RUBBER PEOCESSING AND EQUIPMENT
橡胶加工与设备
by Walter A.Raperski
Farrel Company
An EMHART Unit
Ansonia,Connecticut 06410
Trends in Rubber Processing
橡胶加工趋势
As the many industries of the rubber processing world enter the last two decades of the twentieth century, they are increasingly aware of many serious influences. even impediments, to their goals of progress and growth. The most serious of these are compound quality influence on end product performance, availability of raw materials and energy. Many other factors such as ecology, environment and safety, as well as the more traditonal concerns of manufacturing businesses, also demand attention. It is quite possible that the final resolutions and satisfactory accommodations of these many influencing factors will result in the most significant advances in processing rubber compounds that have ever been made.
随着橡胶加工业进入了20世纪的最后20年，人们正日益意识到许多对橡胶加工的重大影响，也包括对他们的发展和增长有很多的不利影响。其中最突出是胶料的质量对最终产品性能的影响，即原材料的有效性和功能。其它因素如生态问题、环境和安全以及许多传统的加工观念同样需要给予重视。这些影响因素的最终的结论和可接受的调和将很有可能会导致在橡胶胶料加工方面的重大进展，而这些也已在发生。
The automotive industry is still the single most influential factor for technical progress in the rubber industry. This influence applies equally to tire manufacturers as well as to mechanical or technical goods manufacturers. The radial tire is goods example of a very influential factor affecting the direction of the rubber processing industries. In rubber mechanical goods, increased demands in terms of quantity and performance have been placed on rubber parts used throughout the automobile. The non-automotive world also has an increasing appetite for rubber compounds, particularly those that can be injection molded utilizing new polymers that are now available. Competition from plastics have placed additional pressure on the need for developing different and better rubber compounds.
汽车工业仍然是对橡胶工业的技术进步最重要的影响因素。这些也同样影响到轮胎制造以及机械或工业制品的制造商。子午线轮胎就是一个各种因素影响橡胶加工方向的很好例子。在机械橡胶制品方面，遍及汽车行业的橡胶制品的应用已对质量和性能的要求有所提高。非汽车行业对橡胶胶料的要求也呈增加趋势，尤其是利用当前可获得的新型聚合物进行注射法生产的企业。来自塑料行业的竞争所带来的更多的压力对开发不同的和更好的橡胶胶料提出了更多的需求。
Such new developments in the end product use of rubber compounds reflect demands upon the entire compound processing system, including not only the final forming of parts such as tires but also on the initial preparation of the rubber compounds and the processing of the same compounds up to the final steps in the product manufacturing cycle. These efforts tto satisfy such demands on rubber compounds are in two specific major directions which are improved compound uniformity and more complete automatic rubber compound processing.
这些新的用于的橡胶制品的橡胶胶料的发展影响了橡胶胶料的加工系统，这不仅包括产品的最终成型，如轮胎，同样也影响到橡胶胶料初始准备，胶料的加工，以及到最终产品的整个循环。为满足橡胶工业对胶料的这些要求所作的努力主要在两个特定的方面，即改善混炼胶的均匀性和更完善的汽车用橡胶制品胶料的加工。
Improved compound uniformity is being achieved through more exacting analysis of each machine capability to effect and produce uniformity ang coupled with more precise and automatic control of these machine operating paramenters. Furthermore, the entire system for the rubber compound processing line is also being analyzed with respect to the overall effect and contribution to compound uniformity. Such analvtical work starts with the very basic and theoretical definition of mixing and extends through the mathematical modeing of rubber compound processing machinery. It is not possible to adequately evaluate the capability of any machine to contribute to the rubber compounding process without defining in workable terms what rubber mixing is.
通过对影响和产生胶料均匀性的每一台设备能力的更准确的分析，配备对这些设备的操作参数更精确和自动化的控制来改善胶料均匀性。进一步讲，分析混炼胶加工的整个加工生产线得出其对胶料均一性贡献的所有影响。这些分析工作从最基础和理论性的混炼定义开始，通过胶料加工机械的机械模型来进行延伸。在没有关于限定的橡胶混炼可使用条件下，充分地评估任何机械对橡胶胶料加工的贡献这是不可能的。
Significant work has been done with respect to the statistical definitions of mixing, taking into proper consideration the very particular properties of the components being combined. Thus, it is possible to look at the rheological characteristics of molecular weight and understand the significance of these characteristics with tespect to the elasticity and viscosity criteria of the end product itself. Relationships can be established to these values and to the effect of various levels of shear stress and shear strength (under specific temperature conditions) that can be imposed by the specific design of certain processing machinery.
考虑了所加入的组分的非常特殊的性能，关于混炼的统计学解释的重要的工作已经着手进行。因此，观察分子量的流变性能以及理解这些特性对最终产品本身的弹性和粘性标准是可行的。通过专门设计的某些加工机械可以建立这些特性值对剪切应力和撕裂强度（在特定的温度条件下）影响的关系。
Steps in the Rubber Compounding Process
橡胶混炼步骤
1. Breakdown 塑炼
The overall objective in breaking down elastomers before compounding is to soften them, reducing their elasticity and viscosity to a point where other ingredients may be added without difficulty. Furthermore, such changes in the rubber’s basic properties will provide for more efficient processing during subsequent steps.
在混炼之前对弹性体塑炼的唯一目的是将其软化，降低弹性和粘性，达到使其它配合剂毫无困难加入的标准。进一步讲，在这些橡胶基本性能方面的变化使得在后续的加工过程中有更高效率。
Natural rubber and synthetic copolymer elastomers respond somewhat differently during this processing step, but the general procedure and the equipment used is similar with both materials.
