CN101747515A - 高粘度有机硅组合物的连续制备方法 - Google Patents
高粘度有机硅组合物的连续制备方法 Download PDFInfo
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Abstract
本发明涉及一种制备有机聚硅氧烷组合物(A)的连续方法,所述组合物的粘度在25℃下测量为至少500Pa.s.,其中在第一阶段,将有机聚硅氧烷(O)和填料(F)在具有至少两个捏合室的阶式捏合中混合和捏合,得到未加工混合物,所述捏合室彼此串联排列并各自含有两个捏合工具,所述捏合工具具有平行轴并且能同向或反向转动,所述捏合室通过开口彼此连接,物料可沿捏合工具的轴的横向通过所述开口,其中第一捏合室具有进料口,而最后一个捏合室具有卸料口;在第二阶段,所述未加工混合物在100-250℃下,在具有卸料螺杆的连续操作双槽捏合机中捏合并脱气。
Description
技术领域
本发明涉及一种在具有至少两个捏合室的阶式捏合中和在连续操作双槽捏合机中制备有机聚硅氧烷组合物的方法,其中所述捏合室彼此串联排列。
背景技术
EP 570387A描述了一种连续制备HTV有机硅组合物的方法,其中将填料混入聚硅氧烷中以及脱气是在单螺杆往复式捏合机中一步进行的。然而,机器可以分离成混合步骤可以在第一捏合机中发生,而脱气步骤可以在第二捏合机中发生。由于高分子量聚有机硅氧烷的相转化、干摩擦和机械破坏,储存稳定性被降低。另外,用所述机械概念不能实现满意的生产量。
在EP 1033389A中描述了另一个方法的开发。特别为了改善储存稳定性,通过橡胶再循环提供加工,这应该能防止相转化,从而能降低以此方式制备的HTV组合物变硬和变脆的趋势。在EP 1033389A中未提及两阶段法。该方法由于产物的再循环而在工程学上变得非常复杂,因此不可以经济地操作。在该方法中,产量同样不能令人满意,因为产物的再循环大大降低了工厂的时空收率。
EP 1110696A描述了一种制备HTV有机硅组合物的二阶段方法。在该方法的第一部分中,填料和有机硅聚合物以及疏水剂和增塑剂在共旋双螺杆挤出机中混合。在该方法的第二部分中,混合物在单螺杆往复式捏合机中完全混合并脱气。与EP 570387A相比,EP 1110696A的方法在生产量和改善的填料分布上应该是更好的。然而,EP 570387A提到,双螺杆机器在机器磨损和金属磨损方面是有问题的,可能导致所生产的HTV组合物不期望的灰色着色。
EP 807509A描述了用一连串按特定规律排列的捏合机器连续制备储存稳定的有机聚硅氧烷组合物。其目的是用于加成交联液态橡胶的基础组合物。组合物的脱气仅通过脱气容器发生,而不是通过特别设计的机器。依据EP 807509A,HTV组合物也可以用阶式捏合来制备。由于缺乏脱气机会或不适合的脱气设备,通过该方法生产的HTV橡胶是不能用的。
EP 1468803A描述了一种方法,其中使用的阶式捏合包括至少两个捏合室,所述捏合室彼此串联排列,每个含有两个捏合工具,所述捏合工具具有平行轴并且能够同向或反向旋转,捏合室通过开口彼此连接,物料沿所述捏合工具的轴的横向通过所述开口。由所述阶式捏合将目前的塑料生胶泵入往复式捏合机中,在那里所述物料可以被捏合和脱气。
