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Development of a new machine and a new production procedure for rubber compounds

In contrast to existing procedures, the smallest amounts can be produced with the new machine according to demand. The new production process saves energy, reduces stock-keeping and creates independence from large compound manufacturers.

The goal of the project is the development of a new machine facility (mixer) and a new process for the production of rubber compounds according to demand and in the smallest amounts. The machine is to be designed in further development steps in such a way that rubber compound production and the extrusion of rubber profiles made of the compounds can be run on-line on this machine. At present, rubber compounds are produced by large machines and in large quantities. Similar to the production of paste in bakeries, the constituent substances of the rubber compounds are mixed and kneaded by large agitators. This production method requires a large amount of minimum purchase quantities and huge stock-keeping. Therefore, produced rubber compounds have a short preserving time (from 8 to a maximum 30 days) depending on their chemical specifications and must be stored in a refrigerating chamber at certain temperatures. Instead, the new machine will make it possible to produce the smallest quantities according to demand. It is a completely new manufacturing process. The raw materials are not mixed in large agitators, but will be pumped through several pouring holes and vacuum pumps to a special cylinder in two phases (see below). There they will be mixed up to become rubber compounds through a mixing and a carriage screw. The supply of the constituent substances will be controlled by electronic metering units. In contrast to an agitator, the new machine uses a carriage screw to do the mixing up of the substances. Both the vacuum cylinder and screw geometry must be completely invented. Raw materials for phase 1 of the new manufacturing process are: - Kautschuk, Parfin Oil (filler neck 1) - Kalsit (filler neck 2) - Carbon (filler neck 3) - Zinc Oxide (filler neck 4) Raw materials for phase 2 of the new manufacturing process are: - Stearic Acid (filler neck 5) - Calcium Oxide (filler neck 6) - Mebithizol, Tetramethylthiuram Disulphide, Zinkdiethyldithiocarbamat (filler neck 7) The development process will show whether or not it is useful to work with two different vacuum cylinders in order to improve the control of different environmental impacts (such as pressures, temperatures). Furthermore, it will be examined whether or not a double-screw would better fulfil the requirements of transport and the simultaneous mixing up. The aim is to produce the required rubber compounds (with shore hardness of 50 to 90) according to demand and production requirements at our own premise. Thus the rubber compounds fulfil the best preconditions of both compound temperature and pressure produced in the cylinder for the further processing (extruding). We already planned to design the machine in pursuing development steps in such a way that there is an extruding head with appropriate tools at the outlet opening of the vacuum cylinder. This would revolutionise the current production procedures fundamentally. The new machine and the new production process will be applied as a patent.
Acronym: 
RUBBER MACHINE
Project ID: 
4 076
Start date: 
01-06-2007
Project Duration: 
16months
Project costs: 
540 000.00€
Technological Area: 
Moulding, injection moulding, extrusion, sintering
Market Area: 
Hoists, cranes and conveyors

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.