Method for producing rubber filter strip through one-time film pressing forming

Abstract

The invention discloses a method for producing a rubber filter belt through one-time compression molding, and relates to the technical field of rubber filter belt products.The method comprises the steps that firstly, material preparation work of a rubber base material, a reinforcing agent and filler needed by the rubber filter belt is conducted, then plastication and mixing are conducted on the rubber material, compression molding is conducted, and the rubber filter belt is obtained; and finally, demolding and trimming the rubber filter belt. According to the invention, a production method of the rubber filter strip formed by one-time film pressing is adopted, so that the rubber filter strip is stable in overall structure and has relatively high tensile strength and wear resistance, so that the filter strip can bear relatively high wear and tear in a long-time use process, and the service life is prolonged; the one-time forming production method can remarkably reduce production steps and transfer time, and continuous automatic production is achieved, so that the production efficiency is improved; in the production process, energy can be utilized more efficiently, unnecessary waste is reduced, and therefore energy consumption is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of rubber filter belt production, in particular to a method for producing a rubber filter belt by one-time film pressing. Background Art

[0002] Rubber filter belt, also known as rubber filter belt or vacuum filter belt, is a key component of vacuum belt filter, mainly made of rubber material, and embedded in the skeleton layer to enhance its strength and stability. It has good wear resistance, corrosion resistance and elasticity, suitable for filtering, separation and purification of various liquids, and is widely used in chemical, food, medicine, electronics and water treatment fields.

[0003] The rubber one-shot extrusion molding process is an efficient and precise molding method that preheats and softens the plasticized and mixed rubber material, puts it into a mold, applies pressure to fill the mold cavity, and forms a rubber product of the desired shape and size after cooling and solidification.

[0004] The conventional rubber filter belt production method has the problem of insufficient structural stability due to the limitation of manufacturing process, which may lead to deformation, tearing and other phenomena during long-term use, affecting the filtering effect and service life. In addition, the production requires multiple production steps and stages and consumes a lot of energy. Therefore, a rubber filter belt production method with one-time film pressing is proposed. Summary of the invention

[0005] The object of the present invention is to provide a method for producing a rubber filter belt by one-time film pressing to solve the problem that the rubber filter belt proposed in the above background technology is not stable enough, which may lead to deformation, tearing and the like during long-term use, affecting the filtering effect and service life, and the production requires multiple production steps and stages and consumes a lot of energy.

[0006] To achieve the above object, the present invention provides the following technical solution: a method for producing a rubber filter belt by one-step film pressing, comprising the following steps: S1. Preparation of rubber filter belt materials; S2, plasticizing and mixing of rubber materials; S3, film pressing; S4, demoulding and trimming.

[0007] Preferably, the material preparation comprises the following steps: S11, basic materials, including natural rubber, styrene-butadiene rubber, EPDM rubber and chloroprene rubber; S12. Additives, including carbon black N550, white carbon black, zinc oxide, zinc stearate, sulfur, accelerator TBzTD, antioxidant 1010, flame retardant magnesium hydroxide, plasticizer, coupling agent, nano clay and antistatic agent.

[0008] Preferably, the weight percentage of the raw materials is: Natural rubber (NR) 30%, styrene-butadiene rubber (SBR) 22%, ethylene-propylene-diene rubber (EPDM) 18%, chloroprene rubber (CR) 10%, carbon black (N550) 14%, white carbon black 2%, zinc oxide 1%, zinc stearate 0.5%, sulfur 0.7%, accelerator (TBzTD) 0.3%, antioxidant (1010) 1%, flame retardant magnesium hydroxide 3%, plasticizer 1.5%, coupling agent 0.2%, nano clay 2%, antistatic agent 0.3%. The sum of the percentages of each component in the formula is 100%.