该方法的缺点在于受技术限制所有产物的平均产量不能超过1500kg/h。有各种限制因素。首先是填料的引入,其次是驻留时间,由于当产量增加时平均驻留时间不可避免地缩短,这对质量产生负面影响。在过氧化交联的情况下的黄色着色、挤出期间的气泡形成和储存稳定性上,负面影响特别明显。EP 1468803A中所描述的方法不含任何缓冲设备,以至于如果发生故障,原料立即发生回冲,车间必须停掉,或者生胶必须排出,而后再在另一个车间中加工。
发明内容
本发明提供一种制备有机聚硅氧烷组合物(A)的连续方法,所述组合物的粘度在25℃测量为至少500Pa.s.,其中在第一阶段,有机聚硅氧烷(O)和填料(F)在具有至少两个捏合室的阶式捏合中混合和捏合,得到未加工的混合物,所述捏合室彼此串联排列并且均含有两个捏合工具,所述捏合工具具有平行轴并且能同向或反向旋转,所述捏合室通过开口彼此连接,物料沿所述捏合工具的轴的横向通过开口,其中第一捏合室具有进料口,而最后一个捏合室具有卸料口;在第二阶段,所述未加工的混合物在100-250℃下,在具有卸料螺杆的连续操作双槽捏合机中捏合并脱气。
与EP 1468803A的方法相比,本发明的方法的产量可以高2-3倍。另外,质量可以得到改善。而且,本方法的工程学优势为,由于双槽捏合机的良好缓冲作用,因此如果在冷却带、滤网和包装区域中出现小故障,不必停掉整个车间。
在本发明的方法中,阶式捏合的每个捏合室具有独立的驱动器,因此可以精确地控制每个特定室的混合、压缩和捏合加工的强度。
当用EP 1110696A中描述的双螺杆机器时,所述对混合、压缩和捏合加工的精确控制是不可能的。橡胶组合物在阶式捏合的最后一个室中完全均质如成品橡胶;另外,其已经经历了通过每个捏合室的驱动器而重复施加的捏合力。
依据本发明使用的阶式捏合是一种捏合机器,可以控制捏合加工的强度和驻留时间,因为所述捏合工具的转速和旋转方向可以在每个捏合室中独立设定。
由于在阶式捏合中不存在游离气体空间,因此可以省去保护气体。添加填料的进料斗优选用氮气覆盖。
从阶式捏合中卸出产物不存在任何问题,因为成品组合物可以很容易地通过捏合工具转移到卸料口。最后一个捏合室优选具有用于产物卸出的泵叶片。
阶式捏合优选包括最多10个捏合室;优选最多6个室就足够了。最后一个室优选具有用于产物卸出的泵叶片。优选向第一室中供给有机聚硅氧烷(O)和结构改进剂(S)。例如,也可以将填料(F)加入到阶式捏合的一个或多个室中。优选将全部有机聚硅氧烷(O)加入到第一室中。例如为了降低有机聚硅氧烷组合物(A)的粘度,也可以将部分有机聚硅氧烷(O)加入到后面一个室中。可以将需要的填料(F)加入到全部室中;优选在第一室和最后一个室中不加入填料(F)。例如可以仅在室的前一个/两个/三个或四个中添加全部量的需要的填料。填料(F)优选被加入到室2和3中。不过,填料的添加分布在所有室中也是可以的。如果使用结构改进剂(S),其优选被加入到前几个室中,特别是第一室中。优选在最后一个室中不加入结构改进剂(S)。阶式捏合优选具有至少三个,特别是至少五个捏合室。
可以在单独的捏合室之间或全部捏合室之间安装限制有机聚硅氧烷组合物(A)的流动的筛、隔板或滑阀。这些元件在位置和留下的自由开放面积上是可调节的。在单个室中的驻留时间可以通过这种方式受到影响。
捏合工具优选是捏合叶片、辊子或多边形板。
除了第一捏合室的进料口外,优选在所述捏合机器中还提供有其它通向单个捏合室中或位于两个捏合室间的进料口。优选每个捏合室具有一个进料口。特别是,最初2个、3个或4个捏合室的进料口适于加入固体,而其它进料口用于加入液体。
每个捏合室优选具有独立的可控驱动器,所述可控驱动器在每种情况下均优选具有力矩测量。力矩是室中混合物的粘度的量度。
