CN1079687C - 连续挤出块状制品的方法和设备 - Google Patents

连续挤出块状制品的方法和设备 Download PDF

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CN1079687C
CN1079687C CN97198990A CN97198990A CN1079687C CN 1079687 C CN1079687 C CN 1079687C CN 97198990 A CN97198990 A CN 97198990A CN 97198990 A CN97198990 A CN 97198990A CN 1079687 C CN1079687 C CN 1079687C
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cylindrical shell
extrusion device
die assembly
screw rod
axle
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CN1233971A (zh
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维优·X·扬
马克·A·韦塞尔
安东尼·C·科滕霍
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Plymouth Products Inc
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Plymouth Products Inc
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

一种连续挤出多孔活性炭块状过滤器制品(64)的方法和设备。本发明包括将材料送入螺杆挤出机的筒体(20)中，在筒体中对材料进行加热使材料成为烧结块状。将烧结块搅拌并压人模具(46)，在模具中烧结块冷却为半固体状态。材料在这种半固体状态下通过冷却管(60)，在冷却管中材料固化形成活性炭块状过滤器制品。还设有可控制模具压力的背压控制装置(66)。

Description

连续挤出块状制品的方法和设备
发明背景及发明简述
本发明涉及一种挤出机，尤其涉及一种连续挤出多孔活性炭块状过滤器制品的方法和设备。
螺杆挤出机和注射成型设备在本技术领域是常用的设备。目前已有的方法和设备在挤出树脂粘结剂和粉末或颗粒料之类的复合材料时的很大缺陷是，当材料流出螺杆进入模具时开始冷却硬化，螺杆上的螺旋片在材料的外表面形成了螺旋形的“粘合痕迹”。在材料的外表面形成的这种螺旋形的“粘合痕迹”导致了材料在整个轴向长度方向上的螺旋形薄弱区，这个区域贯通整个材料长度，具有低密度和更大的孔隙率。对于产品的强度和过滤性能都有不利影响。
为了弥补材料在螺旋形薄弱区内的低密度和过大孔隙率的缺陷，目前已有的方法和设备采取了用更大的总体密度来制作产品的方法。这样一来，由于使用的材料量的增加，生产率的降低，对挤出设备磨损增加和能源消耗的增加造成了生产成本的提高。
在Koslow的美国专利5,189,092和Koslow的美国专利5,249,948中试图克服已有挤出方法和设备的问题。这两个专利中披露了一种可生产更加均匀的挤出产品的设备和方法。在Koslow的专利提出利用螺杆输送机使粉末材料通过挤出机筒体。材料在挤出机的筒体中被预热器加热，然后被送进模具，在模具中加热元件对材料进一步加热到所需的工作温度。
材料在模具中的加热很关键。如果材料流过模具时的加热段太短，材料流动太快，就不可能传导形成固态产品所需的热量，材料也不能适当的固化。另一方面，如果加热段太长，背压压力的增加就无法控制，会使材料硬化堵塞挤出机。而且，材料的冷却段必须足够长而使材料在离开模具时可保持结构的完整性，不会造成导致材料堵塞的无法控制的背压压力。
但是，与其他已有挤出设备一样，螺杆上的螺旋片在挤压出的块状制品的外表面形成了螺旋形的“粘合痕迹”。挤压出的块状制品在整个轴向长度方向有薄弱区域。如前所述，这个薄弱区域具有低密度和更大的孔隙率。
因此，本发明的主要目的和特点是提出一种连续挤出块状制品的方法和设备，该方法和设备可避免在块状制品的外表面形成了螺旋形的“粘合痕迹”。