在这个加工过程中，天然橡胶与合成的共聚弹性体稍微有不同，但这两种材料的基本工艺和设备是一样的。
A.Natural Rubber天然橡胶
In working with natural rubber it is considered good practice to blend different lots to assure uniform characteristics and physical properties in the resulting compounds. This can be accomplished by making sure that the various pieces from many different cut-up rubber bales are systematically distributed over the number of batches being weighed out. A further extension of this process is to cut the rubber bales into even smaller pieces which can be preblended with the proper equipment .Further advantages can be realized in the conveying and weighing of these smaller pieces of natural rubber and even in the breakdown process itself.
在使用天然橡胶时，混合不同的批次来保证混炼胶的均一特性和物理机械性能是一种很好的方法。可以通过确保来自许多所切开的橡胶包的胶块系统地分布在所称量出的橡胶中来达到均一性。此外，在输送和称量这些胶块时以及在将其进行塑炼时会有更多的便利之处。
Open roll mills can be used for natural rubber breakdown, although this is quite rare in large productions operations today.
开炼机可以进行塑炼，虽然这在今天的大批量生产是相当少见的了。
Almost all natural rubber is broken down in one form or another of internal mixer such as the BANBURY mixer. Two approaches may be used, depending on the processing philosophy and cost analysis of the particular compounder. One method is to break down only that amount of rubber that is proportionally correct for a full batch size of masterbatch compound, leaving room for all of the other ingredients. This particular step would be performed first, with only the rubber being added, and for variable speed machines could be at a different speed than the subsequent compounding steps. The senond more widely used approach is to load the mixer with the full batch size prior to the masterbatching operation.
几乎所有的天然橡胶都以在密炼胶，如本伯利密炼机中进行塑炼。根据加工体系和特殊密炼机的的成本分析，有两种方法可以使用。一种方法是仅塑炼一个母炼胶中所需配合的天然胶的重量，而后再加入所有的其它配合剂。这个步骤可以首先完成，只加入天然橡胶，对于变速密炼机则可以使用与后续混炼不同的速度。第二种广泛使用的方法是在混炼母炼胶之前按照密炼机的容量全部加入天然橡胶进行塑炼。
The breakdown of natural rubber is actually the altering of the visco-elastic properties of the polymer by either extending or disentangling the polymer molecular chains by high shear strain, or by breaking these chains completely with high shear stresses. High levels of total strain are usually obtained by slower turning machinery running for longer periods of time, while high shear stresses are usually obtained at higher rotating speeds; therefore, shorter running times. However, it is possible to obtain maximum productivity and the desired level of breakdown in an internal batch mixer by giving thoughtful consideration to the design of the mixer that has best heat transfer and temperature control characteristics suited for the particular levels of breakdown required.
天然橡胶的塑炼实际上是聚合物粘弹性的改变，即用高剪切应变使得聚合物分子伸展或解脱，或者用高剪切应力完全切断这些分子链。通过长时间降低转动机械的转速可获得整个的高应变；而通常较高的转速则可获得较高的应力，因此可缩短设备的运行时间。然而，在密炼机中获得最高的生产效率和所希望的塑炼效果是可能的，即通过多方面的考虑所设计的具有最好的热传导和温度控制的密炼机来达到各种要求的塑炼效果。
Care must be exercised that the very unique properties of the elastomer are not needlessly downgraded in the quest of effortless compounding and further processing so that these valuable properties are no longer as effectively available in the final product as they could be.
必须考虑到，不需要过分的降低弹性体非常独特的性能来达到方便的配合和进一步的加工，因为这些最终产品所需要的有价值的性能在最终时不可能再有效获得。
One other thing to keep in mind when breaking down nathral rubber and subesquently in the further steps of processing the compound, is that there will be a certain degree of elastic recovery if the material is allowed to cool down and stabilize at basically ambient temperatures. Therefore, values of viscosity measured right after processing will not necessarily reflect starting point values for the next step in the process.
在塑炼天然橡胶及后续的进一步混炼时，另外一个必须要考虑的是如果将材料进行冷却并在室温下存放后，会产生一定程度的弹性恢复。因此，如果在加工后立即进行粘度值的测量，其值不一定与下一步加工时开始的粘度值完全相符。
B.Synthetic Rubber 合成橡胶
Synthetic rubber are produced in a very large number of different types. Many of these are “tailor-made” for specific applications. One of the specifications for tailoring the synthetic polymers is the viscosity. Therefore, many synthetic rubbers do not require a separate and distinct breakdown step. Since the object of synthetic rubber breakdown is essentially the same as for natural rubber, this can usually be accomplished by the addition of the rubber compound to the mixer first, usually followed almost immediately by the addition of the other materials.
有大量的不同品种的合成橡胶在生产。其中有许多是为特殊的用途而“特制的”。特制的合成聚合物技术要求之一是门尼粘度。因此，合成橡胶不需要塑化和严格的塑炼过程。由于合成橡胶塑炼的目的基本上与天然橡胶是相同的，因此通常可以通过在密炼机中首先加入合成橡胶，而且几乎是随即再加入其它的全部填加材料来完成。
Some of the synthetic rubber that, by intention and design, more closely approximate the elastomeric properties of natural rubber may require a certain degree of “softening” in order to improve compounding and processing.
