On March 8, 2005, this achievement applied for China invention patents: "Method and equipment for detecting rheological characteristics and behavior of polymer dynamic injection", "Method and equipment for axial pulsating displacement of screw in injection machine" and "Method and equipment for plasticizing and mixing polymer and its composite materials with multi-screw", which were authorized in May and June, 2007 respectively. In the traditional screw reciprocating injection molding process, the melting and plasticization of materials mainly depends on the combined action of external heat and screw shear heat, which has low melting rate, high melt viscosity, poor heating uniformity and large axial temperature difference. The final result is high energy consumption in molding process, unstable injection and difficult to improve product quality.
In the invention, the vibration force field caused by electromagnetic field is introduced into the whole process of polymer plasticization, injection and pressure-maintaining molding, and pulse pressure-induced injection molding processing is carried out. Compared with the prior art, it has the following advantages: the volume and weight of equipment are reduced by 45-50%, and the manufacturing cost is reduced by more than 40%; Reduce energy consumption by more than 35%; High working reliability, noise reduced to below 75 decibels, less oil pollution; Good plasticizing and mixing effect, high molding and manufacturing quality and wide adaptability to materials. This new technology has been patented by eleven countries and regions, including China, the United States, Europe, Japan, Russia, Australia, Canada and South Korea. The achievement has been successfully industrialized, and the new equipment has been put into operation in Zengcheng, Nanhai, Dongguan, Jieyang, Shantou, Zhejiang, Jiangsu and other plastic products factories in Guangdong Province, with remarkable results and favorable comments from users. This achievement was nominated by the Ministry of Education as the first prize of national scientific and technological invention in 2002. In 2003, he won the Excellence Award of China Patent Invention and Creation, the Gold Award of Guangdong Patent Invention and Creation, the Gold Award of the 15th National Invention Exhibition and the Second Prize of Guangdong Science and Technology Progress in 2005. "Pulsating pressure induced plastic injection molding equipment" and "high-speed, high-efficiency and integrated precision injection molding equipment" developed by applying the core technology of this achievement passed the new product appraisal and technical appraisal in Guangdong Province in February 2005 and February 2005 respectively. In 2006, this achievement won the second prize of national scientific and technological progress together with the dynamic extrusion technology completed in the early stage of the laboratory. This achievement consists of two parts: the 863 project "Research on High Performance Composite Elastic Structural Materials for Vibration Reduction of Rail Transit" (No.200 1A3340 10) and the National Tenth Five-Year Scientific and Technological Key Project "Industrialization Technology of Rubber/Layered Silicate Nanocomposites" (No.2001A/KLOC-0)
The main contents of the results:
(1) A new technology of in-situ reactive modification of carbon black and silica and its application in the elastomer composite for rail transit shock absorption: multifunctional monomers or organic substances are used for in-situ reactive modification in the vulcanization process of dry-mixed rubber or latex state, so that they are chemically combined with rubber at the same time and form valence bonds with fillers such as carbon black and silica, thus significantly improving the interfacial adhesion and the properties of rubber composite materials. This technology is simple, easy to implement and widely used. When applied to the elastomer composite material for rail transit damping, it mainly solves the problem of improving dynamic performance, and obtains vulcanized rubber elastomer composite material with low dynamic heat generation, fatigue resistance, small permanent deformation and moderate dynamic-static stiffness ratio, which has achieved excellent application effect and produced remarkable economic benefits.
(2) New preparation technology of rubber/montmorillonite nanocomposites and its application in elastic composites for rail transit shock absorption: Two new preparation technologies of rubber/montmorillonite nanocomposites, in-situ reaction intercalation method and emulsion mixed intercalation method, were invented, and the mechanical properties, aging resistance and fatigue resistance of the prepared nanocomposites vulcanizate were significantly improved. An annual output of 200 tons of in-situ reactive intercalation modified montmorillonite preparation device and a demonstration production line of 1000 tons of in-situ intercalation rubber/montmorillonite nanocomposites were established. The nano-composite material is applied to the production of high-performance elastic components such as air spring, side bearing, ball hinge, track isolation damper and V-spring, and has excellent comprehensive performance and remarkable economic benefits. The core technology of this achievement is to produce radial tires with low rolling resistance, low fuel consumption and less exhaust gas emission by pouring polyurethane materials on traditional tires. Pouring polyurethane elastomer is the most wear-resistant elastomer at present, and it is harmless to human body, completely biodegradable, without adding carbon black and some carcinogenic rubber additives, and is an ideal material for manufacturing tire treads. The composite tire composed of rubber matrix and polyurethane tread not only maintains the advantages of small rolling resistance, high safety and comfort of rubber tire, but also maintains the advantages of polyurethane elastomer, which is particularly wear-resistant and pollution-free, and can also eliminate the pollution of some rubber compounds and rubber dust to the environment. The performance of the tire has also improved to a higher level, with the advantages of good elasticity, wear resistance, puncture resistance, large bearing capacity and comfortable riding. Its mileage is more than 1 times higher than that of ordinary tires. Compared with traditional tires, it highlights many advantages such as environmental protection, energy saving, new technology and new materials.
The new technology can also be applied to the tire retreading industry, which can greatly improve the technical level of China's tire retreading industry, reduce the number of waste tires, promote the development of circular economy, reduce environmental pollution to a new level, and become a green tire in a higher sense. The finished tire has passed the inspection of the national rubber tire quality supervision and inspection center, the chemical special tire quality supervision and inspection center and other authoritative institutions.
From June 5, 2005 to1October 25, 2005, this achievement passed the technical appraisal organized by China Petroleum and Chemical Industry Association. Appraisal experts believe that the adhesion between polyurethane tread and rubber carcass of this tire has reached the international leading level, and its successful development has great innovation significance and good economic and social benefits prospects. The new technology has obtained two invention patents in China and applied for patent protection in seven major tire producing countries in the world. In June, 2005, 165438+ 10, this kind of compound tire was exhibited at the American International Auto Parts Exhibition, which caused a sensation. This achievement is based on the completion of the national 863 project "Strengthening the New Technology of Preparing Polymer/Inorganic Composites in Physical Field". The polymer multi-screw dynamic mixing extruder breaks through the limitations of traditional mixing extrusion equipment from the mechanism of plasticization and mixing extrusion, and creates a method of introducing vibration force field to strengthen the plasticization and mixing effect of polymer materials during transportation. The equipment introduces vibration force field into the whole process of polymer plastics, mixing (reaction) and exhaust extrusion, which overcomes the shortcomings of traditional mixed extrusion equipment, such as difficult to improve product quality, long molding cycle and high energy, and solves the problems of mass, momentum and energy transfer and balance in the reaction process. It is a major innovation in the field of new polymer molding and processing at home and abroad, with independent intellectual property rights and great theoretical value. It can replace the traditional co-rotating twin-screw extruder and promote the upgrading of traditional mixed extrusion equipment.
On June 5438+ 10, 2005, the core technology of this achievement was applied to the "Dynamic Vulcanization Technology and Equipment for Thermoplastic Elastomers such as EPDM/PP" developed by the research group, and it successfully passed the appraisal sponsored by Guangzhou Science and Technology Bureau. From June 5438 to October 2005 10, the multi-screw plasticizing, mixing and extrusion method and equipment for polymers and their composites applied for the invention patent of China, and was authorized in June 2007.
The technical level of this achievement is in the leading position in the world and has strong market competitiveness. Its popularization and application can not only promote the development of China's plastic processing industry, but also promote the development of China's machinery manufacturing industry and electronic industry.