Shanghai Daoqin Plastics Co., Ltd.

11.1 生胶 塑炼 principle 一．塑炼 定义 through machine force, hot, oxygen or add certain chemical agent and other methods, make 橡胶由 strong/high tough high elastic property 状态转变 is soft/flexible property process. property （ can property ）: in deformation rear, can its 原 状态, or maintain its deformation property 质. 二．塑炼 目 and requirements 1．塑炼 目 decrease small elastic property, improve/increase can property; reduce viscosity; improvement flow property; improve/increase material solvent understanding property and molding viscous property. 2．塑炼胶 quality requirements （1） can degree need 适当应 meet/satisfy processing process requirements, in 此基础 upper tool has most small can property. degree 塑炼会 reduce 硫化胶 strong/high degree, elastic property, wear resistance and other, but also increase force consumption. 塑炼程 degree: according to mixing/compounding process property can and products property can requirements 确定. 如: 供胶, 浸胶, 刮胶, scratch and manufacturing sponge and other applications material, requirements can degree relatively large, 生胶 塑炼程 degree need high. pressure use material, requirements can property small. generally: tube/pipe outer can degree: 0.3~0.35; tube/pipe inner 层胶: 0.25~0.3; 胎面胶: 0.22~0.24; 胎侧胶 0.35 left right; sponge 胶 0.5~0.6（2）塑炼 uniform 三．生胶 increase methods and principle （一） increase methods （二）塑炼 principle molecular weight and can property has 密切 关系. molecular weight small, can property large. 生胶经 machine 械塑炼 rear, molecular weight reduce, viscosity decline, can property increase large. can 见, in process in, can property improve/increase is through molecular weight reduce achieve. 0— polymer melt most large viscosity; A— features 常数; MW— polymer heavy molecular weight 1． machine 械塑炼 process mechanism in low temperature lower: in machine force function lower 首先切断橡胶 large separation 子链生 formed large separation 子自由基. （ machine force 引发橡胶 large separation 子 断链, oxygen as is 自由基接受体, retardant 断自由基 function. ） in high temperature lower: machine force 切断橡胶 large separation formed 自由基 几 rate decrease/reduce. large separation in machine force active function lower, oxygen 引发橡胶 large separation 子 断链. （ machine force to force active function, oxygen as is 自由基引发体, 引发橡胶 large separation 子 断链. ）链终止: hydrogen oxidation material unstable, separation understanding formed relatively small large separation 子, reaction 终止. 2． effect/influence factors: （1） machine force function according to analysis, machine force for separation 子 断链 function, can table/sheet is: in ρ— separation 子链断链 几 rate; K1, K2—常数; E— separation chemical can; F0— as used for separation upper force; δ— separation 子链断链时伸 long long degree; F0 δ— separation 子链断链时消 consumption machine 械功; low temperature requirements can can reduce temperature and temperature. （2） oxygen function 实验证明, 生胶结 combined 0.03% oxygen can make molecular weight decrease/reduce 50%; combined 0.5% oxygen, molecular weight 由10万 drop to 5000. 生胶塑炼时, 随 塑炼 time long, quality and ketone material （ its in has oxidation combined material ） content increase, can oxygen in process in and separation certain types add formed function, and chemical reaction. （3） temperature degree function in di heavy effect/influence: low temperature 区（110℃）, temperature degree rise high, 塑炼效果 improve/increase. —— oxygen oxidation function （4）静 electrical function process in, material to strong/high 烈 摩 scratch function generate electrical. electrical generate electrical phenomenon, make gas in oxygen active is 原子态 oxygen and oxygen, accelerated separation oxidation function. （5） chemical understanding agent a．接受 type understanding agent （ low temperature understanding agent ）: 苯硫酚, chlorine and other. b．引发 type understanding agent （ high temperature understanding agent ）: oxidation 苯甲酰（BPO）, nitrogen 二异丁腈（AIBN） and other. c． mixed combined type understanding agent （链转移 type understanding agent ）: promote agent M, DM and 2, 2’-二苯甲酰 amine 二苯基二硫化 material and other. §11.2 can property methods and mixing/compounding can degree usually has types methods: pressure shrink method, 旋转扭 force method and pressure method. it 们均需 in temperature lower 进行, is can degree temperature degree 变化而变化. 