WO2001060904A1 - Processus de production de lots de composition a base de caoutchouc - Google Patents

Processus de production de lots de composition a base de caoutchouc Download PDF

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Publication number
WO2001060904A1
WO2001060904A1 PCT/CA2000/000177 CA0000177W WO0160904A1 WO 2001060904 A1 WO2001060904 A1 WO 2001060904A1 CA 0000177 W CA0000177 W CA 0000177W WO 0160904 A1 WO0160904 A1 WO 0160904A1
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WO
WIPO (PCT)
Prior art keywords
batch
temperature
rubber
weight
shaft
Prior art date
Application number
PCT/CA2000/000177
Other languages
English (en)
Inventor
Daniel Grenier
Sylvain Bilodeau
Original Assignee
CENTRE DE RECHERCHE INDUSTRIELLE DU QUéBEC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by CENTRE DE RECHERCHE INDUSTRIELLE DU QUéBEC filed Critical CENTRE DE RECHERCHE INDUSTRIELLE DU QUéBEC
Priority to AU2000227880A priority Critical patent/AU2000227880A1/en
Priority to PCT/CA2000/000177 priority patent/WO2001060904A1/fr
Publication of WO2001060904A1 publication Critical patent/WO2001060904A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
    • C09J11/08—Macromolecular additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/02—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type
    • B29B7/06—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices
    • B29B7/10—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices rotary
    • B29B7/12—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices rotary with single shaft
    • B29B7/16—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices rotary with single shaft with paddles or arms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/02—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type
    • B29B7/22—Component parts, details or accessories; Auxiliary operations
    • B29B7/28—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control
    • B29B7/286—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control measuring properties of the mixture, e.g. temperature, density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/74—Mixing; Kneading using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
    • B29B7/7476—Systems, i.e. flow charts or diagrams; Plants
    • B29B7/7495—Systems, i.e. flow charts or diagrams; Plants for mixing rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/80—Component parts, details or accessories; Auxiliary operations
    • B29B7/82—Heating or cooling
    • B29B7/823—Temperature control
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L19/00—Compositions of rubbers not provided for in groups C08L7/00 - C08L17/00
    • C08L19/003—Precrosslinked rubber; Scrap rubber; Used vulcanised rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2021/00—Use of unspecified rubbers as moulding material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling

Definitions

  • the present invention relates to processes for producing batches of rubber-based composition and articles made thereof, and more particularly to processes for producing batches of rubber-based composition and shaped articles made thereof.
  • Such molecular chains blocking is obtained through a process known as vulcanization or curing, which typically consists of cross-linking macromolecular chains at double bond sites which are present along the chains, using sulfur as the linking element or an organic peroxide.
  • curing occurs through heating diene- based rubber materials at a temperature between about 130°C to 150°C in the presence of about 7 - 10% of sulfur.
  • Mechanical properties of sulfur- cured rubbers vary with cross-linking density which is proportional to the initial sulfur concentration.
  • compositions of various virgin (uncured) rubber types such as natural rubber, butyl rubber, polybutadiene and neoprene, with specific additives such as curing starting agents and curing accelerators, have been developed to obtain, after curing, rubber- based material exhibiting various mechanical properties such as tensile strength, maximum tensile elongation, tear strength, embrittlement temperature and resilience.
  • uncured rubber types such as natural rubber, butyl rubber, polybutadiene and neoprene
  • specific additives such as curing starting agents and curing accelerators
  • the technique usually consists of mixing rubber particles with 1% - 5% sulfur and curing the obtained mix in a suitable mold heated at a temperature of about 180°C while applying a pressure between 500 pound/sq.in. to 2000 pound/sq.in. with a conventional hydraulic press. Processes using such technique are generally known to be more cost effective than processes using uncured rubber as raw material, which is significantly more expensive than reclaimed rubber.
  • the mechanical properties exhibited by such reclaimed materials are generally inferior, typically characterized by a maximum tensile strength of about 300 pound/sq.in., a maximum tensile elongation of about 50%, and maximum tear strength of about 100 pound in., which properties are significantly inferior than those exhibited by uncured rubber-based compositions.
  • Such inferior mechanical behavior is mainly due to porosity characteristics and cross-linking level. Materials made of rubber particles or dust are characterized by a porosity which is generally responsible for the appearance of microfissures under mechanical strength.
  • effective contact areas between adjacent particles of a reclaimed rubber material are reduced as compared to those observed in virgin raw material. Under such conditions, cross-linking between macromolecules of adjacent particles are reduced accordingly, since most free double links of adjacent particles are not in sufficiently close proximity to be bound, and accordingly the non-reacted curing agent rapidly becomes in excess.
  • Microfissures appearing within the rubber material initiate flaws therein which rapidly grow toward material rupture, due to the weakness of internal forces binding rubber particles together, observed at low cross-linking level.
  • a known technique to reduce the inherent porosity of a material made of reclaimed rubber particles consists in adding a resin, preferably a thermoplastic resin, to bind the rubber particles and therefore reduce porosity.
