CN101835584B - 用于制造聚合物颗粒的方法和装置 - Google Patents

用于制造聚合物颗粒的方法和装置 Download PDF

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CN101835584B
CN101835584B CN200880112512XA CN200880112512A CN101835584B CN 101835584 B CN101835584 B CN 101835584B CN 200880112512X A CN200880112512X A CN 200880112512XA CN 200880112512 A CN200880112512 A CN 200880112512A CN 101835584 B CN101835584 B CN 101835584B
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B·沃特尔
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Coperion GmbH
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    • B29C48/375—Plasticisers, homogenisers or feeders comprising two or more stages
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
    • B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
    • B29C48/405—Intermeshing co-rotating screws
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Abstract

本发明涉及一种用于制造聚合物颗粒的装置(1)，为能简单、灵活地混入添加剂(25)和发泡剂(31)，该装置具有第一、第二静态熔体冷却器(9、37)，其中第一熔体冷却器(9)设置在一螺旋式机器(13)前，而第二熔体冷却器(37)设置在该螺旋式机器(13)下游。通过在第一熔体冷却器(9)中对所制备的聚合物熔体(2)进行冷却，能特别合适地将添加剂(25)混入聚合物熔体(2)中。

Description

用于制造聚合物颗粒的方法和装置
技术领域
本发明涉及一种用于制造聚合物颗粒的方法。本发明还涉及一种用于制造聚合物颗粒的装置。
背景技术
长期以来便采用有膨胀能力的或已膨胀的聚合物颗粒来制造泡沫材料成型件。其中有膨胀能力的聚合物颗粒大多由聚苯乙烯制成，而已膨胀的聚合物颗粒大多由聚丙烯制成。聚合物颗粒的膨胀能力或膨胀通过发泡剂/促进剂来实现。
用已知的聚合方法制造有膨胀能力的聚合物颗粒，其中在聚合反应时便已添加发泡剂和添加剂。这种方法的缺点是，在可用的发泡剂和添加剂方面灵活性较小，特别是所用的添加剂不利地影响聚合反应。此外，这样制造的聚合物颗粒的尺寸分布较宽，因此必须在制造后复杂地将这些(尺寸不同的)颗粒分开。
由EP 1 517 947 B1已知一种用于制造有膨胀能力的聚苯乙烯的方法。在这种方法中，借助于静态或动态的混合器将发泡剂混入聚苯乙烯熔体中。然后，使含发泡剂的聚苯乙烯熔体冷却并形成颗粒。在这种方法中优选采用静态混合器，原因是应使对聚苯乙烯熔体的机械和热能输入保持得尽可能小。其缺点是，在这种方法中在可用的发泡剂和添加剂方面的灵活性也较小。
