CN101352662B - 用于连续混合的混合捏合机及其使用方法 - Google Patents
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Abstract
一种用于连续混合的混合捏合机(1)及其使用方法。该混合捏合机(1)包括在壳体(2)内旋转且同时轴向平移的螺杆轴(3)。为了有效地提高用单位时间内的物料吞吐量定义的机器效率,提出了一种具有下述几何尺寸比值的螺杆轴:Da/Di=1.5至2.0,也就是说,螺杆轴外径Da与螺杆轴内径Di的比值在1.5至2.0之间;Da/H=4至6,也就是说,螺杆轴外径Da与行程H的比值在4至6之间;T/H=1.3至2.5,也就是说,螺距T与行程H的比值在1.3至2.5之间。装有这种螺杆轴(3)的混合捏合机(1)优选地可以在超过500rpm,特别地可以在超过800rpm的转速下运行。
Description
技术领域
本发明涉及一种用于连续混合的混合捏合机,包括:在壳体内旋转并同时轴向平移的螺杆轴。本发明还涉及一种使用所述的混合捏合机来实现连续混合的方法。
背景技术
目前涉及的混合捏合机被特别应用于大批量可流动的塑料和/或糊状物料。例如:他们用于处理粘性塑料物料,匀化和塑化塑料,混合填料和增强添加剂以及用于食品,化学/制药工业的通常也包括了统一进行的连续排气,混合和膨胀过程的原料生产。但不包括用于生产铝的碳电极物质的处理以及氢氟酸的处理。在某些情况下,混合捏合机也可以被用作反应器。
混合捏合机的工作部件通常被设置为轴向推进待加工材料的所谓螺杆。
在传统的混合捏合机中,工作部件只产生旋转动作。另外,混合捏合机内的工作部件在旋转的同时伴有平移移动也是公知的。工作部件运动轮廓的特定特征是主轴在旋转过程中执行的正弦运动。该运动轮廓允许套装合适的部件例如搅动销或搅动齿。为此,螺杆上被加工出螺纹以安装离散的捏合机叶片。位于主轴上的螺杆螺纹-捏合机叶片和套装的合适零件之间互相作用,并因此在各个不同的加工区域内建立起所需要的剪切/混合和捏合功能。上述类型的这种商标名为Buss 的混合捏合机对于本领域普通技术人员来说是公知的。
公知的上述类型的混合捏合机内的螺杆轴直径最大为700mm,在各种情况下,都是主要由该螺杆轴直径来决定物料吞吐量。通常情况下,螺杆轴外径(Da)和螺杆轴内径(Di)之比大约为1.5,同时螺杆轴外径(Da)和行程(平移部分)(H)之比大约为6.7,且螺距(螺杆叶片的轴向间距)(T)和行程(H)之比在2左右。根据其体积不同,混合 捏合机可以在5至500rpm的速度下运行。
混合捏合机通常根据几何相似性的原则设计。只要比值Da/Di,Da/H和T/H是常数,无论其大小,该原则总是有效的。
决定经过加工后的产品被分散,混合和匀化的优劣的因素有融化温度,产品在机器加工区域内的驻留时间,剪切率和螺杆通道/加工区域内的剪切循环次数。
在很多加工应用中,依次加工区域例如进料,融化,混合,分散和出料区域之间在传输,剪切率水平和填料方面越谐调,产品就被混合,分散和匀化得越好。在混合捏合机技术领域的当前状态下,用于标准混合的常用指标是融化范围内的平均剪速率在15 1/s至150 1/s之间和整个螺杆延伸长度上的平均产品驻留时间在30s至600s之间。
在传统的混合捏合机中,平均剪切率最大地被螺杆的转动速度和比值Da/Di所限定。但是,增加剪切率也会导致更大量的特定能量输入从而会导致无法接受的高融化温度。与混合捏合机内产品的平均驻留时间太长一样,过高的剪切率也可以导致产品的退化(热降解或交联)从而降低质量。
发明内容
本发明是基于所述的改进混合捏合机的目标,以使得用单位时间内的物料吞吐量定义的效率能够被提高并且经过加工后的产品的质量没有明显降低。
