Patent Application
20130161857
The present invention relates in general to the manufacturing of rubber compounds as used in tire manufacturing, and more particularly to mixing apparatus and to processes for the manufacturing of rubber compounds using one or more multiple shaft extruder devices.
Tire manufacturers have progressed to more complicated designs due to an advance in technology as well as a highly competitive industrial environment. In particular, tire designers seek to use multiple rubber compounds in a tire in order to meet customer demands. Using multiple rubber compounds per tire can result in a huge number of required compounds for the various tire lines of the manufacturer. For cost and efficiency reasons, tire manufacturers seek to limit the number of compounds required due to the extensive costs associated with each compound. Each compound typically requires the use of a Banbury mixer, which involves expensive capital expenditures. Furthermore, Banbury mixers have difficulty mixing up tough or very stiff rubber compounds. The compounds generated from the Banbury mixers are typically shipped to the tire building plants, thus requiring additional costs for transportation. The shelf life of the compounds is finite; and if not used within a certain time period, the compounds are scrapped.
Thus an improved method and apparatus is desired which substantially reduces the need for the use of Banbury mixers while providing an apparatus and methodology to provide custom mixing. It should be possible to prepare both non-productive compounds and productive compounds. It is further desired to have a system at the tire building machine which provides for the ability to manufacture customizable compounds. Yet an additional problem to be solved is to generate the compounds continuously at the tire building machine.
US 2011/0146883 A1, US 2011/0146884 A1, US 2011/0146885 A1 and US 2011/0146888 A1 describe various approaches to mixing rubber compounds using an extruder device together with a subsequent gear pump extruder device. The extruder device may be a pin type extruder, a twin screw extruder, a single screw extruder or a ring type extruder. The extruder device is fed with a pre-mixed rubber compound and compounded in the extruder device with additives.
WO 2010/073275 A1 and US 2011/01467800 A1 describe a process and a device for producing an elastomeric compound. The process uses a continuous mixing device such as a multiple screw extruder or a ring extruder together with a batch mixing device. A compound is first mixed in a Banbury, discharged from the Banbury and then fed into the continuous mixing device.
US 2004/0094862 A1, US 2007/0121421 A1 and US 2011/0110178 A1 describe in further detail multiple screw extruder devices (also called multiple shaft extruder devices) as they can be used in the production of elastomeric compounds.
In one aspect, the present invention relates to a process of manufacturing a rubber compound, the process including providing a multiple shaft extruder device; feeding the multiple shaft extruder device with at least one polymer raw material or with a mixture of at least two different polymer raw materials; feeding the multiple shaft extruder device with at least one further raw material; mixing the at least one polymer raw material or the mixture of the different polymer raw materials and the at least one further raw material in the multiple shaft extruder device to prepare a rubber compound; and extruding the rubber compound from the multiple shaft extruder device.
In one aspect of the present invention, the multiple shaft extruder device may be a ring extruder device comprising at least six parallel screws, alternatively at least 8 or at least parallel 12 screws, jointly turning clockwise or counterclockwise in the same or different directions.
In still another example aspect of the present invention, the polymer raw material may be a liquid polymer raw material, a mixture of liquid polymer raw materials, a polymer raw material in the shape of pellets or granules, a mixture of granules or pellets of at least two different polymer raw materials, a polymer raw material in the shape of a powder, a mixture of at least two different polymer raw material powders, a polymer raw material derived from in-situ polymerization, a recycled polymer raw material, a reclaimed polymer raw material, or a depolymerized polymer raw material.
In yet another example aspect of the present invention, the at least one further raw material may be selected from the group consisting of a filler material such as rubber reinforcing carbon black, silica or a platy filler such as clay; a coupling agent; a tackifier resin; a reinforcing resin; a processing aid; an antioxidant; an antiozonant; a stearic acid; an activator; a wax; an oil; a vulcanizing agent such as a sulfur vulcanizing agent; a peptizing agent; and a mixture of one or more of these materials.
In still another example aspect of the present invention, a plurality of different polymer raw materials may be fed into the multiple shaft extruder device.
In yet another example aspect of the present invention, the at least one further raw material may be a further polymer raw material or a mixture of at least two further different polymer raw materials.