捏合室优选是可加热和可冷却的,特别是可以在不同温度下单独操作。捏合产生摩擦热,所述摩擦热优选通过冷却被部分去除以避免组合物过热。
捏合工具优选自立安装在轴承上。而后在外壳的轴承侧壁上提供用于捏合工具的驱动轴的开口。捏合室的外壳优选具有沿工具的轴的横向的分离线路,以使与轴承相对的外壳部分可以沿驱动轴的轴向从分离线路和捏合工具中移开。具有这样的构造的捏合机特别易于清理。
在EP 807509A中描述了这类型的捏合机器。
在本发明的方法中,捏合室中的组合物的温度不高于280℃,优选不高于240℃。
在最后一个捏合室之后,优选通过一个短的弹性连接件将橡胶直接泵入到双槽捏合机中。然而,输送装置也可以用作连接装置。所述双槽捏合机优选配有两个曲拐式捏合叶片和一个卸料螺杆。所述捏合叶片优选均具有独立的驱动器,并优选是可加热和可冷却的。每个叶片的转速优选可以单独进行无级调节。优选可以改变旋转方向。
双槽捏合机的装填程度优选保持稳定在40-60%,即,调节卸料螺杆使得输入和输出保持平衡。在捏合机下游的仪器出现小故障的情况下,剩余的捏合机容量可以用作缓冲,这使得整个过程方法非常耐用并使与规格不符的产物的比例最小化。
捏合机优选在1-150mbar绝对压力的低负压下操作。产物温度保持恒定,依据产物优选至少100℃,特别是至少130℃,优选不超过250℃,特别是不超过220℃。
除了捏合叶片之外,槽也优选配有双壁,以控制产物的温度。
产物在捏合机中的平均驻留时间可以在很宽的范围内变化。优选至少5min,特别是至少30min,优选不超过5h,特别是不超过3h。
为了能够在捏合机中达到窄的驻留时间分布,捏合机的进口和出口保持尽可能远的距离。选择叶片的几何形状以使产物尽可能远离出口。
在有机聚硅氧烷组合物(A)的制备中,运行两个加工步骤而没有中间储存产物。
经良好捏合和脱气的有机聚硅氧烷组合物(A)的进一步加工是没有疑问的,并不是本发明的主题。
有机聚硅氧烷组合物(A)的填料含量为5-80wt%,优选10-50wt%。特别优选制备填料含量为20-40wt%的有机聚硅氧烷组合物(A)。
可能的填料(F)是通常在有机硅组合物中使用的所有填料,也可以使用各种填料的混合物。适合的填料(F)为,例如,二氧化硅、石英粉、炭黑、金属氧化物、金属碳酸盐、金属硫酸盐、金属硅酸盐、金属氮化物、硅藻土、粘土、白垩、云母、金属粉末、活性炭、有机聚合物粉末等。重要的是,由于填料的含量,导致含填料的有机聚硅氧烷组合物(A)的粘度显著高于要以连续方式混入所述含填料有机硅组合物中的有机聚硅氧烷(O)的粘度。优选补强填料(F),也就是通过BET法测定比表面积为至少50m2/g,优选50-500m2/g的填料,例如热解二氧化硅;已经被脱水并保留结构的硅胶,即硅补强剂;其它类型的沉淀二氧化硅以及炭黑。如果期望,特别优选的热解二氧化硅、沉淀二氧化硅和炭黑可以已经过表面处理,例如为了改善其分散性。氧化补强填料(F)可以预疏水化,在此情况下优选由于疏水化导致碳含量为至少0.5。也可以使用预疏水化和未预疏水化的氧化补强填料(F)的混合物。
特别是,也可以存在MwDxTyQz型硅树脂,其在室温下为纯的固体。