一． pressure shrink method this type of type type methods commonly used has: 威廉氏 method, 华莱氏 fast speed can degree method and can degree method types. 1．威廉氏 method （Williams） in temperature, negative lower, 经 一定 time rear according to Sample high degree 变化 评定 can degree. will Φ=16mm, h0=10mm Sample in T=70±1℃ or 100±1℃ lower preheating 3min, pressure shrink 3min, remove negative 荷取出 Sample in room temperature lower 恢复3min, amount Sample high degree pressure shrink deformation amount and negative rear deformation amount, can degree P. h0 — Sample high degree, mm; h1— Sample pressure shrink 3min rear high degree, mm; h2—恢复3min rear high degree, mm if Sample is for 流体, 即h1=h2=0, P=1; Sample is for elastomer, 即h2=h0, P=0; and mixing/compounding is viscous elastic 体, it can degree in 0~1 between, value large table/sheet can property large. 2．华莱氏（Wallace） fast speed can degree method its principle and Williams method same, temperature, negative 荷, time lower sheet/slice thick degree table/sheet can degree. method as 方便, more used for industrial production in as fast speed 检验. 3．德弗 method in temperature and time inner Sample pressure shrink 至规定 high degree 时 需 negative value table/sheet 示. 二．旋转扭 force method —门尼（Mooney） viscosity method principle is: in temperature degree, time and pressure lower, according to Sample in active 动面（转子） and solid 定面（ mold cavity ） between deformation 时 受扭 force 确定胶 material can degree. experiment/testing 时, will Sample requirements mold cavity 里, in 100℃ lower preheating 1min, make in 2r/min speed degree 转动4min, 测 扭 force value is viscosity, generally use table/sheet 示, L table/sheet use large 转子（直径 is 38.1±0.03mm）. viscosity method ratio pressure shrink method speed 简便, table/sheet 示 动态 flow property more 接近于 process 实际情况. 三． pressure method use fine tube/pipe 流变仪 测定. in temperature degree, pressure, type lower, 于一定 time inner use fine tube/pipe 流变仪测定胶 material pressure speed degree, separation pressure milli table/sheet can degree. advantages: method and pressure machine type as versus 似, can more specific understanding mixing/compounding can property for pressure property can effect/influence. disadvantages: pressure method Sample need relatively more material, Sample must relatively long time preheating. §11.3 塑炼 methods and effect/influence factors 一．准备 process 1．烘胶NR烘胶 temperature degree generally in 50~60℃, time is 24~36h, add hot time is 36~72h. CR烘胶 temperature degree generally in 24~40℃, time is 4~6h. temperature degree high, 否则会 effect/influence material mechanical properties. 2．切胶 use machine will 生胶切 formed small block, block weight types 而异, NR每 block 10~20kg, CR每 block ultra- 10kg. 3．破胶橡胶 block use machine 破胶, 以便塑炼. 破胶辊距 generally is 2~3mm, temperature control in 45℃ below/following. 二．开炼 machine process （一）开炼 machine principle machine 两 辊筒以 different speed versus for 回转, material to 两辊筒间 upper 方, in scratch force function lower by belt/tape 入辊距 in. due to surface 旋转线 speed degree different, make material through 辊距时 speed degree different to scratch function and pressure function, material through 辊距而 by 塑炼. （二）开炼 machine process methods 1．包辊塑炼 method sheet/slice in front upper, let its 自然 反复 辊塑炼, 直至达 to can degree requirements is 止. disadvantages: time long, efficiency low, most obtain can degree relatively low. also separation is: 一段塑炼: time long, efficiency low, suitable for can degree requirements relatively high 生胶塑炼. separation 段塑炼: 包辊塑炼10~15min, lower sheet/slice, cooling, 停放4~8h rear, again lower one-time 塑炼, 直至达 to requirements can degree is 止. usually separation is 两段塑炼 and 三段塑炼, specific can degree requirements 而定. 2． thin 通塑炼 method in 1 mm below/following, material through rear 不包辊而直接落 to 接胶盘, let material to upper heavy new through 辊距, this 样反复数次. advantages: material dispersion hot fast, cooling relatively good, 塑炼胶 can degree uniform, quality high, can to 任意 塑炼程 degree. 