CN113878908A - 一种多层橡塑制品一体成型工艺 - Google Patents
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Abstract
本发明公开了一种多层橡塑制品一体成型工艺,S1、制作第一功能橡胶,S2、密炼:将上述步骤S1称量好的物料放入密炼室进行密炼,密炼至145℃‑155℃出料,低温出胶,S3、切胶:将上述步骤S2中①号胶倒入开炼机完全薄通两次降温后投自动摆料架翻胶后切片,冷却待用,S4、开炼:将步骤S3中①号胶片投入开炼机,胶条不切断,S5、制作第二功能橡胶,S6、密炼:将上述步骤S5中称量好的物料依次放入密炼室进行密炼,出料,得②号胶。本发明优化产品弹性、耐臭氧、耐热、耐老化等性能优化;防腐效果、防霉效果1级;防火性能大于等于34%;具有生产速度快、生产的产品规格全、不用进行二次复合节省大量的时间及人力,提高生产效率。
Description
技术领域
本发明涉及动物饲养技术领域,具体涉及一种多层橡塑制品一体成型工艺。
背景技术
随着现代橡塑保温材料应用日益广泛,各领域对橡塑保温材质的多样化应用要求越来越高,现有多层橡塑多为一次成型后进行二次加工贴合而成,其贴合层的密封度、阻燃性、耐腐性、保温效果大大的低于一次成型的橡塑,因此同规格的多层复合而成的橡塑性能劣于一体成型橡塑,在满足日常保温降噪的同时,还需要满足环保和安全方面的要求,在此要求下开发出一种满足上述条件的多层橡塑一体成型保温橡塑,现有的贴合式多层橡胶一般会有如下问题:
1、现有多层橡塑多为一次成型后进行二次加工贴合而成,其贴合层的密封度、阻燃性、耐腐性、保温效果大大的低于一次成型的橡塑;
2、常规技术需二次加工,费时费力;
3、二次加工用到的胶水,大部分环保性能都不过关。鉴于以上缺陷,实有必要设计一种多层橡塑制品一体成型工艺。
发明内容
本发明的目的在于提供一种多层橡塑制品一体成型工艺,以解决上述背景技术中提出的问题。
为实现上述目的,本发明提供如下技术方案:一种多层橡塑制品一体成型工艺,包括以下步骤:
S1、制作第一功能橡胶,配方如下:按质量份数计,EPDM三元乙丙橡胶 5-10份;丁腈N41橡胶15-20份;发泡剂15-18份;消烟剂50-55份;炭黑 3-5份;硬脂酸0.5-1.5份;防老剂0.5-1份;防老剂0.5-1.5份;分散剂2-5份;蒙坦蜡5-8份;石蜡油7-10份;并根据组分以及各组分的重量进行原料准确称量;
S2、密炼:将上述步骤S1称量好的物料放入密炼室进行密炼,密炼至145℃ -155℃出料,低温出胶,得①号胶;
S3、切胶:将上述步骤S2中①号胶倒入开炼机完全薄通两次降温后投自动摆料架翻胶后切片,冷却待用,得①号胶片;
S4、开炼:将步骤S3中①号胶片投入开炼机,压热包辊后依次加入按重量份数称取促进剂:二亚硝基五亚甲基四胺1-1.5份、二丁基二硫代氨基甲酸锌1.5-2份、二乙二硫代氨基甲酸锌0.5-1份;六硫化五亚甲基秋兰姆0.5 份;油膏2-10份;二氧化硅2-5份。搅拌均匀后投胶料到自动翻料擘,胶条不切断直至料下完,得①号胶条;
S5、制作第二功能橡胶,配方如下:按质量份数计,丁腈N41橡胶18-24 份;发泡剂DN-12,18-24份;阻燃剂3-7份;消烟阻燃剂53-57份;色料8-12 份;聚氯乙烯树脂13-17份;硬脂酸1.3-1.7份;分散剂1.3-1.7份;钙锌稳定剂1.3-1.7份;氯化石蜡油28-32份;对上述原料进行种类及重量核对;
