1

CHNG 2 THIT B N
1. Gii thiu Nhim v chnh ca thit b n l to nn p sut ln y vt liu qua khun. p sut ny ph thuc: cu trc hnh hc ca khun, tnh cht dng chy ca vt liu v tc chy. Plastics extrunder (thit b n nha): di chuyn, bm nha. Plasticating extrunder (thit b n gia cng): khng ch vn chuyn nha m cn lm nhuyn hoc nng chy vt liu nha. Vt liu dng ht rn c cp vo thit b v a nha nng chy n khun. Thit b n nha nng chy m khng lm chy nha c gi l melt-fed extrunder. 2. Cu trc my n

A: trc vt, B: thn my n (xylanh), C: thit b gia nhit, D: u o nhit

Bi ging Thit b CN polymer

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E: hng cp liu, F: Phu cp liu, G: gim p lc y, H: gim tc bng bnh rng, I: motor, J:vng cp liu, K: vng nn, L: vng y 3. Cc loi thit b n 3.1. Loi n trc vt Trong cng nghip cht do, c 3 loi my n chnh: n trc vt, n pittng, v n trng hay a (t s dng hn).

3.2. Loi hai trc vt: Loi 2 trc, cng chiu: Hai trc t cnh nhau, quay cng chiu vi nhau (Co-rotating twin screw extrunder). Dng tc cao 200 500 vng/pht (rpm). Cc loi thit b mi c th t tc 1000 - 1600 rpm.

Bi ging Thit b CN polymer

TS. L Minh c

Loi hai trc ngc chiu (counter-rotating twin screw extrunder): tc lm vic ph thuc vo ng dng. S dng ch yu phi trn (compounding), chy tc 200-500 rpm. Loi tc thp hay s dng hn, 10 40 rpm. Loi ngc chiu c c tnh vn chuyn tt hn so vi loi cng chiu. Mt c tnh khc phn bit my n l mc n khp vo nhau (screws intermeshing) ca cnh trc vt . Thng thng, cc trc vt xen vo nhau. Hai trc vt khng xen k nhau c u im l khng c tip xc gia kim loi-kim loi. T s L/D t n 100:1 hay cao hn. L/D ca trc vt xen k nhau thng nh hn 60:1. Mt nhc im ca loi hai trc khng n khp nhau l kh nng trn b hn ch. My n kiu pittng: nh pitttng to mt lc y vt liu i qua khun (Fig.5). Loi ny c vng y liu tt, to c p sut cao. Nhc im l kh nng lm nng chy vt liu thp. Thit b c th hot ng lin tc, tc dy chuyn rt thp, t 25-75 cm/h. 3.3. Cc thnh phn ca thit b n
3.3.1. Trc vt

Hnh tr di, c cc cnh xon xung quanh. Cc chc nng ca trc vt vn chuyn, gia nhit, nng chy v trn vt liu nha. n nh ca qu trnh lm vic, cht lng sn phm ph thuc nhiu vo trc vt.

Bi ging Thit b CN polymer

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Cc thng s quan trng ca trc vt Chiu di trc vt (L) khong 15D 30D; ng knh D; chiu su rnh vt (h); B dy ca cnh vt (axial flight width); Bc vt (Pitch); Gc nghin ca cnh vt (Helix angle)

Bi ging Thit b CN polymer

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Bi ging Thit b CN polymer

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3.3.2. Thn ca my n

C dng hnh tr. Bn trong c ph vt liu cng, chng mi mn. Trn thn my, c cc l thng kh thot cc cht bay hi c trong nha - gi l qu trnh tch kh (devolatilization). V d nh tch lng m trong nha ht m.