发明内容
因此本发明的目的是，提供用于制造聚合物颗粒的方法和装置，从而实现在高的聚合物产量下简单、灵活地将添加剂和发泡剂混入聚合物中。
根据本发明，该目的通过具有权利要求1的特征的方法来实现。通过在添加至少一种添加剂之前对聚合物熔体进行第一冷却，可以合适地将所述至少一种添加剂混入聚合物熔体内。特别是实现了在添加至少一种发泡剂之前柔和地混入至少一种添加剂。因此，也可以将温度敏感的添加剂、例如阻燃剂或晶胞改性剂(Zellmodifikatoren)混入聚合物熔体内。在第一冷却后，聚合物熔体具有低于240℃、特别是低于220℃、特别是低于200℃的温度。通过静态熔体冷却器实现聚合物熔体的均匀冷却和统一的温度分布。通过仅借助于一螺旋式机器/螺杆机(Schneckenmaschine)、亦即一动态混合器来进行至少一种添加剂和至少一种发泡剂的混入，使至少一种添加剂和至少一种发泡剂被非常均匀地混入聚合物熔体中。因为所述至少一种添加剂和至少一种发泡剂被添加到螺旋式机器中，所以能够以比已知的聚合方法更简单、迅速的方式改变添加剂和发泡剂的添加。
通过在混入所述至少一种添加剂和至少一种发泡剂之前使聚合物熔体冷却，使得在通过螺旋式机器进行混入时由引入剪切能量造成的升温不会不利地作用。通过对含添加剂和发泡剂的聚合物熔体的第二冷却来平衡在混入至少一种添加剂和至少一种发泡剂时的升温。此外，通过第二冷却来平衡由添加至少一种发泡剂造成的聚合物熔体的粘度下降，其中聚合物熔体被冷却到造粒所需要的温度。在第二冷却后，聚合物熔体具有低于220℃、特别是低于200℃、尤其是低于170℃的温度。静态熔体冷却器再次实现了聚合物熔体的均匀冷却和统一的温度分布。
可以采用例如聚苯乙烯、聚乙烯、聚丙烯以及这些聚合物的混合物作为所述聚合物。此外，也可以采用基于可重复利用的原料、例如聚交酯以及可降解(
Figure GPA00001106679500021
)的聚合物、例如乙酸纤维素的聚合物。作为添加剂可以向聚合物熔体中混入例如阻燃剂、晶胞改性剂、石墨或颜料。作为发泡剂可以向聚合物熔体中混入碳氢化合物例如正戊烷(n-Pentan)或异戊烷(iso-Pentan)、乙醇、二氧化碳、氮或这些复合物的混合物。根据聚合物和至少一种发泡剂的选择，依照造颗方法既可以制造出有膨胀能力的聚合物颗粒，也可以制造出已膨胀的聚合物颗粒。为制造出有膨胀能力的聚合物颗粒优选采用水下造粒工艺，而为制造出已膨胀的聚合物颗粒优选采用水环造粒工艺。通过根据本发明的连续方法可以以高聚合物产量制造出有膨胀能力的或已经膨胀的聚合物颗粒。
通过根据权利要求2进行冷却，可以使聚合物熔体的温度在混入至少一种添加剂和/或混入至少一种发泡剂期间保持不变。这对聚合物颗粒的质量起有利作用。
通过根据权利要求3产生一阻滞区/蓄积区(Stauzone)，防止了至少一种发泡剂朝向用于混入至少一种添加剂的混合区的方向选出。
通过根据权利要求4的压力，避免了至少一种发泡剂由于压降而从聚合物熔体中析出。为了避免析出，在混入至少一种发泡剂期间可使压力保持不变或提高。
通过根据权利要求5提高压力，一方面产生后续方法步骤所需的压力，另一方面在最大程度上解除了螺旋式机器的提高压力的功能，由此避免在螺旋式机器内聚合物熔体的升温。
通过根据权利要求6制备聚合物熔体可实现本方法的高经济性，其原因是，可以直接从聚合物反应器取出聚合物熔体，而不需要附加能量来产生聚合物熔体。
所述目的还通过具有权利要求7的特征的装置来实现。根据本发明的装置的优点与根据本发明的方法的优点相对应。
根据权利要求11的螺旋式机器的实施方式实现了，在高聚合物产量下特别均匀、合适地混入至少一种添加剂和至少一种发泡剂。