有机聚硅氧烷组合物(A)基于其的有机聚硅氧烷(O)可以是一种有机聚硅氧烷(O)或者是各种有机聚硅氧烷(O)的混合物。基本上,所有迄今已经描述并且是本领域内的技术人员已知的用于HTV、LSR、RTV-1和RTV-2组合物的制备的有机聚硅氧烷(O)都可以使用。这些包括线型、支链、环状或类树脂有机聚硅氧烷,它们可以含有官能团,通常为了可交联性。优选使用线型有机聚硅氧烷(O),如聚合度为50-9000的聚二甲基硅氧烷。有机聚硅氧烷(O)上优选的有机基团是甲基、苯基、乙烯基和三氟丙基,特别优选甲基。优选存在于聚有机硅氧烷中的官能团是-SiOH、-SiOR、Si-乙烯基和-SiH,特别优选乙烯基。特别优选的有机聚硅氧烷(O)是通常用于制备热固化HTV有机硅组合物,并且Brabender值在25℃下测定为200-900daNm,特别是400-700daNm的有机聚硅氧烷(O)。有机聚硅氧烷(O)的组成优选符合平均式(I)
R1 aR2 bSiO(4-a-b)/2 (1),
其中
R1是相同或不同的单价Si键合基团,选自-H、-OH、-OR,其中R是C1-C10烃基;以及未取代的、卤素取代的或氰基取代的C1-C10烃基,其含有至少一个脂肪族碳碳多键并可以通过二价有机基团与硅键合。
R2是相同或不同的未取代的、卤索取代的或氰基取代的单价Si键合C1-C10烃基,其不含脂肪族碳碳多键,
a是非负数,为0-1,和
b是非负数,为1-2.1。
R1优选是能够与SiH官能交联剂或过氧化物反应的烯基。通常使用具有2-6个碳原子的烯基,如乙烯基、烯丙基、甲基烯丙基、1-丙烯基、5-己烯基、乙炔基、丁二烯基、己二烯基、环戊烯基、环戊二烯基、环己烯基,优选乙烯基和烯丙基。
烯基通过其可以与聚合物链的硅键合的有机二价基团包括,例如,如式(2)的那些氧化烯单元
-(O)p[(CH2)qO]r- (2)
其中
p是0或1,优选0,
q是1-4,特别是1或2,和
r是1-20,特别是1-5。
式(2)的氧化烯单元在左手端与硅原子键合。
基团R1可以在任何位置键合在聚合物链上,特别是在端基硅原子上。
R2优选具有1-6个碳原子。特别优选甲基和苯基。
式(1)的聚有机硅氧烷的结构可以是线型、环状或支链的。产生支链聚有机硅氧烷的三官能和/或四官能单元的含量通常非常低,优选不超过20mol%,特别是不超过0.1mol%。
特别优选使用含有乙烯基并且其分子具有式(3)的聚二甲基硅氧烷:
(ViMe2SiO1/2)c(ViMeSiO)d(Me2SiO)e(Me3SiO1/2)f (3)
其中Vi是乙烯基,Me是甲基,非负整数c、d、e和f遵循以下关系:c+d≥1,c+f=2,1000<(d+e)<9000,优选3000<(d+e)<7000,和0<(d+1)/(d+e)<1,优选0<(d+1)/(d+e)<0.1。
有机聚硅氧烷组合物(A)还可以包含使得设定特定性能成为可能的添加剂(Z),特别是加工助剂,如结构改进剂(S);分散剂;疏水剂,如硅氮烷、含硅烷醇基的低聚硅氧烷和结构破坏剂。
特别优选的添加剂是疏水剂,其有助于掺入亲水填料(F),如亲水热解或沉淀二氧化硅,例如含硅烷醇基的低聚硅氧烷以及三甲基硅烷基封端的低聚二甲基硅氧烷。
作为结构改进剂(S),优选25℃下测定粘度为10-200mP.s,优选20-150mP.s的有机聚硅氧烷。优选含硅烷醇基的低聚硅氧烷和三甲基硅烷基封端的二甲基(低聚或聚)硅氧烷。用作结构改进剂(S)的有机聚硅氧烷的基团优选自甲基、苯基、乙烯基和羟基。
