CN113119358A - 一种高强度轮胎硫化胶囊及其生产工艺 - Google Patents

一种高强度轮胎硫化胶囊及其生产工艺 Download PDF

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CN113119358A
CN113119358A CN201911376917.0A CN201911376917A CN113119358A CN 113119358 A CN113119358 A CN 113119358A CN 201911376917 A CN201911376917 A CN 201911376917A CN 113119358 A CN113119358 A CN 113119358A
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rubber
bladder
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谢东
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Zhejiang Huahe Bladder Tech Co ltd
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Abstract

本发明公开了一种高强度轮胎硫化胶囊及其生产工艺，包括以下步骤：S1、原材料选取；S2、一段炼胶；S3、二段炼胶；S4、硫化处理：S41初次硫化；S42后硫化；S5、贮存。本发明通过优化设计，改进生产工艺，采用预前隔离剂涂抹，结合后硫化工序，利用高温时效，提高隔离效果，有利于提高产品后续使用寿命；优化排气结构和工艺，有利于提高轮胎胶囊的品质，特别是极大提升了产品无气泡合格率。

Description

一种高强度轮胎硫化胶囊及其生产工艺
技术领域
本发明涉及轮胎制造技术领域，具体涉及一种高强度轮胎硫化胶囊及其生产工艺。
背景技术
轮胎胶囊主要是轮胎硫化的一个工具，材质为丁基橡胶，相当于轮胎模具的内模。胶囊根据硫化机、夹具不同，分为不同型号。其作用主要在轮胎硫化过程中内部充压缩气、充氮气或充过热水等。使其伸张，撑起轮胎胶胚形成内压硫化轮胎。其优点为导热快，效率高，劳动强度低，操作简便。
轮胎硫化，能够显著提高轮胎的性能，尤其是机械性能。轮胎硫化胶囊是轮胎硫化的一个工具，是轮胎制备过程中一个重要的模具。轮胎硫化胶囊主要针对轮胎内壁，通过胶囊进行加热，因此轮胎硫化胶囊需具备较好的热传递性。
轮胎硫化胶囊必须能够承受持续暴露于高于蒸汽、热水或惰性气体的高温下。可通过使用与活性烷基酚树脂特殊配合的丁基橡胶来实现这一点，混炼胶成分的选择对于胶囊的使用寿命和机械性能非常重要。因此轮胎硫化胶囊面对恶劣的使用必须有足够的强度才能保证其有更长的使用寿命。
发明内容
为解决上述问题，本发明提供了一种高强度轮胎硫化胶囊及其生产工艺，采用预前隔离剂涂抹，结合后硫化工序，利用高温时效，提高隔离效果，有利于提高产品后续使用寿命。
为实现上述目的，本发明采取的技术方案为：
一种高强度轮胎硫化胶囊生产工艺，包括以下步骤：S1、按以下重量份数的原材料选取：丁基橡胶110-125份、氯丁橡胶5-10份、高结构炭黑45-50份、硬脂酸0.8-0.9份、蓖麻油5.1-5.3份、氧化锌3-5份、氯化铁1.5-2.5份、树脂4-12份；S2、一段炼胶：先将丁基橡胶110-125份、氯丁橡胶5-10份倒入密炼机预先塑炼，起始温度控制在40℃-50℃，随后加热至140-160℃，密炼时间为4min-6min，挤压得到一段胶条原料；S3、二段炼胶：将一段胶条原料放入开炼机内，同步将高结构炭黑45-50份、硬脂酸0.8-0.9份、蓖麻油5.1-5.3份、氧化锌3-5份、氯化铁1.5-2.5份、树脂4-12份加入，温度控制在90℃-110℃，时间为10min-15min，进行混炼，混炼结束之后，用压出机压出胶片原料；S4、硫化处理：S41初次硫化：将上述胶条注射到硫化机内，将硫化机内的上模和下模完成闭合，上模和/或下模内设有若干排气孔，完成排气稳压；稳压后，压力持续保持15～16MPa，硫化温度为 