根据权利要求12的熔体泵使螺旋式机器不必具有为后续方法步骤提高压力的功能，从而避免了聚合物熔体在螺旋式机器中升温。在螺旋式机器与静态第二熔体冷却器之间设置第一熔体泵，使熔体泵能将聚合物熔体压过静态熔体冷却器和造粒装置。附加地，可以在静态第二熔体冷却器与造粒装置之间设置第二熔体泵，所述熔体泵优选做成高压齿轮泵。
根据权利要求13的熔体泵实现了，在离开聚合反应器后提高聚合物熔体的压力，从而将聚合物熔体压过静态第一熔体冷却器。该熔体泵优选做成高压齿轮泵。
附图说明
本发明的其它特征、细节和优点由对一个实施例的下述说明得到。附图中：
图1以示意图示出一用于制造聚合物颗粒的装置。
图2示出一螺旋式机器沿图1中的剖面线II-II的剖视图。
具体实施方式
用于制造聚合物颗粒的装置1具有一带反应容器4的聚合反应器3用于制备聚合物熔体2。聚合反应器3以常见的方式构造并且是公知的。
沿输送方向5在聚合反应器3下游布置一第一熔体泵6，聚合反应器3通入该第一熔体泵6中。熔体泵6做成高压齿轮泵并具有两个可旋转驱动的齿轮转子7、7’，所述齿轮转子布置在一泵壳体8内。这种高压齿轮泵的具体结构参看EP 1 295 036 B1(对应于US 6,761,546B2)。
沿输送方向5在第一熔体泵6下游布置一静态第一熔体冷却器9，第一熔体泵6通入该静态第一熔体冷却器9。该熔体冷却器9具有一冷却器壳体10，在该壳体中布置有一常规的静态混合体11。为了冷却聚合物熔体2，冷却器壳体10具有一冷却元件12。静态混合体11以常见的方式构成并例如公开在EP 1 067 352 B1中。
沿输送方向5在第一熔体冷却器9下游布置一做成双轴螺旋混合器的螺旋式机器13。螺旋式机器13的基本结构根据常见的方式设计并具有两个螺杆14、14’，所述螺杆布置在壳体16的相应孔15、15’中。由图2可见，(两)螺杆14、14’紧密啮合并同向旋转。由电机17通过一减速分动传动装置18对螺杆14、14’进行驱动，壳体16与该减速分动传动装置法兰连接。与传动装置18相邻地在螺旋式机器13的上游端部上，第一熔体冷却器9经一熔体输入口19通入壳体16中。
螺旋式机器13沿输送方向5相继具有进给区20、第一混合区21、阻滞区22和第二混合区23。在进给区20中，螺杆14、14’具有用于沿输送方向输送聚合物熔体2的螺棱24。
在第一混合区21的上游端部上，在壳体16中布置有一用于输入添加剂25的添加剂输入口26。一第一输入装置27通过添加剂输入口26通入壳体16中。输入装置27设计成双轴式螺旋输送机。在第一混合区21内，螺杆14、14’具有螺棱24和用于混入添加剂25的混合搅拌元件28。螺旋式机器13在第一混合区21内具有一第一冷却装置29用于冷却聚合物熔体2。
在设置在(两)混合区21、23之间的阻滞区22内，螺杆14、14’具有逆输送方向5输送的螺棱30。
在第二混合区23的上游端部上，为输入发泡剂31而在壳体16中布置有一发泡剂输入口32。第二输入装置33通过发泡剂输入口32通入壳体16中。输入装置33做成活塞泵。在第二混合区23内，螺杆14、14’具有螺棱24和用于将发泡剂31混入聚合物熔体2中的混合搅拌元件34。为了冷却聚合物熔体2，螺旋式机器13在第二混合区23内具有一第二冷却装置35。
沿输送方向5，在螺旋式机器13下游布置有一第二熔体泵36，而在该第二熔体泵36下游布置有一静态第二熔体冷却器37，其中螺旋式机器13通入第二熔体泵36中，而该第二熔体泵36又通入第二熔体冷却器37中。第二熔体泵36的结构与第一熔体泵6相对应。此外，第二熔体冷却器37的结构与第一熔体冷却器9相对应。
