Meshing-Type Rubber Internal Mixer for Dust Control and Mixing
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Solution Overview
Problem
Traditional open mills in the rubber mixing process are prone to industrial accidents and have a hazardous working environment due to the lack of internal mixing at the center, leading to inefficiencies and risks.
Innovation Solution
A meshing-type rubber internal mixer is designed with a frame mechanism, mixing mechanism, and unloading mechanism, featuring meshing-type rotors and telescopic plates that create a closed internal mixing chamber for efficient material processing, reducing dust flying and ingredient loss, and enhancing mixing and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional open mill is used for rubber mixing, then the equipment structure is simple, but the working environment is hazardous and industrial accidents occur frequently
Solution Approach 1:
The mixing chamber is segmented into an upper feeding station and a lower mixing station, with the mixing station enclosed in a closed chamber. This segmentation allows the hazardous mixing process to be isolated from the working environment while maintaining structural simplicity in the overall design.
Solution Approach 2:
A closed mixing chamber with transparent or semi-transparent panels is used to enclose the mixing process. This flexible shell structure protects operators from harmful factors like dust and mechanical hazards while allowing visual monitoring of the mixing process.
2Device complexity
If non-meshing-type rotors are used in internal mixer, then the device structure is simple, but internal mixing at the center does not occur
Solution Approach 1:
The rotors are designed with asymmetric meshing teeth that interlock in a specific pattern. This asymmetric design creates a progressive mixing action that ensures material is thoroughly mixed at the center of the mixing chamber while maintaining relatively simple rotor structures.
Solution Approach 2:
The rotor surfaces are designed with curved profiles that complement each other in a meshing configuration. This curvature design creates effective mixing action throughout the mixing chamber, including the center region, while keeping the rotor geometry manufacturable and not overly complex.
3Ease of manufacture
If open mill is used for rubber mixing, then the equipment cost is low, but dust flying and ingredient loss are severe
Solution Approach 1:
A closed mixing chamber with sealed openings is used to contain the mixing process. This enclosure prevents dust and ingredient particles from escaping into the working environment, significantly reducing substance loss while maintaining cost-effectiveness through simple sealing mechanisms.
Solution Approach 2:
The closed mixing chamber creates a contained environment that isolates the mixing process from the external atmosphere. This prevents dust and ingredients from dispersing into the workspace, reducing loss and improving working conditions without requiring complex atmospheric control systems.
4Productivity
If traditional internal mixer is used, then the mixing capacity is adequate, but steam exhaust performance is poor
Solution Approach 1:
The steam exhaust system is extracted and separated from the main mixing chamber. A dedicated exhaust port and channel are provided in the closed mixing chamber to efficiently remove steam and volatile substances generated during mixing, while maintaining the mixing capacity of the main chamber.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The meshing-type internal mixer achieves effective material mixing and heat transfer, reducing dust and ingredient loss, improving safety and efficiency by compressing materials within a small gap between rotors, and facilitating easy unloading and cleaning.
Implementation Method 1
the first meshing-type rotor and the second meshing-type rotor have a large velocity gradient at a meshing position, strong friction, shearing, and kneading effects are achieved on the material between the rotors
Implementation Method 2
strong friction, shearing, and kneading effects are achieved on the material between the rotors
Implementation Method 3
The internal mixing chamber is connected to a power supply and a heating power supply
Implementation Method 4
introducing cooling water into the interlayer of the internal mixing chamber wall from the water inlet to cool the internal mixing chamber
Data Source
AI summary
A meshing-type rubber internal mixer and a working method thereof are provided. The meshing rubber internal mixer includes a frame mechanism, a mixing mechanism, and an unloading mechanism. The mixing mechanism is on the upper side of the unloading mechanism. The mixing mechanism and the unloading mechanism are in the frame mechanism. An internal mixing chamber is of a closed structure through first automatic telescopic plates and second automatic telescopic plates. The gap between a first meshing-type rotor and a second meshing-type rotor is small, a material is compressed to enter the space between the first meshing-type rotor and the second meshing-type rotor to be extruded with an internal mixing chamber wall. The material is flaky in the internal mixing chamber, so that the material produces great strain deformation, thereby achieving excellent dispersing and mixing effects.