Preparation system of color master batch block and sizing material preparation method of color master batch block

Abstract

The invention relates to the technical field of color master batches, and provides a color master batch block preparation system and a rubber material preparation method thereof.The method comprises the steps of raw material preparation, insulation color master batch manufacturing, cooling and forming, cutting and customization and quality detection; the raw material preparation step, the insulation color master batch manufacturing step, the cooling and forming step, the cutting and customizing step and the quality detection step are in communication connection in sequence, and the raw material preparation step is preparation work before color master batch block manufacturing. Through high-process and accurate material selection and preparation, mold design and manufacturing accuracy, cooling and forming high efficiency, cutting and customization flexibility and quality detection comprehensiveness, high-efficiency, high-quality and high-reliability production of the color master batch block with the insulating property is realized, and the color master batch block has remarkable market competitiveness and application value; according to the technical scheme, the problem that the color master batch block in the prior art does not have insulativity is solved.

Description

Technical Field

[0001] The invention relates to the technical field of masterbatches, and in particular to a system for preparing a masterbatch block and a method for preparing a rubber compound thereof. Background Art

[0002] Insulating materials are indispensable in the electronics, electrical, and wire and cable industries. They are used to isolate current, prevent short circuits, and protect equipment and personnel safety. Traditional insulating materials may not have good coloring properties. Masterbatch is a colorant that evenly disperses pigments in a carrier resin and is used for coloring plastic products. Insulating masterbatch adds insulation properties to this basis, allowing it to provide insulation protection while coloring. Insulating masterbatches are widely used in wires and cables, electronic components, electrical equipment, automotive interiors and other fields that require insulation protection. With the diversification and high performance of electronic and electrical products, the demand for insulating masterbatches is also growing. Now, a masterbatch block preparation system and a rubber preparation method provide a solution. Summary of the invention

[0003] The invention provides a system for preparing a masterbatch block and a method for preparing a rubber material thereof, which solves the problem in the related art that the masterbatch block has no insulation property.

[0004] The technical solution of the present invention is as follows:

[0005] An insulating masterbatch block and a preparation system thereof, comprising raw material preparation, insulating masterbatch production, cooling and molding, cutting and customization, and quality inspection, wherein the raw material preparation, insulating masterbatch production, cooling and molding, cutting and customization, and quality inspection are sequentially connected in communication;

[0006] The raw material preparation is the preparatory work before making the masterbatch block, the making of insulating masterbatch is the making process of the masterbatch block, the cooling and forming is the forming and cooling of the material after processing, the cutting and customization are the formed blocks are not perfect and require manual processing to obtain the finished product, and the quality inspection is that the finished product cannot be put into use directly and needs to be inspected before it can be used.

[0007] Preferably, the raw material preparation includes selecting rubber material, preparing filler, preparing hardener and using a mixer;

[0008] The rubber material selection is used to select a suitable rubber material. Different rubber materials are suitable for different application scenarios. When selecting rubber materials, it is necessary to fully consider the use environment and requirements of the product. The filler preparation is used to adjust the hardness, density, tensile strength and other properties of the rubber to improve the wear resistance and aging resistance of the product. The hardener preparation is used to chemically react with the rubber molecules to form a cross-linked structure between the rubber molecules to improve the hardness and strength of the rubber. The mixer is used to evenly mix the rubber materials, fillers, hardeners and other raw materials to fully disperse the components in the rubber.

[0009] Preferably, the manufacturing of insulating masterbatch includes designing and manufacturing corresponding molds, a method for preparing rubber, injecting the rubber into the mold, and heating and pressurizing the mold;

[0010] The design and manufacture of corresponding molds is used to design accurate molds according to the shape, size and performance requirements of the desired product;

[0011] The method for preparing the rubber material comprises the following steps:

[0012] S1. First, accurately weigh various raw materials based on the ratio of raw rubber to 40%, vulcanizer to 1% to 3%, accelerator to 0.5% to 1%, active agent to 1%, and processing aid to less than 1%;

[0013] S2, then put the weighed raw materials into the mixer and mix them thoroughly. During the mixing process, the temperature, time and speed need to be controlled to ensure uniform mixing and rubber quality;

[0014] S3, the mixed rubber material is formed by a calender or an extruder, and can be made into blocks or strips of different thicknesses, diameters or shapes according to product requirements;

[0015] S4, then put the calendered or extruded rubber into a vulcanizing tank and vulcanize it at a certain temperature and pressure. During the vulcanization process, cross-linking reaction occurs between rubber molecules to form a stable network structure;

