CN204354342U - 一种车用废旧gmt材料回收造粒用的连续双混炼喂料机组 - Google Patents
一种车用废旧gmt材料回收造粒用的连续双混炼喂料机组 Download PDFInfo
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
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Abstract
本实用新型公开了一种车用废旧GMT材料回收造粒用的连续双混炼喂料机组,主要由吃料混炼部分和排料输送部分组成。其中,吃料混炼部分包括变速驱动装置、加料装置、双混炼机筒、三嵌段转子、温控装置;排料输送部分包括传动螺杆、单螺杆和温控装置;且吃料混炼部分的出料口与排料输送部分的单螺杆挤出机的进料口相对接。该种连续式双混炼喂料机组,不需要间歇式的加料及卸料,在充分利用混练机混炼特性的同时实现了连续性加料及混炼,操作灵活方便,对工艺的适应性强,效率高,产量大。
Description
技术领域
本实用新型涉及一种车用废旧材料回收装置,具体地说,是一种车用废旧GMT材料回收造粒用的连续双混炼喂料机组。
背景技术
随着汽车向轻量化、节能减排、舒适美观方向发展,塑料在汽车领域的用量与日俱增,其用量及其应用技术往往成了衡量一个国家汽车工业水平的重要指标。但是出乎预料的是,正是由于这些塑料的大量应用,致使其在使用或消费后成为耐久不腐的垃圾,日积月累,必将进一步加重全球的“白色污染”问题,直接影响人们的生活质量甚至威胁到人们的身心健康。因而对废旧塑料进行回收再利用处理,对提高塑料产业的经济效益和减少塑料污染有重要的意义。
玻璃纤维毡增强热塑性复合材料(Glass Mat Reinforced Thermoplastic)简称GMT,它是一种以热塑性树脂为基体,以长玻璃纤维或连续玻纤毡为增强材料的复合材料,一般做成片材以半成品供应。由于其具有高比强度、高抗冲击性、轻质、成型周期短、生产效率高、加工成本低等诸多优点,而成为汽车工业的青睐者。与热固性复合材料相比,GMT材料的基体为热塑性树脂,加热到基体树脂的熔点以上可使材料软化。因而成型时造成的废品、边角料以及使用过程中破损制品,经回炉加热、再成型处理,可重新获得新的制品。GMT材料的再生利用优势是热固性复合材料无法与之相提并论的,因而其被称为21世纪的“绿色工业材料”。
目前关于GMT材料回收利用的研究已有诸多报道,现已以批量生产的规模在汽车行业中进行试验,并已取得了良好的结果。方法大体如下:(1)回收件被粉碎成碎屑,作为原料再次用于半成品片材生产。如美国GE Plastics与PPG公司合资生产的用于Jaguar 300车保险杠的Azdel GMT材料,是废旧保险杠经回收粉碎后与GMT新材按20/80比例掺混使用,再复合而成。(2)把废弃或破损部件粉碎,与短玻纤一起掺混作为补强材料,经熔融挤出制成改性粒子,用于注塑或挤出制品。如国内专利CN1651502A和CN1651503A中提及的关于汽车内饰件用纤维增强聚丙烯复合材料的回收方法均采用了该工艺。上述两种技术方案即为传统意义上的熔融再生工艺,其工艺基础皆为先粉碎后熔融再成型,然而该工艺在具体实施操作过程中仍有诸多不足。
1.GMT材料中添加了大量玻纤成份,在粉碎过程中不仅噪声大,而且容易生产大量粉尘污染,恶化生产化境,对人体健康造成很大危害;
2.粉碎工艺不适宜轻质GMT,轻质GMT材料受到外加冲击载荷时,吸收冲击能量的途径及能力要高于重质GMT材料。对于重质GMT材料而言,材料受碰撞后,易发生开裂、破碎、呈脆性断裂,而轻质GMT可发生一定程度的形变,以抵抗断裂;
3.GMT材料玻纤成份大,熔体剪切阻力高,现有技术的塑料回收生产设备在熔融造粒时多数未考虑GMT材料改性技术,常因混炼不均,而导致再生制品性能欠佳,一般只能作较低档次的塑料制品;