根据目的和设计，一些相当接近于天然橡胶的弹性的合成橡胶可能需要一定程度的“软化”，以改善其混炼和加工。
Since these synthetic elastomers are more precisely controlled, with respect to various characteristics, so must the operating techniques and procedures used in the initial processing. With rare exception, the processing of synthetic polymer starts in the internal mixer. Various operating conditions such as rotor speed, ram pressure, and, most significantly, mixer temperature conditions, must be selected so as to provide the best results. Although these synthetic polymers can tolerate higher temperature levels than natural rubber, it is usually not necessary to approach these levels for effective breakdown prior to compounding. Higher mixer speeds can be used for synthetic rubbers whether the breakdown is a separate step by itself, or just part of the masterbatching operation. Consideration must be given to the possibility of excessive polymer temperatures being reached, at which time crosslinking or “gelling” of the polymer will take place. Usually, the best compounding procedures can avoid this. Chemicals can also be added to the compound to help prevent this situation. Proper mixer design with respect to effective heat transfer and metal temperature control can provide for the most uniform temperature distribution within the batch and the elimination of localized polymer hot spots that can result in this crosslinking phenomenon.
由于这些合成橡胶是根据其各种特性精确控制的，许多的操作技术和工艺已应用于初始的加工。除极少数的品种外，合成橡胶的加工都在密炼机中进行。各种操作条件，如转子速度、上顶栓压力以及更值得注意的密炼机的温度条件都必须认真选择，以达到最佳结果。虽然这些合成橡胶比天然橡胶可以承受更高的温度，通常情况下没有必要达到这种温度来完成混炼前的有效塑化。合成橡胶可以使用较高的密炼速度，无论塑炼只是自身的塑化，还是做为母炼胶混炼的一部分。必须考虑到聚合物可能会达到超高的温度，在这个温度下，聚合物会产生交联或“凝胶”。通常情况下，最好的混炼工艺可以避免这样情况的发生。加入配合剂也有助于来防止这种情况。考虑了有效的热传导金属温度控制的密炼机设计可以提供在批次内部最均匀的温度分布，聚合物的局部过热点会导致这种交联现象的产生。
With both natural rubber and synthetics, the breakdown cycles can be shortened and more satisfactorily performed by the use of chemical plasticizers. Care must be taken to assure that addition of such chemicals, which alter the polymer structure, will not result in the modification of the elastomeric properties of the polymer below levels which will be desired in the end product.
对于天然橡胶与合成橡胶的塑炼，通过使用化学塑解剂可以缩短塑炼周期，且可以达到更好的效果。必须注意的是所使用的这些改变聚合物结构的化学助剂不会导致聚合物的弹性低于最终产品的希望水平。
II.Masterbatching 母炼
Masterbatching pertains to the incorporation, into the rubber of certain ingredients that will enhance performance of the end product that the rubber compound is to be used. A major element of masterbatch is carbon black. Other chemicals and pigments may be added at this point to enhance final performance and/or to improve handling and process ability in the intermediate steps. Many times oils are added to the masterbatch as a processing aid.
母炼属于将某些配合剂加入橡胶中，这些助剂将提高成品所使用的胶料的性能。母炼胶中的一个主要的成分是炭黑。其它的配合剂和填充剂会在此时加入来增强成品性能和/或改善中间过程的操作和加工能力。很多情况下在母炼胶中加入油料作为加工助剂。
The ultimate objective in masterbatching is the incorporation of all these ingredients and in particular, the best dispersion of the carbon black in the rubber. Dispersion is accomplished by not only those actions that soften and prepare the polymer(reference breakdown, above)to accept these pigments, but to subject the pigments themselves, and particularly any carbon black, to high shear forces that break apart the carbon black agglomerates, providing for more effective dispersion. The level of dispersion of the various ingredients into the rubber affects the final viscosity of the compound. Therefore, the twin objectives of masterbatching are maximum carbon black dispersion and proper final viscosity. These objectives must be accomplished without exceeding temperature limits, which would result in polymer degradation, as mentioned above.
制成母炼胶的最终目的是将这些所有配合剂混入到橡胶中，尤其是炭黑在橡胶中要有最好的分散。分散不仅靠软化和橡胶的准备（上述的塑炼）加入填充剂来完成，同时也受填充剂本身的影响。尤其是无论何种炭黑，高的剪切力会打散炭黑的聚集体，以达到有效的分散。各种配合剂在橡胶中的分散度会影响胶料的最终粘度。因此，母炼的两个目标准是最高的炭黑分散度和适当的胶料粘度。这些目标必须在没有超过温度限制的前提下达到，否则会导致聚合物的降解，如上所述。
Batch type internal mixers are universally used for masterbatching. Rubber compounds can be masterbatched on open mills, but the process is uncomfortable for the mill operator, due to the nature of the various components that must be added. Very good dispersions can be obtained on open mill processing of rubber compounds. Satisfactory distribution of all the ingredients is a function of the mill operator and the diligence shown in following procedres. The best results will always be at the expense of productivity.
普遍使用分批混炼的密炼机制造母炼胶。胶料可以在开炼机上制造母炼胶，此过程对开炼机的操作者来说是很不舒服的，因为必须要加入各种配合剂。在开炼机上胶料的混炼可以达到很好的分散效果。所有配合剂的令人满意的分布是与开炼机操作者和下面的工艺相关的。但最好的结果总是伴随着生产费用的提高。
Mixing procedures in batch type machines are determined by the compound and the nature of the various ingredients to be combined. Mixer designs can produce optimum result when knowledge of what must be done is matched with machine designs that are compatible to the mixing process.
分批混炼密炼机的混炼工艺是由生胶和将要加入的各种配合剂的特性所决定的。当需要做什么的理论与混炼过程一致的机械设计相结合时，密炼机的设计可产生最优化的结果。
Other machinery can be used to aid in the masterbatching process, Certain types of screw extruders can be designed so as to improve pigment dispersion and reduce compound viscosity. This in turn allows for higher productivity of the total compounding line inasmuch as the batch mixer before the extruder can be run on shorter cycles (i.e., higher productivity) although with less than acceptable quality, if measured alone. The mixing extruder beneath the Banbury taking the batch, will complete the mixing to satisfactory levels. However, the matching of such a team of machines must reflect a high level of knowing what must be done to the compounds, how this can be accomplished, and in which way the machinery must be designed to fulfill its particular portion of the compounding function.
