CN111806005A - 一种防静电硅橡胶的合成工艺 - Google Patents
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Abstract
本发明公开了一种防静电硅橡胶的合成工艺,包括以下步骤,S1,混炼,硅橡胶生胶比较柔软,具有一定的可塑性,可不经塑炼而直接采用开炼机或密炼机进行混炼呈硅橡胶,同时在混炼过程中加入防静电填料;S2,压延,利用压延机进行压延作业形成硅胶片,用于压延的硅橡胶胶料必须正确控制其返炼程度,最好在混炼机上先不充分返炼,以期在压延过程中获得足够返炼,可避免胶料在压延过程中因返炼过度而粘辊。本发明本防静电硅橡胶基底采用PL薄膜,使硅橡胶的导热更快,更均匀,且材料防静电,不会出现静电残留和静电击穿的不良,表面涂覆丙烯酸胶粘剂与防静电处理层,配合中层防静电填料处理,提高硅橡胶的防静电性能。
Description
技术领域
本发明涉及硅橡胶生产技术领域,尤其涉及一种防静电硅橡胶的合成工艺。
背景技术
随着越来越多的应用领域提出抗静电要求,特别是电子计算机用途的拓展,静电产生的几率也相应增加,加上人们对静电的防范意思也在增加,许多国家对抗静电的措施日益规范化。
其中最终要的是开发各种抗静电器件,于是抗静电硅胶制品走进大家的视线,广泛的应用在了各行各业当中,抗静电硅胶既要起到除静电的作用,又可防止低压线路泄露所造成的点击事故,如果有条件可以在生产过程中添加和硅胶同性质的防静电液或者把防静电液擦在表面也可以(这样防静电时间比较久),也可以在生产过程中加入防静电剂,效果会更好,如果已经生产好的成品,可以用防静电液擦在吸盘表面,时间能维持半年左右才会衰退。
现有的硅橡胶只是简单添加填料改变其防静电效果,其耐久性和整体的静电聚集表面上的静电处理未进行加强处理,进而造成衰退加剧,影响整体的硅橡胶品质。
发明内容
基于背景技术存在的技术问题,本发明提出了一种防静电硅橡胶的合成工艺。
本发明提出的一种防静电硅橡胶的合成工艺,包括以下步骤:
S1:混炼:硅橡胶生胶比较柔软,具有一定的可塑性,可不经塑炼而直接采用开炼机或密炼机进行混炼呈硅橡胶,同时在混炼过程中加入防静电填料;
S2:压延:利用压延机进行压延作业形成硅胶片,用于压延的硅橡胶胶料必须正确控制其返炼程度,最好在混炼机上先不充分返炼,以期在压延过程中获得足够返炼,可避免胶料在压延过程中因返炼过度而粘辊;
S3:硫化:硅橡胶硫化工艺不是一次完成,而是分两个阶段进行的:一次硫化:压延后的硅胶片在加压下或常压下,加入部分硫化剂进行加热定型;后硫化:在烘箱中高温硫化,达到进一步稳定硫化胶各项物理性能;
S4:基底涂胶:硫化后的硅橡胶进行涂胶用的底层基体为PL薄膜,对其进行热定型,即将PL薄膜在一定牵伸下,进行短时间热处理成型后,再进行表面胶粘剂处理,再进行涂胶;
S5:表面涂胶:在硅橡胶的表面涂布丙烯酸胶粘剂与防静电处理层,然后热压使防静电硅橡胶的胶合层更加紧密;
S6:修边检测:对以PL薄膜基底的防静电硅橡胶进行修边,拆边检查,检测其性能。
优选地,所述S1中混炼通过开炼机混炼时长为20-40min,通过密炼机的混炼时长为6-16min。