该目标通过一种混合捏合机而被实现,即一种用于连续混合的混合捏合机,包括在壳体内旋转且同时轴向平移的螺杆轴,螺杆轴具有多个螺旋设置的螺杆叶片,混合捏合机设有固定至壳体且伸入加工空间内的搅动销;其特征在于:选择混合捏合机的几何尺寸,使得螺杆轴外径Da与螺杆轴内径Di的比值Da/Di在1.5至2.0之间,螺杆轴外径Da与行程H的比值Da/H在4至6之间,以及螺距T和行程H的比值T/H在1.3至2.5之间,由此可以达到优化与最大产量相关的捏合机效率的基本要求,其中螺杆轴能够在超过500rpm的转速下运行。根据该确定的几何尺寸设计的混合捏合机特别适用于在超过500rpm的转动速度下工作,基本上可以理解为速度越高产量越大。
该确定的几何尺寸另外还确保了延轴向依次设置的加工区域,特别是进料区域,融化区域,混合区域以及出料区域现在能够被优化,每个 区域都适合于其他区域的操作容量、剪切率水平填料以允许获得提高了质量同时缩短了产品峰值温度的有效持续时间的平均剪切率范围。
通过根据本发明选择几何尺寸,混合捏合机能够直接在高螺旋速度下运转以提高单位时间内的产量并且不会造成无法接受的过高特定能量的输入。
本发明的另一个目标涉及提出一种利用所述的混合捏合机实现连续混合的方法,通过该方法能够提高单位时间内的物料吞吐量。
为了实现该目标,所述的螺杆轴以超过500rpm,特别地以超过800rpm的转速运行的方法。
提高螺杆轴的转速又使得大大缩短产品驻留时间成为可能。
由螺杆的高转速和高产量造成的1至20秒的短产品驻留时间同时减少了产品热降解或交联的倾向。
根据本发明设计的混合捏合机,扩大了这种机器的应用范围。
附图说明
现在将参照附图对本发明进行详细说明,在附图中:
图1是概略地示出了通过混合捏合机的纵向部分;
图2是示出了根据本发明的螺杆轴的一部分的几何尺寸的透视图;
图3是相对于传统的螺杆叶片示出了搅动销的动作的示意图;
图4是将吞吐量图示为混合捏合机内的平均驻留时间的函数的曲线图。
具体实施方式
现参照图1,概略地示出了穿过混合捏合机1的纵向部分。混合捏合机1包括:被壳体2包围的工作部件,工作部件被设计为具有多个螺旋设置的螺杆叶片4的螺杆轴3的形式。这样的混合捏合机1也被称为单螺杆挤出机,因为该机器只有一个螺杆轴。螺杆轴3的螺杆叶片4被沿圆周间隔设置以形成设置在壳体2上用于搅动销5的轴向孔,使得螺杆轴3能够在其目前的旋转动作之外还进行轴向动作也就是平移动作。 成型在壳体2的内侧和螺杆轴3之间的是通常依次包括了多个加工区域8-11的实际加工空间6。在本实施例的混合捏合机1中,表现为例如进料区域8,融化区域9,混合/分散区域10以及出料区域11。混合捏合机1在其进料端设有送料斗12同时在其出料端设有出料开口13,通过出料开口13混合后的物料能沿箭头14的方向送出。这种混合捏合机的基本结构通过例如瑞士专利CH 278,575而被公知。尽管在本实施例中如图所示的搅动销5仅在混合/分散区域10中被示出,但是在需要时,搅动销5当然也可以被设置在其他区域内。
现参照图2,示出了根据本发明的螺杆轴的一部分的几何尺寸的透视图。应该注意在此情况下如图所示的螺杆轴模块3a的轴几何尺寸并不是真实比例的。螺杆轴3被确定为以所谓的单螺杆挤出机的形式用在混合捏合机1中,其中螺杆轴3被设置为能够同时进行旋转和平移动作的工作部件,正如前文中提及的商标为Buss 的混合捏合机的情况。螺杆轴模块3a共设有8组螺杆叶片,其中的6组4a-4f是可见的。在两组螺杆叶片4a,4b之间依次沿圆周设有保持开放的通孔16,设置在壳体上的搅动销(未示出)能够伸入通孔16中。螺杆轴3的内径被标记为Di同时螺杆轴3的外径被标记为Da。内径Di被螺杆轴3的圆柱形壳体外表面7确定同时外径Da被径向相对,轴向交错排列的螺杆叶片4a,4b的最高或最外部分之间的径向间隔确定。螺距,也就是轴向依次排列的两组螺杆叶片4b,4e之间的平均距离被标记为T,如果需要的话,确定螺距T的螺杆叶片也可以是径向交错排列的。行程,也就是螺杆轴3轴向跨越的距离被标记为H。
