Polymer Crosslinking Simulation for Internal Bubble Estimation
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Solution Overview
Problem
Existing techniques for estimating the vulcanization degree and temperature history of polymers during crosslinking reactions are inaccurate due to variations in shape and composition, leading to difficulties in predicting the vulcanization time and generation of bubbles in polymer products.
Innovation Solution
A crosslinking reaction simulation device that includes a storage unit, heat transfer analysis unit, and crosslinking reaction analysis unit to accurately calculate the reaction rate and thermal diffusivity of polymers, using a slope coefficient and equivalent reaction amount to predict the vulcanization time and suppress bubble generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the Arrhenius equation is used to estimate vulcanization degree from temperature history, then the calculation process is simple, but the estimation accuracy is insufficient
Solution Approach 1:
The patent changes the fundamental parameters of the estimation approach by transitioning from a simple Arrhenius equation-based method to a comprehensive simulation method that incorporates heat transfer analysis, thermal diffusivity calculations, and reaction rate modeling. This multi-parameter approach significantly improves estimation accuracy while maintaining computational feasibility through systematic integration of multiple physical models.
2Measurement precision
If thermal conduction from mold to polymer is considered, then the temperature history estimation becomes more accurate, but the calculation complexity increases due to shape and composition variations
Solution Approach 1:
The patent segments the polymer into multiple discrete elements and applies heat transfer analysis to each element individually. This segmentation allows the complex heat conduction problem to be broken down into manageable calculations for each element, considering their specific positions, shapes, and compositions, thereby achieving accurate temperature history estimation without overwhelming computational complexity.
Solution Approach 2:
The patent applies local quality by assigning different thermal properties, shapes, and compositional characteristics to different elements of the polymer based on their specific locations and roles. This allows the heat transfer calculation to account for local variations in thermal conduction, ensuring accurate temperature history estimation for each element while maintaining overall system manageability.
3Object-affected harmful factors
If the vulcanization time is extended to prevent bubble generation, then the bubble formation is suppressed, but the productivity decreases
Solution Approach 1:
The patent performs preliminary action by conducting comprehensive heat transfer analysis and reaction rate calculations before the actual vulcanization process. This allows the determination of optimal vulcanization time that prevents bubble formation from the outset, eliminating the need for extended trial vulcanization times and thereby maintaining high productivity while ensuring defect-free products.
Solution Approach 2:
The patent implements feedback by using the calculated temperature history and reaction rate information to continuously optimize the vulcanization process parameters. This feedback mechanism ensures that the vulcanization time is precisely controlled to achieve complete curing without bubble formation, balancing product quality and production efficiency.
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
Enables precise estimation of the reaction rate and vulcanization time, allowing for accurate prediction of bubble formation and improved control of the crosslinking process.
Implementation Method 1
the thermal conduction from the mold to the polymer and the thermal conduction inside the polymer are affected by the shape of the polymer, the composition of a filler contained in the polymer
Implementation Method 2
The above technique estimates the vulcanization degree from the temperature history of rubber based on the Arrhenius equation
Implementation Method 3
a three-dimensional network crosslinked structure is formed between rubber molecular chains or in the molecular chains by adding sulfur, another crosslinking agent, a vulcanization promoter, and the like to raw material rubber, and performing heating
Implementation Method 4
a gas originally dissolved in rubber or a gas generated by a vulcanization reaction is dissolved in rubber under a high temperature and high pressure condition of vulcanization
Data Source
AI summary
A crosslinking reaction simulation device including: a heat transfer analysis unit configured to perform a heat transfer analysis during a crosslinking reaction of a polymer portion of a target work model; and a crosslinking reaction analysis unit configured to perform analysis of a reaction rate of a crosslinking reaction of the polymer portion, and the crosslinking reaction analysis unit includes a temperature acquisition unit that acquires, as a result of the heat transfer analysis, a temperature at each time for each element of the polymer portion of the target work model in the crosslinking reaction, and, a reaction rate calculation processing unit configured to calculate an equivalent reaction amount of the polymer portion at each time, and calculates the reaction rate of the crosslinking reaction of the polymer portion based on the calculated equivalent reaction amount.