WO2020118987A1 - 一种用于热塑性聚酯发泡成型装置 - Google Patents

一种用于热塑性聚酯发泡成型装置 Download PDF

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Publication number
WO2020118987A1
WO2020118987A1 PCT/CN2019/082361 CN2019082361W WO2020118987A1 WO 2020118987 A1 WO2020118987 A1 WO 2020118987A1 CN 2019082361 W CN2019082361 W CN 2019082361W WO 2020118987 A1 WO2020118987 A1 WO 2020118987A1
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Prior art keywords
twin
screw extruder
vacuum
screw
melt
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English (en)
French (fr)
Inventor
信春玲
李东生
何亚东
邵俊
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Nanjing Chuangbo Machinery Co Ltd
Beijing University of Chemical Technology
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Nanjing Chuangbo Machinery Co Ltd
Beijing University of Chemical Technology
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • 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
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material

Definitions

  • the invention relates to a polymer processing device, in particular to a thermoplastic polyester foam molding device.
  • thermoplastic polyester has excellent heat resistance and mechanical properties. Compared with traditional foam plastics, thermoplastic polyester foam has good dimensional stability at high temperatures, excellent mechanical properties and fatigue resistance, low smoke, flame retardant, non-toxic , Low water absorption, good gas barrier and recyclable advantages, it has wide application prospects in wind power, rail transportation, automobile industry and other fields. However, thermoplastic polyesters have low melt viscosity, poor thermal stability, and easily absorb moisture to cause thermal degradation and hydrolysis, especially hydrolysis, which will cause the molecular weight of polyesters to drop sharply.
  • the existing technology mainly expands by adding Chain agent or cross-linking agent can increase the viscosity of polyester, multi-functional auxiliary can be added during polymerization and then solid-phase polycondensation to obtain thermoplastic polyester with high melt viscosity; or multi-functional chain extender or branch can be added during extrusion Chemical agent, reactive extrusion to obtain high viscosity polyester.
  • the prior art usually uses a pre-drying technique to remove moisture from the polyester chips. There are three types of pre-drying: vacuum drum drying, rotary packing combined drying, and fluidized bed. The continuous airflow drying is commonly used. The drying process is 140°C for 3-4 hours.
  • the hopper After drying, it must be kept at 100-110°C. Or placed in a dry closed container for use, the hopper should also be irradiated with infrared rays to keep it dry, or use N 2 to protect the feeding device.
  • This pre-drying process equipment is complex, the drying process takes a long time, the efficiency is low and the energy consumption is high.
  • US2015336319A1 discloses a polyester foaming extrusion device, including: a feeding system, a co-rotating twin-screw extruder, a head and a shaping device, wherein the twin-screw extruder has an air exhaust area and Vacuum exhaust zone, the temperature of the air exhaust zone is 10°C lower than the melting point of the polyester, the melt temperature of the vacuum exhaust zone is higher than the melting point of the polyester, especially the preheated nitrogen is injected in the first exhaust zone to enhance the air Exhaust effect.
  • the device can realize direct extrusion processing of polyester without drying, and to a certain extent overcomes the shortcomings of time-consuming, high energy consumption and complicated equipment in the pre-drying process.
  • the disadvantage is that the injection of preheated nitrogen equipment and complicated operation in the first exhaust zone.
  • CN201220654257.5 discloses a PET twin-screw sheet extrusion equipment without crystal drying, including a feeding device, a screw extruder and a sheet extrusion device, wherein the screw extruder is a parallel twin-screw extruder in the same direction, A plurality of vacuuming devices are arranged on it.
  • the patent technical solution discloses in the embodiments that the vacuum absolute pressure of the vacuum pump is ⁇ 0.5 mbar and the degassing capacity is greater than 1000 l/s. This technical solution lacks adaptability to the need to add a variety of low-molecular additive components during the reactive extrusion foaming process of polyester.
  • US5958164 discloses a thermoplastic polyester foaming method, which includes: adding polyester and additives directly to the first-stage twin-screw extruder, the vacuum exhaust section on the twin-screw extruder removes the moisture absorbed by the polyester, and then injects Foaming agent, foamed in the downstream low-pressure zone to obtain PET foamed products, in particular, fluoroplastics are added to the polyester, the vacuum degassing pressure is less than 20Torr (2666pa), the foaming agent is injected from the gas inlet of the second-stage single-screw extruder injection.
  • the technical solution of the blowing agent (butane) is injected from the second-stage single screw extruder, and the diameter of the single screw is equal to the diameter of the twin screw.
  • the single screw speed is higher and the processing It is easy to generate high shear heat, unable to accurately control the temperature of the PET melt, resulting in instability in the extrusion process, low head pressure and other shortcomings, it is difficult to obtain a PET foam sheet with a foaming density of less than 200 kg/m 3 and a thickness of more than 30 mm.
  • thermoplastic polyester foam molding device In order to achieve efficient, stable and high-quality production of thermoplastic polyester foam molding, the present invention provides a thermoplastic polyester foam molding device.
  • a foaming molding device for thermoplastic polyester including a twin-screw extruder, a melt pump, a single-screw extruder, a static mixer, a foaming head, and a molding and setting device
  • the length-diameter ratio of the twin screw of the twin screw extruder is between 35 and 45.
