CN202155159U - 转子一字型排列的锥形三转子连续混炼机组 - Google Patents

转子一字型排列的锥形三转子连续混炼机组 Download PDF

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CN202155159U
CN202155159U CN2011201941165U CN201120194116U CN202155159U CN 202155159 U CN202155159 U CN 202155159U CN 2011201941165 U CN2011201941165 U CN 2011201941165U CN 201120194116 U CN201120194116 U CN 201120194116U CN 202155159 U CN202155159 U CN 202155159U
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王克俭
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Abstract

本实用新型转子一字型排列的锥形三转子连续混炼机组，主要由混炼部分和排料部分组成，可以采用单阶或双阶形式。混炼部分主要由加料装置、机筒、锥形转子、加热冷却装置以及传动装置组成。混炼用锥形转子有三个，安装时其中心线位于同一平面内成一定锥角一字型排列。每个混炼转子外径轮廓由大减小呈锥形，具有加料段和混炼段，加料段采用螺旋输送结构；从垂直于转子外轮廓锥面看，混炼段结构呈现凸轮形、S形或四棱转子型等典型的转子特点。采用单阶形式时，转子末端采用螺旋结构建立压力输送物料到机头；采用双阶形式时，混炼料经阀门进入下一阶螺杆挤出机建立压力输送物料到机头。两种形式都采用适合型腔的机头进行造粒或成型，为进一步提高压力，机头前还可接入熔体泵。三个转子可以是同速或差速的，运转时形成多个剪切、拉伸和捏合区，转子间物料交换更加频繁，有效地提高了设备的塑炼、熔融及分散性能，缩短了加工时间，提高了产量。该混炼机组可用于橡胶、涂料、推进剂、炸药、纸浆、塑料、食品、制药、饲料等加工中的混合和造粒等工艺过程。