  • a resin preferably a thermoplastic resin
  • a certain amount of uncured rubber material can also be added to increase the number of free double bond available for curing.
  • Additives such as compatibility agents may also be added.
  • the resultant composition is used to produce rubber materials which have been found to exhibit improved mechanical properties in the range of 400 pound/sq.in. for tensile strength, 250% for maximum tensile elongation and 180 pound/in for maximum tear strength.
  • Additives including plasticizers, lubricants, mold release agent or viscosity modifiers such as trans-polyoctanamer rubber may also be added.
  • a batch mixer such as the well known Moriyama or Bandbury high intensity mixers is proposed to produce a moldable composition showing a temperature between 120°C and 150°C, which is then transferred to a mold which is preheated at a temperature above a vulcanizing temperature of about 120°C.
  • Another similar process is disclosed in U.S. Patent No. 5,425,904 issued June 20, 1995, to Smits, which uses rubber latex to treat cured waste rubber particles with a curing agent to produce an activated moldable composition.
  • Another similar approach is taught in U.S. Patent No. 4,257,925 issued March 24, 1981, to Freeguard, which consists of swelling reclaimed tire rubber with a monomer and then causing polymerization thereof.
  • a liquid sulfur-curable polymeric binder namely a homopolymer or copolymer of 1,4-butadiene and substituted butadiene, is blended with cured rubber scrap and sulfur to produce a treated rubber material which can be used in large proportion as a filler or extender for uncured rubbers.
  • a process for producing a batch of rubber-based composition capable of being formed into an article comprising the steps of : feeding a batch of mixable material comprising from about 20% to about 99%o by weight of particles of cured rubber material with from about 80%) to about 1% by weight of a resinous material into a closed mixing chamber provided on a high intensity mixer including a central shaft having mixing blades; rotating the shaft to provide a blade tip speed of a level sufficient to intensively mix and thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; discharging the batch from the mixing chamber when said one of temperature and temperature related parameter reaches a reference value ensuring a substantially uniform mix of said rubber material in a matrix of said resinous material to produce said rubber-based composition.
  • a process of producing a shaped article made of a rubber-based material comprising the steps of: feeding a batch of mixable material comprising from about 20% to about 99% by weight of particles of cured rubber material with from about 80% to about 1% by weight of a thermoplastic resinous material into a closed mixing chamber provided on a high intensity mixer including a shaft having mixing blades; rotating the shaft to provide blade tip speed of a level sufficient and under conditions effective to intensively mix and thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; discharging the batch from the mixing chamber when said one of temperature and temperature related parameter reaches a reference value ensuring a substantially uniform mix of said rubber material in a matrix of said resinous material to produce a rubber-based composition capable of being shaped; and shaping the discharged batch of rubber-based composition to produce said shaped article.
  • a process of producing a batch of rubber-based composition capable of being heat- formed into an article comprising the steps of: feeding a batch of mixable material comprising from about 80% to about 99% by weight of particles of cured rubber material with from about 20%) to about 1%> of a curing agent into a closed mixing chamber provided on a high intensity mixer including a shaft having mixing blades; rotating the shaft to provide blade tip speed of a level sufficient to intensively mix and thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; and discharging the batch from the mixing chamber when said one of temperature and temperature related parameter reaches a reference value ensuring a substantially uniform mix of said cured rubber material with said curing agent without causing significant further curing to produce said rubber-based composition.
  • a process of producing a molded article made of a rubber-based material comprising the steps of: feeding a batch of mixable material comprising from about 80 % to about 99% by weight of particles of cured rubber material with from about 20% to about 1% by weight of a curing agent into a closed mixing chamber provided on a high intensity mixer including a shaft having mixing blades; rotating the shaft to provide blade tip speed of a level sufficient to intensively mix and thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; discharging the batch from the mixing chamber when said one of temperature and temperature related parameter reaches a reference value ensuring a substantially uniform mix of said cured rubber material with said curing agent without causing significant further curing to produce a rubber- based composition capable of being molded; and molding the discharged batch of rubber-based composition at a molding temperature substantially above a minimum curing temperature for a sufficient period of time to allow further curing of the rubber-based composition to produce said molded article.