本发明的另一个目的和特点是提出一种连续挤出块状制品的方法和设备，该方法和设备可减少材料的使用量，提高生产率，降低能源消耗。
本发明的再一个目的和特点是提出一种连续挤出块状制品的方法和设备，该方法和设备可生产具有均匀密度和孔隙率的产品。
根据本发明，提出了一种连续挤出块状制品的方法和设备。该设备包括中空的沿纵向轴线方向延伸的圆柱形筒体。筒体带有进料口，出料口和进料口与出料口之间的可安装螺杆的腔体。
与筒体同轴的螺杆安装在螺杆安装腔体中，可以绕纵向轴线旋转。加热器安装在进料口与出料口之间，可将筒体加热到预定温度。模具组件沿纵向轴线方向安装，并靠近筒体。模具组件带有与筒体出料口相连的进口和出口。可将模具组件的温度冷却到预定值的水冷套套在模具组件外面安装。
本发明的方法包括制备预混料，将材料装入筒体中。在筒体中材料被加热成为烧结块状。螺杆上的螺旋片终止处的平面对烧结块进行搅拌并压入模具。将烧结块冷却即成为挤出的块状制品。
为了控制模具内的压力，须对模具压力进行检测并对模具挤压出的材料流动的速度进行控制。使挤出的块状产品从第一和第二轮子之间通过即可实现上述目的。在轮子上施加制动力来限制轮子之间材料的通过速度，也就改变了压力。对附图的简要说明
后面的附图展示了本发明的优选结构，在优选结构中明确体现了本发明的上述的和其他的优点及特点，阅读下面对图示实施例的叙述可对本发明上述的和其他的优点及特点有更好的理解，附图包括：
图1为相应于本发明的连续挤出块状过滤材料的设备的剖面图；
图2为控制图1所示挤出设备挤出的块状制品的背压力的背压控制装置的侧视图；
图3为用于图1所示挤出设备中的螺杆的放大的侧视图；
图4为图3所示的螺杆的端视图；和
图5为用于图1所示挤出设备中的螺杆的另一种端部结构的放大侧视图。
对优选实施例的详细描述
参见图1，序号10为相应于本发明的挤出机。在本实施例中，挤出机10设计成可利用预混料，如用碳颗粒或粉末以及聚烯烃粘结剂如聚乙烯混合成的预混料，连续挤出多孔活性炭块状过滤器制品。但是，提出利用其他材料的混合物来生产其他中空的复合材料固体产品的挤出设备也应认为是属于本发明的范围。
如图1所示，料仓12中可以装混合料。混合料是充分混合的粉末材料，其中包括热塑性粘结剂材料，如聚乙烯，和颗粒或粉末的主体材料，如活性炭。料仓12包括可将混合料输送到供料口16的垂直螺杆输送器14。料仓12的供料口16与圆柱形筒体20的内部连通。
筒体20沿纵向轴线延伸，包括形成筒体20内腔18的内壁22，筒体内腔由上游进口23直至出口端42。在筒体20的内腔18中设有与筒体20同轴的可旋转的螺杆24。螺杆24带有长的外表带有普通螺旋片28的圆柱形心轴26。螺杆的根部直径(心轴26)由进口23向下游方向逐渐增大。
参见图3和4，螺杆24包括第一前端30。螺杆24的前端30为锥形，心轴26的直径急剧减小。当被加热烧结的材料经挤出机流到模具时，前端30的锥形段31的作用是为这些材料提供增大的体积空间，使流动的材料能够进一步混合和搅拌。前端30还包括位于螺杆24前端表面34的凹槽32(图中用虚线表示)以便与芯棒36的端部连接。螺旋片28在靠近螺杆24的前端30处终止，终止处的表面37与螺旋片28的纵向轴线呈横向关系，最好与纵向轴线垂直。
参见图5，图中所示为螺杆24的第二实施例。为了便于理解，使用了相同的序号。螺杆24包括前端30。螺杆24的前端30是锥形的，心轴26的直径逐步减小。螺杆24的锥形段35终止于轴肩39，轴肩39形成了圆盘形的表面41。圆盘形的表面41与螺杆24前端表面34之间有一段心轴26的圆柱部分43。
为了使预混材料保持流动性，必须在筒体20中利用预热元件38对预混的材料加热。然后，利用主加热器40对复合材料进一步加热到所需的树脂熔化或低于树脂熔化的工作温度。随着预混材料从筒体20吸收热量，聚乙烯粘结剂变软，部分熔化，开始在碳颗粒之间“搭桥”，最后形成烧结块从筒体20的出口42挤压出去。
筒体20的出口42与模具组件44的入口相连。模具组件44包括构成穿过模具的长的圆柱形流道的内表面48。水冷套52套装在模具外壳51之外。水冷套52包括进水口54和出水口56，可使冷却水流通过水冷套52。冷却水的温度保持在低于树脂熔化的温度。