[0016] S5. After vulcanization, the rubber needs some time to cool and solidify. After cooling and solidification, the rubber should be inspected for quality, such as tensile strength, tear strength, hardness, etc., to ensure that it meets the use requirements;

[0017] The rubber injection mold is used to evenly fill the rubber into the mold through a suitable injection method to ensure that the shape and structure of the rubber product meet the requirements, and to control the injection speed and injection amount to avoid bubbles or defects. The mold heating and pressurization is used to make the rubber fully flow and solidify in the mold through heating and pressurization, so as to obtain a rubber product with excellent physical properties and appearance quality. Parameters such as temperature, pressure and time are controlled to ensure that the molding effect of the rubber product is optimal.

[0018] Preferably, the cooling and molding include natural cooling or artificial cooling, observing shrinkage deformation and demoulding;

[0019] The self-cooling or artificial cooling is used to help rubber products quickly reach a stable physical and chemical state. Rubber will generate heat during the vulcanization process. Cooling can further stabilize the rubber molecular chain and improve the hardness and strength of the product. The shrinkage deformation observation is used to adjust the production process parameters in time by observing these deformations to avoid dimensional deviation or shape distortion of the product. The demoulding is used to remove the vulcanized and cooled rubber product from the mold. The release agent can reduce the friction and adhesion between the rubber and the mold.

[0020] Preferably, the cutting and customization includes cutting into specific sizes and shapes, customizing edge designs, and removing burrs or cracks;

[0021] The cutting into specific size and shape is used to ensure that it can be adapted to the corresponding equipment or components. The customized edge design is used for different edge designs to meet different application requirements, such as increasing anti-slip properties, improving sealing properties or reducing wear, etc. The deburring or cracking is used for the rubber products that may have burrs or cracks during the cutting or processing process. Through the deburring process, these defects can be eliminated to ensure that the surface of the product is smooth and flat, and improve its overall quality and reliability.

[0022] Preferably, the quality inspection includes appearance inspection, size diameter measurement, physical property test and dielectric strength test;

[0023] The appearance inspection is used to carefully inspect the appearance of the masterbatch block, so as to timely discover possible problems in the product manufacturing process, such as bubbles, cracks, impurities, etc., so as to take corresponding measures to improve them. The size diameter measurement is used for the specific size and thickness of the existing masterbatch block to meet the assembly and use requirements. Through precise measurement, it can be ensured that the product meets the design requirements and avoids performance problems caused by dimensional deviation. The physical property test is used to test the physical properties of the masterbatch block, such as tensile strength, tear strength, abrasion resistance, and resilience, so as to fully understand the performance characteristics of the masterbatch block and provide a basis for the optimal design and improvement of the product. The dielectric strength test is used to test the insulation performance of the rubber masterbatch block under a high-voltage electric field, so as to ensure that no electrical failure or safety hazard occurs during use.

[0024] Compared with the prior art, the advantages of the present invention are: the entire preparation system, from raw material preparation, production of insulating masterbatch, cooling and molding, cutting and customization to quality inspection, is closely connected in each link, achieving a high degree of process, which not only improves production efficiency, but also ensures that each step of operation meets the process requirements, thereby improving product quality;

[0025] By accurately selecting rubber materials, fillers and hardeners, and using a mixer to mix them evenly, the performance of the rubber compound is ensured to be stable and meet the requirements of use. This precise material selection and preparation lays a solid foundation for the subsequent production of masterbatch blocks. According to the shape, diameter and performance requirements of the required products, precise molds are designed and made to ensure that the shape and structure of the masterbatch blocks meet the requirements;

[0026] The control of mold heating and pressurization also ensures the best molding effect of rubber products. Through self-cooling or artificial cooling, rubber products quickly reach a stable physical and chemical state. Observing shrinkage deformation and demoulding operations ensure the size and shape stability of the product, as well as smooth removal from the mold, cutting into specific sizes and shapes, and customized edge design, so that the masterbatch blocks can adapt to different application scenarios;

[0027] The removal of burrs or cracks further improves the overall quality and reliability of the product. The quality of the masterbatch blocks is comprehensively evaluated through appearance inspection, size diameter measurement, physical property testing and dielectric strength testing. This ensures that only finished products that meet the requirements can be put into use, thereby improving the safety and reliability of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0029] Figure 1 The schematic diagram of the insulating masterbatch preparation system of the present invention is as follows;

[0030] Figure 2 The principle block diagram of raw material preparation of the present invention;

[0031] Figure 3 The principle block diagram of making insulating masterbatch of the present invention;

[0032] Figure 4 It is a principle block diagram of cooling and forming of the present invention;

[0033] Figure 5 Schematic diagram of the cutting and customization of the present invention;

[0034] Figure 6 This is a principle block diagram of the quality detection of the present invention;

[0035] Figure 7 It is a step diagram of the method for preparing the rubber compound of the present invention.