3.3.3. Cp liu

B phn cp liu c ni vo thn my n. Hng cp liu (feed throat) c h thng nc lm mt trnh hin tng nng chy vt liu, dnh vo thnh thit b. Chiu di ca hng khong 1,5 ln , rng khong ng knh ca thn my n. Mt s my n khng c hng cp liu, liu c a trc tip vo thn my n. u im: chi ph thp, t chi tit, khng kh khn b tr hng cp liu vi thn my n. Nhc im: rt kh to c cch nhit gia vng nhit cao thn my vi vng nht thp hng cp liu, rt kh lm lnh hng cp liu.
Bi ging Thit b CN polymer TS. L Minh c

Phu np liu c thit k sao cho m bo dng vt liu chy n nh. C cc thit b h tr gip qu trnh np liu n nh.

Bi ging Thit b CN polymer

TS. L Minh c

3.3.4. Gia nhit v lm lnh

Cc thit b gia nhit bng in c t dc theo thn my n. Cc my n thng c t nht 3 vng nhit dc theo chiu di ca thn my n. Cc my n di hn, c trn 8 vng nhit . Mi vng c h thng gia nhit v lm lnh ring, c sensor o nhit . Nhit thng o bn trong thn my. Khun c th c mt hay nhiu vng nhit ph thuc vo phc tp ca n. Khun thng c gia nhit, t khi phi lm lnh. Thn my n phi lm lnh nu nhit ca nha tng, trnh lm nhit ca thn my n tng qu gii hn cho php. iu ny cng xy ra tng t khi n nha c nht cao, tc n ln. Lm lnh c th bng khng kh. Qut gi t pha di my n, mi qut lm lnh cho mi vng.

Khi cn ly i mt lng nhit ln, c th dng nc. My n hot ng tt nht khi trc vt cp nng lng cho qu trnh, gia nhit hoc lm lnh cng s t i. Do vy, vi my n trc vt n, lm lnh bng khng kh l . Nc lm lnh qu nhanh s gy kh khn cho vic khng ch ng nhit .
3.3.5. un nng v lm lnh trc vt

Trc vt c un nng hay lm lnh pha bn trong trc vt, cht lng trao i nhit tun hon bn trong.
Bi ging Thit b CN polymer TS. L Minh c

3.3.6. Tm chn (breaker plate)

c t cui thn my n, l mt tm kim loi dy, dng a, c l. Mc ch chnh: cc li lc, ngn cn chuyn ng xoy ca nha nng chy khi ra khi trc vt. Tm chn hng nha chy theo mt ng thng vo khung. C th kt hp b phn khuy o vo tm chn ny. Tm chn khuy o ny c nhiu rnh nh dn, s chia nh dng chy, ko di dng chy.Thit b ny s ci thin khuy o phn b v phn tn.

Li lc nhin v: gi li cc tp cht. Thng thng, nhiu tm lc c kt li vi nhau, bt u l tm li th, tip n l cc tm li c kch thc nh dn, ri mt tm li th, p st vo tm chn. Tm li th sau cng ch lm nhim v tm li tinh. Sp xp cc li lc to nn hp lc (screen pack)
3.3.7. Hp lc (screen pack)

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Ngoi chc nng lc cc tp cht, hp lc cn lm tng khuy trn trong my n. Hp lc thng gm: li lc 20 mesh, tip n l 40, 60, 80, li 20 mesh c p st vo tm chn. (mesh: s dy kim loi an li trn 1 inch - 25mm, mesh cng cao, l li cng nh).

Micron rate: kch thc ht c th i qua li lc. So snh cc vt liu lm li lc

3.3.8. u to hnh (The Extrunsion Die)

u to hnh t u ra ca my n. To ra sn phm vi hnh dng mong mun. u to hnh dng vnh khuyn (annular die) dng to ng, bc dy in. u to hnh c khe (slit die) dng to mng mng, tm. u n circular die dng to sn phm dng si, que. u to hnh profile to cc sn phm c cc hnh dng khc. u to hnh c nh danh theo loi sn phm nn ta c th gi: u to hnh tm, mng mng . . .

