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硅膠管粘度軟化與催化到什么程度
處理高粘度硅橡膠，高粘度硅橡膠彈性體的處理包括五個(gè)步驟：磨軟化和催化，準(zhǔn)備預(yù)成型件，擠壓或模壓，硫化，和整理。
The treatment of high viscosity silicone rubber and high viscosity silicone elastomer consists of five steps: grinding and catalysis, preparation of preformed parts, extrusion or molding, vulcanization, and finishing.
軟化和催化，在高稠度硅氧烷橡膠彈性體為在任一擠出或模塑應(yīng)用中使用的處理的初始步驟是磨軟化和催化。這個(gè)程序撤消任何“縐硬化”已存儲(chǔ)在庫(kù)存的供應(yīng)商或制造者期間發(fā)生的彈性體。研磨也使用制造者以過氧化物催化劑添加于自由基固化的彈性體，如果需要的話，或混合的加成固化的彈性體的兩個(gè)部分在制造前。
Softening and catalysis, the first step in the processing of high consistency silicone elastomers for use in any extrusion or molding applications is grinding softening and catalysis. This procedure canceling any elastomers that "crepe hardened" has been stored in the supplier or manufacturer of inventory. The grinding is also used by the manufacturer with a peroxide catalyst added to the free radical cured elastomer, and two parts of the added solidified elastomer are before the manufacture, if needed.
銑削和催化不僅勞動(dòng)強(qiáng)度大，而且需要使用雙輥軋機(jī)，其成本約為60,000美元購(gòu)買和安裝的。該彈性體是通過軋機(jī)多次傳遞，直到復(fù)合材料是均質(zhì)的，則在作進(jìn)一步處理片形式去除。
Milling and catalysis are not only labor intensive, but also require the use of twin roll mills, which cost about $60000 for purchase and installation. The elastomer passes through the mill several times until the composite is homogeneous, and is removed in the form of further processing.
1、制備預(yù)制：一旦高稠度彈性體被完全配合，在制造過程中的下一個(gè)步驟是預(yù)型件的制備。這不要求特殊的設(shè)備，但是非常勞動(dòng)密集的，特別是在本質(zhì)上是幾乎連續(xù)的大批量應(yīng)用。用于擠出和注射成型應(yīng)用，該預(yù)成型件是通過切割彈性體片材切成條，其用于喂擠出機(jī)簡(jiǎn)單地制備。轉(zhuǎn)移模塑操作中，預(yù)型體典型地切用模切機(jī)成，將適合在多工位壓力機(jī)的轉(zhuǎn)移儲(chǔ)層的插頭。對(duì)于壓縮成型的應(yīng)用中，過程是稍微復(fù)雜一些，因?yàn)轭A(yù)成型件必須在最終的部件的基本幾何結(jié)構(gòu)進(jìn)行切割。
1. Prefabrication: once the high consistency elastomers are fully matched, the next step in the manufacturing process is the preparation of the preform. This does not require special equipment, but very labor-intensive, especially in essence, is almost continuous mass application. For extrusion and injection molding applications, the preform is cut into strips by cutting elastomer sheets, which are used for simple preparation of extruders. In the transfer molding operation, the preform is typically cut into die-cutting machines, and the plug is suitable for transferring the reservoir in the multi station press. For compression molding applications, the process is a little more complicated, because the preform must be cut in the final part of the basic geometric structure.
2、擠壓：對(duì)于高稠度彈性體，擠出是使用單螺桿擠出機(jī)完成。預(yù)成型帶被饋送到從輥進(jìn)給輪到擠出機(jī)機(jī)筒的擠出機(jī)，和彈性體是通過一個(gè)模具和心軸組件擠出形成所需的輪廓。另外，也可以進(jìn)行與高稠度硅氧烷彈性體支撐擠壓。這是通過一個(gè)十字頭組件裝配在擠出機(jī)中，通過在支撐幾何穿過十字頭，并在它擠出一層硅橡膠的實(shí)現(xiàn)。
2, extrusion: for high consistency elastomers, extrusion is done with a single screw extruder. The preform belt is fed to the extruder from the roller feed wheel to the extruder barrel, and the elastomer is extruded through a mold and spindle assembly to form the desired contour. It is also possible to support extrusion with high consistency silicone elastomers. This is done through a crosshead assembly in the extruder, through the support geometry passing through the crosshead and extruding a layer of silicone rubber.
