CN111590941B - 一种高铁密封件用环形密封圈的生产工艺及其生产装置 - Google Patents
一种高铁密封件用环形密封圈的生产工艺及其生产装置 Download PDFInfo
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Abstract
本发明公开了一种高铁密封件用环形密封圈的生产工艺,包括以下步骤制作丁腈橡胶;将部分天然橡胶在开炼机上切成薄片后加入丁腈,混炼均匀制成丁腈橡胶;蜜炼;将丁腈橡胶投入到密炼机中,再依次加入防老剂4010、氧化锌、硬脂酸、氢氧化钙、氧化铝粉、邻苯二甲酸二丁酯、二氧化硅和硅藻土,混炼10~13分钟,提起上顶栓加入硫磺,再混炼60~90秒后排胶,经开炼机翻炼后下片、冷却;本步骤门尼粘度ML(1+4)120℃控制在80±5;成型;将冷却后的胶料投入到挤出机中,使胶料以恒定的速度通过安装在挤出机出口处的模具挤出筒状;通过模具出口处的切割机构以连续运转或间歇运动的方式将模具出口挤出的筒状的胶料切割成设定宽度的胶圈;此外还公开了一种高铁密封件用环形密封圈的生产设备。
Description
技术领域
本发明属于密封圈生产技术领域,具体地说是涉及一种高铁密封件用环形密封圈的生产工艺及其生产装置。
背景技术
密封圈顾名思义是用在需要两个零件连接处的密封或者两个零件相对运动位置进行密封,现有的密封圈往往以橡胶为基材进行生产。见图5-6,由于密封圈往往为环形结构,传统的工艺中往往先将密封圈经过混炼、蜜炼之后压延至一定厚度,然后裁切成条状胶条810,在胶条两端切割出斜口822/821,最后工人将胶条两端的斜口822/821拼接后使用胶水将其粘接成环形的胶圈800;传统的成型方式虽然能够满足密封圈的成型要求,但是其存在以下几个弊端:1、切条、开斜口、斜口拼接以及胶水粘接都需要人工进行,并且胶水固化也需要较长的时间,这就使得生产效率不高,对于大批量的生产有较大的难度;2、虽然采用斜口拼接胶水粘接的方式能够满足成型的日常使用的基本要求,但是由于接口820的连接强度和牢度都要低于胶圈本身,在使用一段时间后往往容易在连接处出现断裂导致密封失效,那么密封圈的寿命和稳定性往往难以保证,产品质量难以得到提高;3、由于工艺本身导致密封圈本身无法具有足够的强度,一些高压或者要求较高的场合应用将会有较大的困难。
发明内容
本发明的目的是提供一种高铁密封件用环形密封圈的生产工艺及其生产装置,其意在解决背景技术中存在的技术问题。
为解决上述技术问题,本发明的目的是这样实现的:
一种高铁密封件用环形密封圈的生产工艺,包括以下步骤
制作丁腈橡胶;将部分天然橡胶在开炼机上切成2-5mm薄通后加入丁腈,混炼均匀后,制成丁腈橡胶;
蜜炼;将丁腈橡胶投入到密炼机中,再依次加入防老剂4010、氧化锌、硬脂酸、氢氧化钙、氧化铝粉、邻苯二甲酸二丁酯、二氧化硅和硅藻土,混炼10~13分钟,提起上顶栓将硫磺加入,再混炼60~90秒后排胶,经开炼机翻炼后下片、冷却;本步骤门尼粘度ML(1+4)120℃控制在80±5;
成型;将冷却后的胶料投入到挤出机中,使胶料以恒定的速度通过安装在挤出机出口处的模具挤出筒状;通过模具出口处的切割机构以连续运转或间歇运动的方式将模具出口挤出的筒状的胶料切割成设定宽度的胶圈。
在上述方案的基础上并作为上述方案的优选方案:还包括将成型后的胶圈硫化的步骤:
半成品预热;将成型好的半成品放入80~85℃烘箱中预热;
硫化;将预热好的胶料投入模腔按其压延方向均匀径向排列,推入平板硫化机进行硫化:
A、硫化初期将硫化温度控制在140~150℃,平板硫化机合模油压控制在16~18Mpa,硫化时间15分钟;
B、硫化中期将硫化温度控制在160~170℃,平板硫化机合模油压控制在12~14Mpa,硫化时间20~30分钟;
C、硫化后期将硫化温度控制在120~130℃,平板硫化机合模油压控制在10~12Mpa,硫化时间15分钟;
硫化后经修整、检验后复合材料密封圈制作完成。
此外,还通过一种高铁密封件用环形密封圈的生产装置来实现环形胶圈的生产,其中一种高铁密封件用环形密封圈的生产装置包括
挤出机;
模具,连接于所述挤出机的出口处;
切割机构,位于所述模具的出口端,所述切割机构包括一按照设定转速连续旋转的刀具或按照设定时长间歇往复动作的刀具,所述刀具可将所述模具出口排出的胶料切断。
在上述方案的基础上并作为上述方案的优选方案:所述切割机构包括驱动电机和刀具,所述刀具中部固定连接于所述驱动电机的主轴,所述刀具的旋转平面与所述模具的出口轴线垂直。
