CN102529061B - 用于成型轮胎部件的挤出机装置 - Google Patents

用于成型轮胎部件的挤出机装置 Download PDF

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CN102529061B
CN102529061B CN201110435100.3A CN201110435100A CN102529061B CN 102529061 B CN102529061 B CN 102529061B CN 201110435100 A CN201110435100 A CN 201110435100A CN 102529061 B CN102529061 B CN 102529061B
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extruder
gear pump
compound
pump
main extruder
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CN102529061A (zh
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G.R.伯格
C.D.戴尔隆德
B.R.科赫
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Goodyear Tire and Rubber Co
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Goodyear Tire and Rubber Co
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    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/34—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices
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    • B29B7/40—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with single shaft
    • B29B7/42—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with single shaft with screw or helix
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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Abstract

介绍了用于成型轮胎部件的挤出机装置。一种用于将混合的橡胶组合物直接添加到轮胎成型鼓或胎芯上的方法和装置。提供用于第一化合物的第一挤出机和第一齿轮泵。提供用于第二化合物的第二挤出机和第二齿轮泵。第一和第二齿轮泵的输出被送入主挤出机的入口内。提供第三泵送装置用于将促进剂混合物泵送到主挤出机的入口内；将所述第一化合物和所述第二化合物以及所述促进剂混合物在所述挤出机内混合在一起并且将混合物施加到轮胎成型鼓或胎芯上。

Description

用于成型轮胎部件的挤出机装置
其他申请的交叉引用
本申请通过引用2010年12月22日提交的申请号为61/425,816的美国临时申请而要求其权益并将其并入。
技术领域
本发明主要涉及轮胎制造，并且更具体地涉及一种用于成型轮胎部件的装置。
背景技术
