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LINA Machinery Industrial Co.,Ltd

 [Guangdong,China]

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HomeNewsRubber Mixing Technology of Dispersion Kneader about One-stage Mixing Method(1)

Rubber Mixing Technology of Dispersion Kneader about One-stage Mixing Method(1)

2018-11-14

Rubber Mixing Technology of Dispersion Kneader about One-stage Mixing Method(1)

KNEADER

One-stage mixing method refers to a method for preparing a rubber compound by adding all the compounding agents at one time, and is commonly used for preparing those rubber materials which have good scorch performance and contain no or only a small amount of active compounding agent. In order to prevent the temperature of the rubber in the mixing from rising too fast, a low-speed mixing is usually carried out in the dispersion kneader. The method comprises the steps of sequentially adding a compounding agent (including a filler, a working oil, a vulcanizing agent, an accelerator, etc.) to the plasticized raw rubber. The mixing cycle is based on the properties of the compound and the rotor speed. During one-stage mixing, the vulcanizing agent and the accelerator are generally added within about 60 seconds before the end of the mixing, or the vulcanizing agent and the accelerator are added to the open film after the discharging. However, no matter which method is used to add the vulcanizing agent and the accelerator, the temperature of the rubber compound during operation must be controlled below 110 degrees (sulfur and accelerator system) or 120 degrees (DCP vulcanization system) to prevent the rubber from scorching. And to adjust them according to different vulcanization systems. The non-dispersible compounding agent or the smaller amount of the compounding agent can be usually prepared into various masterbatch particles or a paste-like mixture to facilitate the addition and rapid incorporation into the rubber.

One-stage mixing method must strictly abide by the requirements of the process conditions,such as the order of the compounding agent, the mixing temperature, the mixing time, etc., and also pay attention to the pressure of the ram and the position of the ram during the mixing process. Compared with the two-stage or multi-stage mixing method,it saves time between each section,and time of cooling and parking, improving the production efficiency, and reducing the manufacturing cost of the rubber compound. However, the premise is that the performance of the mixer (mainly cooling capacity, speed regulation capability and temperature control capability) is high, and sufficient mixing time is required to achieve the required dispersion degree.
The disadvantage of one-stage mixing method is that the prepared rubber compound has lower plasticity (high Mooney viscosity), and the compounding agent,such as carbon black sometimes is difficult to disperse evenly, which is prone to scorch hazard, and the physical and mechanical properties of the vulcanized rubber are relatively lower.
One-stage mixing method is only suitable for the general purpose (relatively slow vulcanization rate) mixing rubber preparation. It should be used cautiously for large internal mixers. And it should be treated with caution for the preparation of high-fill, high-viscosity or high-hardness compounding compounds. As an improvement, the vulcanizing agent and the accelerator may be added after the rubber discharged from the dispersion kneader is sufficiently cooled on the lower sheet opener.

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