其它的一些机械可用来协助母炼胶的制造。特定类型的螺杆挤出机可用来改善填充剂的分散，并降低胶料的粘度。由于在挤出之前要在分批密炼机中进行短时间混炼，用这种方式可使得整个混炼生产线提高生产效率，尽管这种方式的质量稍差。在密炼机下面接收混炼胶的混炼挤出机，将会使混炼胶达到令人满意的水平。然而，这样一组设备的匹配必须要有高水平的思路，即必须对胶料进行怎样的处理，这样的处理如果来完成，设备设计成何种模式才能在混炼功能中实现其独特的作用等。
III. Remill 回炼
Depending on the nature of the materials to be mixed and the type of compounds to be produced with respect to the type of end products to be made, it may not be possible to combine the various ingredients in the masterbatching stage so as proper level of dispersion and viscosity in one step. It may be that the maximum temperature limits of the compound are reached before totally satisfactory mixing is accomplished. Or it may well be that the philosophy of an economics of operation for a particular compounding facility is such that very high speed mixing equipment is used, producing the temperature results mentioned above, but still justified by the higher overall productivity obtained. In any case, the masterbatch may have to be recycled in order to obtain the proper levels of dispersion and viscosity. In the case, the masterbatch compound, either in slab or pellet form, is fed back into the mixing machinery, mixed to the maximum allowable temperature ,discharged again and processed through the next piece of equipment.
根据将要混炼的材料的性质和将要生产的混炼胶的类型，同时考虑到将要生产的产品的类型，有可能不能将所有要加入的材料在母炼阶段加入，因此在第一段只能达到一定的分散和粘度。有可能在达到完全满意的混炼效果时胶料的温度将达到最高极限。对于一个特定的混炼胶工厂，按照作业经济性的原则而使用高速密设备，尽管产生上述的高温，但从获得的较高的整体生产效率来 看仍然是正确的。在任何情况下，母炼胶都必须要重新回炼来获得适当的分散度和粘度。通常情况下，母炼胶以胶片或造粒形式加入到密炼机，炼到可允许的最高温度，然后排胶，通过后续的设备进行下一步的加工。
Some of the time no other ingredients will added. In other cases, depending on the nature of the compound, some additional pigmentation or additives may be put in at this time. Some rubber compounds in some processes, require more than one remilling cycle.
有时不需要再加入任何配合剂。但也有时根据胶料的特性，一些助剂或填加剂需要在此时加入。对于有些加工工艺的胶料需要不止一次的回炼。
IV.Finish Mixing 终炼
The incorporation of curatives, or crosslinking agents, and other chemicals that may accelerate or retard this particular chemical reaction, are usually added in a separate step to the masterbatch compound. Theoretically, the addition of such chemicals at this point to a particular masterbatch ,could result in different types of final rubber compounds, with different physical properties by the addition of different amounts and different types of these chemicals to basically the same masterbatch. In normal rubber compound production, this is usually not the case, as each masterbatch is tailor-made for a particular finished mix compound.
可以加速或迟缓这种特殊化学反应的硫化剂或交联剂及其它助剂，一般是在母炼胶的一个单独阶段加入。理论上讲，在这时在专用的母炼胶中加入配合剂会产生不同的终炼胶。在基础的母炼胶中加入不同的量或不同类型的配合剂会有不同的物理机械性能。在通常的混炼胶生产中这种情况是不常见的，一般一个母炼胶专用于特定的终炼胶。
The incorporation and dispersion of these additives into the masterbatch is not a difficult task for batch mixers, or continuous mixers for that matter. The primary concern is the most efficient and uniform distribution of these additives within the batch so as to result in the most uniform cure characteristics, avoiding〝scorching〞.
对于分批混炼或连续混炼，这些配合剂的混入和分散是不困难的。 主要的问题是这些配合剂最有效和均匀的分散而产生的最均匀的硫化性能，且避免“焦烧”。
Finish mixing can be accomplished on wills, and is certainly a more predominant method of mixing in this phase of processing than in masterbatching. Finish mixing on mills can be accomplished later in the process or as the next step directly from the batch mixing of the masterbatch. The masterbatch compound is dropped from the internal mixer on to a mill where the finish mixing can take place. The proper amount of curatives and curatives and other chemicals will be distributed on to the rubber and then the operator must pay attention to their proper dispersion.
最终混炼可以按照意愿来完成，而且在这个加工阶段的影响的确比在母炼胶阶段要重要的多。终炼可以在下一工序的开炼机上完成，或直接在分批混炼的母炼胶中加入。在终炼时，母炼胶从密炼机中排到开炼机上。适量的硫化剂和其它助剂会分散在橡胶中，操作者必须要注意的是它们的完全的分散。
Finish mixing can also be accomplished in specially designed screw extruders. However, such machines will usually not have as wide a range of operating capabilities as more standard extruders.
终炼也可以用专门设计的螺杆挤出机完成。然而这种设计与标准的挤出机相比不具备更广泛的作业能力。
The principal objective of obtaining maximum distribution of the finish mix ingredients must be accomplished within specific batch of the compound. Therefore, these mixing machines will usually run slower. However, since maximum batch temperatures rarely are supposed to exceed 120℃,mixing times will be short .In large rubber processing facilities, certain mixers are assigned specific masterbatching tasks while others only perform finish mixing operations. Consequently, their operating speeds may be different. In other plants, one machine may serve both functions and, therefore, must be equipped with multiple speeds or variable speed. In either case, the operations for the mixers will be different from masterbatch to finish mix. One of the most significant differences will be with respect to temperature levels of the mixing equipment as well as the heat transfer capabilities of the designs in order to maintain specific temperature levels that will enhance either masterbatching and/or finish mixing(including relmill, if necessary).