  • a process of producing a batch of rubber-based composition capable of being shaped into an article comprising the steps of: feeding from about 20 % to about 95% by weight of particles of cured rubber material with from about 0.1 % to about 5 % by weight of a bonding agent into a closed mixing chamber provided on a high intensity mixer including a shaft having mixing blades; first rotating the shaft to provide blade tip speed of a level sufficient and for a sufficient period of time to substantially uniformly distribute the bonding agent onto the cured rubber particles to form a coating thereon; feeding from about 80 % to about 4.9 % by weight of a resinous material into the closed mixing chamber to form a batch of mixable material; further rotating the shaft to provide blade tip speed of a level sufficient and under conditions effective to intensively mix the resinous material with the cured rubber particles which are coated with the bonding agent and to thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; discharging the batch from the mixing chamber when
  • a process of producing a shaped article made of a rubber-based material comprising the steps of: feeding from about 20 % to about 95% by weight of particles of cured rubber material with from about 0.1 % to about 5 % by weight of a bonding agent into a closed mixing chamber provided on a high intensity mixer including a shaft having mixing blades; first rotating the shaft to provide blade tip of a level sufficient and for a sufficient period of time to substantially uniformly distribute the bonding agent onto the cured rubber particles to form a coating thereon; feeding from about 80 % to about 4.99 % by weight of a resinous material into the closed mixing chamber to form a batch of mixable material; further rotating the shaft to provide blade tip speed of a level sufficient and under conditions effective to intensively mix the resinous material with the cured rubber particles which are coated with the bonding agent and to thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; discharging the batch from the mixing chamber when said one of temperature and
  • a process of producing a batch of rubber-based composition capable of being heat-formed into an article comprising the steps of: feeding a batch of mixable material comprising from about 20% to about 98% by weight of particles of cured rubber material with from about 10% to about 1% by weight of a curing agent and from about 70% to about 1% by weight of a polymeric binder which is reactive with the curing agent into a closed mixing chamber provided on a high intensity mixer including a shaft having mixing blades; rotating the shaft to provide a blade tip speed of a level sufficient to intensively mix and thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; and discharging the batch from the mixing chamber when said one of temperature and temperature related parameter reaches a reference value ensuring a substantially uniform mix of said cured rubber material with said curing agent, said optional polymeric binder and said optional virgin rubber without causing significant further curing to produce said rubber-based composition.
  • a process of producing a molded article made of a rubber-based material comprising the steps of : feeding a batch of mixable material comprising from about 20% to about 99% by weight of particles of cured rubber material with from about 10% to about 1%> by weight of a curing agent and from about 70% to about 1% by weight of a polymeric binder which is reactive with the curing agent into a closed mixing chamber provided on a high intensity mixer including a shaft having mixing blades; rotating the shaft to provide a blade tip speed of a level sufficient to intensively mix and thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; discharging the batch from the mixing chamber when said one of temperature and temperature related parameter reaches a reference value ensuring a substantially uniform mix of said cured rubber material with said curing agent, said optional polymeric binder and said optional virgin rubber without causing significant further curing to produce a rubber-based composition capable of being shaped; and molding the discharged batch of rubber-based composition
  • a process of producing a batch of rubber-based composition capable of being heat- formed into an article comprising the steps of: feeding a batch of mixable material comprising from about 10% to about 89% by weight of particles of cured rubber material with from about
  • a curing agent 10% to 1% by weight of a curing agent into a closed mixing chamber provided on a high intensity mixer including a shaft having mixing blades; rotating the shaft to provide a blade tip speed of a level sufficient to intensively mix and thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; and discharging the batch from the mixing chamber when said one of temperature and temperature related parameter reaches a reference value ensuring a substantially uniform mix of said cured rubber material with said uncured rubber material and said curing agent without causing significant further curing to produce said rubber-based composition.
  • a process of producing a molded article made of a rubber-based material comprising the steps of : feeding a batch of mixable material comprising from about 10% to about 89% by weight of particles of cured rubber material with from about 80% to about 1%> by weight of uncured rubber material and from about 10% to about 1% by weight of a curing agent into a closed mixing chamber provided on a high intensity mixer including a shaft having mixing blades; rotating the shaft to provide a blade tip speed of a level sufficient to intensively mix and thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; discharging the batch from the mixing chamber when said one of temperature and temperature related parameter reaches a reference value ensuring a substantially uniform mix of said cured rubber material with said uncured rubber material and said curing agent without causing significant further curing to produce a rubber-based composition capable of being shaped; and molding the discharged batch of rubber-based composition at a molding temperature substantially above a minimum curing temperature
  • a process of producing a batch of rubber-based composition capable of being heat- formed into an article comprising the steps of: feeding a batch of mixable material comprising from about 10% to about 39% by weight of particles of cured rubber material with from about 79% to about 30%> by weight of uncured rubber material and from about 1% to 30% by weight of a thermoplastic resinous material into a closed mixing chamber provided on a high intensity mixer including a shaft having mixing blades; rotating the shaft to provide a blade tip speed of a level sufficient to intensively mix and thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; and discharging the batch from the mixing chamber when said one of temperature and temperature related parameter reaches a reference value ensuring a substantially uniform mix of said cured rubber material with said uncured rubber material and said resinous material without causing significant further curing to produce said rubber-based composition.
  • a process of producing a molded article made of a rubber-based material comprising the steps of : feeding a batch of mixable material comprising from about 10%> to about 39% by weight of particles of cured rubber material with from about
  • thermoplastic resinous material 79% to about 30% by weight of uncured rubber material and from about 1% to about 30% by weight of a thermoplastic resinous material into a closed mixing chamber provided on a high intensity mixer including a shaft having mixing blades; rotating the shaft to provide a blade tip speed of a level sufficient to intensively mix and thermokinetically heat the batch of mixable material; continuously monitoring one of temperature and temperature related parameter of the batch; discharging the batch from the mixing chamber when said one of temperature and temperature related parameter reaches a reference value ensuring a substantially uniform mix of said cured rubber material with said uncured rubber material and said resinous material without causing significant further curing to produce a rubber-based composition capable of being shaped; and molding the discharged batch of rubber-based composition at a molding temperature substantially above a minimum curing temperature for a sufficient period of time to allow further curing of the rubber-based composition to produce said molded article.
