical. To prevent the foam block from forming a domed top, a floating cover plate can be placed on the top of the foam during foaming. The cover plate stays closely attached to the top of the foam and gradually moves upward as the foam rises.

The main equipment for boxed foam production includes: 1) Electric-mechanical stirrer, mixing barrel; 2) Mold box; 3) Weighing tools such as scales, platform scales, measuring cups, glass syringes, and other measuring devices; 4) Stopwatch for controlling mixing time. A small amount of mold release agent is applied to the inner walls of the box to facilitate easy removal of the foam.

The advantages of producing soft foam using the boxed foam method include: low equipment investment, small footprint, simple equipment structure, easy and convenient operation and maintenance, and flexible production. Some small and underfunded domestic and township enterprises use this method to produce polyurethane soft foam. Boxed foam molding is a non-continuous production method for soft foam, so the production efficiency is lower than continuous methods, and the equipment is mostly manually operated, resulting in higher labor intensity. Production capacity is limited, and there is a greater loss in cutting foam plastics. The process parameters for boxed foam should be controlled within a certain range because even with the same formula, the foam properties may not be the same when different process parameters are used. The raw material temperature should be controlled at (25±3) degrees Celsius, mixing speed at 900 to 1000r/min, and mixing time at 5 to 12 seconds. The mixing time of the polyether and additives mixture before adding TDI can be flexibly adjusted depending on the situation, and after adding TDI, a mixing time of 3 to 5 seconds is sufficient, with the key being thorough mixing after TDI addition.

During boxed foam molding, attention should be paid to the following aspects:

1) Prepare before production, including material temperature and machine equipment inspection;

2) Measure as accurately as possible;

3) Control the mixing time appropriately;

4) Pour the mixed material liquid quickly and steadily, avoiding excessive force;

5) Ensure the box is placed steadily, with the bottom paper flat, to avoid uneven material flow during pouring;

6) When the foam rises, gently press the cover to ensure the foam rises smoothly;

7) Additives should be used as specified, and pre-mixed materials should not be left for too long.

Three types of foam equipment have emerged in boxed foam molding. Initially, various raw materials were weighed into a container according to the formula, mixed with a high-speed mixer, and poured into the box mold for foaming and shaping. This method often resulted in residue in the mixing container. An improved method used a metering pump to transport the raw materials to the mixing barrel for uniform mixing. A mechanical device automatically closed the bottom of the barrel, and compressed air was used to press the material into the foaming box for shaping. Both of these methods could create eddies due to the rapid influx of materials into the box, which might cause defects or depressions in the foam products. The most reasonable boxed foam device is to place a bottomless mixing barrel directly in the center of the foaming box. A metering pump delivers the various raw materials needed for foaming into the mixing barrel. After mixing for a few seconds, the lifting device raises the mixing barrel out of the foaming box, allowing the foaming material to flow smoothly over the entire box bottom. This prevents foam cracking due to material eddies, and ensures relatively uniform height throughout the foam.

A pressure device can be added to the expanding foam material to produce flat-topped foam, reducing waste during cutting. This device is suitable for the production of polyether-type polyurethane soft foam and high rebound soft block foam. For polyvinyl acetate polyurethane blocks, this method cannot be used due to the high viscosity of the material, and continuous methods are generally employed.

What to do when the chain stitch quilting machine fails to pick up the thread?

First, check whether the upper and lower threads are correctly threaded and if the thread tension is appropriate. Then, push up the light axis and check if the needle and hook are in the correct position, approximately two millimeters apart.

If the pattern jumping stitch is not picking up the thread, you can adjust the parameters on the computerized control interface to increase the thread length parameter, but be careful not to increase it too much.

What to do when the quilting machine produces imperfect circles?

First, reduce the stitch length appropriately, ideally between 4.8 and 5.2. Then, set the backstitch to 4 and slow down the speed. This should result in a nicely formed small circle.

How to quilt a standard and even pattern?

First, identify the root cause of the problem. Uneven patterns can be related to the thickness of the sponge. If the base material is too thin, it can also cause pattern distortion, uneven sizes, and disproportion. Adjust parameters according to different patterns and material thicknesses.

For continuous patterns, if there is horizontal overlapping, reduce the x-axis parameter; if there is vertical overlapping, reduce the y-axis parameter. Conversely, if horizontal and vertical lines are separated, increase the x and y parameters accordingly.

For jumping patterns, adjust the GX and GY parameters. When quilting diamonds, if the diagonal separation is too wide, increase the diagonal pull parameter; if the diamond diagonals intersect, reduce the diagonal pull parameter.

How to properly control the tension of the upper thread?

When removing the thread, be sure to pass through the thread clamp on the upper thread clamp. The thread clamp cannot be adjusted too tight. When you need to adjust the tightness of the upper thread, you cannot pull the upper thread directly. You must control the tightness of the upper thread through the thread clamp on the control device; when adjusting, it should not be too tight or too loose, and there should be no jamming, otherwise it will cause jumpers. Or disconnected.

How to draw a pattern?

When drawing a pattern for a quilting machine, we can use professional pattern drawing software, but the exported format must be HFP. How to enlarge or reduce the size when drawing a floral pattern? In "Edit Pattern", open "Scale Entire Pattern", and based on our needs, click on the pop-up box's "millimeters" or "inches" option, then add the X and Y parameters according to our needs, and click "OK" after entering.

How to troubleshoot the cause of abnormal noise in a quilting machine?

First, check whether the frequently worn parts are lacking oil, and add some machine oil or grease to the dryer areas; then check whether there is any clearance in the bearings of various components; also carefully observe whether the accessories and wear parts are excessively worn, and replace them timely if discovered.

How to Solve the Issue of Thread Breakage or Dropping in a Quilting Machine?

First, check if the thread clamp is rusty or has debris. If such issues are found, clean the thread clamp with a cloth. Additionally, push up the optical axis of the quilting machine and check if the distance between the hook tip and the needle is around 2 millimeters. If there is a deviation, adjust the hook left, right, up, or down accordingly. Regular maintenance and cleaning of the equipment are also essential.

How to Maintain a Quilting Machine?

Clean the equipment at the start and end of each work shift to remove debris and dust, ensuring smooth operation of the needle and hook. Regularly lubricate areas with significant wear using machine oil or grease to facilitate smooth high-speed operation. Bearings with oil nozzles should be greased at least once a year to prevent excessive machine wear. Insufficient air pressure or unopened cylinders can cause temporary loss of some functions, so ensure the cylinders are activated before turning on the machine. When shutting down, do not turn off the machine power directly; first, turn off the computer, then the power.