  • the barrel of the twin screw extruder is provided with a natural exhaust port, at least one vacuum exhaust port and at least one blowing agent injection Inlet; the diameter of the single screw of the single screw extruder is greater than or equal to 1.5 times the diameter of the twin screw, the length to diameter ratio of the single screw is between 15 and 30, and the cooling system is used to control the temperature of the single screw; the device also includes a vacuum system The vacuum system is connected to the vacuum exhaust port of the twin screw extruder, which can adjust the vacuum degree of the vacuum exhaust section of the twin screw extruder between 20Pa and 200Pa.
  • the diameter of the single screw is 1.5 to 3 times the diameter of the twin screw.
  • the twin-screw extruder is provided with a feeding section, a natural exhaust section, a first sealing section, a vacuum exhaust section, a second sealing section, an air injection section, a mixing section and a metering conveyance along the length direction segment.
  • the melt pump is installed between the twin-screw extruder and the single-screw extruder.
  • the rotational speeds of the melt pump and the single screw extruder are automatically adjusted by a closed-loop pressure feedback control system.
  • the foaming head is a fish tail type plate head, a ring head, a T-shaped sheet head or a perforated bar head.
  • the length of the vacuum exhaust section of the twin screw extruder is 10 to 18 times the diameter of the twin screw.
  • thermoplastic polyester foam molding device including a twin-screw extruder, a melt pump, a melt cooler, a static mixer, a foaming head, and a molding and setting device
  • the length-diameter ratio of the twin screw of the twin screw extruder is between 35 and 45.
  • the barrel of the twin screw extruder is provided with a natural exhaust port, at least one vacuum exhaust port and at least one blowing agent injection Inlet;
  • the melt cooler is suitable for cooling the high-viscosity melt and controls the melt temperature through the cooling system;
  • the device also includes a vacuum system, which is connected to the vacuum exhaust port of the twin-screw extruder to make the twin screw
  • the vacuum degree of the vacuum exhaust section of the extruder is adjusted between 20Pa and 200Pa.
  • the melt pump is installed between the twin screw extruder and the melt cooler.
  • the speed of the melt pump is automatically adjusted by a closed-loop pressure feedback control system.
  • the length of the vacuum exhaust section of the twin screw extruder is 10 to 18 times the diameter of the twin screw.
  • the thermoplastic polyester foam molding device provided by the invention is a thermoplastic polyester dry-free reaction extrusion foaming integrated production equipment.
  • the polyester can be prevented from being dried in advance, and the polyester raw material does not need to be dried. Can be directly added to the twin screw extruder, reducing energy consumption and improving production efficiency.
  • the device provided by the invention can stably produce thermoplastic polyester foamed sheet with low density, uniform cell structure and large thickness, and has the advantages of high production efficiency, low energy consumption, easy process operation and high production stability.
  • FIG. 1 is a schematic diagram of a thermoplastic polyester foam molding apparatus according to a preferred embodiment of the present invention.
  • thermoplastic polyester foam molding apparatus is a schematic diagram of a thermoplastic polyester foam molding apparatus according to another preferred embodiment of the present invention.
  • the invention discloses a foaming molding device for thermoplastic polyester, which includes a twin-screw extruder, a melt pump, a static mixer, a foaming head and a shaping and shaping device, and a twin-screw extruder.
  • the length-diameter ratio is between 35 and 45.
  • the barrel of the twin-screw extruder is provided with a natural exhaust port, at least one vacuum exhaust port, and at least one foaming agent injection port; the device also includes a vacuum system, a vacuum system Connected with the vacuum exhaust port of the twin screw extruder, the vacuum degree of the vacuum exhaust section of the twin screw extruder can be adjusted between 20Pa and 200Pa.
  • the device uses a cooling system to accurately control the temperature of the single screw.
  • FIG. 1 is a schematic diagram of a thermoplastic polyester foam molding apparatus according to a preferred embodiment of the present invention.
  • the device includes a multi-station feeding system (not shown), a twin-screw extruder 1, a melt pump 3, a single-screw extruder 4, a static mixer 6, a foaming head 7 and Forming and shaping device 8 and vacuum system 2, in which the melt pump 3 is installed between the twin screw extruder 1 and the single screw extruder 4, the static mixer 6 is installed in the foaming head 7 and the single screw extruder Between 4, the molding and shaping device 8 is installed downstream of the foaming head 7.
  • the barrel of the twin screw extruder is provided with a natural exhaust port, at least one vacuum exhaust port and at least one foaming agent injection port, and the vacuum system 2 is connected to the vacuum exhaust of the twin screw extruder 1 through the pipeline
  • the air port is connected, so that the vacuum degree of the vacuum exhaust section of the twin screw extruder can be adjusted between 20Pa and 200Pa.
  • the multi-station feeding system of the device is a loss-in-weight feeding system, usually including at least one main feeding system and at least one additive feeding system.
  • the additive feeding system is preferably two, which are a chain extender feeding system and an auxiliary feeding system, more preferably three, which are a chain extender feeding system, a foaming nucleating agent feeding system and a processing aid. Agent system to facilitate the regulation of formulations.