在本实施例中,螺杆叶片4a-4f的主表面被设计为自由形成的表面。优选地,搅动销(未示出)的主表面同样也被设计为自由形成的表面。自由形成的表面是一种其三维几何形状不具有任何自然起点的表面。这样,因为螺杆叶片4a-4f的主表面和/或搅动销的主表面被设置为至少部分是自由形成的表面,所以就打开了全新的用于影响螺杆轴静态和动态几何特性的可能性,例如,关于螺杆叶片和相关搅动销之间保留的间隙。特别是在考虑伴随着旋转动作的螺杆轴轴向动作的同时,该间隙的尺寸和朝向实际上能够被改变至任意程度。这最终使得优化机械能量输入和/或优化在加工空间内形成的剪切和拉伸流动区域中并作用于被加工产品的变化成为可能。
根据本发明设计的螺杆轴3的相关比值如下所示:
-Da/Di=1.5至2.0,也就是说,螺杆轴外径Da与螺杆轴内径Di的比值在1.5至2.0之间;
-Da/H=4至6,也就是说,螺杆轴外径Da与行程H的比值在4至6之间;
-T/H=1.3至2.5,也就是说,螺距T与行程H的比值在1.3至2.5之间。
根据本发明设计的螺杆轴的测试在Buss Ko捏合机(旋转并同时平移的单螺杆挤出机)上进行,使机器的结构(加工区域的设置)与以前在100至500rpm的正常转速下用于塑料混合的各种情况相同。
测试结果惊奇地发现,当螺杆转速远远超过500rpm时,物料温度,也就是,机器加工区域中在传输,剪切率水平和填料方面被谐调了的被加工产品的温度仍然没有明显升高。
因此,在实际操作中,这样的螺杆轴优选地在超过500rpm的转速下运行,转速能够高达800rpm甚至高达2000rpm而仍然不会损伤被混合的产品。
优选地,螺杆叶片4a-4f的行程适合于加工空间6(图1)的长度,使得当螺杆轴3在超过500rpm的转速下运行时,产品在机器内的驻留时间最大不超过20秒。
现参照图3,示出了螺杆轴在平移动作中简化了的运动次序,示出了壳体内侧和整个工作空间长度内的各外壳表面,只标记了螺杆叶片4a,4b,4c。为了简化,搅动销5被示为圆形部件。从图中可以明显看出,各个螺杆叶片4a,4b,4c相对于各自的边缘搅动销5的动作。为了更便于观察,动作次序在运动上相反地示出,也就是说,螺杆叶片4a,4b,4c被假设为静止的同时搅动销5沿由螺杆轴的旋转动作和伴随的平移动作形成的正弦路径运动。从图中可以明显看出,在螺杆叶片4c的两个主表面和经过的搅动销5之间留有缝隙形式的自由空间S,其宽度和朝向由螺杆叶片4c的几何形状,相关的搅动销5和旋转工作部件的轴向位移确定。同样标记了分别对应于两个轴向并列的搅动销5之间距离和螺杆叶片4c,4f之间距离的螺距T。还标记了螺杆轴的行程H。
现参照图4,示出了吞吐量G(kg/h)是被加工产品在混合捏合机内驻留停留时间t(秒)的函数。从图中可以明显看出,随着吞吐量的 增加,产品处于高温下的持续时间如何得以明显减少。
进行的测试显示,即使根据过去的经验高温必然会导致质量的下降,但是现在只要高温影响的时间足够短,对于质量来说就是安全的。但是,只有提高吞吐量,才可能实现足够短的驻留时间。
在这些需要考虑的事项中,混合产品的吞吐量和质量取决于所使用的螺杆的几何形状,转速和机器各加工区域的传输特性。
任何混合的目的都是获得均匀的终端产品,通常混合有添加剂。这就是为什么添加剂和任何不均匀物料都需要在机器内被打散和分布混合的原因。为了分解颗粒,剪应力需要在物料通过周围基质被转化为颗粒的过程中被改变。
剪应力τ由以下公式得出:
很多过程由以下因素控制:
稳定的剪切率水平导致了混合,分散和匀化的优劣程度达到最优。在混合捏合机技术领域的当前状态下,用于标准混合的常用指标是融化范围内的平均剪速率在20l/s至150l/s之间且整个螺杆延伸长度上的平均产品驻留时间在30s至600s之间。
从公式(2)可以明显看出,传统混合捏合机中的平均剪切率被螺杆转速和Da/s最大程度地限定。
但是,因为:
所以增加剪切率也会导致更大量的特定能量输入,从而会导致无法接受的高融化温度,因为融化温度的增加量由下式给出:
其中Cp=比热。换句话说,与混合捏合机内产品的平均驻留时间太长一样,过高的剪切率也可以导致产品的退化(热降解或交联)从而降低质量。
因为平均剪切率提高了目前所能达到的产品质量同时由于如上所述调整了比值Da/Di,Da/H和T/H而缩短了产品的峰值温度持续时间,因此根据本发明的混合捏合机可以在500至2000rpm的进行旋转和平移动作的螺杆轴转速下运行。
公式中使用的符号:
espec:平均特定能量输入[KWh/kg]
t:挤出机中的产品平均驻留时间[s]
ρ:融体密度[kg/m^3]
γ:平均剪切率[l/sec]
η:平均动态粘度[Pa*sec]
Da:螺杆轴外径[mm]
Di:螺杆轴内径[mm]
S:螺杆叶片和搅动销/齿之间的平均剪切缝隙
ns:螺杆转速[rpm]或者[l/s]
vu:螺杆轴的圆周速度[m/s]
τ:剪应力[N/mm^2]
cp:比热[kJ/kg*K]
G:吞吐量[kg/h]
ΔT:物料温度增加值[K]
Claims (12)
1.一种用于连续混合的混合捏合机(1),包括在壳体(2)内旋转且同时轴向平移的螺杆轴(3),螺杆轴具有多个螺旋设置的螺杆叶片(4),混合捏合机(1)设有固定至壳体(2)且伸入成型在壳体(2)的内侧和螺杆轴(3)之间的加工空间(6)内的搅动销(5),其特征在于:螺杆轴外径与螺杆轴内径的比值Da/Di在1.5至2.0之间,螺杆轴外径Da与行程H的比值Da/H在4至6之间且螺距T和行程H的比值T/H在1.3至2.5之间,其中螺杆轴(3)能够在超过500rpm的转速下运行。
2.如权利要求1所述的混合捏合机(1),其特征在于:螺杆轴(3)能够在超过800rpm的转速下运行。
3.如权利要求1所述的混合捏合机(1),其特征在于:所述混合捏合机(1)包括沿传输方向依次排列的构成加工空间(6)的多个区域。
4.如权利要求3所述的混合捏合机(1),其特征在于:所述加工空间(6)由至少一个进料区域(8),一个融化区域(9),一个混合/分散区域(10)以及一个出料区域(11)构成。
5.如权利要求3或4所述的混合捏合机(1),其特征在于:螺杆轴(3)的转速适合于所述加工空间(6)的长度,使得机器内的产品驻留时间保持在1至20秒之间。
6.如权利要求3或4所述的混合捏合机(1),其特征在于:螺杆叶片(4)的螺距适合于所述加工空间(6)的长度,使得螺杆轴(3)转速超过500rpm时,机器内的产品驻留时间最大不超过20秒。
7.如权利要求1-4中任意一项所述的混合捏合机(1),其特征在于:螺杆叶片(4)和/或搅动销(5)的主表面被至少部分设置为自由形成的表面。
8.如权利要求7所述的混合捏合机(1),其特征在于:螺杆叶片(4)和/或搅动销(5)的主表面的三维几何形状被至少部分设置为使其不具有任何自然起点。
9.一种使用权利要求1所述的混合捏合机(1)实现连续混合的方法,其特征在于:螺杆轴能够在超过500rpm的转速下运行。
10.如权利要求9所述的方法,其特征在于:螺杆轴的转速被调节为使得机器(1)内的平均产品驻留时间在1至20秒之间。
11.如权利要求9或10所述的方法,其特征在于:用于制备大批量可流动的塑料和/或糊状物料。
12.如权利要求9所述的方法,其特征在于:杆轴能够在超过800rpm的转速下运行。
