固体粉末与聚合物在不同混炼元件中的混合性能

运用聚合物加工专用有限元软件Polyflow,对非啮合同向双螺杆挤出机混炼元件、非啮合异向双螺杆挤出机混炼元件以及双转子混炼机混炼元件,针对固体粉末在聚合物中的混合进行了数值模拟.在停留时间分布、累积最大剪切应力分布及分离尺度等常见评价参数的基础上,用固体粉末团聚体粒径尺度分布函数,来直观表征各混炼元件对固体粉末分散性能的影响.结果表明:双转子混炼元件对聚合物中固体粉末团聚体的分散、分布混合效果最好.     

双转子混炼机中固体粉末与聚合物共混的数值模拟

利用聚合物加工分析软件POLYFLOW模拟了双转子连续混炼机中固体粉末在聚合物中的混合过程,并对不同转子转速下的三维等温非牛顿流场进行了流场和动态混合计算和统计学后处理。采用累积停留时间分布表征混合物的轴向混合性能,用团聚体累积粒径尺度分布表征固体粉末团聚体在聚合物基体中的分散状态,直观反映出团聚体在聚合物流场中粒径的变化情况,并用分离尺度分布表征混合物的分布混合性能。结果表明：在一定范围内提高转子转速有利于固体粉末/聚合物的分散、分布混合性能,确定合理的转速范围对于获得高性能聚合物复合材料至关重要。     

密炼机中碳黑/橡胶混炼的数值模拟

本文利用聚合物加工分析软件POLYFLOW模拟了密炼机中碳黑在橡胶中的混合过程,采用团聚体累积粒径尺度分布函数表征碳黑团聚体在橡胶中的分散状态,以直观反映出碳黑团聚体在橡胶流场中粒径的变化情况;并用分离尺度表征混合物的分布混合性能。模拟结果表明：要得到良好的碳黑/橡胶混炼效果,提高密炼机的使用效率,必须有合理的转子转速与混炼时间,数值模拟可以为实际加工提供理论指导。     

密炼机中炭黑与橡胶混炼的数值模拟

利用聚合物加工分析软件POLYFLOW模拟密炼机中炭黑与橡胶的混合过程,采用团聚体累积粒径分布函数表征炭黑团聚体在橡胶中的分散状态,以直观反映炭黑团聚体在橡胶流场中粒径的变化情况;利用分离尺度表征混合物的分布混合性能。模拟结果表明：要得到良好的炭黑与橡胶混炼效果,提高密炼机的使用效率,必须有合理的转子转速与混炼时间。     

啮合同向双螺杆挤出机中组合螺杆性能的数值研究（Ⅱ）混合特性分析

采用有限元软件POLYFLOW,对组合式啮合同向双螺杆挤出机ZSK60中不同构型的组合螺杆进行了混合分析。通过计算螺杆转过不同角度时的拟稳态流场,采用粒子示踪分析(PTA)方法,对组合螺杆中聚合物熔体的动态混合过程进行了可视化模拟;在此基础上通过对大量粒子运动轨迹的统计处理,分别采用停留时间分布、分布混合指数、分离尺度等累积混合指数表征了组合螺杆的轴向混合性能、分布混合性能以及分散混合性能。此外还研究了不同工艺条件下组合螺杆的混合特性。并将部分数值模拟结果与前人实验研究进行了对比。     

三螺棱孔型拉伸单元加工聚合物混合性能模拟

为解决普通螺杆单元对聚合物粒子混合效果较差的问题，提出了三螺棱孔型拉伸单元，并且，利用流体仿真软件Polyflow与普通螺杆单元加工聚合物进行了模拟对比。结果表明，孔型拉伸单元的聚合物粒子的混合指数分布区间更高，以大于0.5区域为主，最大混合指数达0.778 9;孔型拉伸单元的最大剪切应力集中分布在0.06～0.08 MPa之间，与普通螺杆单元的0.04～0.06 MPa相比较高；孔型拉伸单元的聚合物粒子经历的累积停留时间更长，集中分布在6 s以上，普通螺杆单元的集中分布在4～6 s;孔型拉伸单元的分离尺度曲线下降更迅速，当在轴向长度为20 mm时，迅速下降至最低点；当轴向长度为20～70 mm时，曲线平缓无波动，聚合物粒子无团聚现象。因此，孔型拉伸单元对聚合物粒子的分散混合和分布混合的能力大于普通螺杆单元，孔型拉伸单元能够提高聚合物粒子的混合效果。     