终炼时加入的配合剂在特定的分批混炼胶内必须获得最大的分散这个目的必须达到。因此，这些混炼设备一般都以较低转速运行。然而由于胶料的温度一般设定不能超过120℃，这就使得混炼时间很短。在大型的混炼胶生产工厂，特定的密炼机指定为专门混炼母炼胶，而其它的专门混炼终炼胶，因此它们的操作速度可以是不同的。在另外一些工厂，一台密炼机要完成母炼和终炼，因此必须具备多速或变速的功能。在这种情况下，密炼机的母炼和终炼操作必须有所不同。其中一个最明显的不同是要考虑混炼设备的温度水平以及设计图纸的热传导能力，目的是保证为强化母炼和/或终炼（如果有必要，也包括回炼）而达到的特定的温度水平。
V. The Mill Room 炼胶车间
The Mill Room refers to and encompasses all the machinery and systems dedicated to producing a rubber compound ready to go into its final form in the end product. Although the mill room contains a great deal of equipment with respect to processing the rubber compound, just as much attention is paid to the raw material portion of such a facility.
炼胶车间涉及并包括所有用于生产胶料的机械和装置，这些机械和装置能够完成生产橡胶产品所需的胶料的形式。虽然炼胶车间有大量的加工胶料的设备，还是应当注意所用原材料的放置位置。
This starts with the receipt and storage of all the raw materials to be combined into rubber compounds. Storage of these materials should also include the qualitative evaluation of the same with respect to desired specifications. Many compounding problems can be solved right here.
这涉及到配方和生产胶料所需的全部原材料的库存。这些原材料的库存应当考虑到所要求的技术要求的定性的评估。许多胶胶问题正是在这里可以得到解决。
Preparation of the material for mixing is the next step whether in small shops or large automated factories. The materials to be used are called for in accordance with the compound formula and in quantities reflecting the amount of compound to be produced to be produced.
无论在小型工厂还是在大型的自动化工厂，混炼所用的原材料的准备就是下一步要考虑的问题。库存待用的材料应当与混炼胶的配方一致，其数量则反映出所要将要生产的混炼胶的量。
In very small facilities, one man may be responsible for the preparing and weighing out of all of the ingredients for a particular compound. These ingredients, with the exception of liquids, may be loaded on a conveyor belt (charging conveyor ) in sequential order that will in turn discharge them into the Banbury mixer. Oils may be held in buckets or pails, or pumped into the mixing chamber directly. Loaying of the these materials may be controlled by the mixer operator. In very small operations, the mixer operator may also weigh out all the ingredients.
在很小的工厂，可能由一个人负责某指定胶料的准备与称量。除液体配合剂之外，这些配合剂可能以一定的顺序装在输送带（加料输送带）上，再按顺序将其加入到密炼机中。油可以装在桶中，或用油泵直接打入密炼机中。可以由密炼机的操作者将加入这些材料投入到密炼机中。在更小的工厂，也可以由密炼机的操作工负责称量这些配合剂。
In larger more modern facilities, all material preparation, metering, or weighing, and loading into the mixer, is automatic or semiautomatic. Material such as carbon black and oils are stored in bulk as well as other ingredients. Rubber bales may be precut into predetermined sizes, or even granulated or pelletized. The mixer control system will be programmed to produce a certain number of batches of a particular formula. Once this information is available in the control system, the proper ingredients will be brought forward, accurately weighed out, and discharge in proper sequence into the mixing machine. Operating conditions such as rotor speed and mixer temperatures will be automatically set. Ingredients will be properly loaded in the proper sequence and batch temperaure will be monitored, discharge of the betch occurring at the proper temperatur level. Certain conditions may be monitored during mixing, such as power consumption ,temperature of the batch, and mixing time. All of this information and more may be automatically recorded.
在大型的现代化工厂，所有的原材料准备、计量或称量、投入密炼机，都是自动或半自动完成。如炭黑和油料，以及其它原材料都以散装贮存。橡胶包被预先切割成所需要的尺寸，或进行造粒。可以对密炼机的控制系统编程进行混炼指定的某一配方的车次数量。一旦控制系统获得这些信息，将会取出所要求的配合剂，并准确称量，然后按规定顺序加入到密炼机中。操作条件如转子速度和混炼温度等会被自动设定。配合剂按适当的顺序准确地加入，每批胶料的温度会被监控，且会在适当的温度水平下进行排胶。在混炼过程中，某些条件会被监控，如功率消耗、胶料温度和混炼时间。所有这些或更多的信息会被记录下来。
Semi-automatic operation may include any variation on the theme above with certain elements in the manual mode. The rubber component , may be weighed out by hand. Or certain minor ingredients may be weighed out by hand and discharge into mixer by hand. Figure I shows a totally automated mixer, completely surrounded by weighing and feeding equipment, operated by an automatic control system.
半自动操作可能会将以上的任何项目变为手动操作。对于橡胶，可能为手工称量。也许某些辅助配合剂会手工称量，或手工加入到密炼机中。图1显示了全自动混炼，所环绕的全部是称量和加料设备，由自动控制系统操作。
The same type of control and monitoring may extend to other operations, such as batch-off mills with automatic take-off devices, pelletizing or slabbing extruders, and various types of conveyors and material handling equipment after that point. Once again, the handling of the rubber compound through these steps may be completely automated or partially automated or completely manual. Rubber compound may be transported and stored in many different ways and forms. However, the most important aspect of all of this material handing is to be sure of proper identification of the compound. This is necessary not only to insure that the proper compound ends up in the finished product, but also to provide for the most rapid and effective retrieval of certain batches that may be considered below quality(after analysis).