  • Fig. 1 is a perspective view of a high intensity batch mixer used to practice the process according to the present invention
  • Fig. 2 is a partially cross-sectional perspective view of a front end of the batch mixer shown in Fig.l;
  • Fig. 3 is a graph showing the variation of a mixer motor load cu ⁇ ent measured as a function of time, and related thresholds used to control a process according to the present invention.
  • mixer 10 which could be used to carry out the process according to the present invention is depicted, which mixer 10 comprises a base frame 12 including a pair of longitudinal beams 14 secured to upper ends of front and rear pairs of floor mounted pillars 16 rigidly secured by transverse members 18 and bracing plates 20. On the rear portion of the beams 14 is secured a motor base 22 having a mounting plate 24 on which is secured lower parts of legs 26 supporting an electric industrial motor 28, preferably of a self-cooling type. As shown in Fig.
  • motor 28 is provided with an output shaft 30 connected to a driving end of a flexible coupling 13 of known construction, which has a driven end connected to a driving shaft 15 extending through a cantilever bearing unit 17 permanently lubricated with a pumped oil circuit (not shown).
  • the flexible coupling is covered for protection with a casing 19 (Fig. 1) provided with an aperture 21 giving required clearance for the main driving shaft 15.
  • the cantilever bearing unit 17 is rigidly mounted through rear and front supports 29 (only rear support being shown in Fig. 2) on an horizontal plate 19 as part of a sub-frame assembly 21 secured to the front portions of the beams 14, and having a vertical mounting plate 23 further secured to the horizontal plate 19 through a pair of opposed bracing plates 27.
  • apparatus 10 further comprises a cylindrical mixing chamber 32 having outer double peripheral wall 34 and provided with cooling fluid ports 35 (Fig. 1) to be connected to a cooling circuit line (not shown) as will be later explained in more detail.
  • Wall 34 is further provided with and optional temperature probe 37.
  • Mixing chamber 32 further has a circular double end wall 36 defining a mixing cavity 38.
  • Mixing chamber 32 is secured to the body of a feeding unit 42 having an outer double peripheral wall 39 provided with cooling fluid ports 41 as better shown in Fig. 1, and an input tubular portion 44 in communication with an output annular portion 46 defining a feeding cavity 48 therebetween, as better shown in Fig. 2.
  • peripheral double wall 34 of the mixing chamber 32 defines an annular channel adapted to receive an annular rib protruding from the outer surface of a first collar 52, which is then rigidly welded or otherwise secured to the double wall 34.
  • the inner surface of first collar 52 is in turn joined to the outer mating surface of a second collar 54.
  • Collars 52 and 54 are rigidly bolted together.
  • Output annular portion 46 of the feeding unit 42 tightly engages with an inner opening formed in collar 54, to form an annular inner end wall opposed to circular end wall 36.
  • Input tubular portion 44 defines with the inner rear surface of collar 54 an internal space 33 in fluid communication through a fluid line (not shown) with internal space 31 within double walls 34 and 36, to for a cooling cavity as part of the cooling fluid circuit filled with a cooling fluid such as cold water, for limiting the temperature of the feeding cavity and mixing chamber to a level providing desired process continuity.
  • a fluid line not shown
  • a cooling fluid such as cold water
  • a two- part driven shaft 56 Centrally extending through the output annular portion 46 is a two- part driven shaft 56 having a forward bladed portion 58 contained in the mixing chamber 32 and being opposed to a rearward threaded portion 60 contained in the feeding cavity 48 and acting as a conveyor screw.
  • the cantilever bearing unit 17 provides axial and radial stability for shaft 56 while allowing rotation thereof about axis 66.
  • Rearward shaft portion 60 is rigidly secured to the driven end of the driving shaft 15 using a key screw (not shown), to impart rotation to the rearward shaft portion 60.
  • the outer end of forward shaft portion 58 is formed with a threaded hole 62 for receiving an aligned bolt 64 securing the forward shaft portion 58 to the driven end of the driving shaft 15, to impart rotation to the forward shaft portion 58.
  • An optional aeration port 65 is provided at the outer surface of double end wall 36.
  • port 65 may be replaced by a bearing for receiving a rotating rod (not shown) to be secured to the outer end of the forward shaft portion 58.
  • the outer diameter of threads 66 provided on the driven shaft 56 is chosen to closely fit within output annular portion 46, mixing cavity 38 thereby becoming substantially enclosed.
  • Input tubular portion 44 of feeding unit 42 is coupled with a co ⁇ esponding lower flange 68 of a feeding column 40 provided with a feeding hopper 70 at an upper portion thereof.
  • a feeding door mechanism 72 provided with a hand-held actuating arm 74 allows an operator to dump raw materials previously discharged in the hopper into feeding cavity 48.
