The principle of the compact machine is that though the energy supply the raw material expand and so the mould is fill complete.
The producing of packing with a form machine consist of the follow steps.
Picture IV.21: Steps of producing compact
The delivered raw material is before foam material or the foaming agent containing raw material. The advantage of the before foam stuff is, that the purchase of a before former is not necessary. But the transport and storage is very costly because before foam stuff need many volume. This you can by- pass when you use the foaming agent containing raw material. But you must by a before former.
The first step of the compact producing is the make of the mould. This is not necessary to make this in self producing, because it is possible to let make the mould by other firm. Before you can make the aluminium mould you must design a construct the mould.
The mould has to fasten to the compact machine. This can happen in the machine chamber or with a rise frame. At the first variant the root chamber is provide supply with the seal and fitting flanges. Then the mould is screw in the flanges. Here must the rear wall oft the bonnet wall exchange when the fill and ejecting positions are change. Further more the adjustment of the intensity is not possible.
If you choose the variant of the rise frame so the root chamber at the bonnet side is lower. If the balance occurs in the pitch so the bonnet side of the mould is at the machines solid table. The advantage of this is that the installation is simple and no tilt force works at the driving table. But the stoke and the mould disconnecting plane are change with the exchange of the rise frame. Now the parameters have adjusted new. This problem is removed by fully automatic controls. It is possible to use the steam chamber deepening, but the balance in the pitch is use to 95%.
Now the before foam raw material is measure out and press in to the mould. There is use air. That has to be without abrasion. Because dust develops, this is cover with the valve opening.
For the expansion of the material energy must supply. This energy inserts though the steam. Also they are displacing the air in the spandrel volume. The steam is saturated steam so the before pressure is very low. The steam have insert about big areas and with a constant pressure. Though the steam the expansion is occur, that's means the pearls are wed together and fill the mould complete.
The weld has to stabilize. For that it is need a vacuum. Here ensure a fast inside pressure reduction though the high pressure difference. For make a vacuum you need 25°C cool water.
Furthermore you manage stabilization because the 55°C - 65°C cool cooling water is vaporizing.
Now the mould is cool out and can demolding. For this you need air. For this is exist many different mould interpretations but for 95% of the packing, if you have a good conception handling system with the moulds ejectors are not necessary.
Picture IV.22: Compact machine HS 2200 from the Hirsch Maschinenbau GmbH & Co. KG [6]