同样的控制和监控可以扩展到其它的操作，如带有自动接取装置，造粒或出片装置的压片机，以及在本工序的各种输送、材料处理设备。也就是说，通过这些工序时可以对胶料进行全自动、半自动或全手动方式处理。胶料可以采用多种不同的形式或方式进行运输和贮存。然而，所有的这种材料处理最重要的方面是要保证胶料的同一性。这不仅对于确保成品所使用的适当的胶料是必须的，而且对某些明显低于标准的批次的也提供了最快速和有效的修炼方式。
VI.Mixing 密炼
Mixing is the operation required to obtain a thorough and uniform dispersion in the rubber of ingredients called for by the formula. Whether done on the open roll mill or in an internal mixer, or batch mixer/extruder combination, a definite time, temperature, and order of addition procedure should be followed for each batch. These conditions will vary for each formulation. The evaluation of the compound should be made as quickly as possible after the batch has been discharged so as to make any necessary corrections in the operating procedures for the subsequent batches. The mixing equipment must have as much versatility as economically feasible, and be combined with certain design features that allow for absolute control and complete repeatability with respect to operating conditions. The desired end product property must be related to the characteristics of the compound to be produced, the knowledge of how this can be accomplished with respect to the different characteristics of the materials to be used and the designed-in capability of the processing machinery to enhance the optimization of these criteria. There is an ideal set of operating conditions for mixing equipment for each particular rubber compound that will produce optimum results in terms of order to determine those conditions. Once determined, practical discipline must be exercised to insure that these conditiond are consistently maintained. Only in this way the cause for faulty results can be readily determined.
密炼是需要获得配合剂（即配方）在橡胶中完全均匀分散的操作。无论是用开炼机或密炼机混炼，还是分批混炼/密炼机挤出机联合混炼，对于每一批次，都必须按照一定时间、温度，和/或一定的加料顺序进行。这些条件对于不同的配方可能是不同的。对胶料的评估必须在排胶后尽快进行，以便于在操作过程中对后续的批次进行必要的修正。密炼设备必须具有此类的多功能性，如经济可行性，以及与某些特定的器具组合，这些器具允许绝对的控制和根据操作条件而实现的完全的再现性。最终产品所要求的的性能与所要生产的混炼胶的性能有绝对的关系，与根据所使用的各种材料的不同性能和所设计的加工设备的能力实现这种性能并对强化这些技术要求的优化的知识也有绝对的关系。对每个特定的胶料都有一个密炼设备的理想操作条件设置，根据对这些条件的测定，则会得到一个优化的结果。一旦这些条件被确定下来，则在实际生产中必须确保这些所确定操作条件得以持续执行。只有在这种方式下，造成不完善的结果的原因才能很容易地被找到。
VII. Extruding 挤出
The operation of extruding, with screw type extruders, is widely used in the rubber industry, both as an valcanization directly after the compounding process is completed.
使用螺杆型挤出机的挤出操作广泛应用于橡胶工业中，这种方式可以在混炼工序结束后直接进行硫化。
In the masterbatching , remilling, and finish mixing operation, the batch from the batch type mixer would usually go directly into an extuder. This screw device will convey the material through a die that will provide for making the rubber compound into pellet shapes, or through a pair of rolls which will make the rubber into a slab or sheet form. The principle objective of the extruder is to render the material into a more manageable form in terms of transport and storage, while at the same time providing for cooling down of the material.
在母炼、回炼和终炼操作中，每一个分批混炼的胶料批次可以直接加入到挤出机中。这种螺杆设备将胶料输送至口型，这个口型可以将胶料进行造粒，或输送到双辊筒上制成胶片。挤出机的主要作用是将胶料制成便于管理的形式以便于输送和贮存，与此同时将胶料进行冷却。
These extruders are designed with respect to diameter length, speed of screw, and power input so as to be able to handle the output of the mixing machinery and to provide sufficient pressure for whatever forming device is mounted at the discharge end of the extruder. The design will also provide for minimum temperature rise, or even temperature reduction of the compound while going through the extruder.
这些挤出机在设计时专门考虑了螺杆的长径比、转速以及输入功率，这样便于控制机械的输出，且为无论以何种形式的安装在挤出机排料端的口型提供足够的压力。此设计具有最低的升温，或在胶料通过挤出机时进行降温。
As mentioned earlier, other special design extruders can be installed beneath the batch mixers, to provide higher levels of work to the compound as it is being processed to improve dispersion, reduce viscosity, and improve compound uniformity. More than one type of design can accomplish these objective within certain limits. Such machines usually increase the temperature of the compound, while processing it ,and require larger drive motors and subsequently more sturdy constructions for pelletizing or slabbing as on the simpler extruders. In some cases, this machinery will have essentially an open ended screw, discharging slugs of rubber.
如上所述，一些专门设计的挤出机可以安装在密炼机的下方，以提供对胶料更高水平的加工工作，如改善分散，降低粘度，以及改善胶料的均匀性。不止一种设计可以在一定的限制内完成这些工作。这种设备通常会升高胶料的温度，在造粒和压片时比普通挤出机需要较大功率的电机和持续坚固的结构。在某些情况下，这种机械必须具备开口螺杆端，以排除橡胶的烟雾。
Extruders are usually equipped with variable speed drives in order to match production throughputs with the output from the batch mixer. Some of the machines are equipped with single speed motors that can be disconnected from driving the screw by means of a clutch.