  • a plurality of mixing blades 75 each having a tip portion maintained in substantially close proximity to the inner surface of the double wall 34.
  • Located in a lower portion of the peripheral double wall 34 is a discharge opening 76 delimited by a peripheral sealing edge surface adapted to tightly mate with the corresponding inner surface of a displaceable door 78.
  • Door 78 is rigidly secured to an outer end of a pivoting arm 77 having an inner end rigidly attached to a clamping sleeve 79 receiving an output shaft 80 of a rotary actuator 81 mounted on the sub-frame assembly 21 and being driven through a pneumatic cylinder 84 coupled to a linear-to-rotary converting mechanism of a known construction (not shown).
  • the output shaft 80 is caused to rigidly engage the clamping sleeve, to selectively displace the door away from a discharge opening 76 to provide discharge of mixed material out of the mixing chamber upon rotation of the shaft in a first direction, or to displace the door toward discharge opening 76 and maintain door 78 against it in an opposite direction to tightly obstruct the opening 76 during the feeding and mixing steps.
  • a chute 82 which comprises front and rear wall 85, 86 as better shown in Fig. 2 and side walls 88, 90 as better shown in Fig. 1, which walls define a discharge outlet for dumping a mixed batch to be transferred to a forming station.
  • Apparatus 10 further comprises a control device such as programmable logic controller (PLC) 92 which receives from line 98 a current load indicating signal generated by an electrical current measuring device such as ammeter 96 as part of the motor drive unit 94, or located at a remote location, to derive the estimated temperature of the mix, as will be explained later in more detail.
  • PLC programmable logic controller
  • the PLC may receive via line 102 and optional temperature probe 37, a signal representing the temperature directly measured within mixing cavity 38. Due to the generally short time cycle of the process, the temperature within the batch of material being mixed could be significantly different from the temperature of walls 34 or 36 of mixing chamber 32. Therefore, a remote temperature sensor should preferably be used, such as optical infrared sensor as disclosed in U.S. Patent No.
  • PLC 92 also sends to motor drive unit 94 through line 100, a command signal to control the rotation of motor 28 according to a preset RPM value.
  • the motor drive unit 94 incorporates a feedback device to substantially maintain the preset RPM, whatever the load current variation may be.
  • PLC 92 sends a command signal to pneumatic cylinder 84 via line 97 according to a selected predetermined program stored in the PLC, as will be discussed later in more detail. It should be understood that discharge can also be manually operated a through manual control mode available on the PLC.
  • Lines 106 and 108 are used to send control signals to a lubricating oil pump for bearing unit 17 and a valve (not shown) which controls the cooling circuit.
  • the hand-held arm 74 of the feeding door mechanism 72 can be replaced by a rotary actuator which can be coupled to the feeding door mechanism and activated through the PLC via line 104.
  • the rotation speed in RPM of shaft 56 is preset to a value ensuring that sufficient mixing and friction energy is provided to the mix, in a short processing time while still providing the stability required for efficient process control.
  • the composition homogeneity which is required to obtain uniform physical properties is also obtained. Such results can be obtained when the blade tip speed is above about 17 meter/sec, and preferably between about 22 and 29 meter/sec. Experience has shown that with blade tip speeds above 35 meter/sec, a fast temperature rising rate observed may render the process difficult to control. Since the blade tip speed is directly related to the RPM value as a tangential speed at the co ⁇ esponding radius, the RPM as a standard parameter, is preferably chosen as a reference control parameter for the process.
  • curve 101 which is shown, represents the variation of load cu ⁇ ent (in amp) shown on vertical reference axis 102, and as a function of time (in sec.) on horizontal reference axis 104, measured during mixing of a 1 kg batch of material, from the initial material feeding step to a final state where the 3 liter mixing chamber 32 of the high intensity mixer 10 is empty after discharge of the mixed batch.
  • 63% by weight of vulcanized (cured) rubber crumb of either natural or synthetic type were previously pre-mixed with 32% of a thermoplastic polymer resin, selected from polyethylenes (from low to high density) or ethyl-vinyl acetates, optionally with 5 % by weight of an additive such as acrylic acid.
  • the rubber crumbs were selected to pass through a 8 mesh sieve in the instant example. However, depending on the raw rubber crumb grain size and desired composition quality, any sieve size between 8 to 60 mesh, and preferably between about 20 to 30 mesh may be used. Depending on the desired mechanical properties for the formed material, experience has shown that from about 20% to about 99% by weight of cured rubber crumbs may be added to from about 80% to about 1%> by weight of thermoplastic resin.
  • the load cu ⁇ ent drawn by motor 28 running idle at a preset speed of about 3200 RPM was measured to be about 15 amp.
  • the rotation speed of shaft 56 may be typically set from about 2800 to about 3600 RPM, which limit values co ⁇ espond to a blade tip speed from about 22 to 29 meter/s, respectively.
  • the intensity of the load cu ⁇ ent increases according to a first substantially linear gradient until the whole batch of material has been introduced within the mixing cavity 38, which co ⁇ esponds to a substantially flat intermediate curve part showing an average load cu ⁇ ent value of about 35 amp in the example shown.