185℃～195℃，保压保温 3～5 分钟，泄压后打开上模和下模具，取出胶囊；S42后硫化：将上述胶囊外表层喷涂隔离剂，然后将胶囊间隔排布，放置于100℃-135℃下烘房内静置24～48小时；S5、贮存：上述硫化后的胶囊放置在室内避光条件下存放，存放环境保持清洁、干燥。
上述中，树脂为溴化锌基苯酚甲醛树脂。
上述中，高结构炭黑为N330炭黑。
步骤S41中，若干排气孔呈至少两层排布，同一层内的若干排气孔沿上模或下模周边等距间隔排布。
步骤S42中，隔离剂采用液体隔离剂，隔离剂由羟基聚二甲基硅氧烷、聚甲基氢硅氧烷、乳化剂、助乳化剂、消泡剂、杀菌剂和去离子水构成。
羟基聚二甲基硅氧烷聚甲基氢硅氧烷的质量比为6:1～7：1。
一种高强度轮胎硫化胶囊，基于上述工艺，还包括轮胎胶囊本体，所述轮胎胶囊本体包括丁基橡胶110-125份、氯丁橡胶5-10份、高结构炭黑45-50份、硬脂酸0.8-0.9份、蓖麻油5.1-5.3份、氧化锌3-5份、氯化铁1.5-2.5份、树脂4-12份。
所述轮胎胶囊本体外表层覆盖有隔离层。
本发明具有以下有益效果：本发明通过优化设计，改进生产工艺，采用预前隔离剂涂抹，结合后硫化工序，利用高温时效，提高隔离效果，有利于提高产品后续使用寿命；优化排气结构和工艺，有利于提高轮胎胶囊的品质，特别是极大提升了产品无气泡合格率。
具体实施方式
为了使本发明的目的及优点更加清楚明白，以下结合实施例对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。
实施例1
本发明公开了一种高强度轮胎硫化胶囊生产工艺，包括以下步骤：
S1、按以下重量份数的原材料选取：丁基橡胶110-125份、氯丁橡胶5-10份、高结构炭黑45-50份、硬脂酸0.8-0.9份、蓖麻油5.1-5.3份、氧化锌3-5份、氯化铁1.5-2.5份、树脂4-12份；树脂为溴化锌基苯酚甲醛树脂；高结构炭黑为N330炭黑。
S2、一段炼胶：先将丁基橡胶110-125份、氯丁橡胶5-10份倒入密炼机预先塑炼，起始温度控制在40℃-50℃，随后加热至140-160℃，密炼时间为4min-6min，挤压得到一段胶条原料。
S3、二段炼胶：将一段胶条原料放入开炼机内，同步将高结构炭黑45-50份、硬脂酸0.8-0.9份、蓖麻油5.1-5.3份、氧化锌3-5份、氯化铁1.5-2.5份、树脂4-12份加入，温度控制在90℃-110℃，时间为10min-15min，进行混炼，混炼结束之后，用压出机压出胶片原料；树脂为溴化锌基苯酚甲醛树脂。
S4、硫化处理：
S41初次硫化：将上述胶条注射到硫化机内，将硫化机内的上模和下模完成闭合，上模和/或下模内设有若干排气孔，若干排气孔呈至少两层排布，同一层内的若干排气孔沿上模或下模周边等距间隔排布，完成排气稳压；稳压后，压力持续保持15～16MPa，硫化温度为185℃～195℃，保压保温 3～5 分钟，泄压后打开上模和下模具，取出胶囊；优化排气结构和工艺，有利于提高轮胎胶囊的品质，特别是极大提升了产品无气泡合格率。
S42后硫化：将上述胶囊外表层喷涂隔离剂，隔离剂采用液体隔离剂，隔离剂由羟基聚二甲基硅氧烷、聚甲基氢硅氧烷、乳化剂、助乳化剂、消泡剂、杀菌剂和去离子水构成；羟基聚二甲基硅氧烷聚甲基氢硅氧烷的质量比为6:1～7：1，然后将胶囊间隔排布，放置于100℃-135℃下烘房内静置24～48小时；其中，由于羟基聚二甲基硅氧烷中的羟基是一种极性基团，它增强了聚硅氧烷膜在轮胎胶囊上的附着力，羟基自身能产生分子之间的交联反应，同时结合聚甲基氢硅氧烷，相互作用形成致密的膜附着在胶囊表面，具有附着力强，不易脱落的特性，该膜具有良好的耐久性和弹性，有效的保护了胶囊，延长胶囊的使用寿命。