在上述方案的基础上并作为上述方案的优选方案:所述切割机构包括直线往复驱动机构和刀具,所述刀具固设于所述直线往复驱动机构的输出端;所述直线往复驱动机构带动所述刀具移动方向与所述模具的出口轴线垂直。
在上述方案的基础上并作为上述方案的优选方案:所述刀具的横截面为楔形结构,其包括刀具本体以及一楔形面,所述楔形面位于背离所述模具出口一侧。
在上述方案的基础上并作为上述方案的优选方案:还包括一切割往复移动机构,所述切割机构固设于所述切割往复移动机构的输出端,所述切割往复移动机构的输出端带动所述切割机构移入切割工位或者远离切割工位。
在上述方案的基础上并作为上述方案的优选方案:所述模具出口下方设置有一滑槽,切断的所述胶料沿所述滑槽排出。
本发明相比现有技术突出且有益的技术效果是:1、采用本发明的生产方法获得的胶圈为一个整体,无需切条、开斜口、斜口拼接以及胶水粘接,省去了这些步骤以及工序,节省了人工,因为无需胶水粘接也省去了胶水固化的时间,这就使得批量化的生产效率大幅提高。
2、胶圈为一体化结构,不存在传统斜口拼接胶水粘接的方式由于接口的连接强度和牢度都要低于胶圈本身,导致在使用一段时间后往往容易在连接处出现断裂导致密封失效的问题,大幅提高密封圈的寿命和稳定性,产品质量得到提高。
3、本发明的生产的密封圈本身具有足够的强度并且一致性好,完全可以满足高压或者要求较高场合的应用。
附图说明
图1是环形密封圈生产装置的整体结构示意图;
图2是环形密封圈生产装置的前视图;
图3是环形密封圈生产装置的的右视图;
图4是刀具截面图;
图5是传统胶圈结构示意图;
图6是传统胶圈展开图;
图7是本申请胶圈结构图。
具体实施方式
为使本申请的目的、技术方案和优点更加清楚,下面将结合实施例中的附图,对实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅是本申请一部分实施例,而不是全部实施例。基于已给出的实施例,本领域普通技术人员在未做出创造性劳动前提下所获得的所有其他实施例,都属于本申请保护的范围。
在本申请的描述中,需要理解的是,术语“上”、“下”等指示的方位或位置关系为基于附图所示的方位或位置关系,仅是为了便于描述本申请和简化描述,而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本申请的限制。
在本申请的描述中,术语“第一”、“第二”等仅用于描述目的,而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。
实施例一
一种高铁密封件用环形密封圈的生产工艺,包括以下步骤
制作丁腈橡胶;将部分天然橡胶在开炼机上切成2-5mm薄通后加入丁腈,混炼均匀后,制成丁腈橡胶;
蜜炼;将丁腈橡胶投入到密炼机中,再依次加入防老剂4010、氧化锌、硬脂酸、氢氧化钙、氧化铝粉、邻苯二甲酸二丁酯、二氧化硅和硅藻土,混炼10~13分钟,提起上顶栓将硫磺加入,再混炼60~90秒后排胶,经开炼机翻炼后下片、冷却;本步骤门尼粘度ML(1+4)120℃控制在80±5;
成型;将冷却后的胶料投入到挤出机中,使胶料以恒定的速度通过安装在挤出机出口处的模具挤出成筒状;通过模具出口处的切割机构以连续运转或间歇运动的方式将模具出口挤出的筒状的胶料切割成设定宽度的胶圈。
还包括将成型后的胶圈硫化的步骤:
半成品预热;将成型好的半成品放入80~85℃烘箱中预热;
硫化;将预热好的胶料投入模腔按其压延方向均匀径向排列,推入平板硫化机进行硫化:
A、硫化初期将硫化温度控制在140~150℃,平板硫化机合模油压控制在16~18Mpa,硫化时间15分钟;
B、硫化中期将硫化温度控制在160~170℃,平板硫化机合模油压控制在12~14Mpa,硫化时间20~30分钟;
C、硫化后期将硫化温度控制在120~130℃,平板硫化机合模油压控制在10~12Mpa,硫化时间15分钟;
硫化后经修整、检验后复合材料密封圈制作完成。
实施例二
一种高铁密封件用环形密封圈的生产装置,包括
挤出机100,包括位于挤出机上方的投料口110,挤出机驱动电机200驱动挤出机运转;将经过蜜炼后的胶料从投料口110投入到挤出机100内,挤出机便会在挤出机驱动电机200驱动下将胶料进一步的挤压炼化后从挤出机100的出口排出;
模具300,连接于所述挤出机100的出口处,模具300包括模具固定座320,以及模头310,模头310包括外模套313和内膜头311,外模套313和内膜头311之间形成模头出口311,从挤出机100挤出的胶料通过模头310成型后从模头出口311排出,这样由模头出口311排出的胶料便形成了中空的筒状结构。