优选地,所述所述S1中的防静电填料为炭黑、碳纤维、碳纳米管、石墨烯、金属颗粒及其复合物和表面活性剂中至少一种。
优选地,所述S3中的硫化剂为DBPMH、BP和TBPB与DCBP中任一一种试剂。
优选地,所述S3中的硫化过程中,一次硫化的温度为120-130℃,后硫化的温度为230-235℃。
优选地,所述S4中的表面胶粘剂是一种由烷氧基硅烷、硼酸酯、硫化剂和乙酸乙酯或乙醇组成的混合溶液。
优选地,所述S5中的防静电处理层由低密度聚乙烯、线性型低密度聚乙烯、抗静电母料、色母和稳定剂混合吹塑成型。
本发明中的有益效果为:
1.本防静电硅橡胶基底采用PL薄膜,使硅橡胶的导热更快,更均匀,且材料防静电,不会出现静电残留和静电击穿的不良;压合次数在60-80次,减少上下料用时,增加产能,无硅油析出,不会一些应用中的UV胶封边产生影响;
2.其中控制添加的防静电填料总量,夏季中添加总质量的5-7%,使其达到体积电阻小于109Ω.cm,冬季添加总质量的6-8%使其达到体积电阻小于109Ω.cm,炭黑、碳纤维、碳纳米管、石墨烯、金属颗粒及其复合物和表面活性剂多种试剂配合使用;
3.在表面进行涂覆丙烯酸胶粘剂与防静电处理层,使其两侧均具有良好的防静电处理,配合中层的防静电填料处理,提高整体的硅橡胶的防静电性能提升。
附图说明
图1为本发明提出的一种防静电硅橡胶的合成工艺的工艺流程图。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。
参照图1,一种防静电硅橡胶的合成工艺,包括以下步骤:
S1:混炼:硅橡胶生胶比较柔软,具有一定的可塑性,可不经塑炼而直接采用开炼机或密炼机进行混炼呈硅橡胶,同时在混炼过程中加入防静电填料;
S2:压延:利用压延机进行压延作业形成硅胶片,用于压延的硅橡胶胶料必须正确控制其返炼程度,最好在混炼机上先不充分返炼,以期在压延过程中获得足够返炼,可避免胶料在压延过程中因返炼过度而粘辊;
S3:硫化:硅橡胶硫化工艺不是一次完成,而是分两个阶段进行的:一次硫化:压延后的硅胶片在加压下或常压下,加入部分硫化剂进行加热定型;后硫化:在烘箱中高温硫化,达到进一步稳定硫化胶各项物理性能;
S4:基底涂胶:硫化后的硅橡胶进行涂胶用的底层基体为PL薄膜,对其进行热定型,即将PL薄膜在一定牵伸下,进行短时间热处理成型后,再进行表面胶粘剂处理,再进行涂胶;
S5:表面涂胶:在硅橡胶的表面涂布丙烯酸胶粘剂与防静电处理层,然后热压使防静电硅橡胶的胶合层更加紧密;
S6:修边检测:对以PL薄膜基底的防静电硅橡胶进行修边,拆边检查,检测其性能。
本发明中,其中部分内容的扩展具体如下:
1.开炼机混炼
双辊开炼机辊筒速比以(1.2-1.4):1为宜,快辊在后,较高的速比导致较快的混炼,低速比可使胶片光滑。辊筒必须通有冷却水,混炼温度宜在40℃以下,以防止焦烧或硫化剂的挥发损失。混炼时开始辊距较小(1-5mm),然后逐步增大。
加料和操作顺序:生胶(包辊)-补强填充剂-结构控制剂-耐热助剂-着色剂-薄通5次-下料,烘箱热处理-返炼-硫化剂-薄通-停放过夜-返炼-出片。
胶料也可不经烘箱热处理,在加入耐热助剂后,加入硫化剂再薄通,停放过夜返炼,然后再停放数天返炼出片使用。混炼时间为20-40min.