S5、贮存：上述硫化后的胶囊放置在室内避光条件下存放，存放环境保持清洁、干燥。
本发明通过优化设计，改进生产工艺，采用预前隔离剂涂抹，结合后硫化工序，利用高温时效，提高隔离效果，有利于提高产品后续使用寿命；优化排气结构和工艺，有利于提高轮胎胶囊的品质，特别是极大提升了产品无气泡合格率。
实施例2
本发明公开了一种高强度轮胎硫化胶囊生产工艺，包括以下步骤：
S1、按以下重量份数的原材料选取：丁基橡胶125份、氯丁橡胶8份、高结构炭黑50份、硬脂酸0.8份、蓖麻油5.2份、氧化锌5份、氯化铁2份、树脂10份；树脂为溴化锌基苯酚甲醛树脂；高结构炭黑为N330炭黑；
S2、一段炼胶：先将丁基橡胶、氯丁橡胶倒入密炼机预先塑炼，起始温度控制在45℃，随后加热至160℃，密炼时间为5min，挤压得到一段胶条原料；
S3、二段炼胶：将一段胶条原料放入开炼机内，同步将高结构炭黑、硬脂酸、蓖麻油、氧化锌、氯化铁、树脂加入，温度控制在100℃，时间为15min，进行混炼，混炼结束之后，用压出机压出胶片原料；树脂为溴化锌基苯酚甲醛树脂；
S4、硫化处理：
S41初次硫化：将上述胶条注射到硫化机内，将硫化机内的上模和下模完成闭合，上模和/或下模内设有若干排气孔，若干排气孔呈至少两层排布，同一层内的若干排气孔沿上模或下模周边等距间隔排布，完成排气稳压；稳压后，压力持续保持16MPa，硫化温度为190℃，保压保温5 分钟，泄压后打开上模和下模具，取出胶囊；
S42后硫化：将上述胶囊外表层喷涂隔离剂，隔离剂采用液体隔离剂，隔离剂由羟基聚二甲基硅氧烷、聚甲基氢硅氧烷、乳化剂、助乳化剂、消泡剂、杀菌剂和去离子水构成；羟基聚二甲基硅氧烷聚甲基氢硅氧烷的质量比为7：1，然后将胶囊间隔排布，放置于130℃下烘房内静置48小时；
S5、贮存：上述硫化后的胶囊放置在室内避光条件下存放，存放环境保持清洁、干燥。
实施例3
基于实施例2，在步骤S41中，采用传统单孔排气的上模和下模。
采用该工艺，产品极易存在气泡。
实施例4
基于实施例2，在步骤S42中，去除胶囊外表层喷涂隔离剂工序。
依据上述实施例，试样数量均为10条，各项性能参数对比如下：
检验项目 单位 实施例2 实施例3 实施例4
外观 - 无允许范围外瑕疵 个别存在细微气泡 无允许范围外瑕疵
300%定伸应力 MPa 11.2 9.6 10.9
拉伸强度 MPa 26.3 23.5 25.7
扯断伸长率 % 667 575 648
撕裂强度 KN.M<sup>1</sup> 77 57 72
粘合强度 N 58.3 60.1 142.5
其中，外观检测按HG/T 4626-2014中6.2规定执行。
从上表对比可以得出：
实施例2为我方申请方案的优选工艺，实施例3、实施例4均为参照工艺。
其中实施例2与实施例3的对比中可以得出，气泡对于产品性能具有极大的影响。
其中实施例2与实施例4对比中可以得出，粘合性能的极大提升。
实施例2中产品因在后硫化工序中，提前完成隔离剂的喷涂，使得隔离剂在高温时效过程中，对轮胎胶囊外表面形成一层有效的隔离层，且因经过高温时效，隔离层的覆盖性极好，可以提高轮胶囊的使用寿命。
实施例5
本实施例公开了一种高强度轮胎硫化胶囊，基于实施例1中的工艺，还包括轮胎胶囊本体，轮胎胶囊本体包括丁基橡胶110-125份、氯丁橡胶5-10份、高结构炭黑45-50份、硬脂酸0.8-0.9份、蓖麻油5.1-5.3份、氧化锌3-5份、氯化铁1.5-2.5份、树脂4-12份。
优选的，轮胎胶囊本体外表层覆盖有隔离层，隔离层可以降低轮胎胶囊本体的粘结度，提高轮胎胶囊本体的使用寿命。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以作出若干改进和润饰，这些改进和润饰也应视为本发明的保护。