3． chemical increase 塑塑炼 method using/adopting chemical understanding agent increase 塑炼效果, improve/increase production efficiency 并节约 can consumption. chemical understanding agent 应以母胶 形式 use, 并应适当 improve/increase machine temperature. （三）开炼 machine effect/influence factors 1．装胶容 amount 装胶容 amount 取决于开炼 machine specifications, amount large, dispersion hot difficult, temperature rise high, reduce 塑炼效果; amount small reduce production efficiency. combined 理 容 amount according to experience 公式计算: Q—塑炼容 amount, L; K— experience 系数, value generally is 0.0065~0.0085, L/cm3; D—辊筒直径, cm; L—辊筒工 as separation long degree, cm combined formed 橡胶塑炼时生 hot large, 装胶容 amount ratio NR less. 2．辊距辊距越 small, machine 械塑炼效果越 obvious. thin 通时实际 use generally is 0.5~1mm. 3．辊 speed and speed ratio 辊距一定, improve/increase machine speed or speed ratio increase large material machine 械剪切 function, from improve/increase machine 械塑炼效果. machine speed ratio generally in 1.15~1.27 between. speed ratio large, rise temperature add fast. 4．辊 temperature temperature low, 塑炼效果 good. temperature low easy formed equipment ultra- negative 荷而受 to loss 害. temperature degree and 生胶胶 types has 关, NR usually control front temperature degree in 45~55℃, rear temperature degree in 40~50℃ is 宜. 5．塑炼 time in process most 初10~15min, material viscosity speed reduce, rear 渐趋缓 slow. 6． chemical understanding agent use understanding agent can improve/increase 塑炼效果, shrink short time, decrease small elastic property 复原. use chemical understanding agent 时, improve/increase temperature degree improve/increase 塑炼效果, temperature degree generally 以70~75℃ is 宜. understanding agent use amount, in NR in generally is weight 0.1~0.3%, combined formed 橡胶则应 increase large to 2~3%. 三．密炼 machine process advantages: 自动化程 degree high, production efficiency high, energy saving, strong/high degree low; disadvantages: temperature degree high, cooling difficult, easy 炼, material is 无定形状, need versus pressure sheet/slice machine. （一）密炼 machine as principle material material from add material add 入密炼室 rear, add material 门关闭, pressure material plant/unit upper drop 落, for material material add pressure. material material in upper pressure and scratch force function lower, by belt/tape tool has 螺旋棱, has speed ratio, versus for 回转 两转子 间隙 in, make material material in 由转子 and 转子, and 密炼室壁, upper 顶栓, lower 顶栓组 formed system inner, to 不断变化 and 反复进行 剪切, 撕拉, and scratch strong/high 烈捏炼 function, from to 塑炼 目. material material in 密炼室 in main/primary to types function: 1．转子间 and and mixing/compounding inner function; 2．转子棱间 搅拌 function; 3．转子轴 toward 往复切割 function. （二）密炼 machine process methods machine process methods has one-time method, separation 段塑炼 method and chemical increase 塑塑炼 method types. （三） effect/influence machine factors 1． temperature degree machine high temperature 塑炼, in machine inner high temperature and machine 械剪切 function, high temperature oxidation is 主, can in short time inner obtain need can degree, generally machine temperature degree is 120℃ above, has can to 160℃, temperature degree high 会导致橡胶 material mechanical properties decline. generally NR塑炼时 temperature degree ultra- 155℃ is 宜. using/adopting machine combined formed 橡胶, generate 凝胶. temperature degree scope/range need types specific features 而定. for/regarding SBR, temperature degree control in 155℃ below/following, generate 凝胶. use understanding agent 时, temperature degree can control in 160℃. 2．转 speed speed fast, efficiency high. speed from 25转 improve/increase to 75转, time from 30min shrink short to 10min. speed improve/increase 必然会 accelerated material hot rise temperature, therefore must add strong/high cooling. 3． time use machine 塑炼, material can degree 随塑炼 time increase increase. use understanding agent 进行塑炼时, 塑炼效果会 improve/increase, time can shrink short 30%~50%. 