通过本发明的方法制备的有机聚硅氧烷组合物(A)是具有较高粘度的有机硅组合物,其在25℃下测定的粘度为至少500mP.s。本发明的方法特别可用于制备具有较高粘度的有机聚硅氧烷组合物(A),其在25℃下测定的Brabender塑性为100-1000daN.m;以及具有非常高粘度的有机聚硅氧烷组合物(A),其通过Mooney法测定的粘度为10-200Mooney单位(最终Mooney值,ML(1+4),23℃,DIN 53523)。
本发明的方法特别可用于制备高度填充的高粘度有机聚硅氧烷组合物(A)、高粘度有机硅糊状物和高度填充的有机硅母料。热固性HTV有机聚硅氧烷组合物(Al)也可以是用于生产即用型可交联HTV组合物的基础混合物。
上述式中的所有符号均具有其彼此独立的含义。
附图说明
图1为实施本发明的方法的设备的截面图。
具体实施方式
在下面实施例中,所有量和百分数都以重量计,所有压力都是0.10MPa(abs.),除非另外说明。所有粘度都在20℃下测定。
所有证明本发明的方法的实施例和对比实施例都是用包含下列成分的硅橡胶组合物作为基础来实施的。
固体HTV聚合物:
100重量份的固体HTV聚合物,其在25℃下的粘度为约20000Pa.s,剪切速率为0.81 1/sec,依据1H NMR光谱,其具有下列数均组成:
Vi-Si(Me)2-[OSi(Me)2]m-[OSiMeVi]n-OSi(Me)2-Vi,
其中Me是甲基,Vi是乙烯基,n+m约为6000,m/n约为3000。
结构改进剂:
2-16.7重量份的结构改进剂,依据29Si NMR光谱,其具有下列数均组成,在25℃下测定的粘度为41mm2/s:
HO-Si(Me)2-[OSi(Me)2]m-OSi(Me)2-OH,
其中m约为14。
二氧化硅:
实施例1:本发明的方法
参考图1描述本发明的方法:
第一阶段使用产自IKA Maschinenbau Janke & Kunkel GmbH & Co.KG,Staufen的阶式捏合(3)实施。阶式捏合(3)具有6个室,每个室的体积为10L。总产量为200kg/h。
将聚合物(120kg/h)和结构改进剂(20kg/h)计量加入到室1的进料管(1)中,将填料(60kg/h)计量加入到室2的进料管(2)中。因而总产量为约200kg/h。室1-4中的转速为35rpm。通过每个室的单独驱动器的动力牵引记录显示,组合物在第二和第三捏合室中有结成块的稠度。在第四捏合室中,动力牵引更稳定和更高:在此出现均质的粘性组合物。室1-4在35rpm下操作,在室5和6中,在40rpm下进行进一步捏合,同时从室6中卸出产物。6个室既未被冷却和加热,温度范围从第一室中约45℃至第六室中约150℃。
通过转移部件(9)连续取出从室6中卸出的生胶,并通过产自KraussMaffei,作为输送装置的AZ进料器连续进料至配有灯(6)、真空连接(7)、窥镜(8)和卸料螺杆(5)的100L曲拐式捏合机(4)中。将所述捏合机(4)加热至约200℃,并抽空至约100mbar的负压。当填满捏合机(4)的一半时,通过卸料螺杆(5)连续卸出物料。设定卸料量以使捏合机(4)的装填程度大约保持恒定。
橡胶在可加热平板硫化机的平板之间a)通过0.7%的过氧化二异丙苯(交联剂1)在165℃下硫化15分钟,或b)通过1.5%的过氧化双(2,4-二氯苯甲酰)(50%浓度)(交联剂2)在135℃下硫化10分钟而硫化。硫化物随后在对流式烤箱中200℃下加热4小时,而后评价该硫化物的外观,即变色程度。
生产了三种不同的产品1-3。当达到稳定连续生产一小时后,取每个样品,并进行测试。
表1:试验条件
表2:结果
产品 | 压缩永久变形 | 颜色B值 | Shore A硬度 |
