CN1196573C - 制造纤维增强塑料材料的方法和塑料挤压机 - Google Patents

制造纤维增强塑料材料的方法和塑料挤压机 Download PDF

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CN1196573C
CN1196573C CNB991118006A CN99111800A CN1196573C CN 1196573 C CN1196573 C CN 1196573C CN B991118006 A CNB991118006 A CN B991118006A CN 99111800 A CN99111800 A CN 99111800A CN 1196573 C CN1196573 C CN 1196573C
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plastic extruders
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fiber
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迪特尔·特罗尔夫
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J Dieffenbacher & Co GmbH
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
    • B29C48/402—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders the screws having intermeshing parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C48/25—Component parts, details or accessories; Auxiliary operations
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    • B29C48/535—Screws with thread pitch varying along the longitudinal axis
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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Abstract

本发明涉及制造纤维增强塑料材料的方法和塑料挤压机。本发明依序由下列工艺步骤构成：a)纤维条经过涂层喷嘴被导入塑料挤压机的进料口，b)在进料口内，右侧的涂层喷嘴将一层液体塑料薄膜直接喷涂到纤维条的一个平面侧，并通过将纤维条压入预先由左侧涂层喷嘴喷涂到蜗杆轴上的液体塑料薄膜间接地将液体塑料施加到第二平面侧，这种情况下，纤维条在导入和浸渍段m范围内让其在挤压轴上的每根无端纤维在进入和穿越过程中被液体塑料浸湿或浸渍，以及c)然后，浸渍或浸透塑料的单根纤维或纤维条被带到一刀刃处，经剪切成预先规定的长度。

Description

制造纤维增强塑料材料的方法和塑料挤压机
本发明涉及一种制造纤维增强塑料材料用的方法。另外，本发明还涉及一种实施该方法用的塑料挤压机。