  • the outlet of the feeding system is connected to the feeding port of the twin screw extruder 1.
  • the thermoplastic polyester foam molding device uses a two-stage extruder tandem system, the first stage is a twin-screw extruder 1, and the second stage is a single-screw extruder 4 , Melt pump 3 is connected in series between two extruders, of which twin screw extruder 1 is a co-rotating twin screw extruder.
  • the twin-screw extruder 1 has a twin-screw diameter D1 and a length of L1.
  • the twin-screw extruder 1 is responsible for the functions of melting polyester resin, venting, injecting foaming agent, and uniformly mixing the components.
  • the twin-screw extruder 1 has a twin-screw length-to-diameter ratio L1/D1 between 35:1 and 45:1.
  • the vacuum exhaust section or mixing section will be too short to repeat the exhaust and mix the foaming agent uniformly, affecting the uniformity and stability of the extrusion foaming process ; If the length-to-diameter ratio is greater than 45:1, the thermoplastic polyester is susceptible to severe thermal degradation, which greatly reduces the melt viscosity of the polyester and cannot obtain an ideal foamed product. In order to ensure the effect of vacuum evacuation, it is between 10D1 and 18D1, preferably between 12D1 and 15D1.
  • the length of the vacuum exhaust section greater than 18D1 will cause the overall length-to-diameter ratio of the twin screw to be too long, and less than 10D1 will affect the degassing effect.
  • the polyester raw material can be directly added to the twin-screw extruder without drying, and the adsorbed moisture can be removed through the natural vent and at least one vacuum vent on the twin-screw extruder.
  • the vacuum system of this device is a high vacuum system, which is composed of a multi-stage vacuum pump, an exhaust chamber, and a condensation tank. It is connected to the vacuum exhaust port on the twin screw extruder 1 through a pipeline.
  • the high vacuum system can make the twin screw extruder
  • the vacuum degree of the vacuum exhaust section of the machine is lower than 200pa, and it is preferably adjustable between 20 and 200pa.
  • the pumping rate of the high vacuum system is 100L/s to 500L/s, preferably 300L/s to 500L/s.
  • the main function of the second-stage single-screw extruder 4 is to uniformly cool the polyester melt containing the blowing agent conveyed from the twin-screw extruder 1 T m -10°C ⁇ T ⁇ T m +30°C,T m It is the melting point of polyester, and the chain extension reaction of thermoplastic polyester (such as PET) is completed in a single screw extruder.
  • the device uses a cooling system 9 to precisely control the temperature of the single screw.
  • the single screw of the single screw extruder 4 has a strong heat exchange capacity, which reduces the melt temperature to a temperature suitable for foaming, but also requires the melt temperature to be uniform everywhere, and the shear heat when the single screw rotates is low, And it has a certain melt conveying capacity, so that the structure of the foamed product can be uniform, and the extrusion process can be carried out stably.
  • the single screw extruder 4 of the technical solution of the present application has a single screw diameter D2 and a length of L2.
  • the single screw diameter D2 is greater than or equal to 1.5 times the twin screw diameter D1, preferably 1.5 to 3 times, more preferably 2 ⁇ 2.5 times, the length/diameter ratio L2/D2 of the single screw extruder 4 is between 15-30. If the length-diameter ratio L2/D2 is less than 15, it will not be able to meet the cooling requirements; if the length-diameter ratio L2/D2 is greater than 30, polyester thermal degradation is more serious, affecting the quality of polyester foam products, and the open cell ratio increases.
  • the pressure of the twin screw extruder head is too high, which will easily increase the resistance of the material in the twin screw, and it is difficult to inject the foaming agent.
  • the shear stress experienced by the material in the twin screw Increased heat is susceptible to thermal degradation, which affects product quality. Too low a pressure will make it difficult to dissolve the blowing agent in the polyester melt.
  • melt pump 3 between the twin-screw extruder and the single-screw extruder to adjust the outlet pressure of the twin-screw extruder and the inlet pressure of the single-screw extruder to ensure The extrusion process is stable. As the polyester chain extension reaction proceeds, the melt viscosity will increase sharply, and the fluidity will decrease.
  • the melt pump 3 is set to provide power for high-viscosity melt transportation, which is conducive to stable operation of the extrusion process.
  • the rotational speed of the melt pump 3 can be manually adjusted manually, or it can be controlled by monitoring the pressure at the inlet and outlet and using an automatic feedback control system.
  • the melt pressure between the twin-screw extruder outlet and the melt pump inlet needs to be lower than 8 MPa, preferably between 3 MPa and 8 MPa, and the actual pressure here
  • the pressure sensor is collected into the control system, and the rotational speed of the melt pump 3 is controlled by the programmable logic controller (PLC) program of the control system.
  • PLC programmable logic controller
  • the control system automatically reduces the speed of the melt pump 3, on the contrary, when the pressure here is higher than the set value, the speed of the melt pump 3 automatically increases, thereby stabilizing the pressure there The set value.
  • a closed-loop feedback system can be used to control the speed of the single screw to ensure that the inlet of the single screw extruder has a certain pressure value, for example, any set value between 15MPa and 20MPa.
