Rotary Vulcanization Unit with Planar Radiation Sources
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Solution Overview
Problem
Existing vulcanization methods for rubber-based multi-layer articles are time and energy intensive, and often result in irregular surface cross-linking and blister formation, which negatively impact the physical properties of the articles.
Innovation Solution
A method utilizing a rotary vulcanization unit followed by a pressureless post-heating section with two planar radiation sources, specifically dark radiators, to achieve uniform cross-linking and energy efficiency, allowing for independent control of energy input on both sides of the article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressurized vulcanization methods are employed to prevent bubbles and ensure adhesion, then the quality of the article is improved, but the production speed decreases and energy consumption increases
Solution Approach 1:
The vulcanization process is divided into two independent phases: a pressurized initial vulcanization phase in the rotary vulcanization unit, followed by a pressureless post-heating phase in the radiation section. This segmentation allows each phase to optimize for its specific function, improving overall efficiency and production speed while maintaining quality.
Solution Approach 2:
The invention changes the pressure parameter from constant high pressure throughout the process to a dynamic parameter that is high during initial vulcanization and then reduced to zero during the post-heating phase. This parameter change enables faster production while maintaining uniform cross-linking quality.
2Manufacturing precision
If pressurized vulcanization methods are employed to prevent bubbles and ensure adhesion, then the quality of the article is improved, but the energy consumption increases
Solution Approach 1:
The energy-intensive pressurized heating phase is separated from the pressureless post-heating phase. The radiation section uses energy-efficient infrared radiation to complete the vulcanization process without requiring continued high pressure, significantly reducing overall energy consumption while maintaining uniform cross-linking.
Solution Approach 2:
The mechanical pressurized heating system is partially replaced with a radiation-based heating system in the post-heating section. This substitution eliminates the need for continuous mechanical pressure while maintaining effective heating, reducing energy consumption and enabling faster processing.
3Strength
If rotary vulcanization is used to maintain constant pressure, then adhesion between layers is improved, but irregularities occur on article surfaces affecting physical properties
Solution Approach 1:
The process separates the adhesion-critical pressurized phase from the surface-quality-critical post-heating phase. This allows the rotary unit to focus on achieving strong interlayer adhesion under pressure while the subsequent radiation phase corrects surface irregularities and ensures uniform cross-linking without pressure-induced distortions.
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
This approach significantly increases production speed, saves energy, and ensures uniform cross-linking without bubble formation, improving the physical properties of the articles by extending the effective heating distance and optimizing temperature control zones.
Implementation Method 1
pressurized vulcanization methods are often employed
Implementation Method 2
During the initial vulcanization, initial cross-linking reactions may occur
Implementation Method 3
Dark radiators are used as radiation sources in the second process step. The term 'dark radiator' describes an infrared emitter that emits long-wave radiation in the non-visible range
Implementation Method 4
The presence of at least two planar radiation sources, each irradiating the top and bottom surfaces of the single- or multi-layer article
Implementation Method 5
The ability to insulate the two radiation sources, which form a pressureless post-heating section, significantly improves the overall energy efficiency of the effective heating section
Data Source
Figure 1
AI summary
Vulcanizing a single-layer or multi-layer article which contains at least one layer based on at least one rubber, comprises: (i) carrying out the plastic flow-phase of the rubber of the single-layer or multi-layer article under pressure; and (ii) performing crosslinking phase of the rubber of the single-layer or multi-layer article without the pressure. At least two area radiation sources (5) are used during the pressure-less crosslinking phase, in which the upper side and the lower side of the single-layer or multi-layer article are irradiated. An independent claim is also included for a device for vulcanizing a single layer or multi-layer article comprising a rotation vulcanization unit (1) and a reheating line, where the reheating line has at least two flat light sources, which irradiate the upper side and the lower side of single layer or multi-layer article.