轮胎制造商们由于技术的进步以及高度竞争性的工业环境而不断研发出更加复杂的设计方案。具体地，轮胎设计者们为了满足消费者的需求而设法在轮胎中使用多种橡胶化合物。在每个轮胎中使用多种橡胶化合物可能会导致需要在现场为制造商的各条轮胎生产线提供大量的化合物。出于成本和效率的原因，由于与每一种化合物相关联的可观费用，因此轮胎制造商们要设法限制现有化合物数量。每一种化合物通常都需要使用班伯里密炼机，这就会涉及高额的基建投资。而且，班伯里密炼机难以混合坚固或坚硬的橡胶化合物。从班伯里密炼机中生成的化合物通常都被运往轮胎成型车间，因此就需要额外的运输成本。化合物的保存期是有限的，并且如果没有在确定的时段内使用就要报废。
因此希望有一种改进的方法和装置能够明显减少对使用班伯里密炼机的需求，同时提供一种装置和方法用于通过将两种或多种化合物混合在一起并控制化合物和其他添加剂的比例而在轮胎成型机中提供定制的混合。非生产性化合物和生产性化合物均可被混合在一起。进一步希望在轮胎成型机中有一种系统提供用促进剂制造可定制化合物的能力。而有待解决的另一个问题是在轮胎成型机中连续地生成化合物。
要在轮胎成型机中制造具有小截面积轮廓并且在材料方面有所不同的轮胎部件是非常有挑战性的。因此希望拥有一种改进的方法和装置用于在轮胎成型机中制造轮胎部件。
定义
“高宽比”是指轮胎的截面高度与其截面宽度之比。
“轴向”和“轴向地”是指平行于轮胎旋转轴线的线路或方向。
“胎圈”或“胎圈芯”通常是指包括环形抗拉元件的轮胎部分，径向内胎圈与将轮胎固定至由帘布线缠绕的轮辋有关并且被成形为具有或者不具有其他的加强元件例如钢丝圈外包布、胎跟加强层、胶芯或填充物、胎趾护层和胎圈包布。
“带束层结构”或“加强带束层”是指胎面以下的、织造或非织造的、未锚定至胎圈的、并且相对于轮胎赤道面具有的左右帘线角度均在17度到27度范围内的、平行帘线构成的至少两个环形层或帘布层。
“斜交帘布轮胎”是指胎体帘布层内的加强帘线相对于轮胎赤道面以约25度-65度的角度从胎圈到胎圈跨越轮胎对角延伸，帘布线在交替层内以对角延伸。
“缓冲层”或“轮胎缓冲层”的含义与带束层或带束层结构或加强带束层相同。
“胎体”是指切割为适于拼接长度的或者已经拼接为圆柱形或环形的轮胎帘布层材料和其他轮胎部件的叠层。在将胎体硫化以形成模制轮胎之前可以将附加部件加至胎体。
“周向”是指沿垂直于轴向的环形胎面的表面周边延伸的线路或方向；它也可以指邻接圆形曲线集合的方向，其半径在截面图内看时确定了胎面的轴向曲率。
“帘线”是指被用于加强帘布层的包括纤维在内的一种加强绞线。
“内衬”是指构成无内胎轮胎内表面并且包含轮胎内充气流体的一层或多层弹性体或其他材料。
“嵌件”是指通常被用于加强防爆型轮胎侧壁的加强件；它也可以指胎面下方的弹性体嵌件。
“帘布层”是指由涂有弹性体的径向布设或以其他方式布设的平行帘线构成的帘线加强层。
“径向”和“径向地”是指沿径向朝向或远离轮胎旋转轴线的方向。
“子午线结构”是指一层或多层胎体帘布层，其中至少有一个帘布层具有相对于轮胎赤道面以65度到90度之间的角度取向的加强帘线。
“子午线轮胎”是指带束层结构或沿周向约束的充气轮胎，其中从胎圈到胎圈延伸的帘布线相对于轮胎赤道面以65度到90度之间的帘线角布设。
“侧壁”是指胎面和胎圈之间的轮胎部分。
“层叠结构”是指由一层或多层轮胎部件或弹性体部件例如内衬、侧壁和可选的帘布层制成的未硫化结构。
“生产性化合物”是指包括促进剂、硫以及硫化橡胶所需的其他材料的橡胶化合物。
“非生产性化合物”是指不具有以下项目中的一项或多项的橡胶化合物：1)促进剂；2)硫；或3)一种或多种硫化剂。
附图说明
通过示例并且参照附图来介绍本发明，在附图中：
图1是本发明的混合系统的示意图。
图2是本发明第二实施例的示意图。
具体实施方式
图1示出了适合用于制造供轮胎或轮胎部件使用的橡胶组合物的连续混合系统的方法和装置10的第一实施例。连续混合系统10并不局限于轮胎应用并且可以被用于例如制造与轮胎无关的其他橡胶部件例如传送带、软管、皮带等。连续混合系统特别适用于制造具有不同组分的小轮胎部件例如嵌件、胶芯和胎面(包括用于翻新轮胎的那些部件)。混合系统可以被直接设置在轮胎或部件成型工作站处用于将橡胶组合物直接施加至轮胎成型鼓或其他的部件成型装置。如图1中所示，连续混合装置10包括主挤出机20。主挤出机20具有入口22用于接收将在下文中更加详细介绍的一种或多种橡胶组合物。主挤出机可以包括适用于处理橡胶或弹性体化合物的任意商用挤出机。挤出机可以包括本领域技术人员公知的市场上能够买到的挤出机例如销钉型挤出机、双螺杆或单螺杆挤出机或者环型挤出机。一种适合使用的市场上能够买到的挤出机是由荷兰的VMIHollandBV销售的多流道传递混合型(MCT)挤出机。优选地，挤出机具有的长度直径比(L/D)约为5，但是可以在从约3到约5的范围内变化。环型、销钉型或MCT型挤出机是优选的，但是并不局限于此。主挤出机20用于将化合物A加热至约在80℃到约150℃范围内的温度，优选地是在约90℃到约120℃范围内的温度，以及根据需要来素炼橡胶组合物。
