CN112140668A - 一种高承载复合挂胶履带板橡胶衬垫及制备方法 - Google Patents
一种高承载复合挂胶履带板橡胶衬垫及制备方法 Download PDFInfo
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Abstract
本发明公开了一种高承载复合挂胶履带板橡胶衬垫及其制备方法,属于履带式车辆履带板橡胶衬垫技术领域。本发明的高承载复合挂胶履带板橡胶衬垫,采用内、外双层复合挂胶结构,内层材料采用高模量、高弹性、低生热性能的橡胶材料,可以提高橡胶衬垫的抗冲击能力及降低制品动态生热,解决胶料掉大块问题及提高挂胶制品使用寿命;外层材料采用高模量、高强度、耐磨损、耐撕裂的橡胶材料,可以提高橡胶衬垫耐磨性及耐切割性;从而使橡胶衬垫具备高模量、高强度、高弹性、耐磨、耐撕裂等综合性能优势,可有效改善履带板橡胶制品在使用过程中抗冲击能力差、不耐磨损、易撕裂掉块等问题。另外,本发明方法还具有操作简单、可重复性好等优点。
Description
技术领域
本发明属于履带式车辆履带板橡胶衬垫技术领域,特别是涉及一种高承载复合挂胶履带式车辆履带板橡胶衬垫及其制备方法。
背景技术
工程机械、建筑机械等高性能车辆均属于履带式作业车辆,履带式车辆的履带板橡胶衬垫使用工况苛刻,极易破坏,表现出过度磨损、崩花、掉块等问题,要求橡胶衬垫具备高模量、高强度、高弹性、高撕裂、耐磨损等性能特点。
现有履带板橡胶衬垫都采用单一胶料通过热硫化与金属板粘接制备而成,而单一胶料难以同时具备高模量、高强度、高弹性、高撕裂、耐磨损等综合性能,难以满足履带板橡胶衬垫使用需求。提高履带板橡胶衬垫耐磨、抗崩花掉块性能是提高装备水平及降低装备使用成本的关键。
发明内容
本发明的目的在于提供一种高承载复合挂胶履带板橡胶衬垫及其制备方法,使履带板橡胶衬垫具有高模量、高强度、高弹性、耐磨、耐撕裂等综合性能特点,解决橡胶衬垫在高冲击及越野路面动态温升高、撕裂掉块及磨损严重的问题,提高履带板橡胶衬垫的综合使用性能。
本发明的目的是这样实现的,采用不同性能设计的内外层橡胶材料混炼胶预成型胚胎复合,并与金属履带板热硫化粘接成型制备履带板橡胶衬垫,内层材料采用高模量、高弹性、低生热性能的橡胶材料,提高橡胶衬垫的抗冲击能力及降低制品动态生热,解决胶料掉大块问题及提高挂胶制品使用寿命;外层材料采用高模量、高强度、耐磨损、耐撕裂的橡胶材料,提高橡胶衬垫耐磨性及耐切割性。内外层胶料经厚度匹配设计叠加复合与履带板金属热硫化粘接成型,制备得到本发明涉及的高承载复合挂胶履带板橡胶衬垫。
本发明涉及的高承载复合挂胶履带板橡胶衬垫,由履带金属骨架和橡胶衬垫构成,其特征在于:所述橡胶衬垫由橡胶衬垫内层和橡胶衬垫外层构成;所述橡胶衬垫内层,由300%定伸强度不小于10MPa、回弹性不小于45%、拉伸强度不小于22MPa的橡胶材料制成;所述橡胶衬垫外层,由300%定伸强度不小于12MPa、回弹性不小于33%、拉伸强度不小于26MPa的橡胶材料制成;所述橡胶衬垫内层底面与履带金属骨架顶面匹配放置、顶面与橡胶衬垫外层底面匹配放置。
本发明涉及的高承载复合挂胶履带板橡胶衬垫,其特征在于:所述橡胶衬垫外层厚度占高承载复合挂胶履带板橡胶衬垫总厚度的23.2%~50%。
本发明涉及的高承载复合挂胶履带板橡胶衬垫,其特征在于:所述橡胶衬垫内层与橡胶衬垫外层为凹凸结构配合接触。