  • the foaming head 7 may be a fish tail type plate head, a ring head, a T-shaped sheet head or a porous strip head.
  • the foaming head 7 is connected to the outlet of the single-screw extruder, so that the material flows evenly in the entire width direction.
  • a static mixer 6 can also be provided between the foaming head 7 and the single-screw extruder 4, which can homogenize the temperature and flow rate of the melt before entering the foaming head 7, which helps to maintain the extrusion process Stability and the appearance and quality of products are more uniform.
  • the blowing agent injection system may be a plunger-type liquid metering pump, a diaphragm pump, a piston pump and other liquid pumps, and is connected to the gas injection valve on the twin-screw extruder 1 through a pipeline.
  • a diaphragm pump or plunger metering pump is preferably used, which has a certain explosion-proof level, and the maximum pressure at the pump outlet is greater than or equal to 20 MPa.
  • a physical foaming agent may be injected into the twin-screw polyester melt through the gas injection system 5 shown in FIG. 1 connected to the twin-screw extruder 1.
  • the molding and setting device 8 is installed downstream of the foaming head 7 for cooling and setting the foamed polyester.
  • FIG. 2 is another preferred embodiment of a thermoplastic polyester foam molding device disclosed in the present invention.
  • the device includes a twin screw extruder 1, a vacuum system 2, a melt pump 3, and melt cooling Mixer 10, static mixer 6, foaming head 7 and shaping device 8.
  • the twin-screw extruder 1 has a twin-screw length-diameter ratio between 35 and 45.
  • the barrel of the twin-screw extruder is provided with a natural exhaust port, at least one vacuum exhaust port, and at least one blowing agent injection.
  • the inlet, the vacuum system 2 is connected to the vacuum exhaust port of the twin screw extruder 1, which can adjust the vacuum degree of the vacuum exhaust section of the twin screw extruder between 20Pa and 200Pa.
  • the vacuum of the twin screw extruder 1 The length of the exhaust section is 10 to 18 times the diameter of the twin screw; the melt pump 3 is installed between the twin screw extruder 1 and the melt cooler 10, and the speed of the melt pump 3 is automatically controlled by a closed-loop pressure feedback control system Adjustment; the melt cooler 10 is suitable for the cooling of high viscosity melts, and the precise melt temperature control is realized by the cooling system 9.
  • the static mixer 6 is installed upstream of the foaming head 7.
  • the device may further include a multi-station feeding system (not shown), a single screw extruder (not shown), and the like.
  • a multi-station feeding system not shown
  • a single screw extruder not shown
  • the description of the parameters of each component of the device and the setting of the parameters during use are the same as the description of the device with reference to FIG. 1 above.
  • the process of extruding and foaming thermoplastic polyester using the device of the present invention includes: adding thermoplastic polyester and additives through a multi-station feeding system into a co-rotating twin-screw extruder, a melt pump, and a single screw Extruder, high vacuum system, foaming agent injection system, molding and shaping device, etc.; extrusion system; injecting physical foaming agent into the polyester melt in the extrusion system, mixed by twin screw extruder A homogeneous solution is formed, and then the temperature of the polyester melt containing the blowing agent is reduced by a cooling system, extruded and foamed through a die, and the foamed product is cooled and molded on a molding and setting device to obtain a thermoplastic polyester foamed product.
  • the density of the obtained polyester foamed product is between 60 and 300 kg/m 3 .
  • the thermoplastic polyester foam molding device provided by the invention is a thermoplastic polyester dry-free reaction extrusion foaming integrated production equipment.
  • the polyester can be prevented from being dried in advance, and the polyester raw material does not need to be dried. Can be directly added to the twin screw extruder, reducing energy consumption and improving production efficiency.
  • the device provided by the invention can stably produce thermoplastic polyester foamed sheets with low density, uniform cell structure and large thickness, and has the advantages of high production efficiency, low energy consumption, easy process operation, and high production stability.

