CN114654835A - 一种ht-acm橡胶配方的中冷器胶管及其制备方法 - Google Patents
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Abstract
本发明公开了一种HT‑ACM橡胶的中冷器胶管及其制备方法,包括HT‑ACM内胶层、芳纶线增强层和HT‑ACM外胶层;HT‑ACM内胶层、HT‑ACM外胶层采用相同的材质,HT‑ACM内胶层、HT‑ACM外胶层具体质量分数如下:羧酸型的丙烯酸酯100份、快压出炭黑50份至70份、聚酯/醚型增塑剂1份至4份、硬脂酸1份至2.5份、防老剂1份至3份、加工助剂1份至4份、硫化剂0.3份至2.5份、促进剂0.5份至2份;制作步骤如下:101)半成品管胚成型步骤、102)冷却步骤、103)硫化步骤、104)成品制备步骤;本发明解决了产品标准要求的耐机油、柴油性能,175℃条件下良好的压缩永久变形性,优秀的耐高温175℃热老化性能,以及良好的加工操作挤出性的一种HT‑ACM橡胶的中冷器胶管及其制备方法。
Description
技术领域
本发明涉及橡胶材料领域,更具体的说,它涉及一种HT-ACM橡胶配方的中冷器胶管及其制备方法。
背景技术
在汽车行业、中冷器胶管进气系统、燃油胶管系统及其他工业生产中使用耐175℃老化、耐油及压变性能的胶管制品。目前在汽油、燃油等油类和中冷器传输过程中多使用橡胶+尼龙管路,然而按标准工艺生产的橡胶胶管均存在耐热、耐油、耐压变性能和中冷器方面的不足。橡胶胶管在使用过程中将处在中冷器进气端,且长期处在中冷器进气端,所处环境有很大压力、较高温度、较热油气、较高浓度臭氧的存在,所以需要很精湛的技术条件。
随着技术进步对于一些高要求的部分,现在更常用的是H-ACM橡胶:其是由一种耐高温的丙烯酸酯(CH2=CHC00R),通过烷基酯为主要单体,与少量带有可提供交联反应的活性基团的单体共聚而成的一类弹性体。其具有优良的耐老化、耐热性能,与一般橡胶相比,通常使用在较高温度环境、较热油等恶劣条件下。
但是随着汽车工业的快速发展和人们环保意识的不断增强,对产品性能要求越来越高,制定的标准也越来越高,就目前汽车中冷器胶管,需要优秀的耐机油油、柴油性能,175℃条件下良好的压缩永久变形性,优秀的耐高温175℃热老化性能,还需要良好的加工操作挤出性。就目前H-ACM橡胶及制备的胶管在这四方面,只是初步达标,还存在很大的优化提升空间。
发明内容
本发明克服了现有技术的不足,解决了产品标准要求的耐机油、柴油性能, 175℃条件下良好的压缩永久变形性,优秀的耐高温175℃热老化性能,以及良好的加工操作挤出性的一种基于HT-ACM橡胶的中冷器胶管。
本发明的技术方案如下:
一种HT-ACM橡胶的中冷器胶管,包括HT-ACM内胶层、芳纶线增强层和 HT-ACM外胶层;HT-ACM内胶层、HT-ACM外胶层采用相同的材质,HT-ACM内胶层、HT-ACM外胶层具体质量分数如下:羧酸型的丙烯酸酯100份、快压出炭黑 50份至70份、聚酯/醚型增塑剂1份至4份、硬脂酸1份至2.5份、防老剂1 份至3份、加工助剂1份至4份、硫化剂0.3份至1.5份、促进剂0.5份至2 份。
一种HT-ACM橡胶的中冷器胶管的制备方法,具体包括如下步骤:
101)半成品管胚成型步骤:通过120型的鲁贝肯挤出机进行HT-ACM内胶层、HT-ACM外胶层的挤出;
采用一定的空压保证2.5~3.5mm厚的HT-ACM内胶层能支撑编织和HT-ACM 外胶层的挤出;
HT-ACM外胶层厚度在1.5~2.5mm;
102)冷却步骤:在停放阶段前对步骤101)处理后的半成品进行冷却降温定性,冷却通过15±5℃的冷却水冷却;
103)硫化步骤:在步骤101)处理完后进行停放处理,停放时间到后,将半成品套在产品芯棒上,将其送入蒸汽硫化罐,在蒸汽硫化罐中进行硫化;
104)成品制备步骤:经过步骤103)硫化后取出产品进行清洗切割,获得中冷器胶管。
进一步的,鲁贝肯挤出机HT-ACM内胶层、HT-ACM外胶层挤出的温度设置相同,具体如下:机头80℃,挤出段70℃,塑化段65℃,螺杆60℃,喂料口55℃。
进一步的,芳纶线增强层采用针织结构。
进一步的,步骤103)中的硫化温度在150℃至165℃之间,硫化时间为15min 至35min。
本发明相比现有技术优点在于:
本发明为提高橡胶和胶管的综合性能,采用新型硫化剂CLP5250+促进剂作为硫化体系;加入少量聚酯/醚型增塑剂作为软化剂交联应用。前者很大的增强了橡胶和胶管的耐高温长时间性能,后者很大的提高了橡胶和胶管的耐低温脆性能;新型硫化剂和促进剂配合很大的提高了胶料安全操作性和交联硫化性能,且能使胶料和胶管的性能均有良好的提升以及外观和物理机械性能的提升。