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Knh dn vo ca u to hnh c thit k ph hp vi u ra ca my n. C 3 thnh phn chnh ca my n: knh dn vo (inlet chanel), mt a din (manifold) v vng phng (land region). Knh dn vo c thit k sao cho vn tc dng ct ngang ca nha nng chy l khng i trong sut qu trnh di chuyn.

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Trn hnh Fig.17, khi nha vo u to hnh, chy quanh torpedo. Qua cc u vng king (spider legs), nha chy thnh dng u n. Chy v nh chp, sn phm dng ng c to ra. V c rt nhiu bin nh hng n kch thc v hnh dng ca nha n nn rt kh d on chnh xc kch thc v hnh dng ca nha khi ra khi u to hnh. Chnh v iu ny, s rt kh khn khi tnh ton knh dng nha chy trong u to hnh c c sn phm mong mun. Thng thit k u to hnh ch yu da vo kinh nghim!! Trn Fig.18, l mt dng in hnh ca u to hnh ca my n ng thi (coextrunsion die) hay s dng trong cng nghip. u to hnh ny c th to ra sn phm c nhiu lp trong mt cng on. C hai h chnh: h cp (feed block system) v h nhiu l (multimanifold system). Trong h cp, cc dng nha khc nhau c kt hp v i vo u to hnh ca my n n.

Bi ging Thit b CN polymer

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Loi nhiu l, cc dng nha nng chy khc nhau i vo u to hnh ring bit, mi dng nha c mt l vo ring. Cc dng nha s kt hp vi nhau gn u ra to nn sn phm c nhiu lp.
3.3.9. ng c

ng c in dng ko quay trc vt. Tc quay ca ng c 1800 rpm. Tc quay ca trc vt thng 100 rpm. Do vy cn c b phn gim tc. Khi gn trc tip ng c v hp s - truyn ng trc tip (direct drive). Nu truyn ng qua dy ai (cu-roa) gia ng c v hp gim tc - truyn ng gin tip (indirect drive). ng c DC c s dng trong nhng nm 90, by gi thng s dng ng c AC. Screw Speed Variation at Different Screw Speeds

Bi ging Thit b CN polymer

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Cn phi s dng b gim tc, v tc ca motor ln hn nhiu so vi tc ca trc vt. Thng t l ny l 15:1 n 20:1; c th thp nht 5:1 v cao nht l 40:1. to ra n nh ca sn phm, bm bng rng (gear pump) c gn thm vo my n, t gia my n v u to hnh. Vt liu i vo vng khng gian gia hai bnh rng v di chuyn ln pha trc. Khi hai bnh rng bt u n khp vo nhau, nha nng chy b y ra khi bnh rng v i ra khi bm.

Bi ging Thit b CN polymer

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Nha trong bnh rng c bm bnh rng y, to ra n nh u ra tt hn l khng c bm bnh rng. Mt thun li khc l to ra mt p lc hiu qu cho my n. Bm bnh rng c s dng trong trng hp: i) n vi chnh xc cao, yu cu n nh u ra nh hn 1%, ii) khi my n khng to ra p lc, v d trong my n c thot kh cn hot ng p sut cao.

Tuy nhin, khi s dng bm bnh rng cn ch i) khi trong nha c cc ht n c tnh mi mn cao, bnh rng s b mi mn, lm gim chnh xc ca bm. ii) nha nng chy s hot ng nh l cht bi trn. Nu nha lu li trong bm lu (15 pht hay lu hn), vi nhit cao, nha s phn hu.

Bi ging Thit b CN polymer

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4. Mt vi dy chuyn sn xut c s dng my n 4.1. Dy chuyn to ng

4.2. Dy chuyn to mng hay tm phng

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4.3. Dy chuyn to mng bng cch c (cast film)