  • That temporary load cu ⁇ ent stability is associated with a constant mixing behavior exhibited by the batch material as the temperature is rising toward a first transition temperature where the material enters into a viscous state progressively adding to counter-torque, requiring further increase of the load cu ⁇ ent above to maintain the RPM at the preset level of 3200.
  • the increase in viscosity is associated with a melting of the thermoplastic resin which encapsulates the rubber crumbs which remain in a solid state at that temperature range.
  • the transition temperature was obtained in about 9 sec. Then, the load cu ⁇ ent rises according to a second substantially linear gradient, passing through a minimum value the purpose of which will be explained later, to substantially stabilize at a maximum level of about 56 amp in about 15 sec for the example shown, which maximum co ⁇ esponds to a second transition temperature where the mixed material gradually enters into a fluidized state requiring less energy to be mixed. Thereafter, the load cu ⁇ ent begins to drop accordingly, while the temperature of the fluidized matter still increases, until the desired batch temperature is considered to have been reached, co ⁇ esponding to a predetermined discharge load cu ⁇ ent, which parameter can be derived in various ways.
  • a first way consists in causing PLC 92 to open discharge door 78 for a preset time following the moment where the load cu ⁇ ent reaches through a numerical analysis method programmed in PLC 92. It should be understood that can be set at zero.
  • the preset value for can be chosen experimentally by a direct measurement of the temperature of the discharge material using successive test values for. In the example shown in Fig. 3, was given a value of 2 sec.
  • An alternate way would consist in programming PLC 92 to open the discharge door 78 for a preset time following the moment where the load cu ⁇ ent reaches, both cu ⁇ ent values being experimentally set while ensuring that the derived has a value equal to or under. In the example shown in Fig.
  • a target temperature within a range from about 160°C to about 250°C and preferably from about 180 °C to about 210°C ensures the production of a substantially uniform mix of cured rubber material in a matrix of resinous material to produce a rubber- based composition which could be later formed into an article.
  • a third way would consist in causing PLC 92 to open discharge door 78 for a preset time following the start of the mixing, which co ⁇ esponds to. In the example shown in Fig. 3, was given a value of 19 sec.
  • the material discharge may be caused to occurs in case where the load cu ⁇ ent as measured reaches a predetermined critical value, indicating a possible malfunction of the apparatus.
  • the mixed matter discharge can also be under the control of the operator using manual functions available on PLC 92, based on manual timing carried out after the introduction of the material into feeding cavity 48. If the process control is based on direct temperature measurement through temperature probe 37 as shown in Fig.
  • PLC 92 can be programmed to monitor a temperature signal coming from probe 37, and to command activation of discharge door 78 whenever a target discharge temperature is measured.
  • the discharged material which was in a viscous state was then ready to be transfe ⁇ ed to a shaping station to be shaped into an article.
  • a rubber-thermoplastic composition used in the example described with reference to Fig. 3 a conventional cold-molding press on which is mounted a two-part mold was used to form the article, the latter being allowed to cool into the mold under pressure until mold removal temperature was attained.
  • Example 2
  • cured rubber crumbs of either natural or synthetic type were previously pre-mixed with from about 20% to 1%> of a curing agent such as sulfur, which is characterized by a minimum curing temperature of about 110°C, and then introduced into 3 liter mixing chamber 32 of high intensity mixer 10.
  • the rubber crumbs were selected to pass through a 8 mesh sieve in the instant example.
  • the rotation speed of shaft 56 may be set from about 2200 to about 3600 RPM, which limit values co ⁇ espond to a blade tip speed from about 17 to 29 meter/s, respectively.
  • PLC 92 was programmed to monitor the temperature as previously explained, to command activation of discharge door 78 whenever a target discharge temperature was considered to have been reached, co ⁇ esponding to a temperature for the mixed matter selected within a range from about 115°C to about 140°C, ensuring the production of a substantially uniform mix of cured rubber with the curing agent without causing significant further curing to produce a rubber-based composition which could be later heat-shaped into an article.
  • the mixing cycle is completed within about 30 sec.
  • the discharged composition in the form of a mass of hot particles was then ready to be transfe ⁇ ed to a shaping station to be shaped into an article, the mold being pre-heated to a molding temperature substantially above a minimum curing temperature.
  • the batch of heat-moldable composition is maintained within the pre-heated mold for a sufficient period of time to allow further curing of the composition to produce the shaped article.
  • a conventional hot-molding press on which is mounted a two-part mold pre-heated to a temperature from about 140°C or about 200°C was be used to shape the article, the latter being allowed to further cure under heat into the mold under pressure and then allowed to chill until mold removal temperature was attained.
  • Pre-heating of the composition in the mixing stage followed by molding at a temperature well above minimum curing temperature has been found more energetically effective than known processes using one-step heating while shaping. Typically, curing is completed within about 60 min., which is more than twice faster than the curing time required by known one-step heating shaping processes. The humidity which remained in the molded batch was sufficiently reduced during mixing to ensure safe removal from the mold.