硅橡胶在加入炼胶机时包慢辊(前辊),混炼时则很快包快辊(后辊),炼胶时必须能两面操作。由于硅橡胶胶料比较软,混炼时可用普通腻子刀操作,薄通时不能像普通橡胶那样拉下薄片,而采用钢、尼龙或耐磨塑料刮刀刮下。
为便于清理和防止润滑油漏入胶内,应采用活动胶板。气相法白炭黑易飞扬,对人体有害,应采取相应的保护措施。如果在混炼时直接使用粉状过氧化物,必须采取防爆措施,最好使用膏状过氧化物。
2.密炼机混炼
用实验室2L密炼机混炼时,混炼时间为6-16min.混炼无特殊困难。当装料系数为0.74时,采用Φ160mm开炼机混炼也能正常进行。排料温度与补强填充剂的类型有关,当采用弱补强性填充剂和沉淀法白炭黑时,排胶温度在50℃以下;当使用气相法白炭黑时排胶温度为70℃左右。
胶料停放和返炼:硅橡胶胶料混炼结束后,停放时间应不少于24h,以使各种配合剂(特别是结构控制剂)能与生胶充分起作用。停放后胶料变硬,塑性值下降,使用前必须进行返炼。返炼采用开炼机,开始时辊距较大(3-5mm),此时胶料较硬,表面呈皱纹状,包在前辊上。随着返炼时间的延长,胶料逐渐变软;慢慢缩小辊距(0.25-0.5mm),胶料很快包在后辊上。待胶料变软,表面光滑平整后,即可下料出片。返炼不足,胶片表面有皱纹;返炼过度,则胶料发粘而粘辊。返炼温度一般控制在室温。
挤出:硅橡胶一般比较柔软,挤出效果较好,易于操作,可挤出各种不同形状和尺寸的制品,其加工设备和工具基本上与普通橡胶相似。
出机一般是用Φ30或Φ65mm的单螺纹螺杆,长径比为(10-12):1效果较好。挤出时尽量保持低温,以不超过40℃为宜,故机筒和螺杆均须通冷却水。对质量要求较高的产品可在靠近机头部分加装80-140目滤网,以除去胶料中的杂质,改善挤出质量。
硅橡胶挤出半成品柔软而易变形,因此必须立即进行硫化。最常用的方法是热空气连续硫化;电线、电缆工业通常用高压蒸汽连续硫化。如在挤出后不能连续硫化,为防止变形,挤出后应立即用圆盘、圆鼓或输送带接取,用滑石粉隔离以免相互粘结。若发现胶料过软而不适于挤出时,可在胶料中再混入3-5份气相法白炭黑。
用于挤出的胶料配方,其硫化剂用量应比模压制品的适当增大,硅橡胶的挤出速度低于其它橡胶,当要求与其它橡胶达到相同挤出速度时,应采用较高的螺杆转速。
压延:压延机一般采用立式三辊压延机。用于生产胶片时,中辊是固定的,中辊转速比上辊快,速比为(1.1-1.4):1,下辊的转速和中辊相同。当压延机开动时,上辊温度为50℃,中辊应保持为室温,下辊用冷却水冷却。压延速度一般为60-7500px·min-1,不宜过快,先以低速调整辊距(中、下辊),以保证一定的压延厚度,然后再提高至正常速度进行连续操作。
当三辊压延机用于硅橡胶贴胶和擦胶时,PL薄膜替代了垫布(聚酯薄膜)在中辊和下辊之间通过。三辊压延机只适用于单面覆胶,长期生产时应采用四辊压延机。
用于压延的胶料必须正确控制其返炼程度,最好在炼胶机上先不充分返炼,以期在压延过程中获得足够返炼,这样可以避免胶料在压延过程中因返炼过度而粘辊。胶料配方对压延也有一定的影响,采用补强性填充剂的胶料压延工艺性能较好。
PL薄膜经预处理后,还要进行表面胶粘剂处理,然后才可涂胶。胶粘剂是一种由烷氧基硅烷、硼酸酯、硫化剂和溶剂(乙酸乙酯或乙醇)组成的溶液。
PL薄膜经胶粘剂表面处理后,即可用涂胶机将胶浆均匀涂在PL薄膜上,然后经干燥、硫化即成。
硫化一般分两段进行:一段温度为120~130℃,二段温度为230℃。涂层的厚度可以通过改变胶液的粘度或调节PL薄膜通过涂胶槽的速度来控制。