本发明涉及的高承载复合挂胶履带板橡胶衬垫,其特征在于:所述橡胶衬垫内层与橡胶衬垫外层的凹凸结构截面为长方形或等腰梯形。
本发明涉及的高承载复合挂胶履带板橡胶衬垫,其特征在于:所述橡胶衬垫外层外侧两顶角处设置有倒圆角。
本发明涉及的高承载复合挂胶履带板橡胶衬垫的制备方法,其步骤如下:
1)橡胶材料的制备
按以下质量份配比称取材料:天然橡胶50~70份、顺丁橡胶30~50份、炭黑40~60份、氧化锌5~10份、硫磺3~4份、促进剂1~2份,通过密炼机,制备成橡胶衬垫内层用橡胶材料;
按以下质量份配比称取材料:天然橡胶50~70份、丁苯橡胶30~50份、炭黑50~70份,氧化锌5~10份、白炭黑 10~20份、硫磺2~3份、促进剂0.5~1份,通过密炼机,制备成橡胶衬垫外层用橡胶材料;
2)预成型胚的制备
根据橡胶衬垫内层和橡胶衬垫外层的结构尺寸、以及步骤(1)制备的两种橡胶材料的膨胀系数,分别设计适用的挤出口模,并通过挤出机制备出橡胶衬垫内层和橡胶衬垫外层的预成型胚;
3)硫化成型
将步骤(2)制备的预成型胚复合叠加,放置在履带板金属骨架上,在145~155℃、18~22MPa条件下热硫化,制得高承载复合挂胶履带板橡胶衬垫。
本发明涉及的高承载复合挂胶履带板橡胶衬垫,采用内、外双层复合挂胶结构,内层材料采用高模量、高弹性、低生热性能的橡胶材料,可以提高橡胶衬垫的抗冲击能力及降低制品动态生热,解决胶料掉大块问题及提高挂胶制品使用寿命;外层材料采用高模量、高强度、耐磨损、耐撕裂的橡胶材料,可以提高橡胶衬垫耐磨性及耐切割性;从而使橡胶衬垫具备高模量、高强度、高弹性、耐磨、耐撕裂等综合性能优势,可有效改善履带板橡胶制品在使用过程中抗冲击能力差、不耐磨损、易撕裂掉块等问题。另外,本发明方法还具有操作简单、可重复性好等优点。
四、附图说明
图1是高承载复合挂胶履带板橡胶衬垫第一种结构的示意图;
图2是高承载复合挂胶履带板橡胶衬垫第二种结构的示意图;
图3是高承载复合挂胶履带板橡胶衬垫第三种结构橡胶衬垫内层的俯视图。
其中:1-履带板金属骨架,2-橡胶衬垫内层,3-橡胶衬垫外层
五、具体实施方式
下面结合具体实例对本发明的高承载复合挂胶履带板橡胶衬垫进一步说明,但不作为对本发明内容的限制,任何基于本发明提出的技术方案的复合结构橡胶衬垫均构成本发明的组成部分。
实施例一
本实施例的高承载复合挂胶履带板橡胶衬垫,由履带板金属骨架1、橡胶衬垫内层2和橡胶衬垫外层3构成,如图1所示。
橡胶衬垫内层2,平板结构,长200mm、宽120mm、厚22.5mm,由拉伸强度26MPa、300%定伸强度10MPa、回弹性55%以及膨胀系数1.25的橡胶材料制成。
橡胶衬垫外层3,平板结构,长200mm、宽120mm、厚6.8mm,在外侧两顶角处设置R20mm的倒圆角,由拉伸强度30MPa、300%定伸强度12MPa、回弹性43%以及膨胀系数1.1的橡胶材料制成。
本实施例的高承载复合挂胶履带板橡胶衬垫,由上到下依次放置橡胶衬垫外层3、橡胶衬垫内层2和履带板金属骨架1,接触面紧密贴合。
本实施例的高承载复合挂胶履带板橡胶衬垫,制备方法如下:
(1)橡胶材料的制备:
称取700克天然橡胶、300克顺丁橡胶、400克炭黑N330、50克氧化锌、40克硫磺以及20克促进剂DZ。 将1.8升密炼机的转速设置为40r/min,加热温度设置为40℃,将天然橡胶、顺丁橡胶、炭黑、氧化锌放入密炼机腔室混炼10min时排胶,得到一段胶;将密炼机转速设置为20r/min,加热温度设置为40℃,将一段胶、硫磺、促进剂放入密炼机腔室混炼5min时排胶,得到终炼胶。混炼胶降至室温后,即为橡胶衬垫内层2用橡胶材料。对其按照相应国家标准进行实验测试,测得其拉伸强度为26MPa、300%定伸强度为10MPa、回弹性为55%以及膨胀系数为1.25。
称取700克天然橡胶、300克丁苯橡胶、500克炭黑N110、50克氧化锌、200克白炭黑、30克硫磺以及10.0克促进剂。将1.8升密炼机的转速设置为50r/min,加热温度设置为40℃,将天然橡胶、丁苯橡胶、炭黑、氧化锌放入密炼机腔室混炼10min时排胶,得到一段胶;将密炼机转速设置为20r/min,加热温度设置为40℃,将一段胶、硫磺、促进剂放入密炼机腔室混炼5min时排胶,得到终炼胶。混炼胶降至室温后,即为橡胶衬垫外层3用橡胶材料。对其按照相应国家标准进行实验测试,测得其拉伸强度为30MPa、300%定伸强度为12MPa、回弹性为43%以及膨胀系数为1.1。
(2)预成型胚的制备
设计并制备挤出口模:挤出口模内腔尺寸,由橡胶制品的结构尺寸除以其橡胶材料的膨胀系数得出。由此算出,橡胶衬垫内层2的挤出口模内腔尺寸为1600mm×96mm×18mm,橡胶衬垫3的挤出口模尺寸为181.8mm×109.1mm×6mm。
将制备的挤出口模分别装配到相应挤出机上,分别制备出橡胶衬垫内层2混炼胶的预成型胚和橡胶衬垫外层3混炼胶的预成型胚。
(3)硫化成型
将步骤(2)制备的预成型胚复合叠加,放置在履带板金属骨架1上,在155℃、22MPa条件下热硫化40分钟,得到本实施例的复合履带板橡胶衬垫。
实 施 例 二
本实施例的高承载复合挂胶履带板橡胶衬垫,与实施例一区别之处在于:
橡胶衬垫内层2,长200mm、宽120mm、最大厚度15mm,如图2所示,其顶面沿长度方向设置三个截面为17mm×5mm、长度与橡胶衬垫内层2长度一致的长方形凹槽;由拉伸强度22MPa、300%定伸强度13MPa、回弹性45%以及膨胀系数1.15的橡胶材料制成。
橡胶衬垫外层3,长200mm、宽120mm、最大厚度15mm,如图2所示,其底面设置三个长方形凸台,位置和尺寸与橡胶衬垫内层2顶面凹槽相匹配;在外侧两顶角处设置R10mm的倒圆角,由拉伸强度26MPa、 300%定伸强度16MPa、回弹性33%以及膨胀系数1.05的橡胶材料制成。
本实施例的高承载复合挂胶履带板橡胶衬垫,橡胶衬垫内层2顶面的凹槽与橡胶衬垫外层3底面的凸台配合放置。
本实施例的高承载复合挂胶履带板橡胶衬垫,制备方法如下:
(1)橡胶材料的制备
称取500克天然橡胶、500克顺丁橡胶、600克炭黑N550、100克氧化锌、30克硫磺、20克促进剂。将1.8升密炼机的转速设置为40r/min,加热温度设置为40℃,将天然橡胶、顺丁橡胶、炭黑、氧化锌放入密炼机腔室混炼10min时排胶,得到一段胶;将密炼机转速设置为20r/min,加热温度设置为40℃,将一段胶、硫磺、促进剂放入密炼机腔室混炼5min时排胶,得到终炼胶。混炼胶降至室温后,即为橡胶衬垫内层2用橡胶材料。对其按照相应国家标准进行实验测试,测得其拉伸强度为22MPa、300%定伸强度为13MPa、回弹性为45%以及膨胀系数为1.15。