4.4. Ph nha ln cc vt liu khc

Bi ging Thit b CN polymer

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4.5. To lp

4.6. Thi mng

Bi ging Thit b CN polymer

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4.7. Trn bng my n

4.8. Dy chuyn n profile

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5. Cc cng on ca thit b n Cc chc nng ca my n: vn chuyn cht rn, nng chy hoc lm nhuyn do, trn, vn chuyn vt liu dng nng chy, tch kh, nh hnh sn phm. Cc chc nng ny c quan h qua li ln nhau. Chc nng ca mi vng trong my n ph thuc hnh dng my n, c tnh ca nha, iu kin hot ng ca my. Ranh gii ca cc phn trn trc vt l c nh nhng ranh gii ca cc vng chc nng c th thay i theo tnh cht ca nha v iu kin hot ng ca my n. 5.1. Vn chuyn vt liu rn Vt liu s di chuyn trong phu cp liu v dc theo phng bn knh ca trc vt. Trong phu cp liu, vt liu di chuyn do tc dng ca trng lc (gravity induced conveying). Dc theo trc vt, lc ma st tc ng ln nha, cch ny c gi l vn chuyn do lc ko (drag induced conveying). Trong vng vn chuyn vt liu rn, vng nng chy, vng vn chuyn vt liu nng chy, vt liu vn chuyn c cng theo c ch ny.
5.1.1. C ch trng lc

Dng chy kh phc tp trong vng ny. Khi vt liu gm ht c kch thc ln, nh, ht nh tch khi cc ht ln, to nn dng chy khng n nh trong phu. iu ny gy ra bt n nh u ra ca my n. Vi cc vt liu kh thao tc: phn b kch thc ht trong mt vng rng, mt khi thp, my n cn phi ci tin hot ng c hiu qu - ng knh vng cp liu ln hn vng xp t (metering section, vng y); hoc dng phu cp liu c vt ti. Trong mt s trng hp c th dng vng cp c rnh xon. Cc tnh cht khi quan trng: mt khi, nn, h s ma st trong, h s ma st ngoi, kch thc v phn b kch thc, hnh dng v phn b hnh dng ht. Mt khi l khi lng ring ca vt liu, k c th tch khong trng gia cc ht (khi lng/th tch). Mt khi ca vt liu sau khi to ht

Bi ging Thit b CN polymer

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thng bng 60% mt thng thng. Nu vt liu c mt khi nh hn 30% mt thc, vic vn chuyn s gp rc ri, cn phi thay thit b. Vt liu c nn cao s kh thao tc, d gp tr ngi trong phu cp liu. H s ma st trong l ma st gia cc ht nha vi nhau. H s ma st ngoi l ma st gia cc ht nha v cc b mt khc nh b mt xy lanh my n. Vic vn chuyn hiu qu khi c ma st trong v ngoi u nh. vn chuyn dc my n hiu qu, ma st thnh my n phi cao, ma st trc vt nh. Thit k phu cp liu nh hng ln n dng chy trong phu. Nn trnh vic ng li vt liu trong phu. Phu c tit din hnh trn tt hn tit din vung hoc ch nht.

m bo dng chy trong phu n nh, c th: i)khuy o nh vt liu, tch vt liu ra khi thnh phu, c hiu qu vi cc vt liu c bm dnh cao, ii) to rung ng trnh tc phu, ph lin kt cu (bridge) gia cc vt liu, iii) dng vt xon trong phu (crammer feeder) cp liu.

Bi ging Thit b CN polymer

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m ca hng cp liu cng nh hng n s vn chuyn ca vt liu trong my n. Vi loi vt liu c chy khi thp, cn m rng hng tip liu theo chiu ca di chuyn ca cnh trc vt.
5.1.2. Vn chuyn do lc ko

Do lc ma st nha s vn chuyn dc theo chiu di ca trc vt. Khi trc vt quay, lc ma st gia nha v trc vt y vt liu ln pha trc. Lc ma st no lm cho vt liu vn chuyn ln pha trc v lc no gi vt liu li.