沿输送方向5，在第二熔体冷却器37下游布置有一第三熔体泵38，而在该第三熔体泵38下游布置有一造粒装置39，其中第二熔体冷却器37通入第三熔体泵38中，而第三熔体泵38又通入造粒装置39中。第三熔体泵38的结构与第一和第二熔体泵6、36的结构相对应。
造粒装置39设计成水下造粒装置。这种造粒装置的具体结构参见DE103 22 610 A1或EP 1 110 695 B1(对应于US 6,547,549B2)。
工作原理如下：
在聚合反应器3内产生聚合物熔体2，特别是聚苯乙烯、聚丙烯、聚乙烯、聚交酯，乙酸纤维素或这些聚合物的混合物的熔体。聚合物熔体2在离开反应容器4时具有240℃至300℃的温度。在离开反应容器4后，借助于第一熔体泵6以70～300bar的压力将聚合物熔体2输入第一静态熔体冷却器9。在第一熔体冷却器9内使聚合物熔体2的温度降低，以保证聚合物熔体2能被合适地继续加工。在离开第一熔体冷却器9后，聚合物熔体2具有低于240℃、特别是低于220℃、尤其是低于200℃的温度。
然后，被冷却的聚合物熔体2通过熔体输入口19输入螺旋式机器13。借助于第一输入装置27、经添加剂输入口26为被冷却的聚合物熔体2添加至少一种添加剂25。特别是阻燃剂、晶胞改性剂、石墨或颜料可用作添加剂25。此外可通过添加剂输入口26输入其它工艺助剂。
在第一混合区21中，所添加的添加剂25借助于混合搅拌元件28均匀地混入冷却的聚合物熔体2中。含添加剂的聚合物熔体2在被混入(添加剂)时借助于第一冷却装置29冷却，从而平衡由引入剪切能量造成的聚合物熔体2的升温。通过螺棱30形成阻滞区22，在该阻滞区22内孔15、15’完全被聚合物填满。聚合物熔体2在阻滞区22内用作第一混合区21和第二混合区23之间的密封部。
借助于第二输入装置33、经发泡剂输入口32将至少一种发泡剂31添加到含添加剂的聚合物熔体2中。特别是将例如正戊烷或异戊烷的碳氢化合物、二氧化碳、氮或这些复合物的混合物用作发泡剂31。由于存在阻滞区21，所以发泡剂31不会损失到第一混合区21中。以液态或气态的形式添加发泡剂31，并借助于在第二混合区23内的混合搅拌元件34将发泡剂均匀地混入含添加剂的聚合物熔体2中。含添加剂和发泡剂的聚合物熔体2在第二混合区23内借助于第二冷却装置35冷却，从而平衡由引入剪切能量造成的聚合物熔体2的升温。聚合物熔体2在离开螺旋式机器13时的温度基本上相当于其进入螺旋式机器13时的温度。在添加发泡剂31时使聚合物熔体2的压力在第二混合区23内保持不变或提高，以防止发泡剂31从聚合物熔体2中析出。
在离开螺旋式机器13后，借助于第二熔体泵36以70～300bar的压力将聚合物熔体2输入第二静态熔体冷却器37。第二熔体泵36使螺旋式机器13不必具有提高压力的功能，从而避免了聚合物熔体2的升温。通过第二熔体冷却器37使由添加发泡剂31造成的聚合物熔体2的粘度下降得到补偿。此外，在冷却装置29、35不能提供足够的冷却或根本没有设置冷却装置的情况下，可(通过该第二熔体冷却器36)降低由在螺旋式机器13内引入剪切能量造成的升温。在离开第二熔体冷却器37时，聚合物熔体2具有低于220℃、特别是低于200℃、尤其是低于170℃的温度。
在离开第二熔体冷却器37之后，借助于第三熔体泵38以70～300bar的压力将聚合物熔体2输送给造粒装置39，并以常见的方式形成颗粒，从而由聚合物熔体2产生聚合物颗粒。
根据聚合物熔体2和发泡剂31的选择、依照造颗方法既可以制造出有膨胀能力的聚合物颗粒，也可以制造出已膨胀的聚合物颗粒。为制造出有膨胀能力的聚合物颗粒优选采用水下造粒工艺，而为制造出已膨胀的聚合物颗粒优选采用水环造粒工艺。
