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CN111434489A - 一种耐疲劳氯丁胶空气弹簧气囊及其制备方法 - Google Patents

一种耐疲劳氯丁胶空气弹簧气囊及其制备方法 Download PDF

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CN111434489A
CN111434489A CN201910029653.5A CN201910029653A CN111434489A CN 111434489 A CN111434489 A CN 111434489A CN 201910029653 A CN201910029653 A CN 201910029653A CN 111434489 A CN111434489 A CN 111434489A
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air spring
layer
fatigue
ram
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洪宗跃
曾季
蔡庆
李文东
李鹏
徐立
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Beijing Research and Design Institute of Rubber Industry
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Abstract

本发明公开了一种耐疲劳氯丁胶空气弹簧气囊及其制备方法，包括采用纯氯丁胶为主体胶料对汽车用空气弹簧气囊的内外层胶和帘布层胶的配比和混炼、压出工艺方法。本发明使得空气弹簧的气囊具有更好的耐曲挠疲劳性能，提高了空气弹簧的使用寿命，同时空气弹簧各项综合性能更好。试验结果证实，采用本发明的气囊的空气弹簧疲劳耐久性能和综合性能均有效提高。

Description

一种耐疲劳氯丁胶空气弹簧气囊及其制备方法
技术领域
本发明涉及一种耐疲劳氯丁胶空气弹簧气囊及其制备方法。该耐疲劳氯丁胶空气弹簧气囊由纯氯丁胶为主体胶料设计出内外层胶和帘子布骨架材料胶的专用配比，并制定实施了对此胶料的混炼和压延胶片制备工艺方法。该耐疲劳氯丁胶空气弹簧气囊主要用于重型汽车驾驶室空气弹簧减振上，能有效提高空气弹簧的使用寿命，该发明是属于空气弹簧橡胶气囊生产技术领域。
背景技术
普通的汽车空气弹簧气囊损坏原因一般是气囊使用寿命不够长或者空气中的水分进入到系统内部，还有橡胶老化龟裂可能会造成空气悬挂失效。路面上的碎片也有可能会击穿气囊。气囊表面裸露在外，经受反复的曲挠，疲劳破坏。因而普通橡胶制成的气囊在空气弹簧使用环境中，容易发生早期损坏。这就要求空气弹簧气囊具有良好的气密性和耐曲挠性，还要有极佳的防刺扎性。目前汽车上空气弹簧使用的气囊有天然胶配方、天然胶并用氯丁胶配方，前者在疲劳耐久性、防刺扎性能与气密性能中间难于兼顾两全，后者虽然有所考虑三种性能的兼顾，但是天然胶并用氯丁胶还是疲劳耐久性能不佳，空气弹簧使用寿命受影响。这两种方式均易造成空气弹簧早期损坏，减少其使用寿命。
发明内容
本发明需要解决的技术问题就在于克服现有技术的缺陷，提供一种耐疲劳氯丁胶空气弹簧气囊及其制备方法，采用本发明耐疲劳氯丁胶气囊的空气弹簧减少出现漏气、刺扎、割伤等造成空气弹簧早期损坏的机率，同时具有良好的疲劳耐久性能，提高了使用寿命。
为解决上述问题，本发明采用如下技术方案：
耐疲劳氯丁胶空气弹簧气囊由氯丁胶为主体胶料设计出内外层胶和帘子布骨架材料胶的专用配比，由内层胶、增强层胶和外层胶复合而成，其原料组份的重量配比为：表1，表2
内层胶和外层胶采用同一种配比（表1）：
Figure 495169DEST_PATH_IMAGE001
增强层配比（表2）：
Figure 90098DEST_PATH_IMAGE002
在内外层胶之间，有两层交叉排列的同种贴胶尼龙帘布骨架材料增强层。贴合方式如下图1，制定实施了对此胶料的混炼和压延胶片制备工艺方法。
具有耐疲劳氯丁胶汽车用橡胶空气弹簧橡胶气囊的制造工艺，其特征按如下步骤进行：
1）、分别按重量配比称取内外胶层、骨架增强层贴胶的各种原料组份，由密炼机和开炼机分别加工成内外层混炼胶、骨架增强层混炼胶。
2）、将检测合格的混炼胶，用三辊压延机或四辊压延机将内外层混炼胶压延成符合设计要求的一定厚度和宽度。
用四辊压延机将骨架增强层混炼胶压延贴合至尼龙帘子布骨架增强上，制成符合设计要求的一定厚度和宽度的胶帘布。