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  • Mechanical Engineering (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

一种用于热塑性聚酯发泡成型装置，包括：双螺杆挤出机（1）、熔体泵（3）、静态混合器（6）、发泡机头（7）、成型定型装置（8）和真空系统（2），双螺杆挤出机（1）的双螺杆的长径比为35～45，双螺杆机筒上开设有一个自然排气口、至少一个真空排气口和至少一个发泡剂注入口，真空系统（2）与双螺杆机筒上的真空排气口相连接，可使双螺杆挤出机（1）真空排气段的真空度在20Pa～200Pa之间调节，装置采用冷却系统对熔体温度进行控制。装置是热塑性聚酯免干燥反应挤出发泡一体化生产设备，聚酯原料不需干燥可直接加入双螺杆挤出机中，降低了能耗并提高了生产效率，可以稳定生产低密度、泡孔结构均匀细密、大厚度的热塑性聚酯发泡板材，且具有生产效率高、能耗低、工艺易操作、生产稳定性高的优点。

Description

一种用于热塑性聚酯发泡成型装置 技术领域
本发明涉及一种聚合物加工装置，特别涉及一种用于热塑性聚酯发泡成型装置。
背景技术
热塑性聚酯具有优异的耐热性和力学性能，相比于传统的泡沫塑料，热塑性聚酯泡沫具有高温下尺寸稳定性好、优异的机械性能和抗疲劳性、低烟、阻燃、无毒、低吸水率、良好的气体阻隔性以及可回收再利用等优点，在风力发电、轨道交通、汽车工业等领域具有广泛应用前景。但热塑性聚酯具有熔体粘度低、热稳定性差、易吸收水分发生热降解和水解，特别是水解，会造成聚酯分子量急剧下降；为了克服热塑性聚酯的缺点，现有技术主要通过添加扩链剂或交联剂提高聚酯的黏度，可以在聚合时添加多官能团助剂再后固相缩聚得到高熔体粘度的热塑性聚酯；或者在挤出过程中添加多官能团扩链剂或支化剂，反应挤出得到高粘度聚酯。针对聚酯的吸水性和高温水解缺点，现有技术通常采用预干燥技术除去聚酯切片中的水分。预干燥常用的有真空转鼓干燥、回转充填组合干燥和流动床等三种形式，常用连续式气流干燥，干燥工艺为140℃，3-4小时，且干燥后要在100-110℃下保温或放置于干燥的密闭容器待用，加料斗也要用红外线照射以保持干燥状态，或采用N 2保护喂料装置。这种预干燥工艺设备复杂，干燥工艺耗时长，效率低且能耗高。
为了克服该缺点，US 2015336319A1公开了一种聚酯发泡挤出装置，包括：加料系统，同向双螺杆挤出机，机头和定型装置，其中双螺杆挤出机上有空气排气区和真空排气区，空气排气区的温度低于聚酯熔点10℃，真空排气区的熔体温度高于聚酯的熔点，特别是在第一排气区注入预热的氮气以增强空气排气效果。该装置可实现聚酯免干燥直接挤出加工，一定程度上克服了预干燥工艺耗时、能耗高和设备复杂的缺点。但缺点是在第一排气区注入预热氮气设备和操作复杂。
CN201220654257.5公开了一种PET无需结晶干燥双螺杆片材挤出设备，包括喂料装置、螺杆挤出机和片材挤出装置，其中螺杆挤出机为同向平行双螺杆挤出机，其上配置有多个抽真空装置。该专利技术方案为了提高脱水效率，在实施例中公开真空泵的真空绝对压力≤0.5mbar，脱气能力大于1000l/s。这种技术方案对于聚酯反应挤出发泡过程中需要添加多种低分子添加剂组分来讲缺乏适应性，过高的真 空度和脱气量会造成低分子添加剂(扩链剂、增塑剂等)被真空抽离，从而使得扩链反应效率降低，聚酯熔体粘弹性不能达到发泡要求，无法实现PET免干燥反应挤出发泡一体化生产。
US5958164公开了一种热塑性聚酯发泡方法，包括：将聚酯和添加剂直接加入第一阶双螺杆挤出机中，双螺杆挤出机上真空排气段脱出聚酯吸附的水分，然后注入发泡剂，在下游低压区发泡得到PET发泡制品，特别地聚酯中添加氟塑料，真空脱气压力低于20Torr(2666pa)，发泡剂从在第二阶单螺杆挤出机上注气口注入。该技术方案发泡剂(丁烷)从第二阶单螺杆挤出机注入，且单螺杆直径与双螺杆直径相等，为了使发泡剂与PET熔体充分混合，单螺杆转速较高，加工容易产生高剪切热，无法精确控制PET熔体温度，造成挤出过程不稳定，机头压力低等缺点，难以获得发泡密度低于200kg/m 3且厚度大于30mm的PET发泡板材。
发明内容
为实现热塑性聚酯发泡成型的高效、稳定、高品质生产，本发明提供了一种用于热塑性聚酯发泡成型装置。