Description

转子一字型排列的锥形三转子连续混炼机组
技术领域
本发明涉及转子一字型排列的锥形三转子连续混炼机组，可用于橡胶、涂料、推进剂、炸药、纸浆、塑料、食品、制药、饲料等加工中的混合和造粒等工艺过程。 
背景技术
混炼是决定高分子制品性能关键工艺环节，特别是对橡胶等高黏弹性材料显得尤其重要。物料混炼的均匀和稳定，是确保聚合物制品质量的关键。实现均匀混炼主要依靠混炼技术设备，包括开炼机、密炼机、双转子连续混炼机和螺杆挤出机等。工业上，螺杆挤出机主要用于塑料和食品及热塑性弹性体的塑化加工，其他三种则主要用于橡胶、涂料、炸药和推进剂等组分复杂物料的混炼。开炼机和密炼机属于间歇式混合设备，不仅效率低，而且难以达到不同批量物料的相同混炼质量。 
双转子连续混炼机结合了密炼机优异的混合特性，也以连续运转，在工业批量生产上得到广泛应用。它主要由机筒、转子、卸料装置等部分组成。机筒上的混炼腔为两个相互贯通的、横截面为圆形的孔，物料在混炼腔中受到转子的剪切、粉碎、捏合和混合的作用。非啮合异向旋转的转子主要由加料段、混炼段和出料段组成。转子加料段如同两根非啮合的双螺杆，在转子加料段螺纹的推动下，由加料口加入的物料，到达混炼段。转子混炼段表面螺旋角各不相同、错列排布的螺纹，物料在此熔融、混合、塑化。卸料装置可以控制卸料门的开启度，达到控制物料在混炼腔中停留时间的目的。 
专利200910250493.3开发出一字形排列的锥形三螺杆挤出机，三根螺杆全 部为锥形螺杆，形成两个捏合区。相对双螺杆挤出机，三螺杆挤出机具有摩擦剪切和两个啮合区的特性，物料与螺杆有更大的接触面积。混合充分、热传递性好、熔融能力大、排气能力优良以及温度控制更好，且具有更低的能耗。同时螺杆为锥形螺杆，锥形螺杆挤出机螺杆尾部直径增大，加料量增大，以提高挤出机挤出产量。螺杆尾部直径增大也增大了螺杆的承载能力，齿轮和轴承使用寿命长，有利于布置止推轴承和齿轮；加料段螺槽容积大，易加入较大体积的松密度粉料，也有利于热传导，更易实现对物料加热或冷却；排料段螺杆直径小，圆周速度较小，产生的剪切较低，摩擦热也较小，热损伤的危险性小；螺槽容积沿挤出方向逐渐减小，物料逐渐得到压缩，从而使螺槽更快充满物料，保证物料连续平缓地塑化；在同样的生产能力下，背压可较低。 
类似的，在双转子混炼机的基础上，采用三个锥形转子形成新的混炼机。三根转子一字型排列，不仅提高产量和节能，混合效果也会明显提高，还能适用于粉料和PVC等热敏性材料。 
发明内容
区别于传统双转子混炼机，本发明连续混炼机采用三根锥形转子呈一字型排列，形成锥形三转子混炼结构，如图1。其中混炼部分主要由加料装置、机筒、锥形转子、加热冷却装置以及传动装置组成。混炼用锥形转子有三个，安装时其中心线位于同一平面内成一定锥角一字型排列。每个混炼转子外径轮廓由大减小呈锥形，具有加料段和混炼段，加料段采用螺旋输送结构；从垂直于转子外轮廓锥面看，混炼段结构呈现凸轮形、S形或四棱转子型等典型的转子特点。 
进一步，为连续混炼，必须将混炼好的物料输送到机头进行造粒或成型，即除混炼部分外还需要排料部分。这样，三转子连续混炼机组由混炼部分和排料部分组成。为此形成的完整机组可以是单阶，也可以是双阶的。 
单阶三转子连续混炼机就是转子依次由非啮合螺杆加料段和混炼转子段及 螺杆排料段组成，物料被连续加入和混炼并经输送段强制排到机头进行造粒或成型，机头型腔结构取决于出口制品形状。为提高出口排料压力，机头前还可连接齿轮泵。 
双阶的三转子连续混炼机组如图1，主要有混炼部分和排料部分组成。第一阶中将非啮合螺杆加料段和混炼转子段制造成一个整体，物料被连续加入和混炼，在末端经开度可调的排料阀门排到第二阶。阀门的开度控制排料速率和形成第二阶的充满度，建立压力，改变混合段的混合强度。第二阶可以是螺杆挤出机，采用适合熔融物料加入的螺杆结构，经螺杆输送到机头进行造粒或成型，机头型腔结构取决于出口制品形状。为提高出口排料压力，机头前还可连接齿轮泵。 
三转子混炼机运行时，在加料口加入物料，经螺旋输送到混炼转子段，充分利用有效地转子结构进行反复的混合和塑炼。由于有三个转子，转子间的强拉伸区和捏合区成倍增加。本发明转子混炼段是锥形的，接近加料段直径大，接近排料段直径小。相应地，包含转子的机筒也是由三个圆锥体组合形成。除传统转子在周向和轴向结构周期性变化外，锥形转子直径由大变小，将产生轴向压缩捏合作用并增强了轴向输送作用，促进混合物料向下游移动。因此能明显提高混炼效果并提高产量，具有节能减排的效果。 