主挤出机入口22接收第一化合物A，第一化合物A可以是生产性或非生产性的橡胶组合物。化合物A的组分示例在下文中进行更加详细的介绍。化合物A首先由第一挤出机8并且可选地由第二泵5挤出，第二泵5优选为齿轮泵。挤出机8可以是常规的销钉型、环型、双螺杆或单螺杆型挤出机。泵5用作计量设备和泵并且可以具有齿轮例如行星齿轮、伞齿轮或其他齿轮。挤出机8和齿轮泵5也可以是组合单元。优选地，挤出机8具有约为3的L/D，但是可以在从约3到约6的范围内变化。
被称作“化合物B”的第二化合物也在入口22处进入主挤出机20并且随着化合物行进经过主挤出机而与化合物A混合在一起。化合物B也可以包括生产性或非生产性的橡胶组合物。化合物B的组分示例在下文中进行更加详细的介绍。化合物B首先由第二挤出机40并且可选地由第二泵42挤出，第二泵42优选为齿轮泵。挤出机40可以是常规的销钉型、环型、双螺杆或单螺杆型挤出机。泵42用作计量设备和泵并且可以具有齿轮例如行星齿轮、伞齿轮或其他齿轮。挤出机40和齿轮泵42也可以是组合单元。优选地，挤出机40具有约为3的L/D，但是可以在从约3到约6的范围内变化。
主挤出机20将化合物A和化合物B以精确控制的量混合在一起。也可以可选地通过油泵60将油注入主挤出机22内。油泵可以位于任何期望位置，但是优选地位于入口22处。油控制化合物混合物的粘度。
装置10可以进一步包括第一添加剂泵70用于泵送一种或多种添加剂例如主促进剂，主促进剂在主挤出机入口22处被加入混合物中。装置可以进一步包括第二添加剂泵送设备80用于将一种或多种添加剂例如辅助促进剂泵送到主挤出机入口22内。添加剂泵70,80可以是齿轮泵、齿轮泵式挤出机、文丘里泵或本领域技术人员已知的其他泵送装置。
如果使用了多于一种的促进剂，那么它们可以被分别或共同加入混合物内。例如，主促进剂和辅助促进剂可以一起添加。促进剂被用于控制硫化所需的时间和/或温度以及改善橡胶的性质。促进剂可以是粉末形式或者是封装到树脂或橡胶基内的粉末。促进剂的组分示例在下文中进行更加详细的介绍。
其他的添加剂包括也可以通过添加剂泵90加入密炼机的硫化剂或前体。硫化剂的一个示例是硫。硫可以用固体形式加入。添加剂泵90可以是齿轮泵、齿轮泵和挤出机的组合、文丘里泵或本领域技术人员已知的其他泵送装置。
因此包括化合物A、化合物B、硫、油和任意需要的硫化剂或前体或者所需橡胶组合物的促进剂在内的所有成分都被加入主挤出机20的入口。主挤出机将所有成分混合在一起并且生成输出的化合物混合物C，它是化合物A和B、可选的油、可选的促进剂以及可选的添加剂的精确混合物。输出的化合物混合物C离开主挤出机并进入可选的齿轮泵25。可选的齿轮泵25和主挤出机20优选地如图1中所示被紧邻地设置在轮胎部件成型工作站或轮胎成型工作站95附近用于直接施加到胎芯、心轴、胎坯或轮胎成型鼓上。齿轮泵25优选地具有专用喷嘴95或成形模具以将来自密炼机出口的化合物配料输出以缠绕在轮胎成型鼓或胎芯上的带条的形式直接施加到轮胎成形机95上。
化合物A的体积流速与化合物B的体积流速之比由用于化合物A的齿轮泵5的转速和用于化合物B的齿轮泵42的转速之比精确控制。例如，来自系统10的化合物输出如图1中所示可以包括体积百分比为20%的化合物A以及80%的化合物B。可选地，来自系统的化合物输出可以由混合物D构成，混合物D具有体积百分比为35%的化合物B以及65%的化合物A。可选地，来自系统的化合物输出可以由混合物Z构成，混合物Z具有体积百分比为10%的化合物B以及90%的化合物A。因此，化合物A与化合物B的比例可以在从0:100%到100%:0的范围内变化。该比例可以通过由计算机控制器100改变齿轮泵25和42的转速来进行瞬时调节。计算机控制器100可以另外控制挤出机和齿轮泵的工作参数例如工作压力、工作温度、泵或螺杆的转速。