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Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
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CN1367730A (zh) * | 1998-05-26 | 2002-09-04 | 詹姆斯·D·福格蒂 | 增强均质化的热塑泡沫材料挤压螺杆 |
CN1449328A (zh) * | 2000-09-28 | 2003-10-15 | 贝斯托夫有限公司 | 高粘度介质的螺旋挤压机-齿轮泵装置 |
JP2006315388A (ja) * | 2005-04-14 | 2006-11-24 | Sekisui Chem Co Ltd | 塩化ビニル系樹脂発泡体の製造方法 |
Also Published As
Publication number | Publication date |
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TW200904615A (en) | 2009-02-01 |
CN101352662A (zh) | 2009-01-28 |
SG149747A1 (en) | 2009-02-27 |
US20090027994A1 (en) | 2009-01-29 |
PT2018946T (pt) | 2017-03-15 |
RU2008130775A (ru) | 2010-01-27 |
SI2018946T1 (sl) | 2017-06-30 |
KR101446809B1 (ko) | 2014-10-02 |
JP4997193B2 (ja) | 2012-08-08 |
CA2632423C (en) | 2012-05-22 |
BRPI0801735B1 (pt) | 2018-02-14 |
CA2632423A1 (en) | 2009-01-25 |
HUE031969T2 (en) | 2017-08-28 |
EP2018946B1 (de) | 2017-01-11 |
EP2018946A3 (de) | 2015-09-23 |
BRPI0801735A2 (pt) | 2009-03-10 |
RS55766B1 (sr) | 2017-07-31 |
KR20090012047A (ko) | 2009-02-02 |
EP2018946A2 (de) | 2009-01-28 |
HRP20170341T1 (hr) | 2017-05-05 |
TWI443005B (zh) | 2014-07-01 |
SG169349A1 (en) | 2011-03-30 |
PL2018946T3 (pl) | 2017-07-31 |
HK1125593A1 (en) | 2009-08-14 |
DK2018946T3 (da) | 2017-03-13 |
RU2391203C2 (ru) | 2010-06-10 |
MY149812A (en) | 2013-10-14 |
JP2009029131A (ja) | 2009-02-12 |
US7909500B2 (en) | 2011-03-22 |
UA94076C2 (ru) | 2011-04-11 |
MX2008008232A (es) | 2009-03-04 |
ES2617952T3 (es) | 2017-06-20 |
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