根据DE-PS 40 16 784已有这一类的方法和塑料挤压机。采用该塑料挤压机时，纤维条进入浸渍装置的入口和浸渍后纤维条的出口在平面上不大适应均匀浸湿纤维和扩散材料的要求。但主要问题在于，已经成扇形彼此分开的纤维条的单根纤维在经过扩展凸轮时不能保持彼此分开。单根纤维经过与蜗杆轴交叉的导向装置在导入管口转向90°直到浸渍槽的终端，再到挤压轴的蜗杆单元，并被系接成致密的纤维条。这意味着，由许多长丝纤维构成的致密纤维条形成相当大的粗度，结果导致在蜗杆转臂与料筒壁之间迅速挤出或切断。由此而形成的没有完全浸透的纤维线团就很难(即部分地根本不可能)重新通过混合和揉捏元件进行分解，以便将它与剩余熔体混合，或者混合与揉捏/剪切段必须达到一定的强度和/或长度，从而使产品中特短纤维成分/细纤维成分特别高。
此外还造成致密纤维条的迅速挤出和单根纤维的不可控制的滑动特性。玻璃纤维条出现不同的高速滑动，致使特别难以或不可能使机器达到正常作业状态，即产生不确定的传动比和不可控制的作业状态。
另外还有以下缺点：
预浸渍的纤维条必须在混合区内与单根纤维均匀分布在熔体中。
用液体塑料预浸渍过的纤维条由相应的蜗杆元件导入，在导入过程中被剪切和被挤出。此时作用在纤维条上的动力可能相对较小，因为不可能产生足够大的绕挤压轴的转向角。在给料区，纤维产生相当大的不确定的滑动，因此，塑料中的纤维含量必有明显的变化。测量被输送的纤维条上的速度变化，并经过在挤压轴上的一个转速调节装置补偿其误差，结果导致被输送到浸渍区内的熔化的塑料产生有害的强烈波动，并导致在混合区和产品压出量发生波动。设想利用通过可移动的蜗杆外壳的节流装置对熔体进行调节也解决不了这个问题，因为对于强滑动的单根纤维而言，挤压轴上的转速必定提高，并迫使在蜗杆区内的熔体使用更多的母体熔体。这意味着纤维与母体的混合比会发生不利的变化。另外，除了玻璃纤维成分相对塑料成分精确的重量分布以外，对于产品加工和材料的可重复利用还要求达到没有波动的均匀的产品产量。另一个最高目标是纤维微细成分保持很低。这一目标利用迄今已知的方法和系统是无法达到的。
本发明的目的是提供一种方法和设计一种挤压机，用它能制作混合程度良好和纤维浸渍充分的纤维增强塑料材料，同时产品中的长纤维占有尽可能大的份额，微小或短纤维占有尽可能少的份额，而且产品压出量始终没有波动。
为实现上述目的，按照本发明提供一种使用一塑料挤压机制造纤维增强塑料材料用的方法，按这种方法，纤维条经过导向栅和预热装置被导入一浸渍装置，用液体塑料薄膜浸湿，然后被导入塑料挤压机，在其中切断和混合单根纤维，并作为可继续加工的纤维增强塑料材料输出，其特点在于以下工艺步骤：a)纤维条经过两个或多个涂层喷嘴进入塑料挤压机的进料口，纤维条以其幅宽平行于挤压机的轴线，近似与一挤压轴相切，在向前推进中盘绕挤压轴卷起，并被导入到蜗杆料筒内，料筒口径被扩大到至少是纤维条厚度的4倍；b)在进料口内，右侧的涂层喷嘴将一层液体塑料薄膜直接喷涂到纤维条的一个平面侧，并通过将纤维条压入预先由左侧涂层喷嘴喷涂到蜗杆轴上的液体塑料薄膜间接地将液体塑料施加到第二平面侧，这种情况下，纤维条在导入和浸渍段范围内让其在挤压轴上的每根无端纤维在进入和穿越过程中被液体塑料浸湿或浸渍；以及，c)然后，浸渍或浸透塑料的单根纤维或纤维条由导入和浸渍段经过一刀刃进入一直径缩小了的蜗杆料筒，到达一短的出料和输送段，并被进一步剪切成预先规定的长度。