根据本发明的一个方面，提供了一种用于热塑性聚酯发泡成型装置，包括双螺杆挤出机、熔体泵、单螺杆挤出机、静态混合器、发泡机头以及成型定型装置，双螺杆挤出机的双螺杆的长径比在35～45之间，双螺杆挤出机的机筒上开设有一个自然排气口、至少一个真空排气口和至少一个发泡剂注入口；单螺杆挤出机的单螺杆的直径大于等于双螺杆的直径的1.5倍，单螺杆的长径比在15～30之间，采用冷却系统对单螺杆进行温度控制；装置还包括真空系统，真空系统与双螺杆挤出机的真空排气口相连接，可使双螺杆挤出机真空排气段的真空度在20Pa～200Pa之间调节。
优选的，在上述装置中，单螺杆的直径为双螺杆的直径的1.5～3倍。
优选的，在上述装置中，双螺杆挤出机沿长度方向分别设置加料段、自然排气段、第一密封段、真空排气段、第二密封段、注气段、混合段和计量输送段。
优选的，在上述装置中，熔体泵安装在双螺杆挤出机与单螺杆挤出机之间。
优选的，在上述装置中，熔体泵和单螺杆挤出机的转速通过闭环压力反馈控制系统进行自动调节。
优选的，在上述装置中，发泡机头为鱼尾型板式机头、环形机头、T型片材机头或多孔条机头。
优选的，在上述装置中，双螺杆挤出机的真空排气段长度为双螺杆的直径的10倍～18倍。
根据本发明的另一个方面，提供了一种用于热塑性聚酯发泡成型装置，包括双螺杆挤出机、熔体泵、熔体冷却器、静态混合器、发泡机头以及成型定型装置，双螺杆挤出机的双螺杆的长径比在35～45之间，双螺杆挤出机的机筒上开设有一个自然排气口、至少一个真空排气口和至少一个发泡剂注入口；熔体冷却器适用于高黏度熔体的降温,并通过冷却系统控制熔体温度；装置还包括真空系统，真空系统与双螺杆挤出机的真空排气口相连接，可使双螺杆挤出机真空排气段的真空度在20Pa～200Pa之间调节。
优选的，在上述装置中，熔体泵安装在双螺杆挤出机与熔体冷却器之间。
优选的，在上述装置中，熔体泵的转速通过闭环压力反馈控制系统进行自动调节。
优选的，在上述装置中，双螺杆挤出机的真空排气段长度为双螺杆的直径的10倍～18倍。
本发明提供的用于热塑性聚酯发泡成型装置是一种热塑性聚酯免干燥反应挤出发泡一体化生产设备，在发泡工艺中，可以避免聚酯预先干燥，聚酯原料不需要干燥可以直接加入双螺杆挤出机中，降低了能耗并提高生产效率。本发明提供的装置可以稳定生产低密度、泡孔结构均匀细密、大厚度的热塑性聚酯发泡板材，且具有生产效率高、能耗低、工艺易操作、生产稳定性高的优点。
附图说明
为了更清楚地说明本发明具体实施方式或现有技术中的技术方案，下面将对具体实施方式或现有技术描述中所需要使用的附图作简单地介绍。
图1是根据本发明的优选实施例的用于热塑性聚酯发泡成型装置的示意图。
图2是根据本发明的另一优选实施例的用于热塑性聚酯发泡成型装置的示意图。
具体实施方式
本发明公开了一种用于热塑性聚酯发泡成型装置，包括：双螺杆挤出机、熔体泵、静态混合器、发泡机头和成型定型装置，双螺杆挤出机的双螺杆的长径比在35～45之间，双螺杆挤出机的机筒上开设有一个自然排气口、至少一个真空排气口和至少一个发泡剂注入口；装置还包括真空系统，真空系统与双螺杆挤出机的真空排气口相连接，可使双螺杆挤出机真空排气段的真空度在20Pa～200Pa之间调节，装置采用冷却系统对单螺杆进行温度的精确控制。
图1是根据本发明的优选实施例的用于热塑性聚酯发泡成型装置的示意图。如图1所示，装置包括多工位喂料系统(未示出)、双螺杆挤出机1、熔体泵3、单螺杆挤出机4、静态混合器6、发泡机头7及成型定型装置8和真空系统2，其中，熔体泵3安装在双螺杆挤出机1和单螺杆挤出机4之间，静态混合器6安装在发泡机头7和单螺杆挤出机4之间，成型定型装置8安装在发泡机头7的下游。其中，双螺杆挤出机的机筒上开设有一个自然排气口、至少一个真空排气口和至少一个发泡剂注入口，真空系统2通过管路与双螺杆挤出机1的真空排气口相连接，可使双螺杆挤出机真空排气段的真空度在20Pa～200Pa之间调节。
装置的多工位喂料系统为失重式喂料系统，通常包括至少一个主喂料系统和至少一个添加剂喂料系统。主喂料系统优选为两个，可以将全新的热塑性聚酯树脂和回收的热塑性聚酯树脂按设定要求计量喂料。添加剂喂料系统优选为两个，分别为扩链剂喂料系统和助剂喂料系统，更优选为三个，分别为扩链剂喂料系统、发泡成核剂喂料系统和加工助剂系统，以方便调控配方。喂料系统出口与双螺杆挤出机1的加料口相连接。