[0009] Preferably, the plasticizing and mixing comprises the following steps: S21, after the preparation work such as baking and cutting of natural rubber is completed, the natural rubber, styrene-butadiene rubber, EPDM rubber and chloroprene rubber are thinly plasticized by using an open mixing mill; S22, putting the plasticized natural rubber, styrene-butadiene rubber, EPDM rubber and chloroprene rubber into an internal mixer, after the raw rubber and the main polymer are basically mixed, gradually adding carbon black N550, white carbon black, zinc oxide and zinc stearate, after the solid compounding agent is basically dispersed, adding nano clay, after the nano clay is added and mixed, adding sulfur, accelerator TBzTD, antioxidant 1010, flame retardant magnesium hydroxide, plasticizer, coupling agent, sulfur and accelerator TBzTD are added separately to avoid premature cross-linking reaction; S23. In the later stage of mixing, after the above raw materials are mixed evenly, an antistatic agent is added.

[0010] Preferably, the film forming comprises the following steps: S31, preheating the mixed rubber material to a certain temperature, and preheating the mold; S32, placing the prepared blank into the mold, ensuring that the blank is in close contact with the mold without any gap; S33, closing the mold and applying pressure to allow the rubber to fully fill the mold; S34, heating the rubber in the mold to cause a vulcanization reaction; S35. After vulcanization is completed, the mold is cooled to allow the rubber filter belt to be shaped in the mold.

[0011] Preferably, the demoulding and trimming comprises the following steps: S41, after the rubber filter belt is completely vulcanized and cooled, the mold is opened and the rubber filter belt is taken out; S42, trimming the taken-out rubber filter belt to remove burrs and uneven parts, so that the geometric dimensions of the rubber filter belt are more accurate and the surface is smooth; S43. Test the physical and mechanical properties of the rubber filter belt, requiring the tensile strength to be no less than 15MPa, the elongation at break to be no less than 350%, and the tear strength to be no less than 50kN / m; S44. Detect the surface resistance of the rubber filter belt, and the resistance value is required to be less than 10^9Ω.

[0012] Preferably, the mixing process temperature is controlled at 110° C. to 130° C., and the mixing time is controlled at 8 to 10 minutes.

[0013] Preferably, the vulcanization process temperature is controlled at 140° C. to 180° C., and the time is controlled at 5 to 10 minutes.

[0014] In the present invention, a rubber filter belt production method using one-time film pressing and molding is adopted, which ensures that the overall structure of the rubber filter belt is stable and has high tensile strength and wear resistance, so that the filter belt can withstand greater wear and tear during long-term use, thereby extending its service life; the one-time molding production method can significantly reduce the production steps and transportation time, realize continuous automated production, and thus improve production efficiency; in the production process, energy can be used more efficiently, unnecessary waste can be reduced, thereby reducing energy consumption. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a flow chart of a method for producing a rubber filter belt by one-step film pressing molding according to the present invention; Figure 2 It is a flow chart of film pressing molding of the present invention; Figure 3 It is a demoulding and finishing flow chart of the present invention. DETAILED DESCRIPTION

[0016] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the implementation regulations described 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.

[0017] The present invention will be further described below in conjunction with the embodiments.

[0018] Example See also Figure 1-3 As shown, a method for producing a rubber filter belt by one-step film pressing and forming comprises the following steps: Step 1: Prepare rubber filter belt materials; Specifically, material preparation includes: Basic materials, natural rubber, styrene-butadiene rubber, EPDM and chloroprene rubber; Additives: carbon black N550, white carbon black, zinc oxide, zinc stearate, sulfur, accelerator TBzTD, antioxidant 1010, flame retardant magnesium hydroxide, plasticizer, coupling agent, nano clay and antistatic agent; The weight percentages of the raw materials are: Natural rubber (NR) 30%, styrene-butadiene rubber (SBR) 22%, ethylene-propylene-diene rubber (EPDM) 18%, chloroprene rubber (CR) 10%, carbon black (N550) 14%, white carbon black 2%, zinc oxide 1%, zinc stearate 0.5%, sulfur 0.7%, accelerator (TBzTD) 0.3%, antioxidant (1010) 1%, flame retardant magnesium hydroxide 3%, plasticizer 1.5%, coupling agent 0.2%, nano clay 2%, antistatic agent 0.3%, the sum of the percentages of each component in the formula is 100%; Rubber base material: Natural rubber (NR), which provides excellent elasticity, abrasion resistance and tear strength, is the core material of rubber filter belts; Styrene butadiene rubber (SBR), improves the weather resistance, oil resistance and processing performance of rubber, and the oil-filled type improves flexibility and reduces costs; EPDM, which enhances the rubber's resistance to heat, ozone, chemicals and aging, and is suitable for extreme environments; Chloroprene rubber (CR) improves the tear strength, flame resistance and chemical resistance of rubber and enhances the adhesion between rubber and fiber.

