Rubber Mold Vent Cleaning via Devulcanization Solvent
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Solution Overview
Problem
Current cleaning technologies are ineffective in removing vulcanized rubber, especially heat-aged vulcanized rubber, from small, inaccessible areas of molds used in manufacturing rubber products, such as vent holes, due to their limited physical access and the difficulty in preventing char formation which binds carbon black particles together.
Innovation Solution
A method involving subjecting the vulcanized rubber to a high temperature in the presence of a devulcanization solvent to break down the rubber, followed by solvent extraction to dissolve the polymer, and subsequent removal of the carbon black filler using techniques like pressure washers or air jets, utilizing solvents like toluene to prevent char formation and facilitate easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional cleaning methods (lasers, CO2 dry ice blasting, abrasive particle blasting) are used, then the surface of molds can be cleaned, but the small holes and inaccessible areas cannot be effectively cleaned
Solution Approach 1:
The patent replaces mechanical cleaning methods (lasers, dry ice blasting, abrasive blasting) with a chemical system using devulcanization solvent that can penetrate and react with vulcanized rubber inside small holes and inaccessible areas, enabling effective cleaning where mechanical methods fail
Solution Approach 2:
The devulcanization solvent acts as an intermediary substance that penetrates into the small holes and inaccessible areas, chemically reacting with the vulcanized rubber to enable its removal, thereby bridging the gap between the cleaning system and the difficult-to-reach contaminated areas
2Productivity
If high temperature is applied to remove vulcanized rubber, then rubber can be devulcanized, but char formation occurs which binds carbon black particles together making them difficult to remove
Solution Approach 1:
The patent changes the chemical parameters by introducing a devulcanization solvent that enables rubber devulcanization at lower temperatures or under controlled conditions, preventing the thermal degradation that leads to char formation while maintaining effective rubber removal
Solution Approach 2:
The devulcanization solvent serves as a chemical intermediary that facilitates rubber breakdown without requiring extreme temperatures, thereby preventing the formation of harmful char that would bind carbon black particles together
3Ease of operation
If solvents are used to dissolve rubber polymer, then devulcanized rubber can be removed, but the process requires multiple steps increasing complexity
Solution Approach 1:
The patent combines the devulcanization and dissolution steps into a single integrated process where the devulcanization solvent performs both functions simultaneously, reducing the number of separate steps while maintaining complete rubber removal effectiveness
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
Effectively removes vulcanized and heat-aged rubber from molds, including small and inaccessible areas, without forming char, allowing for efficient cleaning of molds and preventing carbon black residue from becoming hard and difficult to remove.
Implementation Method 1
subjecting the structure and the vulcanized rubber to a high temperature of between 250° C. and 320° C. in the presence of a devulcanization solvent for a reaction time sufficient to devulcanize the vulcanized rubber
Implementation Method 2
subjecting the structure and devulcanized rubber to a dissolving solvent to dissolve rubber polymer from the devulcanized rubber
Data Source
AI summary
Vents and micro-structures of rubber molds may become clogged with rubber that is difficult to remove. These vents and micro-structures can be cleaned of rubber, even if heat aged, by subjecting the mold to high temperatures in the presence of a solvent to devulcanize any rubber present. If the rubber used with the mold being cleaned includes carbon black, a solvent may be used to dissolve the devulcanized polymer, leaving the carbon black which can be removed by water jets or other cleaning means.