S6、密炼:将上述步骤S5中称量好的物料依次放入密炼室进行密炼,出料,得②号胶;
S7、切胶:将上述步骤S6中②号胶倒入开炼机完全薄通两次降温后,投自动摆料架翻胶,冷却后卸料至托盘待用,得②号胶片;
S8、开炼:对辅助原料进行种类及重量核查确认后将步骤S7中②号胶片称重再次投入开炼机进行二次开炼,压热包辊后依次加入按重量份数称取促进剂:油膏5-8份;陶土14-17份;二氧化硅6-8份;二亚硝基五亚甲基四胺0.8-1.2份、二丁基二硫代氨基甲酸锌1-1.5份、二乙二硫代氨基甲酸锌 0.5-0.8份;六硫化五亚甲基秋兰姆0.8-1份;搅拌均匀后投胶料到自动翻料擘,胶条不切断直至料下完,得②号胶条;
S9、挤出:采用两台多螺杆挤出机,多螺杆的啮合区增多,碾压剪切面积成倍增加,进过这种多层挤出,胶料的密度和质量,大大提高。启动挤出机,胶条要均匀喂入喂料口,将步骤S4中①号胶条和步骤S8中②号胶条分别放入两台挤出机喂料口,调整两台挤出机相应挤出比例经复合模头处进行共挤出,复合模头连接着两台橡胶挤出机,挤出的产品复合成型,得成型料;
S10、修整:挤出胶料后再进行牵引、修刀和压延,调整尺寸;
S11、制管:将上述步骤S10中成型料经引料棒送入有多节烘道的烘箱发泡出橡胶管,得橡塑管;
S12、冷却:将上述步骤S11中橡塑管用引料棒将其引入上下三层的风冷轨道,冷却后经传送带至切台;
S13、模切:调整切台的速度,使其与冷却传送带一致,调节计米器,按尺寸要求进行剪切,包装,放至存放区。
优选的,在所述步骤S2中,先投下橡胶及炭黑后密炼3min再依次其它物料,密炼机冷水全通每炉时间炼胶6min以上。
优选的,在所述步骤S3中,翻胶240s后切片,切出的胶片厚度7-8mm,胶片宽度900-1000mm,胶片长度4000-5000mm。
优选的,在所述步骤S4中,开计时器、自动翻料300s开始下料、胶条厚度7-8mm,胶条宽度150mm-200mm。
优选的,在所述步骤S6中,密炼至147℃-150℃进行出料。
优选的,在所述步骤S7中,投自动摆料架翻胶240s后切片,切出的胶片厚度7-8mm,胶片宽度900-1000mm,胶片长度4000-5000mm。
优选的,在所述步骤S8中,开计时器、自动翻料300s开始下料、胶条厚度7-8mm,胶条宽度150mm-200mm。
优选的,在所述步骤S9中,依次调整挤出机上的温度为:机头段30℃ -35℃、挤出段30℃-35℃、塑化段30℃-35℃、螺杆段25℃-30℃,且挤出机转速调整为25-35转/分。
优选的,在所述步骤S11中,多节烘道为六节,各节烘道温度为:一节 120℃-125℃,二节125℃-135℃,三节135℃-145℃,四节145℃-155℃,五节155℃-165℃,六节165℃-175℃。
优选的,在所述步骤S12中,橡塑冷却时长为5-10min。
与现有技术相比,本发明一种多层橡塑制品一体成型工艺,优化产品弹性、耐臭氧、耐热、耐老化等性能优化;防腐效果、防霉效果1级;防火性能大于等于34%;具有生产速度快、生产的产品规格全、不用进行二次复合节省大量的时间及人力,提高生产效率。
具体实施方式
下面对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