在图1所示优选实施例中，用于热塑性聚酯发泡成型装置采用了双阶挤出机串联系统，第一阶为双螺杆挤出机1，第二阶为单螺杆挤出机4，两台挤出机之间用熔体泵3串联，其中双螺杆挤出机1为同向旋转双螺杆挤出机。双螺杆挤出机1的双螺杆的直径D1，长度为L1，双螺杆挤出机1担负着聚酯树脂的熔融、排气、发泡剂注入及各组分的均匀混合等功能，为了更好地实现这些功能，又避免热塑性聚酯在其中发生热降解，双螺杆挤出机1的双螺杆的长径比L1/D1在35:1～45：1之间，沿长度方向分别设置加料段、自然排气段、第一密封段、真空排气段、第二密封段、混合段和计量输送段。如果双螺杆挤出机1的长径比小于35：1，将会使真空排气段或混合段过短，无法重复排气和使发泡剂均匀混合，影响挤出发泡过程的均匀稳定；如果长径比大于45：1，热塑性聚酯易发生较严重的热降解，使得聚酯的熔体粘度大大降低，无法得到理想发泡制品。为了保证真空排气效 果，在10D1～18D1之间，优选在12D1～15D1。真空排气段长度大于18D1会导致双螺杆整个长径比过长，小于10D1会影响脱气效果。在发泡工艺中，聚酯原料不需要干燥可以直接加入双螺杆挤出机中，通过双螺杆挤出机上的自然排气口和至少一个真空排气口脱出吸附的水分。
本装置的真空系统为高真空系统，是由多级真空泵、抽气室、冷凝罐组成，通过管道与双螺杆挤出机1上的真空排气口相连接，高真空系统可以使双螺杆挤出机真空排气段的真空度低于200pa，优选的可调节在20～200pa之间。高真空系统的抽气速率100L/s～500L/s，优选300L/s～500L/s。
第二阶单螺杆挤出机4的主要功能是将双螺杆挤出机1输送过来的含有发泡剂的聚酯熔体均匀冷却T m-10℃≤T≤T m+30℃,T m为聚酯的熔点，同时热塑性聚酯(如，PET)的扩链反应在单螺杆挤出机中完成，装置采用冷却系统9对单螺杆进行温度的精确控制。不仅要求单螺杆挤出机4的单螺杆有较强的换热能力，将熔体温度降低到适合发泡的温度，而且要求熔体温度各处均匀，单螺杆旋转时剪切热较低，且具有一定的熔体输送能力，这样得到发泡制品结构才能均匀，挤出过程能稳定进行。为了实现该目的，本申请技术方案单螺杆挤出机4的单螺杆的直径D2，长度为L2，单螺杆的直径D2大于等于双螺杆直径D1的1.5倍，优选1.5～3倍，更优选2～2.5倍，单螺杆挤出机4的长径比L2/D2在15～30之间。如果长径比L2/D2小于15，将无法达到降温要求；如果长径比L2/D2大于30，聚酯热降解比较严重，影响聚酯的发泡制品质量，开孔率增大。
在热塑性聚酯的发泡过程中，双螺杆挤出机机头压力过高容易造成物料在双螺杆中受到的阻力增大，发泡剂注入困难，另外物料在双螺杆中经受的剪切生热增加，易发生热降解，影响产品质量，而压力过低会造成发泡剂在聚酯熔体中溶解困难。为了提高发泡制品成核密度，通常要求具有足够高的机头压力，而第二阶单螺杆主要是为了降低熔体温度，所以熔体的输送能力较弱，特别是对低温高粘度熔体输送能力。为了解决上述问题，优选的，在双螺杆挤出机和单螺杆挤出机之间安装有一台熔体泵3，用来调节双螺杆挤出机出口压力和单螺杆挤出机入口压力，保证挤出过程稳定运行。随着聚酯扩链反应进行，熔体粘度会急剧增大，流动性降低，熔体泵3设置为高粘度熔体输送提供动力，有利于挤出过程稳定运行。熔体泵3的转速可以通过人工手动调节，也可以通过监测出入口的压力，采用自动反馈控制系统来控制其转速。为了保证双螺杆挤出机1的稳定运行，需要使双螺杆挤出机出口与熔体泵入口之间的熔体压力低于8MPa，优选的在 3MPa～8MPa之间，将此处实际压力通过压力传感器采集到控制系统中，通过控制系统的可编程逻辑控制器(PLC)程序反馈控制熔体泵3的转速。当此处压力低于设定值时，控制系统自动降低熔体泵3的转速，相反，当此处压力高于设定值时，熔体泵3的转速自动提高，从而使该处压力稳定在设定值。同理，可以采用闭环反馈系统控制单螺杆转速以保证单螺杆挤出机入口具有一定的压力值，例如，15MPa～20MPa之间的任一设定值。
发泡机头7可以为鱼尾型板式机头、环形机头、T型片材机头或多孔条机头。发泡机头7与单螺杆挤出机出口相连接，使得物料在其中流动均匀分布在整个宽度方向。
发泡机头7与单螺杆挤出机4之间还可以设置一台静态混合器6，可以使熔体的温度和流速在进入发泡机头7之前得到均化，有利于保持挤出过程稳定及制品的外观和质量更均匀。
发泡剂注入系统可以为柱塞式液体计量泵、隔膜泵、活塞泵等液体泵，并通过管路与双螺杆挤出机1上的注气阀相连接。优选的采用隔膜泵或柱塞式计量泵，其具有一定的防爆等级，泵出口最高压力大于等于20MPa。优选的，在发泡工艺中，可通过图1中所示的与双螺杆挤出机1相连的注气系统5往双螺杆的聚酯熔体中注入物理发泡剂。
挤出系统下游配备有成型定型装置，如图1所示成型定型装置8安装于发泡机头7的下游以用于将发泡的聚酯冷却定型。
图2是本发明公开的用于热塑性聚酯发泡成型装置的另一优选实施例，如图2所示，装置包括双螺杆挤出机1、真空系统2、熔体泵3、熔体冷却器10、静态混合器6、发泡机头7和成型定型装置8。双螺杆挤出机1的双螺杆的长径比在35～45之间，双螺杆挤出机的机筒上开设有一个自然排气口、至少一个真空排气口和至少一个发泡剂注入口，真空系统2与双螺杆挤出机1的真空排气口相连接，可使双螺杆挤出机真空排气段的真空度在20Pa～200Pa之间调节，双螺杆挤出机1的真空排气段长度为双螺杆的直径的10倍～18倍；熔体泵3安装双螺杆挤出机1与熔体冷却器10之间，熔体泵3的转速通过闭环压力反馈控制系统进行自动调节；熔体冷却器10适用于高黏度熔体的降温,并通过冷却系统9实现精确的熔体温度控制。静态混合器6安装在发泡机头7上游。