  • Example 3 from about 20% to 95% by weight of cured rubber crumbs of either natural or synthetic type were previously pre-mixed with from about 0.1 %> to about 5% of a bonding agent, such as acrylic acid, Primacor 3460 (Dow Chemicals) a silane or a titanate, and are first introduced into 3 liter mixing chamber 32 of high intensity mixer 10. The rubber crumbs were selected to pass through a 20 mesh sieve.
  • a bonding agent such as acrylic acid, Primacor 3460 (Dow Chemicals) a silane or a titanate
  • a first step the rotation speed of shaft 56 was maintained for about 30 sec to a value of from about 2200 RPM to about 3000 RPM co ⁇ esponding to a blade tip speed of from about 17 meter/s to about 24 meter/s, to cause a substantially uniform distribution of the bonding agent through the rubber particles to form a coating.
  • the temperature of the mix did not significantly raise.
  • thermoplastic polymer resin selected from polyethylene (from low to high density) or ethyl-vinyl-acetates, from about 80% to about 4.9 % by weight, was introduced into the mix, while shaft 56 was rotated at a speed set from about 2800 to about 3600 RPM, which co ⁇ espond to a blade tip speed from about 22 to 29 meter/s, respectively.
  • PLC 92 was programmed to monitor the temperature as previously explained, to command activation of discharge door 78 whenever a target discharge temperature was considered to have been reached, co ⁇ esponding to a temperature for the mixed matter from about 160°C to about 250°C and preferably from about 180°C to about 210°C to yield a ready to shape matter exhibiting improved mechanical properties due to the bound rubber-thermoplastic matter as compared to material wholly made of cured rubber crumbs.
  • the discharged material in a viscous state was then ready to be transfe ⁇ ed to a shaping station to be formed into an article, using a cold molding press as explained before in conjunction with example 1.
  • Example 4 In this example, from about 20% to 98% by weight of cured rubber crumbs of either natural or synthetic type were pre-mixed with from about 10% to 1%) of a curing agent such as sulfur, with from about 70% to 1% of a low molecular weight polymeric binder which reacts with the curing agent, such as trans-polyoctenamer (supplied by Huls AG) .
  • a curing agent such as sulfur
  • a low molecular weight polymeric binder which reacts with the curing agent, such as trans-polyoctenamer (supplied by Huls AG) .
  • Other polymeric binder such as styrene- 1,4-butadiene, a copolymer of 1,4- butadiene and acrylonitrile or 1,2-polybutadiene may also be used.
  • Known activators such as zinc oxide or stearic acid, and a curing accelerator such as tetramethyl thiuran disulfide (TMTD) or benzothiazyldisulfide (MBTS) were added to control curing of the uncured rubber.
  • TMTD tetramethyl thiuran disulfide
  • MBTS benzothiazyldisulfide
  • This pre-mix was then introduced into 3 liter mixing chamber 32 of the high intensity mixer 10.
  • the rubber crumbs were selected to pass through a 20 mesh sieve.
  • the rotation speed of shaft 56 may be set from about 2200 to about 3600 RPM, which co ⁇ espond to a blade tip speed from about 17 to 29 meter/s, respectively.
  • PLC 92 can be programmed to monitor the temperature as previously explained, to command activation of discharge door 78 whenever a target discharge temperature was considered to have been reached, co ⁇ esponding to a temperature for the mixed material from about 115°C to about 140°C, at which temperature further curing is substantially prevented, thereby producing a rubber-based composition which can be later heat-shaped into an article.
  • the discharged composition in the form of a mass of hot particles was then ready to be transfe ⁇ ed to a shaping station to be shaped into an article, in the same manner as explained in conjunction with Example 2.
  • Example 5 In this example, from about 10% to 89% by weight of cured rubber crumbs of either natural or synthetic type were pre-mixed with from about 80% to 10% of uncured rubber such as styrene-butadiene rubber, isoprene rubber or natural rubber and from about 10% to 1% by weight of a curing agent such as sulfur. More preferably, the weight ranges of the cured rubber crumbs and the uncured rubber were from about 10% to 69% and from about 80% to 30% respectively.
  • Known activators such as zinc oxide or stearic acid and a curing accelerator such as CBS (N-cyclohexyl-2- benzothiazolyl-sulfenamide) were added. The rubber crumbs were selected to pass through a 8 mesh sieve. All other parameters of the process as set forth above in respect of example 4 were used to prepare a batch whose composition is adapted to perform the shaping operation of an article.
  • Example 6 from about 10% to 39% by weight of cured rubber crumbs of either natural or synthetic type were pre-mixed with from about 79% to 30% of uncured rubber such as styrene-butadiene rubber, isoprene rubber or natural rubber, from about 1% to 30% of a thermoplastic polymer resin, selected from polyethylenes (from low to high density), polypropylenes, polyisobutylenes and ethyl- vinyl acetates and from about 10% to 1% by weight of a curing agent such as sulfur
  • a thermoplastic polymer resin helps to obtain a more flowable composition.