4.加工品种单一,如回收软质制品的机器回收硬质制品时,送料不便,经常损坏电机、甚至螺杆减速箱,而普通回收硬质制品的机器则回收软质制品时产量很低。
若借鉴密炼机的混炼特性,先将物料通过密炼机进行熔融塑化,从而确保物料混合的均匀性及稳定性,再将混炼后的物料经强制喂料机强行挤入挤出机进行挤出造粒,则可有效提高了废旧塑料塑炼、熔融和改性均匀性。然而,现有密炼挤出技术中密炼机与挤出机都是分立设备,各自分别加工,不仅占地及投资成本大,而且单位能耗多;同时又由于密炼机属于间歇式混合设备,不仅难以形成连续化加工生产,而且不同批次物料难以达到相同的混炼质量。
实用新型内容
本实用新型的目的就是提出一种车用废旧GMT材料回收造粒用的连续双混炼喂料机组,该喂料机组不仅解决了密炼机与挤出机不能形成连续化加工生产的问题,而且还在有效提高了废旧塑料塑炼、熔融、改性均匀性的同时提高了设备的吃料能力,使其不但适应了未经预先破碎的车用GMT材料生产边角料的加料,而且还适应了大块废旧车用GMT回收件的加料,因而无需对废旧塑料进行粉碎,避免了破碎时因噪声、粉尘等对劳工造成的危害,同时还节省了工艺步骤,降低了生产成本。
为实现上述目的,本实用新型通过以下技术方案实现:
本实用新型公开了一种车用废旧GMT材料回收造粒用的连续双混炼喂料机组,主要由吃料混炼部分和排料输送部分组成。其中,吃料混炼部分包括变速驱动装置、加料装置、双混炼机筒、三嵌段转子、温控装置;排料输送部分包括传动螺杆、单螺杆和温控装置;且吃料混炼部分的出料口与排料输送部分的单螺杆挤出机的进料口相对接。
作为进一步地改进,本实用新型所述的连续双混炼喂料机组,其吃料混炼部分位于排料输送部分的上部,且吃料混炼部分的出料口连接在排料输送部分单螺杆挤出机的进料口上方。在吃料混炼部分的出料口中设置开度可调的排料电控启闭阀。
作为进一步地改进,吃料混炼部分和排料输送部分可采用一个共同的变速驱动装置和温控装置。所述设备的变速驱动装置包括驱动电机、减速分配箱和传动螺杆;所述温控装置包括加热装置和冷却控温装置。
作为进一步地改进,为实现连续混炼与挤出,必须将混炼好的物料输送至挤出机进行成型或造粒,即除吃料混炼部分和排料输送部分外还需要挤出造粒部分,挤出造粒部分选用双螺杆挤出机,物料经连续双混炼喂料机组向双螺杆挤出机供料实现连续性喂料混炼及挤出。
作为进一步地改进,吃料混炼部分的双混炼机筒内装有两根并行的三嵌段转子,每个转子设有吃料段、输送段和混炼段,吃料段由巨型正向多棱螺旋转子组成;输送段采用啮合的螺旋输送结构,且螺纹外径轮廓由大至小呈锥形;混炼段由正向和反向两段多棱螺旋转子组成。
本实用新型技术方案的具体工艺步骤如下:
(1)将回收的废旧车用GMT回收件或生产边角料从投料口投入备料室中,备料室中的废旧塑料经吃料段两巨型正向多棱螺旋转子螺旋挤压强制喂入第一混炼腔,混炼腔中的物料依靠从机筒传入的热量以及转子的剪切、粉碎、挤压和捏合作用被简单塑化,未充分塑化的物料在正向转子的推动下输送至输送段。
(2)输送段采用啮合的螺旋输送结构,且螺纹外径轮廓由大至小呈锥形,螺杆前端大直径设计,增大了螺杆承载力的同时提高了设备的吃料能力;末端小直径设计减小了因摩擦产生的热损伤效应;螺槽容积沿挤出方向逐渐减小,使物料逐渐得到压缩,从而使螺槽更快充满物料,保证物料连续平缓地输送至第二混炼腔。
(3)物料进入第二混炼腔后,由于其内转子混炼段表面螺纹分正向和反向两段多棱螺旋设计,正向段转子把料向前推进,而反向则使物料向后运动,转子间物料交换更加频繁,形成多个剪切、拉伸和捏合区,重而使物料得到更加充分的混炼与塑化。
(4)混炼充分的物料经开度可调的排料电控启闭阀输送至排料输送部分。电控启闭阀的开度可控制物料输送速度和排料输送部分的物料充满度,对建立压力,改变混炼强度有重要意义。
(5)物料在末端经开度可调的排料电控启闭阀输送至排料输送部分后,再经排料输送部分单螺杆作用下建立压力,确保物料连续平缓地输送至挤出机。
(6)挤出的物料经牵伸、冷却、切粒后成为塑料粒子。