1 | 16 | 12 | 39 |
2 | 18 | 7.5 | 58 |
产品 | 压缩永久变形 | 颜色B值 | Shore A硬度 |
3 | 18 | 9 | 70 |
B值越低,黄色着色越低。颜色可以通过三个被称为L、a、b的坐标描述。L是亮度轴,b是黄-蓝轴,而a是红-绿轴。
非依据本发明的类似EP 1468803A的方法的对比实施例
该捏合机被分成5个区域(部分),具有如下结构:第一区为3D,2-5区均为4D。所有区域通过限流环彼此分离。通过水环式真空泵在区域2-5中施加100mbar(abs.)的真空。选择对单个部分的温度控制和捏合机的轴,以使从第二部分开始,在轴的转速为150rpm下,在捏合机中建立约180-200℃的产物温度。在阶式捏合(4)中生成的未加工混合物在约150℃的产物温度下进料至往复式捏合机的区域1中。在区域2-5中加强捏合,同时从橡胶组合物中去除挥发成分。可以将添加剂(Z)加入到第二至第五区域中。通过冷却的卸料螺杆卸出橡胶,并作为产品4-6进行检测。
表3:结果
产品 | 压缩永久变形 | 颜色B值 | Shore A硬度 |
4* | 21 | 14 | 39 |
5* | 20 | 8 | 59 |
6* | 21 | 12 | 70 |
*非依据本发明
总结:与依据EP 1468803A生产的产品4-6相比,依据本发明生产的产品1-3显示出的压缩永久变形稍微得到改善,黄色着色稍微降低,和机械性能不变。
Claims (8)
1.一种制备有机聚硅氧烷组合物(A)的连续方法,所述组合物的粘度在25℃下测量为至少500Pa.s.,其中在第一阶段,将有机聚硅氧烷(O)和填料(F)在具有至少两个捏合室的阶式捏合中混合和捏合,得到未加工混合物,所述捏合室彼此串联排列并各自含有两个捏合工具,所述捏合工具具有平行轴并且能同向或反向转动,所述捏合室通过开口彼此连接,物料可沿捏合工具的轴的横向通过所述开口,其中第一捏合室具有进料口,而最后一个捏合室具有卸料口;在第二阶段,所述未加工混合物在100-250℃下,在具有卸料螺杆的连续操作双槽捏合机中捏合并脱气。
2.权利要求1所述的方法,其中所述阶式捏合包括3-10个捏合室。
3.权利要求1或2所述的方法,其中所述有机聚硅氧烷组合物(A)在所述双槽捏合机中的平均驻留时间为30min-3h。
4.权利要求1-3之一所述的方法,其中所述双槽捏合机的装填程度保持恒定在40-60%。
5.权利要求1-4之一所述的方法,其中所述有机聚硅氧烷组合物(A)的填料含量为5-80wt%。
6.权利要求1-5之一所述的方法,其中通过BET法测定比表面积为至少50m2/g的二氧化硅被用作填料(F)。
7.权利要求1-6之一所述的方法,其中其分子具有通式(3)的聚二甲基硅氧烷被用作有机聚硅氧烷(O):
(ViMe2SiO1/2)c(ViMeSiO)d(Me2SiO)e(Me3SiO1/2)f (3)
其中Vi是乙烯基,Me是甲基,非负整数c、d、e和f遵循以下关系:c+d≥1,c+f=2,1000<(d+e)<9000,优选3000<(d+e)<7000,和0<(d+1)/(d+e)<1,优选0<(d+1)/(d+e)<0.1。
8.权利要求1-7之一所述的方法,其中添加在25℃下测定粘度为10-200mPa.s的有机聚硅氧烷作为结构改进剂(S)。
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