3）、按产品设计施工标准将内、外层胶片和骨架层胶帘布裁断成具有一定角度和宽度的胶片和胶布，在成型机上将内层胶片、骨架层胶帘布和外层胶片经缠绕、贴合、辊压制成囊胚。
4）、将上述囊胚连同芯模一同放入专用硫化机内,在内外温升温至160℃，并保持在160±1℃，外压保持在不低于2.0Mpa 条件下，正硫化20 分钟。
5）、将所得硫化后胶囊在空气中自然冷却至60℃以下，脱去模芯。将胶囊裁断成符合产品设计施工标准要求的具有一定长度的成品胶囊。
6)、将成品胶囊与减振器、下卡环、缓冲块、上卡环、上盖、快速接头、（连接板）进行组装，制成橡胶空气弹簧总成。
上述具有耐疲劳氯丁胶汽车用橡胶空气弹簧橡胶气囊的制造工艺中1）、2）步骤，其关键在于：在1）加工过程中，通过投入生胶及防老剂，防护蜡，增粘树脂，氧化镁，防焦剂等，压砣炼30秒，提砣加炭黑及芳烃油，再压砣炼至80度，提砣加氧化锌，促进剂，压砣炼至85度，再提砣一次，然后压砣炼至92度，提砣排胶。提升机输送至22寸开炼机，调节辊距3mm，落盘4次，包辊出片。密炼机转速33.5转。在2）加工过程中，通过冷却水和辊筒转速匹配，实行低温压延出薄胶片。
本发明的技术效果在于：
1、本发明气囊内外层胶、骨架层贴胶采用的是氯丁胶CR1211为胶料主体材料，与以往以天然橡胶或氯丁胶并用天然胶为主体的内层胶、骨架层贴胶相比，在大幅度疲劳耐久性能的同时提高了囊体的气密性及层间粘合性能，并节约了资源有限的天然橡胶，符合我国橡胶工业大力推进合成橡胶开发应用的产业调控政策和发展方向。
2、本发明与以往气囊胶相比，性能优势具体体现如下：
气囊24 h 的内压降， 小于0.004Mpa （以往气囊0.016Mpa）
气囊台架寿命， 590万次 （以往气囊320万次）
由于气囊采用纯氯丁胶为主，采用低温混炼和压延工艺，保证了气囊的气密性、疲劳耐久性能和耐刺扎性和易于生产制造。在汽车长期的高频率、高负荷作业当中采用该耐疲劳氯丁胶空气弹簧气囊空气弹簧能有效防止早期损坏和更好提高空气弹簧的使用寿命。
附图说明
图1为本发明耐疲劳氯丁胶空气弹簧气囊各层贴合示意图
图中，1为内层胶，2为内帘布增强层，3为外帘布增强层，4、为外层胶。
具体实施方式
具体实施中，耐疲劳氯丁胶空气弹簧气囊囊体是由是由内胶层、骨架增强层和外胶层复合而成，其原料组份的重量配比为：
内层胶和外层胶采用同一种配比（表1）：
Figure 288998DEST_PATH_IMAGE003
帘布增强层胶配比（表2）：
Figure 754615DEST_PATH_IMAGE004
在内外层胶之间，有两层交叉排列的同种贴胶尼龙帘布骨架材料增强层。
制备工艺方法按如下步骤进行：
1）、分别按重量配比称取内外胶层、骨架增强层贴胶的各种原料组份，由密炼机和开炼机分别加工成内外层混炼胶、骨架增强层混炼胶。
2）、将检测合格的混炼胶，用三辊压延机或四辊压延机将内外层混炼胶压延成符合设计要求的一定厚度和宽度。
用四辊压延机将骨架增强层混炼胶压延贴合至尼龙帘子布骨架增强上，制成符合设计要求的一定厚度和宽度的胶帘布。
3）、按产品设计施工标准将内、外层胶片和骨架层胶帘布裁断成具有一定角度和宽度的胶片和胶布，在成型机上将内层胶片、骨架层胶帘布和外层胶片经缠绕、贴合、辊压制成囊胚。
4）、将上述囊胚连同芯模一同放入专用硫化机内,在内外温升温至160℃，并保持在160±1℃，外压保持在不低于2.0Mpa 条件下，正硫化20 分钟。
5）、将所得硫化后胶囊在空气中自然冷却至60℃以下，脱去模芯。将胶囊裁断成符合产品设计施工标准要求的具有一定长度的成品胶囊。
6)、将成品胶囊与减振器、下卡环、缓冲块、上卡环、上盖、快速接头、（连接板）进行组装，制成橡胶空气弹簧总成。
上述具有耐疲劳氯丁胶汽车用橡胶空气弹簧橡胶气囊的制造工艺中1）、2）步骤，其关键在于：在1）加工过程中，通过投入生胶及防老剂，防护蜡，增粘树脂，氧化镁，防焦剂等，压砣炼30秒，提砣加炭黑及芳烃油，再压砣炼至80度，提砣加氧化锌，促进剂，压砣炼至85度，再提砣一次，然后压砣炼至92度，提砣排胶。提升机输送至22寸开炼机，调节辊距3mm，落盘4次，包辊出片。密炼机转速33.5转。在2）加工过程中，通过冷却水和辊筒转速匹配，实行低温压延出薄胶片。
采用本发明耐疲劳氯丁胶气囊的空气弹簧减少出现漏气、刺扎、割伤等造成空气弹簧早期损坏的机率，同时具有良好的疲劳耐久性能，提高了使用寿命。
最后应说明的是：显然，上述实施方式仅仅是为清楚地说明本发明所作的举例，而并非对实施方式的限定。对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而由此所引申出的显而易见的变化或变动仍处于本发明的保护范围之中。