本实用新型的有益效果是:1.该种连续式双混炼喂料机组,不需要间歇式的加料及卸料,在充分利用混练机混炼特性的同时实现了连续性加料及混炼,操作灵活方便,对工艺的适应性强,效率高,产量大。2.喂料、混炼、挤出一体机设计有效提高了废旧塑料改性均匀性及力学性能同时,相比原先两套设备既提高了生产效率,降低了单位能耗,同时简化了生产设备,降低了设备的投资及占地面积。3.提高了设备的吃料能力,使其不但适应了未经预先破碎的车用内饰件生产边角料的加料,而且还适应了大块废旧车用塑料零部件的加料,因而无需对废旧塑料进行粉碎,避免了破碎时因噪声、粉尘等对劳工造成的危害,同时还节省了工艺步骤,降低了生产成本。
附图说明
图1为本实用新型技术方案车用废旧GMT材料回收造粒用的连续双混炼喂料机组的结构示意图;
图中:1是吃料混炼部分,2是排料输送部分,3是挤出造粒部分;
吃料混炼部分包括:1-1是驱动电机,1-2是减速分配箱,1-3是加料装置,1-4是双混炼机筒,1-5是三嵌段转子,1-6是冷却控温装置,1-7是加热装置,1-8电控启闭阀;
排料输送部分包括:2-1是传动螺杆,2-2是单螺杆,2-3是加热装置,2-4是冷却控温装置;
图2为三嵌段转子的结构示意图;
三嵌段转子包括:1-5-1是吃料段,1-5-2是输送段,1-5-3是混炼段。
具体实施方式
下面结合说明书附图,通过具体实施例子对本实用新型的技术方案作进一步地说明:
图1为本实用新型技术方案车用废旧GMT材料回收造粒用的连续双混炼喂料机组的结构示意图,主要由吃料混炼部分1和排料输送部分2组成。吃料混炼部分1由驱动电机1-1、减速分配箱1-2、加料装置1-3、双混炼机筒1-4、三嵌段转子1-5、冷却控温装置1-6、加热装置1-7以及电控启闭阀1-8组成。排料输送部分2包括传动螺杆2-1、单螺杆2-2、加热装置2-3、冷却控温装置2-4组成。吃料混炼部分1位于排料输送部分2的上部,且吃料混炼部分1出料口与排料输送部分2的单螺杆挤出机的进料口相对接,连接部位在图中已用圈标出。在吃料混炼部分的出料口中仍可按传统方式设置开度可调的排料电控启闭阀1-8。电控启闭阀1-8的开度可控制物料输送速度和排料输送部分的物料充满度,对建立压力,改变混炼强度有重要意义。吃料混炼部分1和排料输送部分2可采用一个共同的变速驱动装置和温控装置,以简化整机结构,降低设备成本。本实施例中所述设备的变速驱动装置包括驱动电机1-1、减速分配箱1-2和传动螺杆2-1;所述温控装置包括加热装置1-3、2-3和冷却控温装置1-6、2-4。
吃料混炼部分1用三嵌段转子1-5为双转子,安装时成一定角度排列,见图2。每个转子设有吃料段1-5-1、输送段1-5-2和混炼段1-5-3,吃料段1-5-1由巨型正向多棱螺旋转子组成;输送段1-5-2采用啮合的螺旋输送结构,且螺纹外径轮廓由大至小呈锥形;混炼段1-5-3由正向和反向两段多棱螺旋转子组成。
该连续式双混炼喂料机组的工作原理是:驱动电机1-1带动减速分配箱1-2输入轴旋转,减速分配箱1-2内进行扭矩和转速分配通过两根输出轴带动两个三嵌段转子1-5作旋转运动。三嵌段转子1-5具有正向多棱螺旋吃料段1-5-1、啮合螺旋输送段1-5-2和正、反向两段多棱螺旋混炼段1-5-3组成,并安装于双混炼机筒1-4内。吃料段1-5-1构成第一混炼腔,混炼段1-5-3构成第二混炼腔,双混炼腔内部温度靠冷却装置1-6和加热装置1-7进行调节。未经预先破碎的车用废旧GMT回收件或生产边角料从投料口投入备料室中,备料室中的物料经吃料段1-5-1两个巨型正向多棱螺旋转子螺旋挤压作用下强制喂入第一混炼腔,混炼腔中的物料受到转子作用被剪切、粉碎和粘合,并在正向螺纹的推动下到达输送段1-5-2;输送段1-5-2螺纹外径轮廓由大至小呈锥形设计,助物料建立压力,充满螺槽,保证连续平缓地输送至第二混炼腔;第二混炼腔中的转子混炼段1-5-3表面螺纹分正向和反向两段设计,物料在此形成多个剪切、拉伸和捏合区,得到充分混炼与塑化。混炼充分的物料再开度可调的排料电控启闭阀1-8输送至排料输送部分2。再在排料输送部分2的单螺杆2-2作用下建立压力,确保物料连续平缓地输送至挤出造粒部分3的挤出机进行挤出造粒,重而实现物料的连续喂入、混炼及挤出。