In still another example aspect of the present invention, the multiple shaft extruder device may be fed with the at least one polymer raw material or with the mixture of different polymer raw materials and with one or more further raw materials but exclusive of pre-mixed rubber compounds.
In yet another example aspect of the present invention, the multiple shaft extruder device may comprise an outlet at the end of the multiple shaft extruder device and a plurality of inlets along the shaft of the multiple shaft extruder device including a first inlet being the inlet which is most distant from the outlet, wherein the inlets of the plurality of inlets are located at different respective distances with respect to the outlet, and wherein the at least one polymer raw material or the mixture of at least two different polymer raw materials and the at least one further raw material are fed into the multiple shaft extruder device through the plurality of inlets.
In still another example aspect of the present invention, the least one polymer raw material or the mixture of at least two different polymer raw materials may be fed into the multiple shaft extruder device through the first inlet and the further raw materials may be fed into the multiple shaft extruder device through the further inlets of the plurality of inlets. Alternatively, the least one polymer raw material or the mixture of at least two different polymer raw materials and the further raw materials may be fed into the multiple shaft extruder device through a single inlet, i.e., the extruder device may also have only one such inlet.
In yet another example aspect of the present invention, the process may comprise only a single mixing step for preparing the rubber compound or the process may comprise only a single mixing step followed by a gear pump extrusion step for preparing the rubber compound.
In an alternative aspect of the present invention, the mixing in the multiple shaft extruder device may be followed by a further mixing step in any other known mixing device such as a further multiple shaft extruder device, a ring extruder device, a twin-screw extruder device, or a gear pump device.
In still another example aspect of the present invention, the extruded rubber compound is in the form of a pelletized or granulated rubber compound.
In yet another example aspect of the present invention, the process may further comprise feeding the extruded rubber compound into a second multiple shaft extruder device; mixing the extruded rubber compound and at least one further material in the second multiple shaft extruder device to prepare a second rubber compound; and extruding the second rubber compound from the second multiple shaft extruder device.
In still another example aspect of the present invention, the second multiple shaft extruder device may be fed with one or more further materials selected from the group consisting of a filler material such as rubber reinforcing carbon black, silica or a platy filler such as clay; a coupling agent; a tackifier resin; a reinforcing resin; a processing aid; an antioxidant; an antiozonant; a stearic acid; an activator; a wax; an oil; a vulcanizing agent such as a sulfur vulcanizing agent; and a peptizing agent of one or more of these materials.
In yet another example aspect of the present invention, the second multiple shaft extruder device may be fed with one or more further materials selected from the group consisting of polymer raw material, a mixture of at least two different polymer raw materials, or a rubber compound.
In still another example aspect of the present invention, the process may further comprise feeding the extruded second rubber compound into a third multiple shaft extruder device; mixing the extruded second rubber compound and at least one further material in the third multiple shaft extruder device to prepare a third rubber compound; and extruding the third rubber compound from the third multiple shaft extruder device.
In yet another example aspect of the present invention, the third multiple shaft extruder device may be fed with one or more further materials selected from the group consisting of a filler material such as rubber reinforcing carbon black, silica or a platy filler such as clay; a coupling agent; a tackifier resin; a processing aid; an antioxidant; an antiozonant; a stearic acid; an activator; a wax; an oil; a vulcanizing agent such as a sulfur vulcanizing agent; and a peptizing agent of one or more of these materials.
In still another example aspect of the present invention, the third multiple shaft extruder device may be fed with one or more further materials selected from the group consisting of polymer raw material, a mixture of at least two different polymer raw materials, or a rubber compound.
In yet another example aspect of the present invention, a process of manufacturing a rubber compound is disclosed, the process comprising a plurality of multiple shaft extruder devices; feeding at least one of the multiple shaft extruder devices with at least one polymer raw material or a mixture of different polymer raw materials; feeding each of the multiple shaft extruder devices with at least one material; operating the plurality of multiple shaft extruder devices in parallel and mixing in each of the multiple shaft extruder devices a respective rubber compound; and extruding the respective rubber compounds from each of the multiple shaft extruder devices.
This process may further include mixing the respective rubber compounds extruded from each of the multiple shaft extruder devices in a subsequent mixing device such as a subsequent multiple shaft extruder device, or feeding the respective rubber compounds extruded from each of the multiple shaft extruder devices to a common gear pump device.