优选地，计算机控制器100设定用于每一台挤出机出口压力的压力目标值。挤出机速度由控制器控制并且改变，直到满足压力目标值为止。压力目标值通过促使挤出机内的材料回流来影响质量。
本发明的系统10有利地由于以下的设计特征而具有短的驻留时间。首先，化合物C中的所有组分都在主挤出机的入口添加。因为所有组成成分都在完全相同的位置加入，所以就能够生成和控制精确的配料。其次，每一台挤出机都具有小的长度直径比。再次，该系统优选地被设置在部件成型工作站或轮胎成型工作站附近以最小化系统生产线的长度从而进一步缩短系统的驻留时间。
图2示出了本发明的挤出机装置的第二实施例。除了以下内容以外的所有事项均与上述内容相同。化合物A被送入主挤出机20的入口22内。化合物B如上所述经过与齿轮泵42相结合的挤出机40，并且随后在本文中为了引用目的而标记为“L”的特定上游位置被送入主挤出机内。主促进剂通过泵送设备70泵送并在相同的位置L进入主挤出机。可选的辅助促进剂经过泵送设备80并随后在相同的位置L进入主挤出机20。其他的添加剂包括硫化剂或前体，也可以将其通过添加剂泵90在位置L加入密炼机。因此在相同的挤出机位置加入所有组成成分就允许精确控制化合物的成分。
以下是可以与本发明一起使用的各种组合物。
I.促进剂组合物
在一个实施例中可以使用单促进剂系统也就是主促进剂。可以使用的主促进剂总量在从约0.5phr到约4phr的范围内变化，可选地是在约0.8phr到约1.5phr的范围内变化。在另一个实施例中，可以使用主促进剂与辅助促进剂的组合，其中辅助促进剂可以较少量使用，例如从约0.05phr到约3phr，目的是为了激活并改善硫化橡胶的性质。这些促进剂的组合应该可以对最终性质产生协同效应并且在某种程度上优于单独使用任何一种促进剂所产生的效果。另外，可以使用延迟作用促进剂，它不会受到正常操作温度的影响但是可以在正常的硫化温度下得到令人满意的硫化。也可以使用阻硫化剂。可以在本发明中使用的合适类型的促进剂有胺、二硫化物、胍、硫脲、噻唑、秋兰姆、亚磺酰胺、二硫代氨基甲酸盐和黄酸盐。在一个实施例中，主促进剂是亚磺酰胺。如果使用了辅助促进剂，那么辅助促进剂可以是胍、二硫代氨基甲酸盐或秋兰姆化合物。合适的胍包括二苯胍等。合适的秋兰姆包括二硫化四甲基秋兰姆、二硫化四乙基秋兰姆和二硫化四苄基秋兰姆。
II.橡胶组合物
可以在橡胶化合物中使用的代表性橡胶包括丙烯腈/二烯烃共聚物、天然橡胶、卤化丁基橡胶、丁基橡胶、顺式-1,4-聚异戊二烯、苯乙烯-丁二烯共聚物、顺式-1,4-聚丁二烯、苯乙烯-异戊二烯-丁二烯三元共聚物、乙烯-丙烯三元共聚物，也被称作乙烯/丙烯/二烯烃(EPDM)以及具体为乙烯/丙烯/二环戊二烯三元共聚物。可以使用上述橡胶的混合物。每一个橡胶层均可包括相同的橡胶组合物或者交替层可以由不同的橡胶组合物构成。
橡胶化合物可以包含板状填充物。板状填充物的代表性示例包括滑石、粘土、云母及其混合物。在使用时，板状填充物的量在从约每100橡胶重量份(以下称为phr)中有约25份到约150份的范围内变化。优选地，橡胶化合物内的板状填充物水平在从约30phr到约75phr的范围内变化。
各种橡胶组合物可以与常规的橡胶化合配料合成。常用的常规配料包括碳黑、硅石、偶联剂、增粘树脂、加工助剂、抗氧化剂、抗臭氧剂、硬脂酸、活化剂、蜡、油、硫磺硫化剂和胶溶剂。如本领域技术人员所知，根据所需的耐磨度和其他性质，通常以常规用量使用上述的某些添加剂。典型的碳黑添加量包括从约10橡胶重量份到150橡胶重量份，优选为50phr到100phr。典型的硅石用量在从10重量份到250重量份的范围内变化，优选为30重量份到80重量份，并且还包括将硅石和碳黑混合。典型的增粘树脂用量包括从约2phr到10prh。典型的加工助剂用量包括1phr到5phr。典型的抗氧化剂用量包括1phr到10phr。典型的抗臭氧剂用量包括1phr到10phr。典型的硬脂酸用量包括0.50phr到约3phr。典型的促进剂用量包括1phr到5phr。典型的蜡用量包括1phr到5phr。典型的油用量包括2phr到30phr。硫磺硫化剂用量例如单质硫、二硫化胺、聚合多硫化物、硫烯烃加合物及其混合物的用量在从约0.2phr到8phr的范围内变化。典型的胶溶剂用量包括从0.1phr到1phr。