4． upper pressure upper 顶栓必 must add pressure, increase for material function. pressure small, can pressure material, pressure large, also formed equipment negative large. upper pressure generally is 0.5~0.8MPa. 5．装胶容 amount various specifications machine 装胶容 amount is 密炼室容积 48%~62%. 6． chemical understanding agent machine temperature degree high, using/adopting chemical understanding agent increase method combined has 效, not only can separation 发挥塑 understanding agent increase 塑效果, but also in conditions lower reduce temperature degree, improve/increase 塑炼胶 quality. 四． screw machine process (一) screw machine as principle in screw machine in, 生胶一方面受 to screw strong/high machine 械搅拌 function, 另一方面, due to 生胶受 screw and machine inner 壁 摩 scratch generate a large amount of hot, temperature degree high 达150~180℃, from accelerated oxidation understanding, obtain 塑炼效果. advantages: can production, production can force large, suitable for large type 轮胎 injection molding processing processing. disadvantages: temperature degree high, 塑炼胶 hot can property large, quality 不均, 排胶不规则. （二） effect/influence screw machine factors 1．塑炼 temperature degree temperature degree low, equipment negative large, 塑炼胶 can degree low, non-uniform temperature degree high, easy make large separation degree oxidation degradation loss material quality. therefore, temperature degree must control in scope/range inner. NR塑炼 temperature degree generally control in machine 尾60℃ below/following, machine 身80~90℃, machine 头90~100℃, temperature degree 180℃ below/following. 2．喂 material speed degree material speed degree need 适当而 uniform. speed degree fast, material in machine inner time short, non-uniform, 出现夹生 phenomenon. speed degree slow, not only reduce production efficiency. 3．排胶孔隙 large small 排胶孔隙 large small material 塑炼程 degree requirements 而定. small, speed degree and amount decrease small, material can degree large, production efficiency reduce. 反之, 出胶孔隙 add large, amount large, production can force improve/increase, 但塑炼胶 can degree low non-uniform. 五．塑炼 rear processing 1． pressure sheet/slice or pelletizing 2． cooling and drying 3．停放 drying rear sheet/slice 按规定堆放4~8h above can lower 道工序 use. 4． quality 检验§11.4 commonly used 橡胶 塑炼 features 一．橡胶塑炼 difficult easy causes 1．NR塑炼容 easy causes: （1） large separation in in and di 键 共轭效应, can reduce, easy fracture; （2） molecular weight large, easy 断链; （3） large separation 子断链 rear formed 自由基 stability property high; （4） large separation oxidation formed hydrogen oxidation material separation understanding large separation fracture bad. 二．几 types commonly used 橡胶 塑炼 features 1．NRNR comparison easy 进行塑炼, product types different features different. sheet/slice 胶初始门尼 viscosity relatively high （ generally in 95~120 between ）, must 进行塑炼 processing can obtain can property. SMR series NR its 初始门尼 viscosity relatively low （ generally in 40~75 between ）, generally need 塑炼. NR use machine 塑炼, usually using/adopting low temperature （40~50℃）, thin 通塑炼效果 good. use machine 塑炼时, temperature degree in 155℃ below/following. NR塑炼时, add chemical understanding agent improve/increase 塑炼效果. 2．SBR soft SBR 初始门尼 viscosity generally in 54~64 between, 不需进行塑炼. SBR using/adopting machine 械塑炼效果不 large, comparison has methods using/adopting high temperature method, 以130~140℃ temperature degree most good, temperature degree high easy formed 凝胶. 3．BRBR generally need 进行塑炼. 4．CRCR 初始门尼 viscosity relatively low, generally need 进行塑炼. in process in its can property decline, therefore CR still 需经 塑炼 processing, can obtain requirements can property. CR宜 using/adopting machine 进行塑炼, low temperature thin 通塑炼效果 most good. 5．IIR门尼 viscosity in 38~75 between product types generally need 塑炼. IIR using/adopting machine 械塑炼效果不 large, use machine in 120℃ above, and add understanding agent high temperature 塑炼则 can relatively good 塑炼效果. 6．NBRNBR 塑炼应 using/adopting machine in low temperature （40℃ below/following ）, small 辊距（1mm left right ）, low amount （约 is NR容 amount 1/2~1/3）. generally use machine 进行塑炼, NBR very easy formed 凝胶.