[0036] In the figure: 1. Raw material preparation; 10. Selection of rubber material; 11. Preparation of filler; 12. Preparation of hardener; 13. Use of mixer;

[0037] 2. Make insulating masterbatch; 20. Design and make corresponding molds; 21. Preparation method of rubber compound; 22. Inject rubber compound into mold; 23. Heat and pressurize mold;

[0038] 3. Cooling and molding; 30. Natural cooling or artificial cooling; 31. Observation of shrinkage and deformation; 32. Demolding;

[0039] 4. Cutting and customization; 40. Cutting into specific sizes and shapes; 41. Custom edge design; 42. Removing burrs or cracks;

[0040] 5. Quality inspection; 50. Appearance inspection; 51. Size and diameter measurement; 52. Physical properties test; 53. Dielectric strength test. DETAILED DESCRIPTION

[0041] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0042] Example 1

[0043] like Figure 1 to Figure 7As shown, a system for preparing a masterbatch block and a method for preparing a rubber material thereof include raw material preparation 1, making insulating masterbatch 2, cooling and molding 3, cutting and customization 4 and quality inspection 5, wherein the raw material preparation 1, making insulating masterbatch 2, cooling and molding 3, cutting and customization 4 and quality inspection 5 are sequentially connected in communication; the raw material preparation 1 is the preparation work before making the masterbatch block, making insulating masterbatch 2 is the making process of the masterbatch block, cooling and molding 3 is the molding and cooling of the material after processing, cutting and customization 4 is that the molded block is not perfect and needs to be manually processed to obtain the finished product, and the quality inspection 5 is that the finished product cannot be put into use directly and needs to be inspected before use.

[0044] In this embodiment, raw material preparation 1 includes selecting rubber material 10, preparing filler 11, preparing hardener 12 and using mixer 13; selecting rubber material 10 is used to select suitable rubber material. Different rubber materials are suitable for different application scenarios. When selecting rubber material 10, it is necessary to fully consider the use environment and requirements of the product. Prepare filler 11 is used to adjust the hardness, density, tensile strength and other properties of rubber to improve the wear resistance and aging resistance of the product. Prepare hardener 12 is used to chemically react with rubber molecules to form a cross-linked structure between rubber molecules to improve the hardness and strength of rubber. Use mixer 13 is used to uniformly mix rubber materials, fillers, hardeners and other raw materials to make each component fully dispersed in the rubber.

[0045] In this embodiment, the manufacturing of insulating masterbatch 2 includes designing and manufacturing a corresponding mold 20, a method for preparing a rubber material 21, injecting the rubber material into a mold 22, and heating and pressurizing the mold 23; the designing and manufacturing of the corresponding mold 20 is used to design a precise mold according to the shape, size and performance requirements of the desired product;

[0046] The preparation method 21 of the rubber compound comprises the following steps: S1. First, various raw materials are accurately weighed according to the ratio of raw rubber to 40%, the ratio of vulcanizing agent to 1% to 3%, the ratio of accelerator to 0.5% to 1%, the ratio of active agent to 1%, and the ratio of processing aid to less than 1%; S2. Then, the weighed raw materials are placed in a mixer for thorough mixing. During the mixing process, the temperature, time and speed need to be controlled to ensure uniform mixing and the quality of the rubber compound; S3. The mixed rubber compound is formed by a calender or an extruder. According to the product requirements, it can be made into blocks or strips of different thicknesses, diameters or shapes; S4. Then, the calendered or extruded rubber compound is placed in a vulcanizing tank and heated at a certain temperature and pressure. Vulcanization is carried out. During the vulcanization process, cross-linking reactions occur between rubber molecules to form a stable network structure; S5. After vulcanization is completed, the rubber needs a period of time to cool and solidify. After cooling and solidification, the rubber should be inspected for quality, such as tensile strength, tear strength, hardness, etc., to ensure that it meets the use requirements; Cooling and solidification After cooling and solidification, the rubber should be inspected for quality, such as tensile strength, tear strength, hardness, etc. to ensure that it meets the use requirements. The rubber should be tested for time strength, tensile strength, tear strength, strength congestion. How to cool and solidify the rubber molecules after vulcanization is completed? The rubber is injected into the mold for a suitable injection method. During the vulcanization process, cross-linking reactions occur between rubber molecules to form a stable network structure.