In yet another example aspect of the present invention, a process of manufacturing a rubber compound is disclosed, the process providing a plurality of multiple shaft extruder devices; operating the plurality of multiple shaft extruder devices sequentially; feeding a first of the plurality of multiple shaft extruder devices with at least one polymer raw material or a mixture of different polymer raw materials; feeding the first multiple shaft extruder devices with at least one further raw material; mixing in the first multiple shaft extruder devices the at least one polymer raw material or the respective mixture of the different polymer raw materials and the at least one further raw material to prepare in the first multiple shaft extruder device a rubber compound; extruding the rubber compound from the first multiple shaft extruder device; feeding the rubber compound into a second multiple shaft extruder device of the plurality of multiple shaft extruder devices.
In still another example aspect of the present invention, a mixing apparatus for manufacturing a rubber compound is provided, the mixing apparatus comprising a plurality of multiple shaft extruder devices each comprising at least one inlet for receiving a plurality of materials to be fed into the extruder device and an outlet for discharging a mixed material extruded by the extruder device, wherein the multiple shaft extruder devices are arranged in such a way that operatively the extrudate of at least one of the plurality of multiple shaft extruder devices can be fed into the inlet of at least one other of the plurality of multiple shaft extruder devices.
In yet another example aspect of the present invention, a mixing apparatus for manufacturing a rubber compound is provided, the mixing apparatus comprising a plurality of multiple shaft extruder devices each comprising at least one inlet for receiving a plurality of materials to be fed into the extruder device and an outlet for discharging a mixed material extruded by the extruder device, wherein the multiple shaft extruder devices are arranged to operate in parallel in such a way that operatively the extrudates of the plurality of multiple shaft extruder devices can be fed together into the inlet of at least one further mixing device.
“Polymer raw material” means a rubber material or a polymer material which can be compounded to a rubber composition (also referred to as an elastomeric composition) but which is exclusive of (or at least essentially exclusive of) a filler such as carbon black, silica or a platy filler, a coupling agent, a tackifier resin, a reinforcing resin; a processing aid, an antioxidant, an antiozonant, a stearic acid, an activator, a wax, an oil, a sulfur vulcanizing agent and a peptizing agent. The term “polymer raw material” however includes such a rubber material or a polymer material that comprises a mineral separating agent such as calcium carbonate or silica powder in an amount of up to 15% in weight of the rubber or polymer material.
“Productive compound” means a rubber compound that includes accelerators, sulfur and other materials needed to cure the rubber.
“Non-productive compound” means a rubber compound that does not have one or more of the following items: 1) accelerator; 2) sulfur; or 3) curing agent(s).
The invention will be described by way of example and with reference to the accompanying drawings in which:
The polymer raw material is a rubber material which can be compounded to a rubber composition (also referred to as an elastomeric composition) but which is exclusive of or at least substantially exclusive of a filler such as carbon black, silica or a platy filler, a coupling agent, a tackifier resin, a reinforcing resin; a processing aid, an antioxidant, an antiozonant, a stearic acid, an activator, a wax, an oil, a sulfur vulcanizing agent, and a peptizing agent. The polymer raw material may, however, comprise a separating agent, preferably calcium carbonate or silica powder, in an amount of up to 15%, preferably 2% to 10%, or between 5% to 10%, in weight of the respective polymer raw material. Such separating agent is particularly useful when the polymer raw material is granulated or pelletized. Preferably, the polymer raw material is a granulated or pelletized polymer raw material comprising up to 15% of a separating agent such as calcium carbonate or silica powder.
The second and third raw material(s) may include a filler material such as carbon black, silica or a platy filler, a coupling agent, a tackifier resin, a reinforcing resin; a processing aid, an antioxidant, an antiozonant, a stearic acid, an activator, a wax, an oil, a sulfur vulcanizing agent, and a peptizing agent. The multiple shaft extruder device 11 mixes a rubber compound 5 which is extruded through the outlet 12. Preferably, the mixed rubber compound 5 is a productive compound, i.e., a rubber compound that includes accelerators, sulfur and other materials needed to cure the rubber. It may, however, also be a non-productive compound, i.e. a rubber compound that does not have one or more of the following items: 1) accelerator; 2) sulfur; or 3) curing agent(s). Such a non-productive compound requires a further mixing step as further explained below.
