Andreas Limper. Mixing of. Rubber Compounds HANSER. Hanser Publishers, Munich. Hanser Publications, Cincinnati

Transcription

1 Andreas Limper Mixing of Rubber Compounds Hanser Publishers, Munich HANSER Hanser Publications, Cincinnati

2 Configuration Table of Contents 1 Internal Mixer - Dieter Berkemeier and Design Machine Design Overall Features Mixing Chamber Types of Internal Mixers Tangential Rotors Intermeshing Rotors Technological Comparison Intermeshing Rotors with Variable Clearance (VIC) Tandem Mixing Feeding Hopper Design Considerations Pneumatic: Feeding Hopper Hydraulic Feeding Hopper Comparative Aspects Digital Ram Position Control Mixing Chamber Hard-Coating Dust Sealing Spring Loaded Dust Seals Hydraulic Dust Seals with Yoke Hydraulic Dust Seals with Cylinders (CH) Comparison of Spring Loaded and Hydraulic Dust Seal Systems Temperature Sensor Plasticizer Oil Injection Rotors Assembly and Cooling Rotor Bearings 31

3 1.8.3 Rotors for Tangential Internal Mixers 32 Basics 32 Two-Wing Rotors 33 Four-Wing rotors 33 N-Rotor (Normal Rotor; also Called Standard-Rotor) 34 Full-4-Wing (F4W)-Rotor 34 ST -Rotor (Synchronous Technology) 35 ZZ2-Rotor 36 HDSC-Rotor (High Dispersion Super Cooled) 37 MDSC-Rotor (Maximum Dispersion Super Cooled) 38 Six-Wing Rotor Rotors for Intermeshing Internal Mixers 39 History of Development 39 Interlocking Technology 40 PES-Technology Mixer Base Plate Design Drop Door and Latch Assembly Drop Door and Toggle 45 References 46 2 Processing Aspects of Rubber Mixing 47 A. Limper 2.1 Mixing Principles Process Description Influence of Raw Material Properties Influences of Process Parameters Basic Considerations for the Development of a Mixing Cycle 66 References 68 3 Mixing Characteristics of Polymers in an Internal Mixer 71 M. Rinker, A. Limper 3.1 Natural Rubber (NR) Ethylene Propylene Diene Rubber (EPDM) Chloroprene Rubber (CR) Styrene Butadiene Rubber (SBR) Butadiene Rubber (BR) (Acryl)Nitrile Butadiene Rubber NBR 84

4 a 3.7 Butyl Rubber Fluor Rubber Resins General Considerations 88 References 93 4 Internal Mixer - Oliver Klockmann Reaction Vessel The Silica Network Influence of Mixing Time and Temperature on Hydrophobation Chemistry of the Silica-Silane Reaction Temperature Limits Summary and Consequences 103 References Effect of Process Parameters on Product Properties 107 Dr.-lng. Harald Keuter 5.1 Introduction Quality Parameters of Raw Material Quality Parameters of EPDM Polymers Quality Parameters of Carbon Black Raw Material Changes in the Rubber Mixing Room Increase of Carbon Black Fines Content during the Conveying Process Baking Behavior of Carbon Black in Conveying Pipes Effect of Variations in Raw Material Quality Parameters on the Mixing Process EPDM Long Chain Branching Carbon Black Fines Content Carbon Black Pellet Hardness Delivery Form of Sulphur Weighing Accuracy Predicting Product Quality The Quality Assurance Concept "Future Mixing Room" 134

5 5.8 Rubber Compounding and its Impact on Product Properties 141 Dr.-Ing. Peter Ryzko 5.9 Testing Methods for Rubber Compounds Mooney Viscometer Vulcameter Rubber Process Analyzer Carbon Black Dispersion Measurement Factors Influencing Rubber Part Properties The Mixing Process The Mixing Process and its Tasks Further Processes Factors Influencing the Mixing Process Influence of Plasticizer Addition on the Mixing Process and Compound Properties Influences of the Mixing Process on the Injection Molding Process Influence of the Mixing Process on Extrusion Influence of the Milling Process on Compound and Part Properties Summary 169 References Dispersion and Distribution of Fillers 173 R. H. Schuster 6.1 Dispersive and Distributive Mixing Dispersive Mixing Distributive Mixing Quality or "Goodness" of Mixes Mechanism of Filler Dispersion Theoretical Approach Phases of Mixing Process Polymer-Filler versus Filler- Filler Interactions Dispersion Measurements Macro-Dispersion Optical Transmission Microscopy Optical Roughness Measurements Mechanical Scanning Microscopy Reflectometry 193

6 6.3.2 Micro-Dispersion Electrical Measurements Transmission Electron Microscopy Atomic Force Microscopy Control of Dispersion by Process Parameters Mixing Procedures Temperature, Torque, and Power Consumption Mixing Time and Rotor Speed Cooling Alternative Dispersion Techniques Materials Influences on Filler Dispersion Influence of the Polymer Adsorption from Solution and Melt Influence of the Polymer on Filler Dispersion Influence of the Filler Morphology and Surface Properties Influence of Surface Specific Area Influence of Structure Influence of Filler Surface Activity Dispersion Kinetics Filler Re-Agglomeration Influence of Oil on Filler Dispersion Effects of Filler Dispersion on Material Behavior Effects on Rheological Properties Effects on Dynamical-Mechanical Properties Influence of Loading Strain Dependency Effect of Filler Surface Modification Effect on Ultimate Properties Filler Distribution in Polymer Blends Compatibility of Rubbers Filler Partition Evaluation of Filler Distribution Distribution in Blends with Different Polymer Polarity Filler Distribution in Blends with Similar Polarity Filler Transfer Effects of Filler Distribution 229