Claims (3)

1.一种耐疲劳氯丁胶空气弹簧气囊，其特征在于：由内层胶、增强层胶和外层胶复合而成，其原料组份的重量配比为：
内层胶和外层胶采用同一种配比：
Figure 778753DEST_PATH_IMAGE001
增强层配比：
Figure 173962DEST_PATH_IMAGE002
在内外层胶之间，有两层交叉排列的同种贴胶尼龙帘布骨架材料增强层。
2.如权利要求1所述具有耐疲劳氯丁胶汽车用橡胶空气弹簧橡胶气囊的制造工艺，其特征按如下步骤进行：
1）、分别按重量配比称取内外胶层、骨架增强层贴胶的各种原料组份，由密炼机和开炼机分别加工成内外层混炼胶、骨架增强层混炼胶；
2）、将检测合格的混炼胶，用三辊压延机或四辊压延机将内外层混炼胶压延成符合设计要求的一定厚度和宽度；
用四辊压延机将骨架增强层混炼胶压延贴合至尼龙帘子布骨架增强上，制成符合设计要求的一定厚度和宽度的胶帘布；
3）、按产品设计施工标准将内、外层胶片和骨架层胶帘布裁断成具有一定角度和宽度的胶片和胶布，在成型机上将内层胶片、骨架层胶帘布和外层胶片经缠绕、贴合、辊压制成囊胚；
4）、将上述囊胚连同芯模一同放入专用硫化机内,在内外温升温至160℃，并保持在160±1℃，外压保持在不低于2.0Mpa 条件下，正硫化20 分钟；
5）、将所得硫化后胶囊在空气中自然冷却至60℃以下，脱去模芯；
将胶囊裁断成符合产品设计施工标准要求的具有一定长度的成品胶囊；
6)、将成品胶囊与减振器、下卡环、缓冲块、上卡环、上盖、快速接头、（连接板）进行组装，制成橡胶空气弹簧总成。
3.如权利要求2所述具有耐疲劳氯丁胶汽车用橡胶空气弹簧橡胶气囊的制造工艺中1）、2）步骤，其特征在于：在1）加工过程中，通过投入生胶及防老剂，防护蜡，增粘树脂，氧化镁，防焦剂等，压砣炼30秒，提砣加炭黑及芳烃油，再压砣炼至80度，提砣加氧化锌，促进剂，压砣炼至85度，再提砣一次，然后压砣炼至92度，提砣排胶，提升机输送至22寸开炼机，调节辊距3mm，落盘4次，包辊出片，密炼机转速33.5转；在2）加工过程中，通过冷却水和辊筒转速匹配，实行低温压延出薄胶片。
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