在如图2所示的装置的优选实施例中，装置还可以包括多工位喂料系统(未示出)和单螺杆挤出机(未示出)等。在该优选实施方式中，装置的各组成部分参数的描述以及使用过程中参数的设置与以上参照图1的装置的描述相同。
使用本发明的装置对热塑性聚酯进行挤出发泡成型的工艺，包括： 将热塑性聚酯以及添加剂经多工位喂料系统加入由同向旋转双螺杆挤出机、熔体泵、单螺杆挤出机、高真空系统、发泡剂注入系统、成型定型装置等组成的挤出系统中；往挤出系统内的聚酯熔体中注入物理发泡剂，经双螺杆挤出机混合作用形成均相溶液，然后通过冷却系统将含有发泡剂的聚酯熔体温度降低，经口模挤出发泡，发泡制品在成型定型装置上冷却成型得到热塑性聚酯发泡制品。所得到的聚酯发泡制品的密度在60～300kg/m 3之间。
本发明提供的用于热塑性聚酯发泡成型装置是一种热塑性聚酯免干燥反应挤出发泡一体化生产设备，在发泡工艺中，可以避免聚酯预先干燥，聚酯原料不需要干燥可以直接加入双螺杆挤出机中，降低了能耗并提高生产效率。且本发明提供的装置可以稳定生产低密度、泡孔结构均匀细密、大厚度的热塑性聚酯发泡板材，具有生产效率高、能耗低、工艺易操作、生产稳定性高的优点。
以上实施例，仅为本发明的具体实施方式，用以说明本发明的技术方案，而非对其限制，本发明的保护范围并不局限于此，尽管参照前述实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，其依然可以对前述实施例所记载的技术方案进行修改或可轻易想到变化，或者对其中部分技术特征进行等同替换；而这些修改、变化或者替换，并不使相应技术方案的本质脱离本发明实施例技术方案的精神和范围，都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应以权利要求的保护范围为准。

Claims (10)

  1. 一种用于热塑性聚酯发泡成型装置，包括双螺杆挤出机、熔体泵、单螺杆挤出机、静态混合器、发泡机头以及成型定型装置，其特征在于，所述双螺杆挤出机的双螺杆的长径比在35～45之间，所述双螺杆的机筒上开设有一个自然排气口、至少一个真空排气口和至少一个发泡剂注入口；所述单螺杆挤出机的单螺杆的直径大于等于所述双螺杆的直径的1.5倍，所述单螺杆的长径比在15～30之间，采用冷却系统对所述单螺杆进行温度控制；所述装置还包括真空系统，所述真空系统与所述双螺杆挤出机的所述真空排气口相连接，可使双螺杆挤出机真空排气段的真空度在20Pa～200Pa之间调节。
  2. 根据权利要求1所述的装置，其特征在于，所述单螺杆的直径为所述双螺杆的直径的1.5～3倍。
  3. 根据权利要求1所述的装置，其特征在于，所述双螺杆挤出机沿长度方向分别设置加料段、自然排气段、第一密封段、真空排气段、第二密封段、注气段、混合段和计量输送段。
  4. 根据权利要求1所述的装置，其特征在于，所述熔体泵安装在所述双螺杆挤出机与所述单螺杆挤出机之间。
  5. 根据权利要求1所述的装置，其特征在于，所述熔体泵和所述单螺杆的转速通过闭环压力反馈控制系统进行自动调节。
  6. 根据权利要求1所述的装置，其特征在于，所述发泡机头为鱼尾型板式机头、环形机头、T型片材机头或多孔条机头。
  7. 一种用于热塑性聚酯发泡成型装置，包括双螺杆挤出机、熔体泵、熔体冷却器、静态混合器、发泡机头以及成型定型装置，其特征在于，所述双螺杆挤出机的双螺杆的长径比在35～45之间，所述双螺杆的机筒上开设有一个自然排气口、至少一个真空排气口和至少一个发泡剂注入口；所述熔体冷却器适用于高黏度熔体的降温，并通过冷却系统控制熔体温度；所述装置还包括真空系统，所述真空系统与所述双螺杆挤出机的所述真空排气口相连接，可使双螺杆挤出机真空排气段的真空度在20Pa～200Pa之间调节。
  8. 根据权利要求7所述的装置，其特征在于，所述熔体泵安装在所述双螺杆挤出机与熔体冷却器之间。
  9. 根据权利要求7所述的装置，其特征在于，所述熔体泵的转速通过闭环压力反馈控制系统进行自动调节。
  10. 根据权利要求7所述的装置，其特征在于，所述双螺杆挤出 机的真空排气段长度为所述双螺杆的直径的10倍～18倍。
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