CN102516676B - 药用合成垫片及其制备方法 - Google Patents

药用合成垫片及其制备方法 Download PDF

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CN102516676B
CN102516676B CN2011103966424A CN201110396642A CN102516676B CN 102516676 B CN102516676 B CN 102516676B CN 2011103966424 A CN2011103966424 A CN 2011103966424A CN 201110396642 A CN201110396642 A CN 201110396642A CN 102516676 B CN102516676 B CN 102516676B
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CN102516676A (zh
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扈永刚
冯加友
郑述玲
毕研祯
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Shandong Pharmaceutical Glass Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/914—Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/91—Heating, e.g. for cross linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/92—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/92561—Time, e.g. start, termination, duration or interruption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/92704—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92819—Location or phase of control
    • B29C2948/92857—Extrusion unit
    • B29C2948/92876—Feeding, melting, plasticising or pumping zones, e.g. the melt itself
    • B29C2948/92895—Barrel or housing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92819—Location or phase of control
    • B29C2948/92923—Calibration, after-treatment or cooling zone

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Abstract

本发明涉及一种药用包装材料，具体涉及一种药用合成垫片及其制备方法，其特征在于由以下原料制成：氯化丁基橡胶、煅烧高岭土、叔辛基苯酚甲醛树脂、硬脂酸、氧化锌、改性聚乙烯、钛白粉、半补强炉法炭黑和氧化镁。本发明的优点在于：(1)以医用弹性体为主要原料，在保证垫片所需物理机械性能的同时，极大地降低了生产成本；(2)配方中所用的各种原料，均无任何毒副作用，并且完全符合医用原材料的标准，完全环保、无环境污染；(3)生产工艺简单，极大地减少了能耗，提高了生产效率；(4)工序的减少使人为出错的因素大大降低，保证了质量的稳定性；(5)产品性能佳，无落屑现象。

Description

药用合成垫片及其制备方法
技术领域
本发明涉及一种药用包装材料，具体涉及一种药用合成垫片及其制备方法。
背景技术
药用垫片是药用包材领域最常用的一种密封元件，用于防止流体泄露等。传统的药用合成垫片是由聚异戊二烯橡胶及其相关辅料，经炼胶、硫化、压片、切片、冷冲、硅化、制冷等二十多道工序生产而成，生产工艺繁琐、耗能耗时、并对环境有一定的污染，不但生产成本居高不下，而且产品质量得不到保障，针刺落屑的现象时有发生。一种成本低廉、工艺简单、安全环保、品质优良的药用合成聚异戊二烯垫片的替代品亟待出现。
发明内容
本发明的目的是提供一种药用合成垫片及其制备方法，能够具有成本低、工艺简单、安全环保并且品质优良，不会有落屑现象的发生。
本发明所述的一种药用合成垫片，由以下重量份数的原料制成：氯化丁基橡胶45000份、煅烧高岭土40500份、叔辛基苯酚甲醛树脂675份、硬脂酸450份、氧化锌2250份、改性聚乙烯900份、钛白粉1350份、半补强炉法炭黑166份和氧化镁60份。
本发明所述的药用合成垫片的制备方法，包括以下步骤：
(1)配料、密炼：将各种原料均匀的混合在一起，在密炼机中密炼操作8-10min，排胶温度为95-105℃，然后加入到XKY-550橡胶开放式炼胶机中进行开炼，开炼操作8-10min，前、后辊温度分别为60±5℃和65±5℃，最后通过挂架式冷却装置进行冷却，冷却至40℃以下，经冷却后的胶片进行卷取、停放，停放时间在1天～10天内；
(2)预成型：将胶片经过导向辊进入冷喂料挤出机的喂料口，开始挤出，挤出的胶料被机头刀片割开，由圆筒变成片状，其中，加压、塑化温度为35℃，挤出温度为30℃，挤出的胶片送往三辊压延机，通入蒸汽加热三辊压延机的辊筒，三辊压延机上辊温度为60±5℃，经压延后的胶片直接送到八辊冷却装置，打开的八辊冷却装置的冷却水，使胶片冷却到40℃以下，冷却好之后定长裁片装置，通过调整编码器参数，使胶片裁断的长度达到683～700mm，将胶片放入不锈钢盘，再放进胶盘存放架上，停放，停放时间在8小时～10天内；
(3)硫化：采用抽真空模塑成型机对胶片进行硫化，硫化温度193±2℃，硫化时间280～320s，硫化压力≥3100KN，硫化结束后，垫片成型；
(4)除边：采用除边机对垫片进行除边，除边机的空气压力表控制在0.55-0.75MPa；
(5)筛屑、清洗、包装：是采用震动筛和转鼓筛对垫片进行筛屑，筛屑完成后在清洗机里对垫片完成清洗、漂洗、硅化、干燥和冷却的一体化操作，最后得到产品，包装即可。
其中，步骤(5)中的清洗机优选按照以下标准设置：转速控制在1转/分钟、硅化时间控制在5～30分钟、干燥时间控制在60～90分钟。
本发明的优点在于：(1)以医用弹性体为主要原料，在保证垫片所需物理机械性能的同时，极大地降低了生产成本；(2)配方中所用的各种原料，均无任何毒副作用，并且完全符合医用原材料的标准，完全环保、无环境污染；(3)生产工艺简单，极大地减少了能耗，提高了生产效率；(4)工序的减少使人为出错的因素大大降低，保证了质量的稳定性；(5)产品性能佳，无落屑现象。
具体实施方式
以下结合实施例对本发明做进一步说明。
实施例1：
本实施例的原料配方为：氯化丁基橡胶45000g、煅烧高岭土40500g、叔辛基苯酚甲醛树脂675g、硬脂酸450g、氧化锌2250g、改性聚乙烯900g、钛白粉1350g、半补强炉法炭黑166g和氧化镁60g。
本实施例按照以下步骤制备产品：
(1)配料、密炼：将各种原料均匀的混合在一起，在密炼机中密炼操作10min，排胶温度为100℃，然后加入到XKY-550橡胶开放式炼胶机中进行开炼，开炼操作10min，前、后辊温度分别为60±5℃和65±5℃，最后通过挂架式冷却装置进行冷却，冷却至25℃，经冷却后的胶片进行卷取、停放5天；
(2)预成型：将胶片经过导向辊进入冷喂料挤出机的喂料口，开始挤出，挤出的胶料被机头刀片割开，由圆筒变成片状，其中，加压、塑化温度为35℃，挤出温度为30℃，挤出的胶片送往三辊压延机，通入蒸汽加热三辊压延机的辊筒，三辊压延机上辊温度为60±5℃，经压延后的胶片直接送到八辊冷却装置，打开的八辊冷却装置的冷却水，使胶片冷却到40℃以下，冷却好之后定长裁片装置，通过调整编码器参数，使胶片裁断的长度达到700mm，将胶片放入不锈钢盘，再放进胶盘存放架上，停放5天；
(3)硫化：采用抽真空模塑成型机对胶片进行硫化，硫化温度193±2℃，硫化时间300s，硫化压力≥3100KN，硫化结束后，垫片成型；
(4)除边：采用除边机对垫片进行除边，除边机的空气压力表控制在0.70MPa；
(5)筛屑、清洗、包装：是采用震动筛和转鼓筛对垫片进行筛屑，筛屑完成后在清洗机里对垫片完成清洗、漂洗、硅化、干燥和冷却的一体化操作，最后得到产品，包装即可。
其中，步骤(5)中的清洗机按照以下标准设置：转速控制在1转/分钟、硅化时间控制在20分钟、干燥时间控制在60分钟。
实施例2：
将硫化时间改为280s，其它制备步骤同实施例1一样。
实施例3：
将硫化时间改为320s，其它制备步骤同实施例1一样。
实施例1的物理机械性能测试：
将垫片夹入电子拉力试验机两夹具(标距为25mm)，力量归零、伸长量归零，然后启动测试，进行拉力测试。将拉伸强度、扯断伸长率、300％定伸应力值记录于原始记录上。如果垫片扯断时断裂面不在标距范围内，则此数据不作为有效结果。下表为实施例1物理性能所达到的技术指标：
  扯断伸长率(Mpa)   300％定伸强力(Mpa)   拉伸强度(Mpa)
  ≥550   ≥1.2   ≥4.0
实施例1～实施例3的快速性能项目检测及指标：
硫化阶段对应的指标说明：
  T10   【ML+(MH-ML)×10％】时扭矩所对应的时间
  T90   【ML+(MH-ML)×90％】时扭矩所对应的时间
  ML   胶料流动过程中的最低扭矩值，它反应胶料在一定条件(温度)下的冲模流动性
  MH   胶料流动过程中的最高扭矩值，它反应胶料的物性
下表为实施例1～实施例3的产品的密度、硬度及T10和T90的技术指标：
  密度  硬度(邵尔A)   T10(Sec)   T90(Sec)
  实施例1   1.38±0.03  54±5   ≥35   ≤240
  实施例2   1.38±0.03  58±5   ≥40   ≤260
  实施例3   1.26±0.03  48±5   ≥30   ≤350