[0047] The rubber material injection mold 22 is used to fill the rubber material into the mold evenly through a suitable injection method, ensuring that the shape and structure of the rubber product meet the requirements, and controlling the injection speed and injection amount to avoid bubbles or defects. The mold heating and pressurization 23 is used to make the rubber material fully flow and solidify in the mold through heating and pressurization, so as to obtain a rubber product with excellent physical properties and appearance quality. Parameters such as temperature, pressure and time are controlled to ensure that the molding effect of the rubber product is optimal.

[0048] In this embodiment, cooling and molding 3 includes self-cooling or artificial cooling 30, shrinkage deformation observation 31 and demolding 32; self-cooling or artificial cooling 30 is used to help the rubber product quickly reach a stable physical and chemical state. Rubber will generate heat during the vulcanization process. Cooling can further stabilize the rubber molecular chain and improve the hardness and strength of the product. Observation of shrinkage deformation 31 is used to adjust the production process parameters in time by observing these deformations to avoid dimensional deviation or shape distortion of the product. Demolding 32 is used to remove the vulcanized and cooled rubber product from the mold. The demolding agent 32 can reduce the friction and adhesion between the rubber and the mold, making the demolding 32 process smoother.

[0049] In this embodiment, cutting and customization 4 includes cutting into specific size and shape 40, customized edge design 41 and deburring or cracking 42; cutting into specific size and shape 40 is used to ensure that it can be adapted to corresponding equipment or components, customized edge design 41 is used for different edge designs can meet different application requirements, such as increasing anti-slip properties, improving sealing or reducing wear, etc., deburring or cracking 42 is used for rubber products that may produce burrs or cracks during cutting or processing. Through deburring or cracking 42, these defects can be eliminated, ensuring that the surface of the product is smooth and flat, and improving its overall quality and reliability.

[0050] In this embodiment, the quality inspection 5 includes an appearance inspection 50, a size diameter measurement 51, a physical property test 52, and a dielectric strength test 53; the appearance inspection 50 is used to carefully inspect the appearance of the masterbatch block, so as to timely discover possible problems in the product manufacturing process, such as bubbles, cracks, impurities, etc., so as to take corresponding measures to improve them; the size diameter measurement 51 is used for the specific size and thickness of the existing masterbatch block to meet the assembly and use requirements. Through precise measurement, it can be ensured that the product meets the design requirements and avoids performance problems caused by dimensional deviation; the physical property test 52 is used to test the physical properties of the masterbatch block, such as tensile strength, tear strength, wear resistance, and resilience, so as to fully understand the performance characteristics of the masterbatch block and provide a basis for the optimal design and improvement of the product; the dielectric strength test 53 is used to test the insulation performance of the rubber masterbatch block under a high voltage electric field, so as to ensure that no electrical failure or safety hazard occurs during use.

[0051] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A system for preparing insulating masterbatch blocks, characterized in that: The method comprises raw material preparation (1), making insulating masterbatch (2), cooling and molding (3), cutting and customization (4) and quality inspection (5), wherein the raw material preparation (1), making insulating masterbatch (2), cooling and molding (3), cutting and customization (4) and quality inspection (5) are sequentially connected in communication; The raw material preparation (1) is the preparation work before making the masterbatch block, the making of insulating masterbatch (2) is the making process of the masterbatch block, the cooling and forming (3) is the forming and cooling of the material after processing, the cutting and customization (4) is that the formed block is not perfect and needs manual processing to obtain the finished product, and the quality inspection (5) is that the finished product cannot be put into use directly after it is obtained and needs to be inspected before it can be used.

2. The system for preparing insulating masterbatch according to claim 1, characterized in that: The raw material preparation (1) includes selecting rubber material (10), preparing filler (11), preparing hardener (12) and using a mixer (13); The selection of rubber material (10) is used to select a suitable rubber material. Different rubber materials are suitable for different application scenarios. When selecting rubber materials, it is necessary to fully consider the use environment and requirements of the product. The preparation of filler (11) is used to adjust the hardness, density, and tensile strength of the rubber to improve the wear resistance and aging resistance of the product. The preparation of hardener (12) is used to chemically react with rubber molecules to form a cross-linked structure between rubber molecules to improve the hardness and strength of the rubber. The use of the mixer (13) is used to evenly mix the rubber material, filler, and hardener raw materials so that each group is dispersed in the rubber.