  • Known activators such as zinc oxide or stearic acid and a curing accelerator such as CBS (N-cyclohexyl-2-benzothiazolyl-sulfenamide) were added.
  • All other parameters of the process as set forth above in respect of example 4 were used to prepare a batch whose composition is adapted to perform the shaping operation of an article.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

Abstract

La présente invention concerne des processus de production de lots de compositions à base de caoutchouc qui peuvent être mises en forme, et des articles formés à partir de ces compositions. Ces processus consistent à mélanger intensément des particules de caoutchouc traité avec d'autres composés sélectionnés dans une chambre de mélange fermée prévue dans un mélangeur à haute intensité comprenant un arbre central à pales mélangeuses. A grande vitesse de rotation de l'arbre, l'extrémité de ces pales atteignent une vitesse supérieure à environ 20 mètres/s de façon à mélanger intensément et chauffer thermocinétiquement le lot de matière mélangeable, dont la température est surveillée continuellement. On évacue le lot de cette chambre de mélange lorsqu'on considère que la température a atteint une valeur de référence qui assure un mélange sensiblement uniforme de la matière de caoutchouc et des composés ajoutés, afin de produire cette composition à base de caoutchouc.
PCT/CA2000/000177 2000-02-17 2000-02-17 Processus de production de lots de composition a base de caoutchouc WO2001060904A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU2000227880A AU2000227880A1 (en) 2000-02-17 2000-02-17 Process for producing batches of rubber-based composition
PCT/CA2000/000177 WO2001060904A1 (fr) 2000-02-17 2000-02-17 Processus de production de lots de composition a base de caoutchouc

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002045930A2 (fr) * 2000-12-04 2002-06-13 Innovative Elastics Limited Production d'articles elastiques
CN103831904A (zh) * 2012-11-21 2014-06-04 陈下放 一种混合室

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US4244841A (en) * 1980-03-24 1981-01-13 Frankland Enterprises, Inc. Method for recycling rubber and recycled rubber product
US4386182A (en) * 1979-07-24 1983-05-31 Vredestein Icopro B.V. Thermoplastic elastomeric composition containing vulcanized rubber particles and surfactant and process for preparation thereof
US4481335A (en) * 1981-08-10 1984-11-06 Stark Jr Fred J Rubber compositions and method
EP0254307A1 (fr) * 1986-07-25 1988-01-27 The B.F. Goodrich Company Alliage polymérique d'un caoutchouc thermoplastique et sa méthode de production
US5094905A (en) * 1990-02-13 1992-03-10 Murray Kevin N Structural articles made of recycled rubber fragments from tires
DE4100581A1 (de) * 1991-01-10 1992-07-16 Kraiburg Gummi Formkoerper aus vulkanisiertem altgummimaterial
US5151230A (en) * 1990-10-01 1992-09-29 Dinoflex Manufacturing Ltd. Process for production of products formed of polymer bonded and granulated particles
US5425904A (en) * 1990-12-05 1995-06-20 Vredestein Icopro B.V. Process for activating vulcanized waste rubber particles and a process for producing a rubber-like article using said activated waste rubber particles
JPH07237217A (ja) * 1994-02-28 1995-09-12 Matsushita Electric Works Ltd 攪拌槽
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US4386182A (en) * 1979-07-24 1983-05-31 Vredestein Icopro B.V. Thermoplastic elastomeric composition containing vulcanized rubber particles and surfactant and process for preparation thereof
US4244841A (en) * 1980-03-24 1981-01-13 Frankland Enterprises, Inc. Method for recycling rubber and recycled rubber product
US4481335A (en) * 1981-08-10 1984-11-06 Stark Jr Fred J Rubber compositions and method
EP0254307A1 (fr) * 1986-07-25 1988-01-27 The B.F. Goodrich Company Alliage polymérique d'un caoutchouc thermoplastique et sa méthode de production
US5094905A (en) * 1990-02-13 1992-03-10 Murray Kevin N Structural articles made of recycled rubber fragments from tires
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US5425904A (en) * 1990-12-05 1995-06-20 Vredestein Icopro B.V. Process for activating vulcanized waste rubber particles and a process for producing a rubber-like article using said activated waste rubber particles
DE4100581A1 (de) * 1991-01-10 1992-07-16 Kraiburg Gummi Formkoerper aus vulkanisiertem altgummimaterial
JPH07237217A (ja) * 1994-02-28 1995-09-12 Matsushita Electric Works Ltd 攪拌槽
EP0780430A1 (fr) * 1994-09-16 1997-06-25 National Rubber Technology Inc. Composition de caoutchouc modifiée par des polymères
US5714219A (en) * 1995-09-21 1998-02-03 Soft Stone Corporation Support member formed of recycled material and process of manufacture

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002045930A2 (fr) * 2000-12-04 2002-06-13 Innovative Elastics Limited Production d'articles elastiques
WO2002045930A3 (fr) * 2000-12-04 2003-01-16 Innovative Elastics Ltd Production d'articles elastiques
CN103831904A (zh) * 2012-11-21 2014-06-04 陈下放 一种混合室

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