附图说明
图1是中冷器胶管结构图。
图2是图1的剖面图。
图中标注:
1.HT-ACM内胶层;2.芳纶线增强层;3.HT-ACM外胶层。
具体实施方式
下面具体实施方式对本发明进一步说明。
一种HT-ACM橡胶配方的中冷器胶管,包括HT-ACM内胶层1、芳纶线增强层 2和HT-ACM外胶层3;HT-ACM内胶层1、HT-ACM外胶层3采用相同的材质,HT-ACM 内胶层1、HT-ACM外胶层3具体质量分数如下:羧酸型的丙烯酸酯100份、快压出炭黑50份至70份、聚酯/醚型增塑剂1份至4份、硬脂酸1份至2.5份、防老剂1份至3份、加工助剂1份至4份、硫化剂0.3份至1.5份、促进剂0.5 份至2份。
具体最佳方案的成份如下:羧酸型的丙烯酸酯100份、快压出炭黑63份、聚酯/醚型增塑剂3.5份、硬脂酸2份、防老剂2.5份、加工助剂3份、硫化剂 0.7份、促进剂1.8份。其中硫化剂采用新型硫化剂CLP5250。新型硫化剂CLP5250, 其结构为[2,2-双(4-(4'-氨基苯氧基)苯基)]丙烷,其有效成分含量50%左右,具有优良的防止焦烧,耐动力疲劳性能。
而传统的丙烯酸酯采用卤素型,其制备的ACM胶层具体配方如下:ACM橡胶 (卤素型)100份、快压出炭黑55~65份、油酸钠3.0~4.0份、防老剂1.0~2.0 份、硬脂酸1.5份、金属皂类硫化剂0.5份、促进剂0.5~1.5份。
本方案的配方相比于传统的材料其尤其在内胶层有优越的耐机油和柴油性能(抗拉强度≥9MPa,拉断伸长率≥250%)、提升了长时间耐175℃热老化温度性能、降低了耐35%的压缩永久变形性能、优化耐大口径挺性、可操作加工性能提升、还有优越的耐高频振动性能。具体在为提高橡胶和胶管的综合性能上,本配方采用新型硫化剂CLP5250+促进剂作为硫化体系;加入少量聚酯/醚型增塑剂作为软化剂交联应用。前者很大的增强了橡胶和胶管的耐高温长时间性能,后者很大的提高了橡胶和胶管的耐低温脆性能。
新型硫化剂和促进剂配合很大的提高了胶料安全操作性和交联硫化性能,且能使胶料和胶管的性能均有良好的提升以及外观和物理机械性能的提升。且该配方材料将满足在中冷器方面的性能和成本方面较传统、进口胶料和胶管有很大优势。
具体采用如下实验组进行比对相应测试数据:
按所列配方中原材料及用量进行正常工序的混炼加工(此中不再详细赘述具体过程,其可通过传统工艺方法获得):
S1:橡胶及原材料称量点检。
S2:一段密炼→一段开炼→A炼胶下片停放,其中控制一段排胶在110℃~140℃为最佳。
S3:二段密炼→二段开炼→B炼胶下片停放,其中控制二段排胶在90℃~130℃为最佳。
S4:B炼胶取样检测,检测数据进行汇总分析。具体结果如下表:
通过对上述试验可得,选用耐高温性好的HT-ACM、聚酯/醚型增塑剂,新型硫化剂+促进剂设计的方案4配方混炼胶配方开发,实例1-4配方胶料的性能相比耐机油、柴油性能抗拉强度≥9MPa,拉断伸长率≥250%更优秀,耐高温175℃长时间老化抗拉强度≥7.0MPa,拉断伸长率≥100%性能更突出,压缩永久变形性能<60%能够满足且有一定的空间,而且炼胶操作可靠性更好。油气胶料挤出加工时容易满足需求、还有优越的耐高频振动性能,该配方材料将满足在中冷器方面的性能要求,且橡胶的其他性能都有明显改善,胶管装车耐油效果良好没有发生折瘪问题。大大提高了橡胶的耐高温长时间老化性能,低温性能以及使用价值,对于本方案的HT-ACM橡胶材料及其制品在汽车行业等领域能更好的发挥作用,大大提高了制品的安全保障和使用寿命。
具体的生产方法包括如下步骤:
101)半成品管胚成型步骤:通过120型的鲁贝肯挤出机进行HT-ACM内胶层1、HT-ACM外胶层3的挤出。
采用一定的空压保证2.5~3.5mm厚的HT-ACM内胶层1能支撑编织和HT-ACM 外胶层3的挤出。具体的空压值可以根据实际进行调整,只要满足本条件的空压都是可以的,故不做进一步限定。其中,芳纶线增强层2采用针织结构。
HT-ACM外胶层3厚度在1.5~2.5mm;因为此厚度才能更好的保证内外胶在增强层上能有优良粘接。具体的鲁贝肯挤出机HT-ACM内胶层1、HT-ACM外胶层 3挤出的温度设置相同,具体如下:机头80℃,挤出段70℃,塑化段65℃,螺杆60℃,喂料口55℃。
102)冷却步骤:在停放阶段前对步骤101)处理后的半成品进行冷却降温定性,冷却通过15±5℃的冷却水冷却。因为材料从机头挤出,经过针织,在经过包外胶,温度较高,故需要在停放前进行快速冷却。