III.油
橡胶组合物也可以包括多达70phr的加工油。加工油可以包含在橡胶组合物内作为通常用于填充合成橡胶的填充油。加工油也可以通过在橡胶化合期间直接加入油而包含在橡胶组合物中。使用的加工油可以包括存在于合成橡胶内的填充油以及在化合期间加入的加工油。合适的加工油包括本领域内已知的各种油，包括芳香烃、石蜡族、环烷、植物油以及低多环芳烃油例如MES,TDAE,SRAE和重环烷油。合适的低多环芳烃油包括具有的多环芳香烃含量在通过IP346方法确定时小于3%重量百分比的品种。用于IP346方法的过程可以在由英国石油学会2003年出版的《StandardMethodsforAnalysis&TestingofPetroleumandRelatedProductsandBritishStandard2000Parts》第62版中找到。
根据本文中提供的说明可以得到本发明的各种变形。尽管已经为了介绍本主题发明而示出了一些代表性的实施例和细节内容，但对本领域技术人员显而易见的是可以在其中进行各种修改和变形而并不背离本主题发明的保护范围。因此，应该理解可以对所述实施例进行修改，这些修改仍将落在由下附权利要求确定的本发明完整意图的保护范围内。

Claims (10)

1.一种用于施加第一化合物和第二化合物的混合物的装置，所述装置的特征在于：
第一挤出机与第一齿轮泵流体连通用于处理第一化合物；以及
第二挤出机与第二齿轮泵流体连通用于处理第二化合物，其中所述第一齿轮泵和所述第二齿轮泵中每一个的出口都与主挤出机的同一个入口流体连通；
所述装置具有专用喷嘴或成形模具，所述专用喷嘴或成形模具用以将来自所述主挤出机的出口的化合物配料输出以带条的形式直接施加到轮胎成形机上。
2.如权利要求1所述的装置，进一步的特征在于主齿轮泵与所述主挤出机的所述出口流体连通。
3.如权利要求1所述的装置，进一步的特征在于计算机控制器用于通过第一齿轮泵与第二齿轮泵的传动比来控制第一化合物与第二化合物的混合比。
4.如权利要求1所述的装置，其特征在于主挤出机具有的长度直径比在3到5的范围内。
5.如权利要求1所述的装置，进一步的特征在于第三挤出机与第三齿轮泵流体连通，其中第三齿轮泵的出口与主挤出机的入口流体连通用于将促进剂混合物喷入主挤出机内。
6.如权利要求1所述的装置，进一步的特征在于第四挤出机与第四齿轮泵流体连通，其中第四齿轮泵的出口与主挤出机的入口流体连通用于将辅助促进剂混合物喷入主挤出机内。
7.如权利要求3所述的装置，其特征在于所述计算机控制器与所述第一齿轮泵、第二齿轮泵和第三齿轮泵以及所述第一挤出机和第二挤出机电通信。
8.如权利要求1所述的装置，进一步的特征在于泵用于将油泵送到所述主挤出机的入口内。
9.一种将混合的橡胶组合物直接施加到轮胎成型鼓或胎芯上的方法，所述方法的特征在于以下步骤：
提供用于第一化合物的第一挤出机和第一齿轮泵，并且通过所述第一挤出机以及随后通过第一齿轮泵来处理所述第一化合物；
提供用于第二化合物的第二挤出机和第二齿轮泵，并且通过所述第二挤出机以及随后通过所述第二齿轮泵来处理所述第二化合物；
将化合物A从第一齿轮泵的出口引入主挤出机内；
将化合物B从第二齿轮泵的出口引入主挤出机内；
提供用于促进剂混合物的第三挤出机和第三齿轮泵；引导促进剂混合物通过所述第三挤出机和第三齿轮泵并进入主挤出机的入口内；
通过主挤出机挤出化合物A、化合物B和促进剂混合物以形成第三化合物C；以及
将第三化合物C以一条或多条直接施加到轮胎成型设备上。
10.如权利要求9所述的方法，进一步提供用于添加剂的第四挤出机和第四齿轮泵，引导添加剂通过第四挤出机并进入第四齿轮泵内，将添加剂泵送到主挤出机的入口内。
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