In one aspect, the multiple shaft extruder device 11 may have a design as basically shown in US-A-2006/0140048 (see in particular
The extruder device warms the mixed materials to the temperature in the range of 80° C. to 200° C., preferably 80° C. to 150° C., and masticates them as needed.
Downstream of the multiple shaft extruder device 11, a gear pump extruder device 25 may be provided as further explained with
The embodiment of
The multiple shaft extruder device 11′ may include an inlet for the extruded mixed rubber compound 5 and preferably also one or more further inlets for feeding the multiple shaft extruder device 11′ with a fourth raw material 17 (or a mixture of raw materials) and optionally also a fifth raw material 18 (or a mixture of raw materials). The fourth or fifth raw material 17, 18 may include a pre-compounded rubber material, a polymer raw material, a filler such as carbon black, silica or a platy filler, a coupling agent, a tackifier resin, a reinforcing resin; a masterbatch material, a processing aid, an antioxidant, an antiozonant, a stearic acid, an activator, a wax, an oil, a sulfur vulcanizing agent, and a peptizing agent. Preferably, the fourth or fifth raw materials are materials needed to make a productive rubber compound out of the non-productive rubber compound fed into the multiple shaft extruder device 11′ (i.e., one or more accelerators, sulfur and curing agent(s)).
The multiple shaft extruder device 11′ mixes a rubber compound 5′ which is extruded through the outlet of the multiple shaft extruder device 11′.
The embodiment of
In this third embodiment, the mixed rubber compound 5″ is preferably a non-productive compound.
Downstream of the apparatus 10″, a further mixing device may be provided to mix a productive compound. This device may be a gear pump mixing device, or the multiple shaft mixing device 11 as shown in
The mixing apparatus 10 of
Using the extruder 40 and the gear pump 42, a rubber compound may be added to the multiple shaft extruder device 11. This rubber compound is preferably a non-productive rubber composition.
Oil may be optionally injected into the multiple shaft extruder device 11 via the oil pump 60 and/or at any other desired location to controls the viscosity of the compound mixture.
If more than one accelerator is used, they may be added into the mixture separately or together. For example, a primary accelerator and a secondary accelerator may both be added. Accelerators are used to control the time and/or temperature required for vulcanization and to improve the properties of the rubber. The accelerator may be in powder form or an encapsulated powder with a resin or rubber base. Examples of accelerator compositions are described in more detail below.
Other additives include a curative agent or precursor, which may also be added to the extruder 10 via additive pump 90. One example of a curative agent is sulfur. The sulfur may be added in solid form or an encapsulated powder with a resin or rubber base.
The gear pump 25 is preferably located adjacent to a tire building station 95 for direct application onto a core, tire blank buffed carcass for a retreaded tire or tire building drum. Gear pump 25 may include a nozzle or shaping die 92 which applies the compound formulation output from the gear pump 25 directly onto the tire building machine 95 in preferably continuous strips which are wound onto a tire building drum or core.
In addition to what is shown in
The following are compositions which may be used in conjunction with the present invention.
In one embodiment, a single accelerator system may be used in the rubber compound, i.e., a primary accelerator. The primary accelerator(s) may be used in total amounts ranging from 0.5 to 4.0, alternatively 0.8 to 1.5, phr. In another embodiment, combinations of a primary and a secondary accelerator might be used with the secondary accelerator being used in smaller amounts, such as from 0.05 to 3.00 phr, in order to activate and to improve the properties of the vulcanized rubber. In addition, delayed action accelerators may be used which are not affected by normal processing temperatures but produce a satisfactory cure at ordinary vulcanization temperatures. Vulcanization retarders might also be used. Suitable types of accelerators that may be used in the present invention are amines, disulfides, guanidines, thioureas, thiazoles, thiurams, sulfenamides, dithiocarbamates and xanthates. In one embodiment, the primary accelerator is a sulfenamide. If a second accelerator is used, the secondary accelerator may be a guanidine, dithiocarbamate or thiuram compound. Suitable guanidines include dipheynylguanidine and the like. Suitable thiurams include tetramethylthiuram disulfide, tetraethylthiuram disulfide, and tetrabenzylthiuram disulfide.