为了与分批密炼的产量相匹配，挤出机通常装配变速电机。有些机器装备的是可用离合器将其与螺杆分离的单速电机。
With the exception of the specially designed mixing extruders, relatively little variable control can be accomplished with an extruder underneath a batch mixer with the exception of variable screw speed and machine temperature conditions.
除专门设计的混炼挤出机之外，使用安装在下分批密炼机下方，具有相对低的可变控制的挤出机也可完成这种作业，这种挤出机不具备可变螺杆速度和温度控制。
Extruders can also be used to warm up material for calender feed. That is, strips or pellets of rubber compounds from earlier operations can be fed to extruders that will uniformly warm up the compound extruding it in slug or rope fashion to be fed into the nip of a rubber calender.
挤出机还可为压延机热炼胶料。也就是说，将在前工序所制胶条或胶粒供给挤出机，挤出机将胶料均匀加热，并以胶片或胶条形式供给到橡胶压延机的辊距中。
Extruders can also be used to provide shapes of rubber compounds for subsequent vulcanization into final product parts, or for fabrication along with other components into more complex parts, such as tires. Extruders can be designed to take cold rubber compound in the from of rubber strip, slab, or pellets, and warm it up uniformly and extrude the given shape. In certain cases, the precision demanded of the extruded part may mean that the rubber is warmed up first on a mill or on a primary warm-up extruder and then fed to the shaping extruder. Many of these extruded shapes are subsequently and continuously vulcanized right after the extruder so as to produce a finished part, such as rubber hose. Some of these extruded shaps may require a level of purity in the rubber compound with respect to foreign particle or compound agglomerates so as to require straining of the compound. This is accomplished by the installation of wire screens of specific mesh sizes in the discharge end of the extruder. Usually, this is accomplished in the extruder operating underneath the mixing machine.
挤出机同样也可供给一定的形状进行连续硫化而制成成品，或与其它组件一起制成多部件复合的成品，如轮胎。挤出机也可设计成使用冷胶条、胶片或胶粒喂料，将其均匀加热，并挤出成所需要的形状。在某种情况下，挤出制品精密度的要求就意味着橡胶胶料首先将胶料在开炼机上或初级热炼挤出机上进行热炼，然后供给成型挤出机。许多这种挤出半成品在挤出后随即进行连续硫化制成成品，如胶管。一些这种成型件要求胶料有一定的纯度，如杂质颗粒或凝胶，因此需要对胶料进行过滤。这可以通过在挤出机的排料口安装一定目数的金属网来实现。通常，这种操作安排在密炼机下面的挤出机来完成。
VIII.Calendering 压延
The rubber calendar, originally consisting of three iron rolls, is now available in a number of types and designs for specialized applications. The machine is essentially a device for forming rubber sheeting of various lengths and thicknesses, which are used in subsequent building operations. It is also used extensively for frictioning or skim coating fabrics. Cord and are coated with rubber for making plies used in the construction of tires and conveyor belts. Temperature control of the calender rolls is important and is accomplished by adding a circulating system for a heat transfer medium with cored or drilled rolls for effective heat transfer. The drilled rolls provide for a far more superior mode of temperature control when combined with an automatically controllable temperature system. Roll speeds are interrelated by connecting gear ratio and with a single motor drive. More advanced calenders have individual variable speed motor for each roll. Consequently, it is possible to obtain different friction ratios between each pair of interacting rolls.
以前只有三个辊筒的压延机，而现在已有许多种不同设计的类型用于各种专业产品。该设备是制造不同厚度和长度胶片的基本设备，这些胶片应用于后工序的成型操作。压延机也可用于纤维的擦胶和刮胶。纤维骨架附胶后被用于轮胎和输送带的制造。压延机辊筒的温度控制是很重要的，可以通过用芯型或辊筒钻孔法的附加循环系统传递介质进行有效的热传递。辊筒的速度与所联接的齿轮的速比和单驱动电机有关。比较先进的压延机的每个辊筒都采用单独的变速电机。因此，在各个相邻的辊筒间都可获得不同的辊筒速比。
The more sophisticated rubber calenders have devices designed into them for bending the rolls and altering the relative position of rolls so as to insure a more uniform gap between rolls, with material between them, so as to produce the most uniform thickness of material. These calenders may be coupled to extremely sophisticated thickness measuring equipment after the calender which in turn provides for automatic adjustment of roll position and bending so as to produce even more accurate gauges.
专业的橡胶压延机都专门设计有弯曲辊筒，用改变辊筒间的相对位置来保证有较均匀的辊距，在辊筒间有胶料时，则可以生产出最均匀的胶料厚度。这种压延机可能在压延机后连接高精密的专业厚度测量设备，依次对辊筒的位置和弯曲提供自动的调整，得到更准确的辊距。
A most thorough knowledge of the relationship between the friction ratio of the various rolls, temperatures, speeds, and roll position is necessary in order to obtain the optimum performance from a rubber calender. Knowledge of the rubber compounds is just as important so that the operating conditions of the calender can be set to best suit the particular compound being processed. Such knowledge is quite critical in order to be able to know whether a particular problem is the result of calender operating conditions or improper compounding of the rubber in earlier stages.
各种辊筒的速比、温度、转速和辊筒位置之间关系的最准确的知识是必须要掌握的，这样才能获得橡胶压延最适宜的性能。橡胶胶料的知识也同样重要，只有这样压延机的工作条件才能更好地设置，以满足不同胶料的加工。这些知识是相当重要的，只有了解这些知识才能知道一个特定的问题是由于压延机的操作条件的原因还是在前期的胶料不适当的混炼所造成。
Calenders can also be used to produce lengths of rubber compound with particular cross-sectional shapes. This is accomplished by installing special rolls having configurations, grooves, profiles, etc. that will squeeze out the desired shape. This type of forming of rubber compounds is not as popular as the extrusion method.