按照本发明，提供另一种使用一塑料挤压机制造纤维增强塑料材料用的方法，按这种方法，纤维条经过导向栅和预热装置被导入一浸渍装置，用液体塑料薄膜浸湿，然后被导入塑料挤压机，在其中切断和混合单根纤维，并作为可继续加工的纤维增强塑料材料输出，其特点在于以下工艺步骤：a)纤维条经过涂层喷嘴进入塑料挤压机的进料口，纤维条以其幅宽平行于挤压机的轴线，近似与一挤压轴相切，在向前推进中盘绕挤压轴卷起，并被导入到蜗杆料筒内，料筒孔径被扩大到至少是纤维条厚度的4倍；b)在进料口内，由一布置在进料口右侧的涂层喷嘴将一层液体塑料薄膜直接喷涂到纤维条的一个平面侧，或通过将纤维条压入预先由一布置在进料口左侧的涂层喷嘴喷涂到蜗杆轴上的液体塑料薄膜间接地将液体塑料施加到第二平面侧，这种情况下，纤维条在导入和浸渍段范围内让其在挤压轴表面上的每根无端纤维在进入和穿越过程中被液体塑料浸湿或浸渍；以及，c)然后，浸渍或浸透塑料的单根纤维或纤维条由导入和浸渍段经过一刀刃进入一孔径缩小了的蜗杆料筒，到达一短的出料和输送段，并被进一步剪切成预先规定的长度。
作为本发明方法的优点，特别值得列举的特点是：输入的纤维径迹走向相互平行和相切，以及在前进过程中(需要时可以多重地)把纤维条幅宽卷绕起来和卷绕到蜗杆轴上，以生成足够的导入作用力。另外一个优点在于，纤维条在进料口接受涂层时，以及在穿越导入和浸渍段时，纤维已经通过涂擦和缩绒充分浸渍液体塑料、塑化和按正确的混合比吸附塑料。在此之后纤维条才被切割。对于在切割被浸渍的纤维或纤维条时在出料和输送段入口处的刀刃上部分地产生的纤维束而言，有一短的出料和输送段足以把这些纤维束分解成均匀的产品，并以适当的蜗杆填料度(Fullgrad)把成品纤维条无波动地从塑料挤压机中输送出去。由于在出料和输送段中没有混合和揉捏元件，因此几乎不会因被磨碎的纤维而产生纤细成分。
按照本发明，提供实施上述两种制造纤维增强塑料材料用的方法所用的一种塑料挤压机，该挤压机包括在输送到塑料挤压机的输送线上的一将纤维条加热的辐射加热装置，在塑料挤压机内的浸渍装置；为了导入纤维条、进行剪切和混合，塑料挤压机包括一外壳，外壳上有两个孔及两根转动驱动挤压轴的轴线，同时外壳上还设有一将纤维条导入孔内的进料口，其特点在于，塑料挤压机长度划分为一导入和浸渍段和一出料和输送段，其中导入和浸渍段的外壳是将直径扩大到至少为4倍纤维条厚度的料筒孔设计而成，并有一个或两个涂层喷嘴设在进料口上，同时进料口在其纵向延伸方向被设计成与轴线平行，大致与一挤压轴相切；而出料和输送段在进口处则有一刀刃，其料筒孔具有一般在挤压机上常见的直径。
根据本发明，由于纤维条在向前推进中能够很好地将纤维条卷绕到导入和浸渍段中呈圆形的元件上，因此，尽管有相当大的拉力作用到纤维条上，而不会切碎、挤压或扯断单根纤维。为了能使传送带有塑料薄膜的纤维条不受阻碍，因此将挤压轴范围内的外壳孔径加以扩大。如果纤维条重叠到近似于圆形的蜗杆转臂上和倒圆的蜗杆根部，则孔径被扩大到至少为4倍纤维条厚度，以便纤维条中的单根纤维不会被剪断，并通过扩大包缠角保证纤维条的可靠传送。由于以确定的滑动运动经过蜗杆转臂和蜗杆根部输送纤维条，以及经过切成圆角的8字形孔端进行拉动，因此，塑料熔体在单根纤维上、下和四周的分布、涂擦和集结极佳。