称取500克天然橡胶、500克丁苯橡胶、700克炭黑N234、50克氧化锌、100克白炭黑、20克硫磺、5.0克促进剂。将1.8升密炼机的转速设置为50r/min,加热温度设置为40℃,将天然橡胶、丁苯橡胶、炭黑、氧化锌放入密炼机腔室混炼10min时排胶,得到一段胶;将密炼机转速设置为20r/min,加热温度设置为40℃,将一段胶、硫磺、促进剂放入密炼机腔室混炼5min时排胶,得到终炼胶。混炼胶降至室温后,即为橡胶衬垫外层3用橡胶材料。对其按照相应国家标准进行实验测试,测得其拉伸强度为26MPa、300%定伸强度为16MPa、回弹性为33%以及膨胀系数为1.05。
(2)预成型胚的制备
根据实施例一挤出口模内腔尺寸的计算方法,算出橡胶衬垫内层2的挤出口模内腔尺寸为173.9mm×104.3mm×13mm,其中凹槽尺寸为14.8mm×4.3mm;橡胶衬垫3的挤出口模尺寸为190.5mm×114.3mm×14.3mm,其中凸台尺寸为16.2mm×4.8mm。
将制备的挤出口模分别装配到相应挤出机上,分别制备出橡胶衬垫内层2混炼胶的预成型胚和橡胶衬垫外层3混炼胶的预成型胚。
(3)硫化成型
将步骤(2)制备的预成型胚复合叠加,放置在履带板金属骨架1上,在145℃、18MPa条件下热硫化40分钟,得到本发明涉及的复合履带板橡胶衬垫。
实 施 例 三
本实施例的高承载复合挂胶履带板橡胶衬垫,与实施例一区别之处在于:
橡胶衬垫内层2,长350mm、宽120mm、最大厚度18mm,顶面均布两排六个长50mm的凹槽,如图3所示,其纵截面为等腰梯形,底边长24mm、深5mm、底面夹角为95°;由拉伸强度26MPa、300%定伸强度12MPa、回弹性51%以及膨胀系数1.20的橡胶材料制成。
橡胶衬垫外层3,长350mm、宽120mm、最大厚度12mm,其底面设置五个凸台,位置和尺寸与橡胶衬垫内层2顶面凹槽相匹配;在外侧两顶角处设置R10mm的倒圆角,由拉伸强度29MPa、300%定伸强度14Mpa、回弹性38%以及膨胀系数1.08的橡胶材料制成。
本实施例的高承载复合挂胶履带板橡胶衬垫,橡胶衬垫内层2顶面的凹槽与橡胶衬垫外层3底面的凸台配合放置。
本实施例的高承载复合挂胶履带板橡胶衬垫,制备方法如下:
(1)橡胶材料制备:
称取600克天然橡胶、400克顺丁橡胶、500克炭黑N330、75克氧化锌、35克硫磺、15克促进剂。将1.8升密炼机的转速设置为40r/min,加热温度设置为40℃,将天然橡胶、顺丁橡胶、炭黑、氧化锌放入密炼机腔室混炼10min时排胶,得到一段胶;将密炼机转速设置为20r/min,加热温度设置为40℃,将一段胶、硫磺、促进剂放入密炼机腔室混炼5min时排胶,得到终炼胶。混炼胶降至室温后,即为橡胶衬垫内层2用橡胶材料。对其按照相应国家标准进行实验测试,测得其拉伸强度为26MPa、300%定伸强度为12MPa、回弹性为51%以及膨胀系数为1.20。
称取600克天然橡胶、400克丁苯橡胶、600克炭黑N110、75克氧化锌、150克白炭黑、25克硫磺、7.5克促进剂。将1.8升密炼机的转速设置为50r/min,加热温度设置为40℃,将天然橡胶、丁苯橡胶、炭黑、氧化锌放入密炼机腔室混炼10min时排胶,得到一段胶;将密炼机转速设置为20r/min,加热温度设置为40℃,将一段胶、硫磺、促进剂放入密炼机腔室混炼5min时排胶,得到终炼胶。混炼胶降至室温后,即为橡胶衬垫外层3用橡胶材料。对其按照相应国家标准进行实验测试,测得其拉伸强度为29MPa、300%定伸强度为14MPa、回弹性为38%以及膨胀系数为1.08。