如同后面的叙述，进入模具组件的烧结块在模具组件中部分固化形成了挤出的块状制品64。由模具46的输出端58挤出的块状制品64须通过位置与模具46靠近的冷却管60。冷却管60包括入口62，冷空气可经入口62吹过挤出的块状制品64使最终的复合产品完全固化。
参见图2，为了控制模具46中材料的压力，设置了背压控制装置66。背压控制装置66可向挤出的块状制品64自模具46向外的运动施加阻力。背压控制装置66包括分开的第一和第二轮子68，70，当连续挤出的产品64以所需挤出速度自冷却管60中出来时，轮子68，70与挤出的产品形成旋转接触。在优选实施例中，轮子68，70是用氨基甲酸乙酯材料制成，并且带有与挤出的产品的圆柱表面吻合的槽。
轮子68，70分别安装在对应的支承板72和74上。每个支承板72和74分别带有支承构件76和78。支承构件76和78通过铰链80互相连接，可使支承板72和74绕铰链80转动来改变轮子68和70之间的垂直距离。拉杆82也与支承板72和74连接。拉杆82包括使支承板72和74分开的弹簧84。拉杆82的第一端88设有蝶形螺母86，借助轮子68和70蝶形螺母86可向在两个轮子中间通过的挤出的产品施加确定的和可调的负荷力。
支承板74和固定的表面93之间装有可检测背压力的负荷传感器90。负荷传感器90通过数据线92将与背压力成比例的电信号输送给压力控制器94。压力控制器94可通过空气制动器控制一个或两个轮子68和70上的制动压力，压力控制器94可以是自动调节的或是由操作人员调节来设定背压力，在挤出的产品64上施加恒定的背压作用。空气制动器可以通过制动器管路96的压力来控制。
在操作中，碳和聚乙烯粘结剂的预混料在室温下装入料仓12。垂直螺杆输送器14以低速运转，通过供料口16将预混料送进筒体20的内腔18。随着螺杆24的旋转，预混料沿着筒体20的内腔18向螺杆24的前端30移动。逐渐增大的螺杆心轴26的根部直径使得前进的预混料受到压缩，预混料中夹带的空气被挤出去。预热器38然后是加热器40对预混料进行预热。预混料从筒体20吸收热量，聚乙烯粘结剂变软，部分熔化，开始在碳颗粒之间“搭桥”。然后形成烧结块从筒体20的出口42被挤压出去进入模具组件44。
锥形的直径减小的螺杆24的前端30提供了使流动的预混料能够进一步被螺旋片28混合和搅拌的空间，见图3。螺旋片28的表面37的作用是搅拌烧结块，将烧结块压入模具44。可以证实在螺杆24的端部30处对材料的混合和搅拌能够破坏复合材料沿螺杆移动时所带有的螺旋形态。本挤出方法可以连续形成均匀的挤出产品，消除可见的螺旋形痕迹和密度偏高或偏低的螺旋形区域。
在螺杆24的另一个实施例中，增大了圆柱表面24和筒体20的内壁22之间的间隙，这样就提供了使流动的预混料混合和搅拌的空间。
烧结块被压入模具46的流道50中和芯棒36的四周的空间，芯棒36形成了待成形的挤出块状制品的内径。冷却水流通过水冷套52循环，带走烧结块的过剩热量，形成挤出的块状制品64。树脂的熔化温度一般在200-500°F范围，因此冷却水可以保持在任何适当的低温度，一般在90-140°F范围内。由模具46挤出的块状制品64具有一定的刚性。因此，可使挤出的块状制品64通过冷却管60，将挤出的块状制品64进一步固化形成固态的最终产品。
然后，挤出的块状制品64从背压控制装置66的第一和第二轮子68，70之间通过。作用在挤出的块状制品64上的背压可控制挤出的块状物64的密度。作用在挤出的块状制品64上的背压越大，其密度就越大，反之亦然。
如前所述，挤出过程中的背压是通过两个氨基甲酸乙酯材料的轮子68，70控制的。操作人员可以通过编程来控制压力控制器94确定背压力。作用在第一和第二轮子68，70上的压力最初通过调节蝶形螺母86在拉杆82上的上下位置来设定。第一和第二轮子68，70之间的压力使轮子夹持住挤出的块状制品64。压力控制器94通过改变制动器管路96的压力来控制轮子68和70的制动器压力。
作用在挤出的块状制品64上的背压力的大小是由压力控制器94控制的，压力控制器94与安装在支承板74和固定面93之间的负荷传感器90相连接。负荷传感器90可提供表示作用在挤出的块状物64上的背压力大小的信号，并通过数据线92将信号输送给压力控制器94，压力控制器94就改变第一轮子68和/或第二轮子70的制动器压力以保持恒定的背压力。
实施本发明的各种方式都可以看作是属于后面的权利要求的范围，特别提到的和权利要求中所明确的主要内容可以看作是本发明的范围。