模型制品硫化:可采用平板硫化、传递模压硫化和注压硫化。
硅橡胶制品平板硫化时,一般不使用脱模剂,应迅速装料、合模、加压,否则容易焦烧,特别是含有硫化剂BP和DCBP的胶料。
传递模压硫化是一种加工硅橡胶胶料应用较广泛的工艺,与每模单孔的平板硫化比较,其优点是加工周期短,并能硫化复杂的特别是带有插入物和销钉的橡胶件。与注压硫化比较,设备成本较低。注压硫化模制品,可提高劳动生产率,降低劳动强度,同时还可以减小过氧化物的用量,提高制品的抗撕裂性能,改善压缩永久变形性能,但制品收缩率较大。
挤出制品的硫化。可采用蒸汽加压硫化、热空气连续硫化、液体硫化槽连续硫化、鼓式硫化和辐射硫化等方法。前3种方法较常用。
二段硫化
硅橡胶制品经过一段硫化后,有些低分子物质存在于硫化胶中,影响制品性能,例如,采用通用型硫化剂(如硫化剂BP或DCBP)的胶料,经过一段硫化后,其硫化剂分解的酸性物质量,将增大海绵孔的孔度,降低密度。
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,根据本发明的技术方案及其发明构思加以等同替换或改变,都应涵盖在本发明的保护范围之内。
Claims (7)
1.一种防静电硅橡胶的合成工艺,其特征在于,包括以下步骤:
S1:混炼:硅橡胶生胶比较柔软,具有一定的可塑性,可不经塑炼而直接采用开炼机或密炼机进行混炼呈硅橡胶,同时在混炼过程中加入防静电填料;
S2:压延:利用压延机进行压延作业形成硅胶片,用于压延的硅橡胶胶料必须正确控制其返炼程度,最好在混炼机上先不充分返炼,以期在压延过程中获得足够返炼,可避免胶料在压延过程中因返炼过度而粘辊;
S3:硫化:硅橡胶硫化工艺不是一次完成,而是分两个阶段进行的:一次硫化:压延后的硅胶片在加压下或常压下,加入部分硫化剂进行加热定型;后硫化:在烘箱中高温硫化,达到进一步稳定硫化胶各项物理性能;
S4:基底涂胶:硫化后的硅橡胶进行涂胶用的底层基体为PL薄膜,对其进行热定型,即将PL薄膜在一定牵伸下,进行短时间热处理成型后,再进行表面胶粘剂处理,再进行涂胶;
S5:表面涂胶:在硅橡胶的表面涂布丙烯酸胶粘剂与防静电处理层,然后热压使防静电硅橡胶的胶合层更加紧密;
S6:修边检测:对以PL薄膜基底的防静电硅橡胶进行修边,拆边检查,检测其性能。
2.根据权利要求1所述的一种防静电硅橡胶的合成工艺,其特征在于,所述S1中混炼通过开炼机混炼时长为20-40min,通过密炼机的混炼时长为6-16min。
3.根据权利要求1所述的一种防静电硅橡胶的合成工艺,其特征在于,所述所述S1中的防静电填料为炭黑、碳纤维、碳纳米管、石墨烯、金属颗粒及其复合物和表面活性剂中至少一种。
4.根据权利要求1所述的一种防静电硅橡胶的合成工艺,其特征在于,所述S3中的硫化剂为DBPMH、BP和TBPB与DCBP中任一一种试剂。
5.根据权利要求1所述的一种防静电硅橡胶的合成工艺,其特征在于,所述S3中的硫化过程中,一次硫化的温度为120-130℃,后硫化的温度为230-235℃。
6.根据权利要求1所述的一种防静电硅橡胶的合成工艺,其特征在于,所述S4中的表面胶粘剂是一种由烷氧基硅烷、硼酸酯、硫化剂和乙酸乙酯或乙醇组成的混合溶液。
7.根据权利要求1所述的一种防静电硅橡胶的合成工艺,其特征在于,所述S5中的防静电处理层由低密度聚乙烯、线性型低密度聚乙烯、抗静电母料、色母和稳定剂混合吹塑成型。
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