在塑料挤压机上，蜗杆在塑化区内的填料度是造成产品压出量波动的主要原因，就是说，当蜗杆每转动一圈，其充填的材料、玻璃纤维和塑料熔体过少时，在排出喷嘴上就出现不均匀的产出速度(波动)，表现为按一定长度被剪切的产品发生干扰性的重量上的波动。根据本发明，由于均匀引入被喷上涂层的纤维条，以及根据塑料用量与纤维用量的混合比，按单根纤维数或其纤维条比重(特克斯重)进行均衡调配，因而避免了有害的波动。纤维条纤维与塑料熔体在蜗杆内的填料度需要达到40％到80％，方可实现连续的和无波动的输送。为此，可以进一步提高可作用到纤维条上的驱动力，因为在导入和浸渍段内，在达到刀刃之前，正在形成的盘绕在挤压轴上向前推进的纤维增强塑料卷以及蜗杆和8字形孔端被切成圆角的形状不会使单根纤维遭到破坏。为了能更好地影响向前推进速度和重叠度，纤维条在输送方向上被适当倾斜地导入塑料挤压机的进料口。
以下，结合附图所作的说明，可进一步了解按照本发明的塑料挤压机的其它有益措施和设计造型。
附图中：
图1为根据本发明用图2的A-A截面表示的塑料挤压机，
图2是根据本发明用侧视图表示的塑料挤压机，以及
图3是用侧视图表示在起动-停机操作方式时的成品卸料。
图1和图2表示根据本发明长度为L的作为双轴挤压机的塑料挤压机1。如图2所示，塑料挤压机1的长度被分成3个功能段，并相应地进行设计，即分成一个准备和熔化塑料的预塑熔区o，一个导入和浸渍段m和一个出料和输送段n。为了成品33(＝纤维增强塑料材料)的成型卸料，在端部装设了一个出料喷嘴8。图1为图2的A-A截面，该图表示经过布置在进料口18左、右侧的涂层喷嘴12和13导入纤维条14的情况。在涂层喷嘴12和13之前，纤维条14在其幅宽的两侧各设有一辐射加热装置16。塑料挤压机1另外还包括外壳25与孔2和3，以及导入和浸渍段m的挤压轴4和5的轴线6和7，出料和输送段n挤压轴4′和5′的外壳26与孔2′和3′，预塑熔区o的挤压轴29和30。在输入塑料粒料的外壳25上还设有一给料斗19用于备料。塑料供给线28把准备好的塑料输送到涂层喷嘴12和13。驱动装置20用于驱动挤压轴29/30、4/5和4′/5′。在加工作业时，纤维条14通过传输送进导入通道27，并由该通道在挤压机的蜗杆元件拉动下沿产品卸料方向经过蜗杆转臂9和倒圆的蜗杆根部22移动。随之，纤维条14的每股纤维还在具有一外径和核径的蜗杆转臂9上作上下运动，而在同向转动的双蜗杆挤压机上则分别从一根蜗杆轴转移到另一根蜗杆轴。这就是说，纤维条14根据其纤维网幅宽b沿着某种8字形循环轨道或多或少重叠地被输送到纤维分解区方向。在这一传送滑动运动中，与纤维一起被导入的液体塑料(塑料薄膜)10和11被擦到纤维上，随后所有单根纤维丝都浸渍/涂敷上塑料。所有未被分解的无端纤维的导入和浸渍端m的长度取决于必须作用在纤维条上的拉力，以使在不产生干扰性速度变化的条件下拉动纤维条14。
纤维条经过装在或按一定距离布置在外壳25上涂层喷嘴12和13被导入塑料挤压机1的进料口18，纤维条的幅宽b平行于挤压机的轴线6和7，并近似与一挤压轴相切，在向前推进中盘绕挤压轴4和5卷起，并被导入到孔径D扩大到至少是2倍纤维条14厚度S的蜗杆料筒内。在进料口18内，右侧的涂层喷嘴12将一层液体塑料薄膜10直接喷涂到纤维条14的一个平面侧，同时通过将纤维条14压入预先由左侧涂层喷嘴13喷涂到挤压轴5上的液体塑料薄膜11间接地将液体塑料施加到第二平面侧，这种情况下，纤维条14在导入和浸渍段m范围内让其在挤压轴4和5上的每根无端纤维在进入和穿越过程中被液体塑料薄膜10和11浸湿或浸渍。然后，浸渍或浸透塑料薄膜10和11的纤维条14的单根纤维或由导入和浸渍段m经过一刀刃21进入一孔径d缩小了的带有螺杆转臂23的剪切孔，被导入出料和输送段n，并在该处被进一步剪切成预先规定的长度。当纤维条只需进行简单浸渍和塑料熔体粘度适度的情况下，根据第二实施例，纤维条14只要用塑料涂敷一个平面侧就足够了。