(2)预成型胚的制备
根据实施例一挤出口模内腔尺寸的计算方法,算出橡胶衬垫内层2的挤出口模内腔尺寸为291.7mm×100 mm×15mm,其中凹槽长为41.7mm、纵截面尺寸为20mm×4.2mm;橡胶衬垫3的挤出口模尺寸为324.1mm×111mm×11mm,其中凸台长为46.3mm、纵截面尺寸为22.2mm×4.6mm。
将制备的挤出口模分别装配到相应挤出机上,分别制备出橡胶衬垫内层2混炼胶的预成型胚和橡胶衬垫外层3混炼胶的预成型胚。
(3)硫化成型
将步骤(2)制备的预成型胚复合叠加,放置在履带板金属骨架1上,在150℃、20MPa条件下热硫化40分钟,得到本发明涉及的复合履带板橡胶衬垫。
Claims (6)
1.一种高承载复合挂胶履带板橡胶衬垫,由履带金属骨架和橡胶衬垫层复合而成,其特征在于:所述橡胶衬垫层由橡胶衬垫内层(2)和橡胶衬垫外层(3)复合而成;所述橡胶衬垫内层(2),由300%定伸强度不小于10MPa、回弹性不小于45%、拉伸强度不小于22MPa的橡胶材料制成;所述橡胶衬垫外层(3),由300%定伸强度不小于12MPa、回弹性不小于33%、拉伸强度不小于26MPa的橡胶材料制成;所述橡胶衬垫内层(2)底面与履带金属骨架(1)顶面匹配放置、顶面与橡胶衬垫外层(3)底面匹配放置。
2.根据权利要求1所述的高承载复合挂胶履带板橡胶衬垫,其特征在于:所述橡胶衬垫外层(3)最大厚度占高承载复合挂胶履带板橡胶衬垫总厚度的23.2%~50%。
3.根据权利要求1或2所述的高承载复合挂胶履带板橡胶衬垫,其特征在于:所述橡胶衬垫内层(2)与橡胶衬垫外层(3)为凹凸结构配合接触。
4.根据权利要求3所述的高承载复合挂胶履带板橡胶衬垫,其特征在于:所述橡胶衬垫内层(2)与橡胶衬垫外层(3)的凹凸结构截面为长方形或等腰梯形。
5.根据权利要求1所述的高承载复合挂胶履带板橡胶衬垫,其特征在于:所述橡胶衬垫外层(3)外侧两顶角处设置有倒圆角。
6.一种权利要求1所述高承载复合挂胶履带板橡胶衬垫的制备方法,其步骤如下:
1)橡胶材料的制备
按以下质量份配比称取材料:天然橡胶50~70份、顺丁橡胶30~50份、炭黑40~60份、氧化锌5~10份、硫磺3~4份、促进剂1~2份,通过密炼机,制备成橡胶衬垫内层(2)用橡胶材料;
按以下质量份配比称取材料:天然橡胶50~70份、丁苯橡胶30~50份、炭黑50~70份,氧化锌5~10份、白炭黑 10~20份、硫磺2~3份、促进剂0.5~1份,通过密炼机,制备成橡胶衬垫外层(3)用橡胶材料;
2)预成型胚的制备
根据橡胶衬垫内层(2)和橡胶衬垫外层(3)的结构尺寸、以及步骤1)制备的两种橡胶材料的膨胀系数,分别设计并制备适用的挤出口模,并通过挤出机制备出橡胶衬垫内层(2)和橡胶衬垫外层(3)的预成型胚;
3)硫化成型
将步骤2)制备的预成型胚复合叠加,放置在履带板金属骨架(1)上,在145~155℃、18~22MPa条件下热硫化,制得高承载复合挂胶履带板橡胶衬垫。
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