適合于各種行業(yè)的應(yīng)用的擠出機(jī)的成本大約是10萬(wàn)美元，包括安裝。然而，大多數(shù)擠出系統(tǒng)制造者裝備他們的機(jī)器用激光微米和反饋控制器以監(jiān)測(cè)產(chǎn)品質(zhì)量，增強(qiáng)了顯著到設(shè)置擠壓工藝的成本增加。另外，擠出可以考慮勞動(dòng)密集的，因?yàn)樗枰僮髡咴谌魏螘r(shí)候都存在，以確保該擠出機(jī)具有彈性體的恒定供應(yīng)，運(yùn)行正常。
The cost of extruders suitable for various industries is about $100 thousand, including installation. However, most of the extrusion system makers are equipped with their machines using laser microns and feedback controllers to monitor the quality of the product, enhancing the significant increase in the cost of setting the extrusion process. In addition, the extrusion can be considered labor intensive, because it requires the operator to exist at any time to ensure that the extruder has a constant supply of elastic body and runs normally.
3、成型：高粘度硅應(yīng)用隨所用的成型設(shè)備的類型。傳遞和注塑成型工藝需要操作人員來加載彈性體進(jìn)入設(shè)備和脫模成品零件。對(duì)于壓縮模制，操作人員必須放置在各模具所有單個(gè)空腔預(yù)型件。因?yàn)榫哂懈哒扯葟椥泽w所采用的相對(duì)緩慢的固化周期的，它有可能為所述模具具有大量空腔。安裝轉(zhuǎn)讓或注塑機(jī)的成本大約為1000至2000美元每噸的夾緊力。壓縮成型機(jī)是相當(dāng)便宜。
3, molding: high viscosity silicon application with the type of molding equipment used. Transfer and injection molding processes require the operator to load the elastomers into the equipment and the moulded finished parts. For compression molding, operators must place all single cavity preforms in each mold. Because of the relatively slow curing cycle used by high viscosity elastomers, it is possible to have a large number of cavities for the dies. The cost of installing the transfer or injection molding machine is about 1000 to 2000 dollars per ton of clamping force. The compression molding machine is quite cheap.
4、硫化：擠出產(chǎn)品的硫化通常實(shí)現(xiàn)了與熱空氣硫化爐，或HAVS。這些HAVS是在水平和垂直配置。在水平模式中，擠壓型材通過烘箱，熱空氣被強(qiáng)制在擠出物以引發(fā)硫化機(jī)理鋪設(shè)在一個(gè)連續(xù)帶通過。在垂直爐結(jié)構(gòu)中，HAV配備有變速鼓在頂部通過烘箱，在那里它被固化向上拉動(dòng)擠壓型材。一個(gè)典型的HAV爐的成本大約是3萬(wàn)美元。其他類型的就業(yè)硫化爐包括輻射熱烤箱和蒸汽烤爐高壓滅菌。
4, vulcanization: vulcanization of extruded products is usually achieved with hot air vulcanizing furnace or HAVS. These HAVS are configured horizontally and vertically. In horizontal mode, the extruded profiles are passed through the oven, and hot air is forced on the extrudate to initiate the vulcanization mechanism in a continuous band. In the vertical furnace structure, the HAV is equipped with a variable speed drum at the top through the oven, where it is solidified upward to pull the extruded profiles. The cost of a typical HAV furnace is about 30 thousand dollars. Other types of vulcanizing furnaces include radiating hot oven and steam oven for autoclaving.
5、整理：整理所需的程度取決于具體的應(yīng)用。對(duì)于擠塑方法，精加工涉及視覺檢查和切割管材的成特定長(zhǎng)度。如果管子已經(jīng)固化用過氧化物，自動(dòng)整理處理也需要一個(gè)烤箱后固化副產(chǎn)物，以除去過氧化物。用于模塑應(yīng)用，精加工包括所述模制零件的修整或修邊，往往采用模切機(jī)械以從較大的模塑片材切成各個(gè)部分，以及任何烤箱后固化是必要的。除了浪費(fèi)材料，高濃度有機(jī)硅整理是勞動(dòng)密集型的，并且需要額外的設(shè)備，如烤箱和模切機(jī)。然而，這種設(shè)備是相對(duì)廉價(jià)購(gòu)買。
5, collate: the degree of sorting depends on the specific application. For extrusion methods, finishing involves visual inspection and cutting of pipes into specific lengths. If the pipe has been solidified with peroxide, the automatic finishing process also requires a curing by-product after the oven to remove peroxide. For molding applications, finishing or trimming of the moulded parts is usually made of die cutting machines to cut into parts from larger plastic sheets, and it is necessary for any oven to be cured after curing. In addition to wasting materials, high concentration organosilicon finishing is labor-intensive and requires additional equipment, such as oven and die-cutting machine. However, this device is a relatively cheap purchase.