在本发明的其它实施例中，聚合物熔体可通过另一螺旋式机器提供，因此不需要用于提供聚合物熔体的聚合物反应器和熔体泵。此外，可以省去在混合区内的冷却装置，而完全在第二熔体冷却器中平衡由引入剪切能量造成的聚合物熔体的升温。

Claims (13)

1.一种用于制造聚合物颗粒的方法，包括如下步骤：
-制备聚合物熔体(2)；
-借助于一静态第一熔体冷却器(9)对聚合物熔体(2)进行第一冷却；
-对被冷却的聚合物熔体(2)添加至少一种添加剂(25)；
-借助于一螺旋式机器(13)将所述至少一种添加剂(25)混入聚合物熔体(2)中；
-将至少一种发泡剂(31)添加到含添加剂的聚合物熔体(2)中；
-借助于所述螺旋式机器(13)将所述至少一种发泡剂(31)混入聚合物熔体(2)中；
-借助于一静态第二熔体冷却器(37)对含添加剂和发泡剂的聚合物熔体(2)进行第二冷却；以及
-对被冷却的、含添加剂和发泡剂的聚合物熔体(2)进行造粒。
2.根据权利要求1所述的方法，其特征为：
对位于螺旋式机器(13)内的聚合物熔体(2)进行冷却。
3.根据权利要求1或2所述的方法，其特征为：
在混入所述至少一种添加剂(25)后、添加所述至少一种发泡剂(31)前，借助于螺旋式机器(13)由聚合物熔体(2)形成一阻滞区(22)。
4.根据权利要求1或2所述的方法，其特征为：
在混入所述至少一种发泡剂(31)期间在添加所述至少一种发泡剂(31)时，使聚合物熔体(2)的压力至少保持不变。
5.根据权利要求1或2所述的方法，其特征为：
在混入所述至少一种发泡剂(31)后，借助于一熔体泵(36、38)来提高聚合物熔体(2)的压力。
6.根据权利要求1或2所述的方法，其特征为：
借助于一聚合反应器(3)来制备聚合物熔体(2)。
7.一种用于制造聚合物颗粒的装置，具有
-用于对聚合物熔体(2)进行第一冷却的静态第一熔体冷却器(9)；
-设置在静态第一熔体冷却器(9)下游的螺旋式机器(13)；该螺旋式机器具有
--用于混入至少一种添加剂(25)的第一混合区(21)；和
--设置在所述第一混合区(21)下游的、用于混入至少一种发泡剂(31)的第二混合区(23)；
-设置在所述螺旋式机器(13)下游的、用于对含添加剂和发泡剂的聚合物熔体(2)进行第二冷却的静态第二熔体冷却器(37)；
-用于对被冷却的、含添加剂和发泡剂的聚合物熔体(2)进行造粒的造粒装置(39)。
8.根据权利要求7所述的装置，其特征为：
设有一用于制备聚合物熔体(2)的聚合反应器(3)。
9.根据权利要求7或8所述的装置，其特征为：
所述螺旋式机器(13)具有至少一个冷却装置(29、35)。
10.根据权利要求7或8所述的装置，其特征为：
所述螺旋式机器(13)设计成能在所述第一、第二混合区(21、23)之间形成一阻滞区(22)。
11.根据权利要求7或8所述的装置，其特征为：
所述螺旋式机器(13)设计成同向旋转、紧密啮合的两轴螺旋混合机。
12.根据权利要求7或8所述的装置，其特征为：
设有至少一个设置在所述螺旋式机器(13)下游的第二熔体泵(36、38)。
13.根据权利要求8所述的装置，其特征为：
在所述聚合反应器(3)与所述静态第一熔体冷却器(9)之间设有一第一熔体泵(6)。
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ATE547226T1 (de) 2012-03-15
RU2010110003A (ru) 2011-11-27
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CN101835584A (zh) 2010-09-15
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