表1为利用本实用新型喂料机组进行挤出造粒对试样力学性能的影响,从中可见,利用本实用新型喂料机组向挤出机供料进行挤出造粒所得试样拉伸强度和冲击强度都得到了有效提高。这是由于传统的塑料回收生产设备在熔融造粒时多数未考虑材料改性技术,GMT材料玻纤成份大,熔体剪切阻力高,常因混炼不均,而导致再生制品性能欠佳,一般只能作较低档次的塑料制品;利用该喂料机组向挤出机供料,有效提高了废旧塑料塑炼、熔融和改性均匀性,对废旧塑料进行回收利用,提高塑料产业的经济效益和减少塑料污染有重要的意义。
表1利用本实用新型喂料机组进行挤出造粒对试样力学性能影响
注:工艺一、利用本实用新型喂料机组向挤出机供料进行挤出造粒;工艺二、利用传统双螺杆挤出机造粒。
最后,还需要注意的是,以上列举的仅是本发明的一个具体实施例。显然,本发明不限于以上实施例,还可以有许多变形。本领域的普通技术人员能从本发明公开的内容直接导出或联想到的所有变形,均应认为是本发明的保护范围。
Claims (10)
1.一种车用废旧GMT材料回收造粒用的连续双混炼喂料机组,主要由吃料混炼部分(1)和排料输送部分(2)组成,其特征在于:所述的吃料混炼部分包括驱动电机(1-1)、减速分配箱(1-2)、加料装置(1-3)、双混炼机筒(1-4)、三嵌段转子(1-5)、冷却控温装置(1-6)和加热装置(1-7);所述的排料输送部分包括传动螺杆(2-1)、单螺杆(2-2)、加热装置(2-3)和冷却控温装置(2-4);所述的吃料混炼部分(1)的出料口与排料输送部分(2)的单螺杆挤出机的进料口相对接。
2.根据权利要求1所述的车用废旧GMT材料回收造粒用的连续双混炼喂料机组,其特征在于,所述吃料混炼部分(1)位于排料输送部分(2)的上部,且吃料混炼部分(1)的出料口连接在排料输送部分(2)的单螺杆挤出机的进料口上方。
3.根据权利要求1或2所述的车用废旧GMT材料回收造粒用的连续双混炼喂料机组,其特征在于,在吃料混炼部分(1)的出料口中设置开度可调的排料电控启闭阀(1-8)。
4.根据权利要求1或2所述的车用废旧GMT材料回收造粒用的连续双混炼喂料机组,其特征在于,所述吃料混炼部分(1)和排料输送部分(2)采用一个共同的变速驱动装置和温控装置,所述的变速驱动装置包括驱动电机(1-1)、减速分配箱(1-2)和传动螺杆(2-1);所述温控装置包括加热装置(1-7)、(2-3)和冷却控温装置(1-6)、(2-4)。
5.根据权利要求1或2所述的车用废旧GMT材料回收造粒用的连续双混炼喂料机组,其特征在于,所述连续双混炼喂料机组还包括挤出造粒部分(3)。
6.根据权利要求5所述的车用废旧GMT材料回收造粒用的连续双混炼喂料机组,其特征在于,所述挤出造粒部分(3)包括双螺杆挤出机。
7.根据权利要求1或2所述的车用废旧GMT材料回收造粒用的连续双混炼喂料机组,其特征在于,所述吃料混炼部分(2)的双混炼机筒(1-4)内装有两根并行的三嵌段转子(1-5),每个转子设有吃料段(1-5-1)、输送段(1-5-2)和混炼段(1-5-3)。
8.根据权利要求7所述的车用废旧GMT材料回收造粒用的连续双混炼喂料机组,其特征在于,所述的吃料段(1-5-1)由两个巨型正向多棱螺旋转子组成。
9.根据权利要求7所述的车用废旧GMT材料回收造粒用的连续双混炼喂料机组,其特征在于,所述的输送段(1-5-2)采用啮合的螺旋输送结构,且螺纹外径轮廓由大至小呈锥形。
10.根据权利要求7所述的车用废旧GMT材料回收造粒用的连续双混炼喂料机组,其特征在于,所述的混炼段(1-5-3)由正向和反向两段多棱螺旋转子组成。
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