Representative rubbers that may be used in the rubber compound include acrylonitrile/diene copolymers, natural rubber, liquid polymers as described in EP-B1-2065221, halogenated butyl rubber, butyl rubber, cis-1,4-polyisoprene, styrene-butadiene copolymers, cis-1,4-polybutadiene, styrene-isoprene-butadiene terpolymers ethylene-propylene terpolymers, also known as ethylene/propylene/diene monomer (EPDM), and in particular ethylene/propylene/di-cyclopentadiene terpolymers. Mixtures of the above rubbers or functionalized rubbers may also be used. Preferably, the rubber is granulated or pelletized natural rubber, cis-1,4-polyisoprene, styrene-butadiene copolymers, or cis-1,4-polybutadiene.
The processes in accordance with the present invention are particularly suitable for compounding highly filled batches by a single stage process. For instance, they allow it to obtain masterbatches directly from synthetic rubber polymerization (for example, for butyl rubber, polybutadiene rubber or styrene-butadiene rubber). In this case, the multiple shaft extruder device is preferably directly fed with rubber pieces or ground rubber (or mixtures of such rubber materials) obtained from the polymerization production. This avoids the compacting of manufactured rubber in bales. To produce a masterbatch, the multiple shaft extruder device is then also fed at one of its inlets, with one or more fillers, a coupling agent and additives if necessary (such as processing aids, anti-oxidants, and oil). In case of a coupling agent addition to the masterbatch, a coupling reaction between silica and coupling agent can be initiated.
The rubber compound may contain a platy filler. Representative examples of platy fillers include clay, mica and mixtures thereof. When used, the amount of platy filler ranges from 25 to 150 parts per 100 parts by weight of rubber (hereinafter referred to as phr). Preferably, the level of platy filler in the rubber compound ranges from 30 to 75 phr.
The various rubber compositions may be compounded with conventional rubber compounding ingredients. Conventional ingredients commonly used include carbon black, silica, coupling agents, tackifier resins, a reinforcing resin; processing aids, antioxidants, antiozonants, stearic acid, activators, waxes, oils, sulfur vulcanizing agents and peptizing agents. As known to those skilled in the art, depending on the desired degree of abrasion resistance and other properties, certain additives mentioned above are commonly used in conventional amounts. Typical additions of carbon black may be from 10 to 150 parts by weight of rubber, preferably 50 to 100 phr. Typical amounts of silica range from 10 to 250 parts by weight, preferably 30 to 130 parts by weight, and blends of silica and carbon black are also included. Typical amounts of tackifier resins comprise from 2 to 10 phr. Typical amounts of reinforcing resins comprise from 2 to 40 phr. Typical amounts of processing aids comprise 1 to 5 phr. Typical amounts of antioxidants comprise 1 to 10 phr. Typical amounts of antiozonants comprise 1 to 10 phr. Typical amounts of stearic acid comprise 0.50 to 3 phr. Typical amounts of accelerators comprise 1 to 5 phr. Typical amounts of waxes comprise 1 to 5 phr. Typical amounts of oils comprise 2 to 50 phr. Sulfur vulcanizing agents, such as elemental sulfur, amine disulfides, polymeric polysulfides, sulfur olefin adducts, and mixtures thereof, are used in an amount ranging from 0.2 to 12.0 phr. Typical amounts of peptizers comprise from 0.1 to 1 phr.
The rubber composition may also include up to 70 phr of processing oil. Processing oil may be included in the rubber composition as extending oil typically used to extend elastomers. Processing oil may also be included in the rubber composition by addition of the oil directly during rubber compounding. The processing oil used may include both extending oil present in the elastomers, and process oil added during compounding. Suitable process oils include various oils, including aromatic, paraffinic, naphthenic, vegetable oils, and low PCA oils, such as MES, TDAE, SRAE and heavy naphthenic oils. Suitable low PCA oils include those having a polycyclic aromatic content of less than 3 percent by weight as determined by the IP346 method. Procedures for the IP346 method may be found in Standard Methods for Analysis & Testing of Petroleum and Related Products and British Standard 2000 Parts, 2003, 62nd edition, published by the Institute of Petroleum, United Kingdom.
Numerous embodiments have been described, hereinabove. It will be apparent to those skilled in the art that the above methods and apparatuses may incorporate changes and modifications without departing from the general scope of this present invention. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
