The role of melt gear pump in foam mesh production

The melt gear pump is the core precision matching equipment of the plastic foam mesh production line, specially adapted to the low magnification and high uniformity foaming conditions of PE, PP and other foam mesh raw materials. It is installed between the extruder and the foaming die, and through the principle of volumetric forced conveying, completely solves the pain points of uneven foam holes, large deviation in mesh thickness, and frequent wire breakage in traditional foam mesh extrusion process. It is a key configuration to improve the yield and quality of foam mesh products.

Stabilize voltage and control bubbles, eliminate bubble defects

The production of foam mesh requires extremely high pressure stability of the mold head. Small fluctuations in pressure can directly cause fatal defects such as bubble burst, collapse, excessive or ruptured local bubbles. After installing a melt gear pump, the pressure fluctuation at the inlet of the die can be controlled within ± 1%, completely isolating the feeding and temperature pulsation of the upstream extruder, ensuring that the melt pressure entering the die remains constant throughout the process. The nucleation of bubbles is highly consistent with the growth environment, avoiding uneven foaming at the root. The overall density deviation of the mesh can be reduced by more than 70%.

Accurate measurement, stable mesh size

It relies on the fixed displacement characteristic of high-precision gear meshing, with a strict linear correspondence between output flow and speed, and a measurement accuracy of ± 0.5%, completely unaffected by upstream feeding fluctuations. By precisely adjusting the pump speed, the adhesive output and extrusion speed can be stably controlled, ensuring that the thickness of each mesh is uniform and consistent. This completely solves the problems of uneven mesh size and uneven mesh thickness in traditional processes, and greatly improves the tensile strength and impact resistance of the foam mesh.

Division of labor reduces workload and lowers the risk of burning

In traditional processes, extruders not only need to complete the plasticization of raw materials, but also undertake the entire pressure building task. Long term high back pressure operation will generate a large amount of additional shear heat, which can easily lead to premature decomposition of foaming agents and local overheating degradation of the melt. After installing a melt pump, the extruder focuses on plasticizing and mixing, and the melt pump independently completes pressurized transportation. The main engine load is directly reduced by 40%, and the unit energy consumption can be reduced by about 25%. At the same time, the residence time of the melt in the barrel is greatly reduced, avoiding problems such as premature release of foaming agent and black spots of melt burning from the root.

Adapt the process to enhance the stability of continuous production

For the commonly used physical foaming process of foam nets, it can provide a stable melt conveying environment for the uniform dispersion of foaming agents such as CO ₂ and nitrogen, ensuring a precise and constant mixing ratio between the foaming agent and the melt throughout the process, and avoiding the loss of control of the foaming ratio caused by fluctuations in the ratio. At the same time, it can establish a stable output pressure of up to 35MPa, completely overcoming all the resistance of the screen changer, pipeline, and mold head, making the entire production line run more smoothly, significantly reducing the frequency of wire breakage and shutdown for material replacement, and reducing the long-term scrap rate by more than 30%.

It is widely compatible with various PE/PP foam net continuous extrusion scenarios such as fruit foam net, EPE pearl cotton net cover, and building safety foam net. It is the core supporting equipment for upgrading foam net production lines to low waste rate and high stability. Generally, the equipment investment cost can be recovered by improving efficiency and reducing costs within six months to one year.

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