切割机构400,位于所述模具300的出口端,所述切割机构400包括一按照设定转速连续旋转的刀具所述刀具可将所述模具出口排出的胶料切断。
具体的,所述切割机构400包括驱动电机410和刀具420,所述刀具420中部固定连接于所述驱动电机410的主轴,所述刀具420的旋转平面与所述模具300的模头310出口轴线垂直,这样的话胶料按照恒定的速度从模头出口311排出,此时刀具420按照设定转速连续旋转,因为本实施方式中的刀具420中部固定在驱动电机410的输出轴上,那么刀具420没转动一圈,刀具420将进行两次切割,那么也就是说会切下两个胶圈900;那么只要控制挤出机的挤出速度和驱动电机410带动刀具转动的速度相匹配那么就可以实现将胶料切割成恒定宽度的胶圈900。为了使胶圈900的切口平整,本实施方式优选所述刀具420的横截面为楔形结构,其包括刀具本体421以及一楔形面422,所述楔形面422位于背离所述模具出口311一侧,此时在刀具420切割由模具出口311挤出的胶料时,就可以通过刀具本体421的平面423形成一个整齐的切口。
当然,切割机构还可以是按照设定时长间歇往复动作的刀具;具体的,切割机构包括直线往复驱动机构和刀具,所述刀具固设于所述直线往复驱动机构的输出端;所述直线往复驱动机构带动所述刀具移动方向与所述模具的出口轴线垂直。那么通过直线往复驱动机构带动刀具间歇动作便可以对按照恒定速度从模具出口挤出的胶料进行切断,那么同样可以获得宽度一致的胶圈。
进一步优选的,考虑到更换模头310以及维修更换刀具的便捷性,本实施方式还包括一切割往复移动机构500,所述切割机构400固设于所述切割往复移动机构500的输出端,所述切割往复移动机构500的输出端带动所述切割机构400移入切割工位或者远离切割工位。需要说明的是切割工位即刀具420旋转时能够完全将胶料切断的位置。那么这样在更换模头310或者维修更换刀具的时候就可以是刀具远离模头310,避免切割机构对更换操作造成影响,另一方面也可以防止刀具对操作人员造成伤害。
进一步优选地,所述模具出口311下方设置有一滑槽600,切断的所述胶料900沿所述滑槽600排出。具体的,所述滑槽600包括第一滑道610和第二滑道620,刀具420切割下的胶圈在重力以及刀具带动离心作用下先落入到第一滑道610内,然后沿倾斜的第一滑道610下滑至第二滑道620内,在第二滑道620的尽头具有集料板630,那么从第二滑道620滑出的胶圈就可以直接集中在集料板630上,通过滑槽600将胶圈引导至设备外部,便于非常方便的进行收集,同时使工人的操作区域远离刀具的工作区域,保证工人安全。
上述实施例仅为本发明的较佳实施例,并非依此限制本发明的保护范围,故:凡依本发明的结构、形状、原理所做的等效变化,均应涵盖于本发明的保护范围之内。
Claims (1)
1.一种高铁密封件用环形密封圈的生产工艺,其特征在于:包括以下步骤
制作丁腈橡胶;将部分天然橡胶在开炼机上切成 2-5mm薄通后加入丁腈,混炼均匀后,制成丁腈橡胶;
蜜炼;将丁腈橡胶投入到密炼机中,再依次加入防老剂 4010、氧化锌、硬脂酸、氢氧化钙、氧化铝粉、邻苯二甲酸二丁酯、二氧化硅和硅藻土,混炼10~13分钟,提起上顶栓将硫磺加入,再混炼60~90秒后排胶,经开炼机翻炼后下片、冷却;本步骤门尼粘度ML(1+4)120℃控制在80±5;
成型;将冷却后的胶料投入到挤出机中,使胶料以恒定的速度通过安装在挤出机出口处的模具挤出成筒状;通过模具出口处的切割机构以连续运转或间歇运动的方式将模具出口挤出的筒状的胶料切割成设定宽度的密封圈半成品;
还包括将密封圈半成品硫化的步骤:
半成品预热;将密封圈半成品放入80~85℃烘箱中预热;
硫化;将预热好的密封圈半成品投入模腔按其压延方向均匀径向排列,推入平板硫化机进行硫化:
A、硫化初期将硫化温度控制在140~150℃,平板硫化机合模油压控制在16~18Mpa,硫化时间15分钟;
B、硫化中期将硫化温度控制在160~170℃,平板硫化机合模油压控制在12~14Mpa,硫化时间20~30分钟;
C、硫化后期将硫化温度控制在120~130℃,平板硫化机合模油压控制在10~12Mpa,硫化时间15分钟;
硫化后经修整、检验后复合材料密封圈制作完成。
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