压延机还可用于生产具有特殊横断面的长胶片。这种胶片可以通过安装具有构形、沟槽、异形断面等的特殊辊筒，压延出所期望的形状。这种胶料的成型方式不如挤出方法的应用广泛。
IX.Quality Control 质量控制
Quality control in rubber compounding has a far wider meaning if maximum uniformity is to be combined with highest productivity. It means far more than looking at the final product or at the various materials during progressive steps in the total process cycle. It means planning the mill room with respect to equipment installation and material flow so as to complement and support the most effective operation of the equipment for maxing of the material for maximum compound uniformity. Storage, preparation, and weighing of the material for every step of the compound process should be organized and designed so as to help uniformity in every way possible. Like materials can be blended during transport to the weighing equipment, and compounds can be blended during transport to storage areas.
橡胶混炼中的质量控制具有相当广泛的含义，即最大的一致性与最高的生产效率的结合。它比着眼于最终产品或在整个工艺循环中每个阶段的各种材料的意义要大的多。它意味着对考虑到设备的安装和材料的流转以便补充和支持用于胶料的混炼设备的最有效的操作，以达到胶料最大的一致性的全面的规划。在胶料加工过程中每一个阶段的材料的贮存、准备、以及称量都需要进行有机的组织和设计，以便于以任何方式达到胶料的一致性。如材料在输送到称量区域时有可能混淆，以及胶料在输送到贮存区域时的混淆等。
Every machine in the compounding process must be analyzed with respect to its basic function and how much more it can contribute to uniformity. Uniformity of the compound must be specified and defined in terms of the minimum tolerance of an acceptable level of measurement. It is not necessary to wait for physical evaluation and defined in terms of the minimum tolerance of an acceptable level of measurement. It is not necessary to wait for physical evaluation and analysis of final compounds. Compound viscosities can be measured from the very first step in the compounding process, and limits on acceptable variations determined. Such measurements can be made within the time span of a normal masterbatching cycle. The same can be done for finish mix compounds. The instrumentation for accomplishing this is readily available. Carbon black dispersion, which requires a longer time for effective evaluation, can be checked on a back-up basis. Relationships between level of carbon black dispersion and compound viscosity the initial establishment and optimization of matchine operating and processing procedures.
对胶料加工过程中的每一台机器必须对其基本功能和如何对胶料提供一致性进行分析。胶料的一致性必须根据测量设备可接受水平的最小的公差确定和定义。这没有必要等待混炼胶的物理性能的评估和分析。胶料的粘度可以在混炼过程的最初阶段进行测定，并限制其所测定的可接收的变化。这种测定可以在母炼胶的混炼周期时间段内进行。同样的测定可用于最终混炼胶。实现这种测定的设备是很容易获得的。需要较长时间有效评估的炭黑分散的测量，可以与备份的数据进行对比。（炭黑的分散度与胶料粘度的关系，初始的建立和设备操作及加工工艺的优化）
More importantly, the best operating procedures and techniques of each machine for every compound must be determined not only with respect to the levels of quality to be obtained at that point, but with respect to the minimum variation in uniformity that can be obtained. There is, for every type of rubber compound processing machinery, a set of operating conditions coupled with proper techniques that will produce the optimum results. Procedures for determining these parameters can be established for each machine so that as each new compound is introduced into the system , these conditions can be found. The time must be taken to do this. Batch size, loading procedures and sequences, material condition and shape, speeds, pressdures, temperatures, time, even machinery size and type are some of the conditions that must be evaluated for each particular compound. All these factors will not only influence quality, but also the uniformity of that quality. It is necessary to evaluate in every way that the minimum variation in quality can be obtained. With complete knowledge of this nature, it is then possible to make better judgments with respect to the overall philosophy of the compounding system to be used. The operation should be the most economical, within the accounting rules to be followed, to accomplish the best uniformity with the maximum productivity.
更重要的，每一台设备对每一种胶料最佳的操作工艺和技术必须得到确定，这不仅要考虑在此条件下所获得的质量水平，也要考虑到所能获得的一致性的最小变差。对于各种胶料加工机械来说，这是操作条件与技术的结合，这种结合将产生最佳结果。决定这些参数的程序可以针对各种设备制定，这样可以建立起各种新的使用这种设备的胶料操作条件。做这些工作肯定要花费时间。每个批次胶料的重量、投料过程和顺序、物料的状态和形状、转子转速、温度、时间，以及设备的容量和类型，这些是对每个特定的胶料都必须进行评估的条件。所有这些条件不仅影响质量，也会影响到这种质量的一致性。对所可获得的质量方面的最小的变差进行评估是必须的。具备这些特性全部的知识，即可对所使用的混炼系统从全面哲学角度进行更好的评判。按照会计学原则，操作必须是以最高的生产效率最经济地完成最好的一致性。
Attention to obtaining maximum uniformity form the very first steps of compound processing cannot be overemphasized. The more exacting discipline, the greater the assurance of the highest quality product, but also the highest levels of consistent productivity. For the rubber compounder not only makes on the quality of his product, and also on the processability of his compounds. One definition for processability is consistency, and consistency is compound uniformity.
不能过分强调从混炼的最初阶段所获得的最大的一致性的关注。规则越严格，就越能保证最高质量的产品，同样也可获得的一致生产率的最高水平。对胶料混炼者来说，不仅要关注于本身所生产的胶料的质量，还要更关注于所生产胶料的过程能力。对过程能力的定义是一致性，而一致性即是胶料的均匀性。
翻译：rubberchem 来源：www.sto.net.cn