Claims (2)

1.一种药用合成垫片，其特征在于由以下重量份数的原料制成：氯化丁基橡胶45000份、煅烧高岭土40500份、叔辛基苯酚甲醛树脂675份、硬脂酸450份、氧化锌2250份、改性聚乙烯900份、钛白粉1350份、半补强炉法炭黑166份和氧化镁60份；
制备方法包括以下步骤：
(1)配料、密炼：将各种原料均匀的混合在一起，在密炼机中密炼操作8-10min，排胶温度为95-105℃，然后加入到XKY-550橡胶开放式炼胶机中进行开炼，开炼操作8-10min，前、后辊温度分别为60±5℃和65±5℃，最后通过挂架式冷却装置进行冷却，冷却至40℃以下，经冷却后的胶片进行卷取、停放，停放时间在1天～10天内；
(2)预成型：将胶片经过导向辊进入冷喂料挤出机的喂料口，开始挤出，挤出的胶料被机头刀片割开，由圆筒变成片状，其中，加压、塑化温度为35℃，挤出温度为30℃，挤出的胶片送往三辊压延机，通入蒸汽加热三辊压延机的辊筒，三辊压延机上辊温度为60±5℃，经压延后的胶片直接送到八辊冷却装置，打开的八辊冷却装置的冷却水，使胶片冷却到40℃以下，冷却好之后定长裁片装置，通过调整编码器参数，使胶片裁断的长度达到683～700mm，将胶片放入不锈钢盘，再放进胶盘存放架上，停放，停放时间在8小时～10天内；
(3)硫化：采用抽真空模塑成型机对胶片进行硫化，硫化温度193±2℃，硫化时间280～320s，硫化压力≥3100KN，硫化结束后，垫片成型；
(4)除边：采用除边机对垫片进行除边，除边机的空气压力表控制在0.55-0.75MPa；
(5)筛屑、清洗、包装：采用震动筛和转鼓筛对垫片进行筛屑，筛屑完成后在清洗机里对垫片完成清洗、漂洗、硅化、干燥和冷却的一体化操作，最后得到产品，包装即可。
2.根据权利要求1所述的药用合成垫片，其特征在于步骤(5)中清洗机转速控制在1转/分钟、硅化时间控制在5～30分钟、干燥时间控制在60～90分钟。
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