本发明提供一种技术方案:一种多层橡塑制品一体成型工艺,包括以下步骤:
S1、制作第一功能橡胶,配方如下:按质量份数计,EPDM三元乙丙橡胶 5-10份;丁腈N41橡胶15-20份;发泡剂15-18份;消烟剂50-55份;炭黑 3-5份;硬脂酸0.5-1.5份;防老剂0.5-1份;防老剂0.5-1.5份;分散剂 2-5份;蒙坦蜡5-8份;石蜡油7-10份;并根据组分以及各组分的重量进行原料准确称量;
S2、密炼:将上述步骤S1称量好的物料放入密炼室进行密炼,先投下橡胶及炭黑后密炼3min再依次其它物料,密炼机冷水全通每炉时间炼胶6min 以上,密炼至145℃-155℃出料,低温出胶,得①号胶;
S3、切胶:将上述步骤S2中①号胶倒入开炼机完全薄通两次降温后投自动摆料架翻胶后切片,翻胶240s后切片,切出的胶片厚度7-8mm,胶片宽度 900-1000mm,胶片长度4000-5000mm冷却待用,得①号胶片;
S4、开炼:将步骤S3中①号胶片投入开炼机,压热包辊后依次加入按重量份数称取促进剂:二亚硝基五亚甲基四胺1-1.5份、二丁基二硫代氨基甲酸锌1.5-2份、二乙二硫代氨基甲酸锌0.5-1份;六硫化五亚甲基秋兰姆0.5 份;油膏2-10份;二氧化硅2-5份。搅拌均匀后投胶料到自动翻料擘,开计时器、自动翻料300s开始下料、胶条厚度7-8mm,胶条宽度150mm-200mm,胶条不切断直至料下完,得①号胶条;
S5、制作第二功能橡胶,配方如下:按质量份数计,丁腈N41橡胶18-24 份;发泡剂DN-12,18-24份;阻燃剂3-7份;消烟阻燃剂53-57份;色料8-12 份;聚氯乙烯树脂13-17份;硬脂酸1.3-1.7份;分散剂1.3-1.7份;钙锌稳定剂1.3-1.7份;氯化石蜡油28-32份;对上述原料进行种类及重量核对;
S6、密炼:将上述步骤S5中称量好的物料依次放入密炼室进行密炼,密炼至147℃-150℃进行出料,得②号胶;
S7、切胶:将上述步骤S6中②号胶倒入开炼机完全薄通两次降温后,投自动摆料架翻胶,投自动摆料架翻胶240s后切片,切出的胶片厚度7-8mm,胶片宽度900-1000mm,胶片长度4000-5000mm,冷却后卸料至托盘待用,得②号胶片;
S8、开炼:对辅助原料进行种类及重量核查确认后将步骤S7中②号胶片称重再次投入开炼机进行二次开炼,压热包辊后依次加入按重量份数称取促进剂:油膏5-8份;陶土14-17份;二氧化硅6-8份;二亚硝基五亚甲基四胺0.8-1.2份、二丁基二硫代氨基甲酸锌1-1.5份、二乙二硫代氨基甲酸锌 0.5-0.8份;六硫化五亚甲基秋兰姆0.8-1份;搅拌均匀后投胶料到自动翻料擘,开计时器、自动翻料300s开始下料、胶条厚度7-8mm,胶条宽度 150mm-200mm,胶条不切断直至料下完,得②号胶条;
S9、挤出:采用两台多螺杆挤出机,多螺杆的啮合区增多,碾压剪切面积成倍增加,进过这种多层挤出,胶料的密度和质量,大大提高。启动挤出机,胶条要均匀喂入喂料口,将步骤S4中①号胶条和步骤S8中②号胶条分别放入两台挤出机喂料口,依次调整挤出机上的温度为:机头段30℃-35℃、挤出段30℃-35℃、塑化段30℃-35℃、螺杆段25℃-30℃,且挤出机转速调整为25-35转/分,调整两台挤出机相应挤出比例经复合模头处进行共挤出,复合模头连接着两台橡胶挤出机,挤出的产品复合成型,得成型料;
S10、修整:挤出胶料后再进行牵引、修刀和压延,调整尺寸;