同时，锥形转子尾部直径增大，加料量增大，也提高了产量；增大了转子承载能力，齿轮和轴承使用寿命长，有利于布置止推轴承和齿轮；接近加料段容积大，易加入较大体积的松密度粉料，也有利于热传导，更易实现对物料加热或冷却；接近排料段的容积小，圆周速度较小，产生的剪切较低，摩擦热也较小，热损伤的危险性小；随着转子外径逐渐减小，物料逐渐得到压缩，从而使螺槽更快充满物料，保证物料连续平缓地混炼；在同样的生产能力下，背压可较低。这样，该类混炼机也可用于粉料和PVC等热敏性材料。 
附图说明
图1为转子一字型排列的锥形三转子连续混炼机组结构示意图 
1-电机，2-减速和分配箱，3-机筒，4-加料装置，5-加热装置，6-锥形转子，7-转子冷却装置，8-电机，9-减速箱，10-机筒，11-加热装置，12-螺杆，13-机头，14-排料阀门，15-连接筒体。 
图2为转子混炼段采用凸轮形状的断面示意图 
图3为转子混炼段采用S形转子的断面示意图 
图4为转子混炼段采用四棱转子的断面示意图 
具体实施方式
本实施案例为一个双阶的锥形三转子连续混炼机组。 
锥形转子一字型排列的锥形三转子连续混炼机组可以是锥形三转子连续混炼机连接螺杆挤出机组成，见图1。混炼部分主要包括：电机1，减速和分配箱2，机筒3，加料装置4，加热装置5，锥形转子6，转子冷却装置7组成。螺杆挤出部分包括：电机8，减速箱9，机筒10，加热装置11，螺杆12，机头口模13组成。混炼部分和螺杆挤出部分之间通过筒体15连接，其中设有开度可调节的排料阀门14。电机1、减速和分配箱2组成设备的传动装置。 
混炼部分用三个锥形转子，安装时其中心线位于同一平面内成一定锥角一字型排列。每个混炼转子外径轮廓由大减小呈锥形，具有加料段和混炼段，加料段采用螺旋输送结构；从垂直于转子外轮廓锥面看，混炼段结构呈现凸轮形、S形或四棱转子型等典型的转子特点。 
该连续混炼机组的工作原理是：电机1带动减速箱输入轴旋转，减速箱2内进行扭矩和转速分配通过三根输出轴带动三个锥形转子6在机筒内作旋转运 动。三个锥形转子6靠末端冷却系统调节内部温度。转子具有非啮合螺旋输送段和转子型混炼段，并安装于机筒3内，机筒在加热装置5作用下调节外部温度。物料经加料装置4加入机筒3内，经螺旋输送到混炼转子段。依靠从机筒传入的热量、转子的剪切、拉伸和挤压捏合作用，物料进行塑化和混合。混炼充分的物料经排料阀门14和连接筒体15进入螺杆挤出部分，在螺旋输送作用下建立压力经机头13挤出，进行造粒或成型。为进一步提高压力，机头前可接入熔体泵。 
三个转子混炼段是非啮合的，因此可以是同速或差速的，三个转子的旋转方向可以进行不同组合。为此，可以采用一体化减速和分配箱，也可以采用分离式减速箱和分配箱来实现转子运动组合，同时需要考虑锥形转子轴线呈锥角排布的要求。转子混炼段可充分利用各种典型的混炼转子结构，如图2的凸轮形、图3的S形和图4的四棱转子型等。 
由于有三个转子，转子间的强拉伸区、强剪切区和强挤压区成倍增加，转子间物料交换更加频繁，使物料在螺杆中的塑炼，均化，剪切的次数成倍增加；本结构将三转子混炼和锥形转子轴向挤压捏合作用相复合，更有效地提高了设备的塑炼、熔融及分散性能，缩短了加工时间，具有节能减排的特点，也可用于粉料和PVC等热敏性材料的混炼。 

Claims (2)

1.转子一字型排列的锥形三转子连续混炼机组，主要由混炼部分和排料部分组成，可以采用单阶或双阶形式；其中混炼部分主要由加料装置、机筒、锥形转子、加热冷却装置以及传动装置组成，其特征在于：混炼用锥形转子有三个，安装时其中心线位于同一平面内成一定锥角一字型排列。
2.根据权利要求1所述的转子一字型排列的锥形三转子连续混炼机组，其特征在于：每个混炼转子外径轮廓由大减小呈锥形，具有加料段和混炼段，加料段采用螺旋输送结构；从垂直于转子外轮廓锥面看，混炼段结构呈现凸轮形、S形或和四棱转子型典型的转子特点。 
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
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