103)硫化步骤:在步骤101)处理完后进行停放处理,停放时间到后,将半成品套在产品芯棒上,将其送入蒸汽硫化罐,在蒸汽硫化罐中进行硫化;硫化温度在150℃至165℃之间,硫化时间为15min至35min。
104)成品制备步骤:经过步骤103)硫化后取出产品进行清洗切割,获得中冷器胶管。
根据上述制备得到的中冷器胶管,对操作性、进行产品性能检测和装车验证,结果汇总如下:
根据以上实验结构表明,其中第4种方案,生产中冷器进气管的工艺操作和性能上有了明显提高,装车不会发生折瘪,且效果良好。内外层间的附着力也有明显提升,产品的振动脉冲实验(压力:2.5bar,介质温度:125℃,环境温度:175℃,频率:0.5HZ)也取得了非常大的突破,120万次还没有破坏。从装车路试情况来看,方案2~4均较方案1有从试验结果明显看出结果最好的配方实例4;其在主要性能综合分析评价,改良后的实例4配方和产品能够有效解决材料极限性能和产品不能满足装车的情况。
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,在不脱离本发明构思的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明保护范围内。
Claims (5)
1.一种HT-ACM橡胶配方的中冷器胶管,其特征在于,包括HT-ACM内胶层、芳纶线增强层和HT-ACM外胶层;HT-ACM内胶层、HT-ACM外胶层采用相同的材质,HT-ACM内胶层、HT-ACM外胶层具体质量分数如下:羧酸型的丙烯酸酯100份、快压出炭黑50份至70份、聚酯/醚型增塑剂1份至4份、硬脂酸1份至2.5份、防老剂1份至3份、加工助剂1份至4份、硫化剂0.3份至2.5份、促进剂0.5份至2份。
2.一种HT-ACM橡胶配方的中冷器胶管的制备方法,其特征在于,具体包括如下步骤:
101)半成品管胚成型步骤:通过120型的鲁贝肯挤出机进行HT-ACM内胶层、HT-ACM外胶层的挤出;
采用一定的空压保证2.5~3.5mm厚的HT-ACM内胶层能支撑编织和HT-ACM外胶层的挤出;
HT-ACM外胶层厚度在1.5~2.5mm;
102)冷却步骤:在停放阶段前对步骤101)处理后的半成品进行冷却降温定性,冷却通过15±5℃的冷却水冷却;
103)硫化步骤:在步骤101)处理完后进行停放处理,停放时间到后,将半成品套在产品芯棒上,将其送入蒸汽硫化罐,在蒸汽硫化罐中进行硫化;
104)成品制备步骤:经过步骤103)硫化后取出产品进行清洗切割,获得中冷器胶管。
3.根据权利要求2所述的一种HT-ACM橡胶配方的中冷器胶管的制备方法,其特征在于,鲁贝肯挤出机HT-ACM内胶层、HT-ACM外胶层挤出的温度设置相同,具体如下:机头80℃,挤出段70℃,塑化段65℃,螺杆60℃,喂料口55℃。
4.根据权利要求2所述的一种HT-ACM橡胶配方的中冷器胶管的制备方法,其特征在于,芳纶线增强层采用针织结构。
5.根据权利要求2所述的一种HT-ACM橡胶配方的中冷器胶管的制备方法,其特征在于,步骤103)中的硫化温度在165℃至180℃之间,硫化时间为15min至35min。
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CN101628485A (zh) * | 2009-08-13 | 2010-01-20 | 浙江峻和橡胶科技有限公司 | 中冷器胶管的制造方法 |
CN101987906A (zh) * | 2010-11-18 | 2011-03-23 | 天津鹏翎胶管股份有限公司 | 丙烯酸酯橡胶涡轮增压管及制备方法 |
CN104558999A (zh) * | 2015-01-21 | 2015-04-29 | 山东美晨科技股份有限公司 | 一种抗焦烧性能优异的羧酸型丙烯酸酯橡胶原料配制 |
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CN101628485A (zh) * | 2009-08-13 | 2010-01-20 | 浙江峻和橡胶科技有限公司 | 中冷器胶管的制造方法 |
CN101987906A (zh) * | 2010-11-18 | 2011-03-23 | 天津鹏翎胶管股份有限公司 | 丙烯酸酯橡胶涡轮增压管及制备方法 |
CN104558999A (zh) * | 2015-01-21 | 2015-04-29 | 山东美晨科技股份有限公司 | 一种抗焦烧性能优异的羧酸型丙烯酸酯橡胶原料配制 |
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