[0019] Reinforcement agents and fillers: Carbon black (N550), as a reinforcing agent, significantly increases the hardness and tensile strength of rubber, while also improving abrasion resistance and tear strength; White carbon black improves the tear strength and abrasion resistance of rubber, provides excellent reinforcement effect, and improves the transparency and gloss of rubber; Zinc oxide promotes the vulcanization reaction of rubber, increases the crosslinking density and vulcanization speed, and also improves the thermal stability and weather resistance of rubber; Zinc stearate, as a lubricant, improves the processing performance and demoulding properties of rubber and reduces mold wear Sulfur, as a vulcanizing agent, forms a cross-linking structure, improves the strength of the rubber, and ensures the stability and uniformity of the vulcanization process; Accelerator (TBzTD) accelerates the vulcanization reaction of rubber, improves production efficiency, and ensures that the vulcanized rubber has good physical properties; Anti-aging agent (1010) prevents rubber from aging due to oxidation, heat and light, prolongs its service life, and improves its heat resistance and weather resistance; Flame retardant magnesium hydroxide improves the flame retardant properties of the rubber filter belt, ensuring safety. It also has good filling and dispersibility, meeting environmental protection requirements; Plasticizers improve the softness and processability of rubber, while meeting environmental protection requirements, causing no harm to the environment and human body, and are not easy to migrate; Coupling agent improves the binding ability of inorganic fillers (such as white carbon black) and rubber macromolecules, improves the reinforcement effect, and enhances the adhesion between rubber and fiber, and has low toxicity; Nanoclay, as a nanofiller, further improves the mechanical properties, heat resistance and flame retardancy of rubber, while improving the processing properties of rubber; Antistatic agents to reduce the risk of static electricity build-up and discharge.

[0020] Step 2: Plasticizing and mixing the rubber material; Specifically, plasticating and mixing include the following steps: After the preparation work such as baking and cutting of natural rubber is completed, the natural rubber, styrene-butadiene rubber, EPDM rubber and chloroprene rubber are thinly plasticized by an open mill; the plasticized natural rubber, styrene-butadiene rubber, EPDM rubber and chloroprene rubber are put into an internal mixer, and after the raw rubber and the main polymer are basically mixed evenly, carbon black N550, white carbon black, zinc oxide and zinc stearate are gradually added, and after the solid compounding agent is basically dispersed evenly, nano clay is added, and after the nano clay is added and mixed evenly, sulfur, accelerator TBzTD, antioxidant 1010, flame retardant magnesium hydroxide, plasticizer, coupling agent are added, and sulfur and accelerator TBzTD are added separately to avoid premature cross-linking reaction; in the later stage of mixing, after the above raw materials are mixed evenly, an antistatic agent is added; the temperature of the mixing process is controlled at 110° C. to 130° C., and the time is controlled at 8 to 10 minutes.

[0021] Step 3: Film pressing and forming; Specifically, the film forming process includes the following steps: Preheat the mixed rubber material to a certain temperature and preheat the mold; put the prepared blank into the mold to ensure that the blank is in close contact with the mold without any gaps; close the mold and apply pressure to fully fill the mold with rubber; heat the rubber in the mold to cause vulcanization reaction; after vulcanization is completed, cool the mold to shape the rubber filter belt in the mold; the temperature of the vulcanization process is controlled at 140℃~180℃ and the time is controlled at 5~10 minutes.

[0022] Step 4: demoulding and trimming; Specifically, demoulding and trimming include the following steps: After the rubber filter belt is completely vulcanized and cooled, open the mold and take out the rubber filter belt; trim the taken out rubber filter belt to remove the burrs and uneven parts to make the geometric dimensions of the rubber filter belt more accurate and the surface smoother; test the physical and mechanical properties of the rubber filter belt, requiring the tensile strength to be no less than 15MPa, the elongation at break to be no less than 350%, and the tear strength to be no less than 50kN / m; test the surface resistance of the rubber filter belt, requiring the resistance value to be less than 10^9Ω.