Khi vt liu chuyn ln pha trc do trc vt quay, dng nh lc ma st gia nha v trc vt lm cho vt liu tin ln pha trc. Nghe c v hp l, nhng thc ra khng hon ton din ra nh vy. Lc ma st ti thnh my n y vt liu tin ln pha trc. Nu thnh my n khng c ma st, vt liu s ri vo cc rnh ca trc vt v ch c chuyn ng trn. Thc vy, ma st trn thnh my n l iu kin cn vn chuyn vt liu ln pha trc. Khng c ma st s khng c vn chuyn.
5.1.3. Cp ngho vt liu (starve feeding)

Vt liu ri trc tip vo trc vt, khng lu li phu cp. Vt liu ph mt lp trn rnh vt ch bng vi ln ng knh trc. Khi rnh trc vt khng y hon ton, p sut trn vt liu nha s khng tng, t nhit sinh ra do ma st v khuy trn.

Bi ging Thit b CN polymer

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Cch cp liu ny s gim chiu di hiu qu ca my n, c li nu my n di hn chiu di cn thit trong qu trnh gia cng. Tuy nhin, khi chiu di ti hn, cch cp liu ny s dn n hot ng km hiu qu. Vi my n hai trc vt tc cao, cch cp liu ny kh ph bin. Vi my n n trc th t ph bin hn. Kiu cp liu ny cn gim ti cho ng c ca my n, gim nhit to ra khi nha nng chy, c th b sung nhiu thnh phn phi trn ch cn mt cng cp liu. Trong cng on trn, phi trn cp ngho vt liu hay c s dng v c th loi b c s vn cc ca cht n.
5.1.4. Cp liu c rnh xon

ng lc vn chuyn vt liu l lc ma st ca b mt thnh trong ca my n. Lc ma st c th b nh hng bi nhit thnh xy lanh. Tuy nhin nh hng ny khng ln. Mt phng php tng ma st thnh xylanh l gia cng cc rnh b mt trong. Vic ny s nh hng kh ln n c tnh cp liu ca my n. Rnh thng chy dc theo thn my, chiu di khong vi ln ng knh. Pha ngoi cc phn c rnh, thng c lm lnh trnh nha nng chy ti cc v tr ny.

Trn hnh Fig.34, cc rnh phn cp liu ca my n c th iu chnh c. C th thay i cch vn chuyn vt liu ph hp vi c tnh ca nha v cu trc my n. C th iu chnh trong lc my ang vn hnh.
Bi ging Thit b CN polymer TS. L Minh c

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Nhu vy, c th t c nh su ca rnh c c dao ng p lc l nh nht ti u ra ca my n. Mt vi u im: 1)nng sut t ph thuc vo p lc ra nn n nh ca qu trnh n c ci thin 2) nng sut cao hn 3) c th n loi nha c khi lng phn t cao

Nhc im: 1)Phi lm lnh phn c rnh trnh hin tng nng chy nha trong rnh. iu ny lm gim hiu sut nng lng v my n hot ng phc tp, 2) Xut hin ng lc (stress) cao trong rnh, gy mi mn. Cn quan tm n vic la chn vt liu, 3) p sut trong rnh ln, 70 140 Mpa. Thnh my n phi chu c p sut ln. 4)My n loi ny c thit k c bit. Nu thit k bnh thng s gp kh khn nh qu nhit ca nha, lp kim loi chng mi mn 5) Ti trng ln cho ng c, lc xon cho trc vt ln. tng hiu qu vn chuyn, ngoi tng ma st ca thnh my n, cn c th gim ma st trn trc vt. Thc hin bng cch: thit k trc vt thch hp, nhit trc vt, vt liu lm trc vt.

Bi ging Thit b CN polymer

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Gim ma st trc vt c th thc hin bng vic t nng bn trong trc vt (dng du trao i nhit). Mt cch khc, t b phn gia nhit bn trong trc vt. X l hoc ph mt lp kim loi khc ln b mt trc vt c th gim ma st b mt. 5.2. Nng chy Nng chy trong my n xy ra khi nha t n nhit nng chy. C hai dng nng chy xy ra trong my n
5.2.1. Nng chy tip gip(contiguous solid melting CSM)

Cc ht rn b nn cht, quay dc theo chiu di ca knh trc vt. Mt lp nha nng chy mng hnh thnh gia cc ht rn v thn my n. Nng chy thng xy ra gia b mt tip xc pha gia ht rn v mng nha nng chy.