Claims (16)

1.一种利用螺杆挤出机将树脂粘结剂和颗粒基础材料的混合料连续挤出成多孔复合块状产品的方法，这种螺杆挤出机具有在圆柱形筒体内部安装的可旋转的供料螺杆和与筒体相连可接受来自筒体的材料并形成挤出产品的模具，该方法包括以下步骤：
(1)将固体混合料装入筒体；
(2)加热筒体中的混合料，使树脂粘结剂熔化形成烧结混合料；
(3)在筒体的下游端和模具的上游端，设置一个筒体中的混合区以增加材料的搅拌效果；和
(4)将烧结材料直接向前送进模具。
2.如权利要求1所述的方法，其特征在于，供料螺杆包括心轴和由心轴径向向外延伸的螺旋片，设置混合区的步骤包括在心轴下游端减小螺杆心轴的直径。
3.如权利要求2所述的方法，其特征在于，减小心轴的直径的步骤包括在大约最后一节螺旋片的长度上将心轴端做成锥形。
4.如权利要求2所述的方法，其特征在于，减小心轴的直径的步骤包括制成一个轴肩，以形成直径减小的圆柱形轴端部分。
5.一种可将具有特定工作温度的树脂粘结剂和颗粒基础材料加工成复合块状产品的挤出装置，包括：
沿纵向轴线延伸的中空的圆柱形筒体，筒体带有可供粘结剂和基础材料进入的进料口和出料口；
在筒体中位于进料口和出料口之间与筒体同轴且带有螺旋片的螺杆，螺杆可绕纵向轴线旋转；
位于进料口和出料口之间可将树脂粘结剂加热到工作温度的加热器；
由螺杆在筒体出料口处形成的混合和搅拌区域；
沿纵向轴线延伸靠近筒体的模具组件，模具组件带有与筒体出料口相连的进口和复合块状物挤出的出口，模具组件的温度保持在低于基础材料的工作温度；和
套装在模具组件外面的水冷套，水冷套的作用是将模具组件的温度冷却到预定值。
6.如权利要求5所述的挤出装置，其特征在于，还包括沿着垂直于筒体纵向轴线的轴线设置的料仓，料仓带有与筒体进料口连通的供料口。
7.如权利要求6所述的挤出装置，其特征在于，还包括沿着垂直于筒体纵向轴线的轴线设置并可绕此轴线旋转的垂直螺杆输送器。
8.如权利要求5所述的挤出装置，其特征在于，螺旋片在出料口处以与筒体的纵向轴线呈横向关系的平面形式终止。
9.如权利要求8所述的挤出装置，其特征在于，螺杆的螺旋片分布在圆柱形心轴的外表面，心轴带有靠近筒体进料口的第一端和靠近筒体出料口的第二端。
10.如权利要求5所述的挤出装置，其特征在于，模具组件包括位于模具组件进口和出口之间的挤出块状制品成型腔。
11.如权利要求10所述的挤出装置，其特征在于，还包括贯穿在模具组件挤压的块状制品成型腔中的圆柱形的芯棒。
12.如权利要求5所述的挤出装置，其特征在于，还包括靠近模具组件沿纵向轴线延伸的冷却管，冷却管中可通过预定温度的空气流。
13.如权利要求5所述的挤出装置，其特征在于，还包括背压控制装置，背压控制装置包括可与模具出口挤压出的块状制品配合的对置的第一和第二轮子，每个轮子可绕各自的与纵向轴线呈横向布置的轴线旋转。
14.如权利要求13所述的挤出装置，其特征在于，还包括改变两个轮子之间压力的装置。
15.如权利要求13所述的挤出装置，其特征在于，还包括可限制两个轮子转动的可变阻力制动器。
16.如权利要求15所述的挤出装置，其特征在于，还包括检测制动阻力并将制动阻力调节到设定值的装置。
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WO1998009709A1 (en) 1998-03-12
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