如图3所示，对于一定的批量生产和机器流水作业以及制造周期而言可能有利，因为对于挤压加工要求不连续的产品33时，塑料挤压机1可以采用起动-停机-作业方式进行工作。这就是说，塑料挤压机1将所要求来自出料喷嘴8的产品33输送到输送带34上，并停机以剪切产品纤维条。在剪切好的产品33被送走以后，再起动塑料挤压机1，根据挤压周期打开剪切装置32，以进行下一批产品33的卸料。这一工作方式是可行的，因为纤维条4能够被传动而不发生干扰性滑动。
塑料挤压机1的其它一些合理的设计包括：
-2刀刃21安装在一可更换的和可重新磨锐的修磨套筒31上，
-2出料和输送段n的蜗杆轴2′和3′被用一个或几个蜗杆转臂23引导，向导入和浸渍段m返回一个导入量程p，
-2设一单独的辅助塑料挤压机(没有示出)取代一预塑熔区o，以便向涂层喷嘴12和13提供准备好的塑料。
设备单独的辅助塑料挤压机的设想优点是：在熔化塑料和直接用聚合物和添加剂准备塑料熔体以在纤维上喷涂塑料时，可以不受制约地利用转数。
对于塑料挤压机1的某些特定的应用场合而言，采用下述方法可能是合适的，即：当纤维条14进入塑料挤压机1的进料口18时，用加热的气体，例如空气或氮气，将塑料薄膜吹送到(纤维条的)一面或两面。

Claims (18)

1.一种使用一塑料挤压机制造纤维增强塑料材料用的方法，按这种方法，纤维条经过导向栅和预热装置被导入一浸渍装置，用液体塑料薄膜浸湿，然后被导入塑料挤压机，在其中切断和混合单根纤维，并作为可继续加工的纤维增强塑料材料输出，
其特征在于以下工艺步骤：
a)纤维条经过涂层喷嘴进入塑料挤压机的进料口，纤维条以其幅宽b平行于挤压机的轴线，并近似与一挤压轴相切，在向前推进中盘绕挤压轴卷起，并被导入到孔径扩大到至少是4倍纤维条厚度S的蜗杆料筒内；
b)在进料口内，右侧的涂层喷嘴将一层液体塑料薄膜直接喷涂到纤维条的一个平面侧，同时通过将纤维条压入预先由左侧涂层喷嘴喷涂到蜗杆轴上的液体塑料薄膜间接地将液体塑料施加到第二平面侧，这种情况下，纤维条在导入和浸渍段(m)范围内让其在挤压轴上的每根无端纤维在进入和穿越过程中被液体塑料薄膜浸湿或浸渍；以及
c)然后，浸渍或浸透塑料薄膜的单根纤维或纤维条由导入和浸渍段(m)经过一刀刃进入一蜗杆料筒孔径缩小了的出料和输送段(n)，并在该处被进一步剪切成预先规定的长度。
2.一种使用一塑料挤压机制造纤维增强塑料材料用的方法，按这种方法，纤维条经过导向栅和预热装置被导入一浸渍装置，用液体塑料薄膜浸湿，然后被导入塑料挤压机，在其中切断和混合单根纤维，并作为可继续加工的纤维增强塑料材料输出，
其特征在于以下工艺步骤：
a)纤维条经过涂层喷嘴进入塑料挤压机的进料口，纤维条以其幅宽b平行于挤压机的轴线，并近似与一挤压轴相切，在向前推进中盘绕挤压轴卷起，并被导入到孔径扩大到至少是2倍纤维条厚度S的蜗杆料筒内；
b)在进料口内，由一布置在进料口右侧的涂层喷嘴将一层液体塑料薄膜直接喷涂到纤维条的一个平面侧，或通过将纤维条压入预先由一布置在进料口左侧的涂层喷嘴喷涂到蜗杆轴上的液体塑料薄膜间接地将液体塑料施加到第二平面侧，这种情况下，纤维条在导入和浸渍段(m)范围内让其在挤压轴表面上的每根无端纤维在进入和穿越过程中被液体塑料浸湿或浸渍；以及
c)然后，浸渍或浸透塑料的纤维条由导入和浸渍段(m)经过一刀刃进入一孔径缩小了的蜗杆料筒，到达一短的出料和输送段(n)，并被进一步剪切成预先规定的长度。