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Nha tip tc nng chy c thu vo trong mng nha, nhng b y ra, p vo cnh trc vt ang hot ng. Kiu ny thng thy vi my n n trc vt.
5.2.2. Nng chy phn tn (dispersed solid melting DSM)

Cc ht rn phn tn trong mt mi trng nng chy. Chng gim kch thc cho n khi chy hon ton. Kiu nng chy ny thng thy trong my n hai trc vt, my n n trc phi trn. Theo chiu di ca trc, nng chy xy ra im 1 2D. Trong my n n trc chiu di ny l 1015D

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y l im khc bit quan trng ca my n n trc v hai trc vt. Trong my n n trc vt, vng vn chuyn v nng chy ca vt liu khong 15-20D. iu ny c ngha trong my n 25L/D, khng nhiu khong trng cho vic vn chuyn nng chy, trn v tch kh. Nu tch kh, chiu di ca my n phi 30-35D. Trong my n hai trc vt, vng vn chuyn v nng chy vt liu ch c th rng n 5-6D. Nu my n hai trc vt di 30D, c ngha vn cn khng gian cho trn, tch kh, phn ng ho hc. Do my n hai trc s dng linh hot hn my n n trc. L thuyt CSM do Tadmor pht trin nhng nm 60. Chng ta c th xc nh s nh hng ca tnh cht nha, iu kin gia cng, cu trc ca trc vt n nng chy ca nha. C hai ngun nhit cho nng chy. Ngun nhit t bn ngoi thn, qua mng nha nng chy ri n lp vt liu. Mt ngun khc l nhit nht (viscous heating) trong mng nha nng chy. Lng nhit nht ny xc nh bng nht ca vt liu v tc trt trn mng nng chy. C ch nng chy ny c gi l di chuyn nng chy do ko (drag induced melt removal). Vt liu nng chy khi to ra thm vo mng nng chy b ko ra khi vng nng chy do trc vt quay. Do vy, mng nng chy cn li rt mng, gii hn duy tr tc nng chy cao. Nu cc cht va b nng chy khng c y ra, chiu dy mng nng chy s tng dn, hiu sut nng chy gim nhanh chng. L do ny gii thch trong my n n trc, hiu sut nng chy cao hn nhiu so vi my n pittng v cng l l do trong cc my n thi ln, thng s dng my n trc vt hn l my n pittng (ram extrunder). Chiu dy ca mng nng chy r rng l mt thng s quan trng trong qu trnh nng chy. Mng nng chy mng l quan trng duy tr hiu sut nng chy cao. Khi mng nng chy mng, s to ra nhit nht cao trong mng nng chy v nhit t thnh my n truyn n khi vt liu rn nhanh

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chng hn. Chiu dy ban u ca mng nng chy l khong h ca cnh trc vt (flight clearance). Khong h cng ln, mng nng chy cng dy. Trc vt hay thnh my n b mn s lm tng khong h, s nh hng khng tt n qu trnh nng chy ca nha v hot ng chung ca my n. Khi tng nhit thnh xylanh, nha c cp nhiu nhit nng chy. Nhit cao, nht ca mng nha nng chy, sinh nhit nht gim. Nu gim sinh nhit nht nhiu hn nhit thn my n th hiu ng tng cng l gim tc nng chy. iu ny nghe c v khng ng. Tuy nhin, khi tc trc vt cao, nhit sinh ra ch yu l nhit nht.

Gc xon ca cnh trc vt nh hng ln n hiu qu nng chy. Khi gc tng, nng chy hon ton, chiu di nng chy trn trc gim. Hiu qu nng chy cao nht khi gc nghing 90o. Gc nghing ny tt cho vic nng chy

Bi ging Thit b CN polymer

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