Claims (8)

1.一种高强度轮胎硫化胶囊生产工艺，其特征在于包括以下步骤：
S1、按以下重量份数的原材料选取：丁基橡胶110-125份、氯丁橡胶5-10份、高结构炭黑45-50份、硬脂酸0.8-0.9份、蓖麻油5.1-5.3份、氧化锌3-5份、氯化铁1.5-2.5份、树脂4-12份；
S2、一段炼胶：先将丁基橡胶110-125份、氯丁橡胶5-10份倒入密炼机预先塑炼，起始温度控制在40℃-50℃，随后加热至140-160℃，密炼时间为4min-6min，挤压得到一段胶条原料；
S3、二段炼胶：将一段胶条原料放入开炼机内，同步将高结构炭黑45-50份、硬脂酸0.8-0.9份、蓖麻油5.1-5.3份、氧化锌3-5份、氯化铁1.5-2.5份、树脂4-12份加入，温度控制在90℃-110℃，时间为10min-15min，进行混炼，混炼结束之后，用压出机压出胶片原料；
S4、硫化处理：
S41初次硫化：将上述胶条注射到硫化机内，将硫化机内的上模和下模完成闭合，上模和/或下模内设有若干排气孔，完成排气稳压；稳压后，压力持续保持15～16MPa，硫化温度为 185℃～195℃，保压保温 3～5 分钟，泄压后打开上模和下模具，取出胶囊；
S42后硫化：将上述胶囊外表层喷涂隔离剂，然后将胶囊间隔排布，放置于100℃-135℃下烘房内静置24～48小时；
S5、贮存：上述硫化后的胶囊放置在室内避光条件下存放，存放环境保持清洁、干燥。
2.根据权利要求1所述的一种高强度轮胎硫化胶囊生产工艺，其特征在于：上述中，树脂为溴化锌基苯酚甲醛树脂。
3.根据权利要求1所述的一种高强度轮胎硫化胶囊生产工艺，其特征在于：上述中，高结构炭黑为N330炭黑。
4.根据权利要求1所述的一种高强度轮胎硫化胶囊生产工艺，其特征在于：步骤S41中，若干排气孔呈至少两层排布，同一层内的若干排气孔沿上模或下模周边等距间隔排布。
5.根据权利要求1所述的一种高强度轮胎硫化胶囊生产工艺，其特征在于：步骤S42中，隔离剂采用液体隔离剂，隔离剂由羟基聚二甲基硅氧烷、聚甲基氢硅氧烷、乳化剂、助乳化剂、消泡剂、杀菌剂和去离子水构成。
6.根据权利要求5所述的一种高强度轮胎硫化胶囊生产工艺，其特征在于：羟基聚二甲基硅氧烷聚甲基氢硅氧烷的质量比为6:1～7：1。
7.一种高强度轮胎硫化胶囊，其特征在于：基于上述工艺，还包括轮胎胶囊本体，轮胎胶囊本体包括丁基橡胶110-125份、氯丁橡胶5-10份、高结构炭黑45-50份、硬脂酸0.8-0.9份、蓖麻油5.1-5.3份、氧化锌3-5份、氯化铁1.5-2.5份、树脂4-12份。
8.根据权利要求7所述的一种高强度轮胎硫化胶囊，其特征在于：所述轮胎胶囊本体外表层覆盖有隔离层。
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