CN104327244B - 聚氨酯管夹阀芯生产工艺 - Google Patents

聚氨酯管夹阀芯生产工艺 Download PDF

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CN104327244B
CN104327244B CN201410635694.6A CN201410635694A CN104327244B CN 104327244 B CN104327244 B CN 104327244B CN 201410635694 A CN201410635694 A CN 201410635694A CN 104327244 B CN104327244 B CN 104327244B
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李波
任兵
卢述林
谭兴明
范军
何正江
王国栋
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SICHUAN GUOXIN MACHINE MANUFACTURING CO., LTD.
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Abstract

本发明公开了一种聚氨酯管夹阀芯生产工艺，属于化工技术领域。该工艺包括如下步骤：a、将100重量份的聚醚多元醇和6～12重量份的邻苯二甲酸二丁酯加入反应釜，加热并搅拌均匀，然后加热抽真空脱除水分；b、降温，加入15～40重量份的甲苯二异氰酸酯，在75～85℃下搅拌反应生成预聚体，抽真空脱除反应产生的气体；c、将预聚体导入浇注机，与扩链剂、催化剂和消泡剂混合并发生扩链反应，反应后浇注成型；d、将浇注成型的聚氨酯管夹阀芯连同成型模，在烤箱内加热到100～130℃进行烘烤；e、将烘烤后的聚氨酯管夹阀芯冷却、脱模，然后进行产品修边得到最终产品。本发明工艺投入少、成本低，还能提高产品的整体性能。

Description

聚氨酯管夹阀芯生产工艺
技术领域
本发明属于化工技术领域，具体涉及一种新的聚氨酯管夹阀芯生产工艺。
背景技术
管夹阀芯即矿产企业用于物料(矿浆、尾矿)输送管道上安装的截止阀、节流阀阀芯。传统使用耐磨橡胶进行模压生产，满足耐磨、回弹等功能。
目前，随着聚氨酯在原料合成、设备更新、工艺技术、应用研究等领域的快速发展，传统橡胶材质的物料输送管道截止阀、节流阀用阀芯有被新型高耐磨、高回弹、抗水解的聚氨酯材质的阀芯所取代的趋势。
传统橡胶材质管夹阀芯采用耐磨性能较好的母胶(如顺丁、天然胶、氯磺化聚乙烯等)配合恰当的补强剂、配合剂等在开炼机上进行半成品胶料混炼，经平板硫化机模压成型而得产品。工艺优点：1、产品形象，操作可视化程度高；2、配方定型后，产品性能受其他因素影响较小。缺点：1、配方复杂，原辅材料，尤其是配合剂种类较多；2、工艺路线长，工序、生产设备较多，操作复杂；3、成型模具笨重，加工制作难；4、平板硫化机行程高度限制产品尺寸；5、模压硫化工艺操作控制难，产品缺陷多；6、长期频繁开闭使用，产品回弹疲劳，物料通过性能差；7、产品耐磨性能差，使用寿命短。
发明内容
本发明所要解决的技术问题是提供一种产品性能更好的聚氨酯管夹阀芯生产工艺。
本发明解决其技术问题所采用的技术方案是：聚氨酯管夹阀芯生产工艺，包括如下步骤：
a、将100重量份的聚醚多元醇和6～12重量份的邻苯二甲酸二丁酯(DBP)加入反应釜，加热并搅拌均匀，然后加热到100～150℃抽真空脱除反应釜内的水分；
b、将步骤a脱除水分后的混合物降温，加入15～40重量份的甲苯二异氰酸酯，然后在75～85℃下搅拌反应生成预聚体，反应后抽真空脱除反应产生的气体；
c、将预聚体导入浇注机，与浇注机内准备的扩链剂、催化剂和消泡剂混合并发生扩链反应，反应后进行浇注成型；
d、将浇注成型的聚氨酯管夹阀芯连同成型模，在烤箱内加热到100～130℃进行烘烤；
e、将烘烤后的聚氨酯管夹阀芯冷却、脱模，然后进行产品修边得到最终产品。
本发明所述的甲苯二异氰酸酯优选TDI-100，即纯净的2,4-甲苯二异氰酸酯。
其中，上述工艺中，扩链剂可以使用三羟甲基丙烷(TMP)，1,4-丁二醇(BDO),三异丙醇胺(TIPA)，二邻氯二苯胺甲烷(MOCA)中的一种或几种。本工艺优先使用的是TMP为主(含量＞70％)，配以TIPA和MOCA的混合扩链剂。
其中，上述工艺中，催化剂可以采用市售的环保型催化剂，如型号为BICAT8118和BICAT8的催化剂，优先使用BICAT8，添加量优选为预聚体的0.05～0.1％。消泡剂可以采用市售的消泡剂，如型号为BYK-088的消泡剂，添加量优选为预聚体的0.1～0.3％。
其中，上述工艺中，聚醚多元醇100重量份，邻苯二甲酸二丁酯7～10重量份，甲苯二异氰酸酯17～34重量份。
其中，上述工艺中，扩链剂的量为预聚体重量的6～12％。
其中，上述工艺中，聚醚多元醇的平均分子量在1000～2000之间。
其中，上述工艺步骤a和b中抽真空采用的真空度大于0.08MPa；即真空度在0.08MPa到一个大气压之间，最优选抽到接近绝对真空，这样可节省抽真空时间，也能保证物料的纯净。
其中，上述工艺中，将步骤a脱除水分后的混合物降温至65～75℃。
其中，上述工艺步骤c中，浇注机内物料的温度控制在80～85℃。
其中，上述工艺步骤d中烘烤的时间为10～16小时。
本发明的有益效果是：本发明工艺实现了聚氨酯管夹阀芯浇注操作，通过对工艺的严格控制，提高了产品的整体性能，合格率高，较传统橡胶模压硫化成型工艺路线更为简便、设备投入更少，成本更低。
具体实施方式
本发明具体可以按照以下方式实施，聚氨酯管夹阀芯生产工艺，包括如下步骤：
a、原料熔化：将分子量1000～2000的100重量份的聚醚多元醇和7～10重量份的邻苯二甲酸二丁酯(DBP)加入反应釜，加热并搅拌均匀，然后加热到100～150℃抽真空脱除反应釜内的水分；
b、预聚体合成：将步骤a脱除水分后的混合物降温至65～75℃，加入17～34重量份的2,4-甲苯二异氰酸酯，然后在75～85℃下搅拌反应生成预聚体，控制反应时间2小时，反应后抽真空脱除反应产生的气体；
c、扩链与浇注成型：将预聚体导入浇注机，与浇注机内准备的扩链剂、催化剂和消泡剂混合并发生扩链反应，控制反应温度80～85℃，反应后进行浇注成型；扩链剂的量为预聚体重量的6～12％；
d、后硫化：将浇注成型的聚氨酯管夹阀芯连同成型模，在烤箱内加热到100～130℃进行烘烤10～16小时；
e、产品加工：将烘烤后的聚氨酯管夹阀芯冷却、脱模，然后进行产品修边得到最终产品。
其中，上述工艺步骤a和b中抽真空采用的真空度大于0.08MPa。
下面通过实施例对本发明具体实施方式做进一步的说明，但并不因此将本发明的保护范围限制在实施例之中。
实施例
将分子量2000的100重量份的聚醚多元醇和8重量份的邻苯二甲酸二丁酯(DBP)加入反应釜，加热并搅拌均匀，然后加热到120℃抽真空脱水2小时。降温至65～75℃，加入25重量份的2,4-甲苯二异氰酸酯(TDI-100)，在75～85℃下搅拌反应2小时生成预聚体，反应后抽真空脱气2小时。将预聚体导入浇注机，与扩链剂、催化剂和消泡剂混合并发生扩链反应，反应温度80～85℃，反应后进行浇注成型，扩链剂的量为预聚体重量的8％。将浇注成型的聚氨酯管夹阀芯连同成型模，在烤箱内加热到120℃进行烘烤12小时；将烘烤后的聚氨酯管夹阀芯冷却、脱模，然后进行产品修边得到最终产品。
本工艺生产的管夹阀芯：硬度(邵尔A)57±3度；拉伸强度10～15MPa；扯断伸长率＞550％阿克隆磨耗＜0.1。在工况条件和安装操作较好的情况下，使用寿命达8～11个月；在工况极度恶劣和安装不符合要求的情况下，使用寿命也能达到4～6个月，同橡胶材质管夹阀芯2～4个月的使用寿命比较，耐用性能大幅提高。本工艺产品合格率大于70％不等。