[0023] Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. 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 method for producing a rubber filter belt by one-step film forming, characterized in that: The following steps are involved: S1. Preparation of rubber filter belt materials; S2, plasticizing and mixing of rubber materials; S3, film pressing; S4, demoulding and trimming.

2. The method for producing a rubber filter belt by one-step film forming according to claim 1, characterized in that: In step S1, the material preparation includes the following steps: S11, basic materials, including natural rubber, styrene-butadiene rubber, EPDM rubber and chloroprene rubber; S12. Additives, including carbon black N550, white carbon black, zinc oxide, zinc stearate, sulfur, accelerator TBzTD, antioxidant 1010, flame retardant magnesium hydroxide, plasticizer, coupling agent, nano clay and antistatic agent.

3. The method for producing a rubber filter belt by one-step film forming according to claim 2, characterized in that: The weight percentage of the raw materials is: Natural rubber (NR) 30%, styrene-butadiene rubber (SBR) 22%, ethylene-propylene-diene rubber (EPDM) 18%, chloroprene rubber (CR) 10%, carbon black (N550) 14%, white carbon black 2%, zinc oxide 1%, zinc stearate 0.5%, sulfur 0.7%, accelerator (TBzTD) 0.3%, antioxidant (1010) 1%, flame retardant magnesium hydroxide 3%, plasticizer 1.5%, coupling agent 0.2%, nano clay 2%, antistatic agent 0.3%. The sum of the percentages of each component in the formula is 100%.

4. The method for producing a rubber filter belt by one-step film forming according to claim 1, characterized in that: In step S2, the mastication and mixing comprises the following steps: S21, after the preparation work such as baking and cutting of natural rubber is completed, the natural rubber, styrene-butadiene rubber, EPDM rubber and chloroprene rubber are thinly plasticized by using an open mixing mill; S22, putting the plasticized natural rubber, styrene-butadiene rubber, EPDM rubber and chloroprene rubber into an internal mixer, after the raw rubber and the main polymer are basically mixed, gradually adding carbon black N550, white carbon black, zinc oxide and zinc stearate, after the solid compounding agent is basically dispersed, adding nano clay, after the nano clay is added and mixed, adding sulfur, accelerator TBzTD, antioxidant 1010, flame retardant magnesium hydroxide, plasticizer, coupling agent, sulfur and accelerator TBzTD are added separately to avoid premature cross-linking reaction; S23. In the later stage of mixing, after the above raw materials are mixed evenly, an antistatic agent is added.

5. The method for producing a rubber filter belt by one-step film forming according to claim 1, characterized in that: In step S3, the film forming comprises the following steps: S31, preheating the mixed rubber material to a certain temperature, and preheating the mold; S32, placing the prepared blank into the mold, ensuring that the blank is in close contact with the mold without any gap; S33, closing the mold and applying pressure to allow the rubber to fully fill the mold; S34, heating the rubber in the mold to cause a vulcanization reaction; S35. After vulcanization is completed, the mold is cooled to allow the rubber filter belt to be shaped in the mold.

6. The method for producing a rubber filter belt by one-step film forming according to claim 1, characterized in that: In step S4, the demoulding and trimming comprises the following steps: S41, after the rubber filter belt is completely vulcanized and cooled, the mold is opened and the rubber filter belt is taken out; S42, trimming the taken-out rubber filter belt to remove burrs and uneven parts, so that the geometric dimensions of the rubber filter belt are more accurate and the surface is smooth; S43. Test the physical and mechanical properties of the rubber filter belt, requiring the tensile strength to be no less than 15MPa, the elongation at break to be no less than 350%, and the tear strength to be no less than 50kN / m; S44. Detect the surface resistance of the rubber filter belt, and the resistance value is required to be less than 10^9Ω.

7. The method for producing a rubber filter belt by one-step film forming according to claim 4, characterized in that: The temperature of the mixing process is controlled at 110° C. to 130° C., and the time is controlled at 8 to 10 minutes.

8. The method for producing a rubber filter belt by one-step film forming according to claim 5, characterized in that: The temperature of the vulcanization process is controlled at 140° C. to 180° C., and the time is controlled at 5 to 10 minutes.

Images