S11、制管:将上述步骤S10中成型料经引料棒送入有多节烘道的烘箱发泡出橡胶管,多节烘道为六节,各节烘道温度为:一节120℃-125℃,二节 125℃-135℃,三节135℃-145℃,四节145℃-155℃,五节155℃-165℃,六节165℃-175℃,得橡塑管;
S12、冷却:将上述步骤S11中橡塑管用引料棒将其引入上下三层的风冷轨道,冷却时长5-10min后,经传送带至切台;
S13、模切:调整切台的速度,使其与冷却传送带一致,调节计米器,按尺寸要求进行剪切,包装,放至存放区。
综上,本发明一种多层橡塑制品一体成型工艺,使用温度范围为50℃~160℃;EPDM三元乙丙橡胶进一步优化产品弹性、耐臭氧、耐热、耐老化等性能优化;防腐效果、防霉效果1级;防火性能大于等于34%;而且通过多台多螺杆挤出机共挤出,充分保障了产品层次间密闭性的气泡孔和有弹性有光泽的表面;通过对油膏、陶土的掺入,进一步增加产品的抗冻性和稳定性。具有生产速度快、生产的产品规格全、不用进行二次复合节省大量的时间及人力,提高生产效率。
在本发明的描述中,除非另有明确的规定和限定,术语“设置”、“安装”、“相连”、“连接”、“固定”应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或成一体;可以是机械连接,也可以是电连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通或两个元件的相互作用关系。对于本领域的普通技术人员而言,可以具体情况理解上述术语在本发明中的具体含义。
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。
Claims (10)
1.一种多层橡塑制品一体成型工艺,其特征在于:包括以下步骤:
S1、制作第一功能橡胶,配方如下:按质量份数计,EPDM三元乙丙橡胶5-10份;丁腈N41橡胶15-20份;发泡剂15-18份;消烟剂50-55份;炭黑3-5份;硬脂酸0.5-1.5份;防老剂0.5-1份;防老剂0.5-1.5份;分散剂2-5份;蒙坦蜡5-8份;石蜡油7-10份;并根据组分以及各组分的重量进行原料准确称量;
S2、密炼:将上述步骤S1称量好的物料放入密炼室进行密炼,密炼至145℃-155℃出料,低温出胶,得①号胶;
S3、切胶:将上述步骤S2中①号胶倒入开炼机完全薄通两次降温后投自动摆料架翻胶后切片,冷却待用,得①号胶片;
S4、开炼:将步骤S3中①号胶片投入开炼机,压热包辊后依次加入按重量份数称取促进剂:二亚硝基五亚甲基四胺1-1.5份、二丁基二硫代氨基甲酸锌1.5-2份、二乙二硫代氨基甲酸锌0.5-1份;六硫化五亚甲基秋兰姆0.5份;油膏2-10份;二氧化硅2-5份。搅拌均匀后投胶料到自动翻料擘,胶条不切断直至料下完,得①号胶条;
S5、制作第二功能橡胶,配方如下:按质量份数计,丁腈N41橡胶18-24份;发泡剂DN-12,18-24份;阻燃剂3-7份;消烟阻燃剂53-57份;色料8-12份;聚氯乙烯树脂13-17份;硬脂酸1.3-1.7份;分散剂1.3-1.7份;钙锌稳定剂1.3-1.7份;氯化石蜡油28-32份;对上述原料进行种类及重量核对;
S6、密炼:将上述步骤S5中称量好的物料依次放入密炼室进行密炼,出料,得②号胶;