Claims (8)

1.聚氨酯管夹阀芯生产工艺，其特征在于包括如下步骤：
a、将100重量份的聚醚多元醇和6～12重量份的邻苯二甲酸二丁酯加入反应釜，加热并搅拌均匀，然后加热到100～150℃抽真空脱除反应釜内的水分；
b、将步骤a脱除水分后的混合物降温，加入15～40重量份的甲苯二异氰酸酯，然后在75～85℃下搅拌反应生成预聚体，反应后抽真空脱除反应产生的气体；
c、将预聚体导入浇注机，与浇注机内准备的扩链剂、催化剂和消泡剂混合并发生扩链反应，反应后进行浇注成型；
d、将浇注成型的聚氨酯管夹阀芯连同成型模，在烤箱内加热到100～130℃进行烘烤；
e、将烘烤后的聚氨酯管夹阀芯冷却、脱模，然后进行产品修边得到最终产品。
2.根据权利要求1所述的聚氨酯管夹阀芯生产工艺，其特征在于：聚醚多元醇100重量份，邻苯二甲酸二丁酯7～10重量份，甲苯二异氰酸酯17～34重量份。
3.根据权利要求1所述的聚氨酯管夹阀芯生产工艺，其特征在于：扩链剂的量为预聚体重量的6～12％。
4.根据权利要求1、2或3所述的聚氨酯管夹阀芯生产工艺，其特征在于：聚醚多元醇的平均分子量在1000～2000之间。
5.根据权利要求1、2或3所述的聚氨酯管夹阀芯生产工艺，其特征在于：步骤a和b中抽真空采用的真空度大于0.08MPa。
6.根据权利要求1、2或3所述的聚氨酯管夹阀芯生产工艺，其特征在于：将步骤a脱除水分后的混合物降温至65～75℃。
7.根据权利要求1、2或3所述的聚氨酯管夹阀芯生产工艺，其特征在于：步骤c中，浇注机内物料的温度控制在80～85℃。
8.根据权利要求1、2或3所述的聚氨酯管夹阀芯生产工艺，其特征在于：步骤d中烘烤的时间为10～16小时。
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