3. The system for preparing insulating masterbatch according to claim 2, characterized in that: The manufacturing of the insulating masterbatch (2) includes designing and manufacturing a corresponding mold (20), a method for preparing a rubber compound (21), injecting the rubber compound into the mold (22), and heating and pressurizing the mold (23); The design and manufacture of the corresponding mold (20) is used to design a precise mold according to the shape, size and performance requirements of the desired product.

4. A method for preparing a rubber compound according to the system for preparing an insulating masterbatch block according to claim 3 comprises the following steps: S1. First, accurately weigh various raw materials based on the ratio of raw rubber to 40%, vulcanizer to 1% to 3%, accelerator to 0.5% to 1%, active agent to 1%, and processing aid to less than 1%; S2, then put the weighed raw materials into the mixer and mix them thoroughly. During the mixing process, the temperature, time and speed need to be controlled to ensure uniform mixing and rubber quality; S3, then the mixed rubber material is formed by a calender or an extruder, and can be made into blocks or strips of different thicknesses, diameters or shapes according to product requirements; S4, then put the calendered or extruded rubber into a vulcanizing tank and vulcanize it at a certain temperature and pressure. During the vulcanization process, cross-linking reaction occurs between rubber molecules to form a stable network structure; S5. After vulcanization, the rubber needs some time to cool and solidify. After cooling and solidification, the rubber should be inspected for quality, such as tensile strength, tear strength, and hardness, to ensure that it meets the use requirements; The rubber material injection mold (22) is used to uniformly fill the rubber material into the mold through a suitable injection method to ensure that the shape and structure of the rubber product meet the requirements, and to control the injection speed and injection amount to avoid bubbles or defects. The mold heating and pressurization (23) is used to make the rubber material fully flow and solidify in the mold through heating and pressurization, so as to obtain a rubber product with excellent physical properties and appearance quality. The temperature, pressure and time parameters are controlled to ensure that the molding effect of the rubber product is optimal.

5. The system for preparing insulating masterbatch according to claim 4, characterized in that: The cooling and molding (3) includes natural cooling or artificial cooling (30), observing shrinkage deformation (31) and demoulding (32); The self-cooling or artificial cooling (30) is used to help the rubber product quickly reach a stable physical and chemical state. Rubber will generate heat during the vulcanization process. Cooling can further stabilize the rubber molecular chain and improve the hardness and strength of the product. The shrinkage deformation observation (31) is used to observe these deformations and timely adjust the production process parameters to avoid dimensional deviation or shape distortion of the product. The demoulding (32) is used to remove the vulcanized and cooled rubber product from the mold. The demoulding (32) agent can reduce the friction and adhesion between the rubber and the mold.

6. The system for preparing insulating masterbatch according to claim 5, characterized in that: Cutting and customization (4) includes cutting to specific sizes and shapes (40), custom edge design (41), and removing burrs or cracks (42); The cutting into specific size and shape (40) is used to ensure that it can be adapted to the corresponding equipment or components. The customized edge design (41) is used for different edge designs to meet different application requirements, such as increasing anti-slip properties, improving sealing properties or reducing wear. The deburring or cracking (42) is used to remove burrs or cracks that may occur on rubber products during cutting or processing. These defects can be eliminated through deburring to ensure that the surface of the product is smooth and flat, thereby improving its overall quality and reliability.

7. The system for preparing insulating masterbatch according to claim 6, characterized in that: The quality inspection (5) includes appearance inspection (50), size diameter measurement (51), physical property test (52) and dielectric strength test (53); The appearance inspection (50) is used to carefully inspect the appearance of the masterbatch block to promptly discover possible problems in the product manufacturing process, such as bubbles, cracks, and impurities, so as to take corresponding measures to improve them. The size diameter measurement (51) is used to measure the specific size and thickness of the existing masterbatch block to meet the assembly and use requirements. Through precise measurement, it is ensured that the product meets the design requirements and avoids performance problems caused by dimensional deviation. The physical property test (52) is used to fully understand the performance characteristics of the masterbatch block by testing the tensile strength, tear strength, wear resistance, and resilience of the masterbatch block, so as to provide a basis for the optimal design and improvement of the product. The dielectric strength test (53) is used to test the insulation performance of the rubber masterbatch block under a high voltage electric field, so as to ensure that no electrical failure or safety hazard occurs during use.

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