S7、切胶:将上述步骤S6中②号胶倒入开炼机完全薄通两次降温后,投自动摆料架翻胶后切片,冷却后卸料至托盘待用,得②号胶片;
S8、开炼:对辅助原料进行种类及重量核查确认后将步骤S7中②号胶片称重再次投入开炼机进行二次开炼,压热包辊后依次加入按重量份数称取促进剂:油膏5-8份;陶土14-17份;二氧化硅6-8份;二亚硝基五亚甲基四胺0.8-1.2份、二丁基二硫代氨基甲酸锌1-1.5份、二乙二硫代氨基甲酸锌0.5-0.8份;六硫化五亚甲基秋兰姆0.8-1份;搅拌均匀后投胶料到自动翻料擘,胶条不切断直至料下完,得②号胶条;
S9、挤出:采用两台多螺杆挤出机,多螺杆的啮合区增多,碾压剪切面积成倍增加,进过这种多层挤出,胶料的密度和质量,大大提高。启动挤出机,胶条要均匀喂入喂料口,将步骤S4中①号胶条和步骤S8中②号胶条分别放入两台挤出机喂料口,调整两台挤出机相应挤出比例经复合模头处进行共挤出,复合模头连接着两台橡胶挤出机,挤出的产品复合成型,得成型料;
S10、修整:挤出胶料后再进行牵引、修刀和压延,调整尺寸;
S11、制管:将上述步骤S10中成型料经引料棒送入有多节烘道的烘箱发泡出橡胶管,得橡塑管;
S12、冷却:将上述步骤S11中橡塑管用引料棒将其引入上下三层的风冷轨道,冷却后经传送带至切台;
S13、模切:调整切台的速度,使其与冷却传送带一致,调节计米器,按尺寸要求进行剪切,包装,放至存放区。
2.根据权利要求1所述一种多层橡塑制品一体成型工艺,其特征在于:在所述步骤S2中,先投下橡胶及炭黑后密炼3min再依次其它物料,密炼机冷水全通每炉时间炼胶6min以上。
3.根据权利要求2所述一种多层橡塑制品一体成型工艺,其特征在于:在所述步骤S3中,翻胶240s后切片,切出的胶片厚度7-8mm,胶片宽度900-1000mm,胶片长度4000-5000mm。
4.根据权利要求1所述一种多层橡塑制品一体成型工艺,其特征在于:在所述步骤S4中,开计时器、自动翻料300s开始下料、胶条厚度7-8mm,胶条宽度150mm-200mm。
5.根据权利要求1所述一种多层橡塑制品一体成型工艺,其特征在于:在所述步骤S6中,密炼至147℃-150℃进行出料。
6.根据权利要求1所述一种多层橡塑制品一体成型工艺,其特征在于:在所述步骤S7中,投自动摆料架翻胶240s后切片,切出的胶片厚度7-8mm,胶片宽度900-1000mm,胶片长度4000-5000mm。
7.根据权利要求1所述一种多层橡塑制品一体成型工艺,其特征在于:在所述步骤S8中,开计时器、自动翻料300s开始下料、胶条厚度7-8mm,胶条宽度150mm-200mm。
8.根据权利要求1所述一种多层橡塑制品一体成型工艺,其特征在于:在所述步骤S9中,依次调整挤出机上的温度为:机头段30℃-35℃、挤出段30℃-35℃、塑化段30℃-35℃、螺杆段25℃-30℃,且挤出机转速调整为25-35转/分。
9.根据权利要求1所述一种多层橡塑制品一体成型工艺,其特征在于:在所述步骤S11中,多节烘道为六节,各节烘道温度为:一节120℃-125℃,二节125℃-135℃,三节135℃-145℃,四节145℃-155℃,五节155℃-165℃,六节165℃-175℃。
10.根据权利要求1所述一种多层橡塑制品一体成型工艺,其特征在于:在所述步骤S12中,橡塑冷却时长为5-10min。
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