3.根据权利要求1或2的方法，其特征在于，纤维条在导入和浸渍段(m)范围内向前推进中多次地卷绕在挤压轴上，
4.根据权利要求1或2的方法，其特征在于，纤维条的纤维网幅宽(b)被重叠卷绕。
5.根据权利要求1或2的方法，其特征在于，纤维条在输送方向上被倾斜地导入塑料挤压机的进料口。
6.根据权利要求1或2的方法，其特征在于，在出料和输送段(n)内40％到80％的蜗杆填料度是根据塑料用量和纤维用量的混合比，按单根纤维数或其纤维条比重(特克斯重)进行调配的。
7.根据权利要求1或2的方法，其特征在于，在纤维条进入塑料挤压机的进料口之前或进入过程中，借助吹风机用热的空气或氮气将液体塑料薄膜吹送到纤维辐的一面或两面。
8.根据权利要求1的方法，其特征在于，对于不连续的塑料材料卸料，塑料挤压机用起动—停机操作方式工作。
9.根据权利要求1，2，8中任一项的方法，其特征在于，塑料挤压机将完成的塑料材料或成品投放到输送带上，根据预先规定的出料量停机、剪切和继续输送，然后重新开始一新的出料量循环周期。
10.一种实施权利要求1或2的方法以制造纤维增强塑料材料用的塑料挤压机，包括在输送到塑料挤压机的输送线上的一将纤维条加热的辐射加热装置，在塑料挤压机内的浸渍装置；为了导入纤维条、进行剪切和混合，塑料挤压机包括一外壳，外壳上有两个孔及两根转动驱动挤压轴的轴线，同时外壳上还设有一将纤维条导入孔内的进料口，
其特征在于，塑料挤压机长度(L)划分为一导入和浸渍段(m)和一出料和输送段(n)，其中导入和浸渍段(m)的外壳是将直径(D)扩大到至少为4倍纤维条厚度(S)的料筒孔(2和3)设计而成，并有一个或两个涂层喷嘴(12和13)设在进料口(18)上，同时进料口(18)在其纵向延伸方向被设计成与轴线(6和7)平行，大致与一挤压轴(5)相切；而出料和输送段(n)在进口处则有一刀刃(21)，其料筒孔(2′和3′)具有一般在挤压机上常见的直径d。
11.根据权利要求10的塑料挤压机，其特征在于，设有一单独的辅助塑料挤压机，在其中进行涂层塑料的准备，并可将准备好的涂层塑料经过通道/管路输送给涂层喷嘴(12/13)。
12.根据权利要求10或11的塑料挤压机，其特征在于，刀刃(21)安装在一可更换的修磨套筒(26)上。
13.根据权利要求10或11的塑料挤压机，其特征在于，塑料挤压机(1)有一预塑熔区(o)以准备涂层塑料，其出口经过一导入通道(28)与一个或两个涂层喷嘴(12/13)相联接。
14.根据权利要求10或11的塑料挤压机，其特征在于，出料和输送段(n)的挤压轴(2′和3′)被用一个或几个蜗杆转臂(23)引导，向导入和浸渍段(m)返回一个导入量程(p)。
15.根据权利要求10或11的塑料挤压机，其特征在于，设有一单独的辅助塑料挤压机取代预塑熔区(o)，以便向涂层喷嘴(12/13)提供准备好的塑料。
16.根据权利要求10或11的塑料挤压机，其特征在于，塑料挤压机(1)或辅助塑料挤压机与塑料挤压机(1)相结合对于不连续的作业采用起动-停机工作的操作方式。
17.根据权利要求10或11的塑料挤压机，其特征在于，在出料喷嘴(8)处设有一剪切装置(32)，用来切割成条的增强塑料材料(33)或出料的产品(33)。
18.根据权利要求10或11的塑料挤压机，其特征在于，经过切割的成品(33)可以通过一采用起动—停止工作方式操作的输送带(34)继续输送。
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