螺杆转速对热熔挤出吲哚美辛混合性能的影响

热熔挤出技术已成为一种制备药物固体分散体的新方法，螺杆转速作为挤出过程中的工艺参数对药物的混合具有重要影响。以吲哚美辛(INM)和聚乙二醇(PEG10000)为原料，设计了挤出机混合段螺杆构型，采用Polyflow进行数值模拟，基于加权平均剪切应力、累积最大剪切应力分布、累计停留时间分布和平均回流系数，分析螺杆转速对INM混合性能的影响。同时，以INM为原料药，采用热熔挤出技术制备了不同螺杆转速下的挤出样品，使用扫描电子显微镜(SEM)和溶出实验对样品进行表征。结果表明，在一定范围内，随着螺杆转速的增大，药物的分散混合和分布混合性能增强，但是，螺杆转速较大会导致药物分布混合性能降低，不利于药物的混合。     

基于香农熵的超细粉体填料混合均匀度的评价研究

以香农熵理论为基础,提出了一种量化表征超细粉体填料在基体中混合均匀度的方法。以高密度聚乙烯/碳酸钙(PE-HD/CaCO3)复合材料为研究对象,首先用Photoshop和Image-pro-plus对样品扫描电子显微镜照片中的颗粒和团聚体尺寸进行统计,计算出了相对香农熵和团聚系数,分别表征超细铝粉的分布混合和分散混合,然后引入混合系数对混合均匀性进行综合评价。结果表明,添加了分散剂的PE-HD/CaCO3,CaCO3混合系数较高,拉伸强度和弯曲强度较大,验证了此方法对超细粉体填料混合均匀度评价的适用性。     

聚合物熔体中团聚体分散问题的研究进展

从团聚体结构和外界流场对团聚体的应力作用两个方面综述了各因素时团聚体分散过程的影响。讨论了不同的团聚体强度模型、“腐蚀”和“破碎”分散方式厦其影响因素，并对团聚体分散效果进行了理论分析。评价了相关模型的特点和局限性，所提出的理论模型厦模拟研究对混合设备中实际分散过程的深入研究具有指导意义。     

固体推进剂同向双螺杆元件混合性能模拟

首先设计了4种固体推进剂用螺杆元件,并进行了固体推进剂药浆的流变性能测试,通过使用Polyflow软件对4种螺杆元件的流场进行数值模拟。对各螺杆元件流场的剪切速率、加权平均剪切应力、平均回流系数、累积停留时间分布等表征螺杆元件混合性能以及流场特性的指标进行分析,对比4种螺杆元件的分散和分布混合性能,并建立了螺杆元件混合性能的评价体系。结果表明,KB元件和S型元件对药浆有较好的综合混合性能,有利于固体推进剂的混合。     

Polymer powders mixing part I: Mixing characterization in rotating cylinders

In the production of rotomolded parts, the distribution of particle sizes in the form of polymer powder is highly important to produce parts of good quality. In the case of polymer blends, the particle size distribution becomes even more important to assure that good mixing occurs before the polymer melts. In this work, the mixing of free flowing polymer powders in a horizontal rotating cylinder has been studied. Special attention is given to the initial moments of mixing and the transition from a standstill to a fully developed rolling regime. The parameters studied include Froude number (rotational speed), cylinder loading, relative powder composition and particle sizes. For the first time, mixing dynamics are quantified using two image analyzes: grey-level co-occurrence matrix (GLCM) and Threshold methods. Using the experimental data, a model is proposed to follow the mixing dynamics and to determine the equilibrium time. The results also indicate that the Froude number is not enough to characterize the flow regime and the filling ratio must be accounted for.     

Predicting the effect of viscosity ratios on the mixing of polymer blends using the boundary element method

Mixing or blending two or more fluids of different viscosities is an important and complex issue in the polymer industry. Simulating these types of processes leads to a better understanding of the flow phenomena that take place during mixing. The boundary element method is ideal to simulate mixing flows, because of the large deformations and moving boundary nature of internal batch mixers and extruders. This paper presents a boundary element simulation of the flow of multi-viscous polymer blends inside extruders and internal mixers. In addition, the governing equations, boundary integrals, and their numerical implementation for creeping flows are presented. The simulation is used to predict the mixing quality of polymer blends in realistic mixing processes. A model describing the relationship of drop strain to matrix strain as a function of viscosity ratio is also presented. The flow simulation results are in good agreement with analytical and experimental results.     

复合工艺对压电复合材料性能的影响

采用直接混合和溶液混合两种不同的复合工艺,将铌锌锆钛酸铅（PZN—PZT）压电陶瓷粉体分散于有机聚偏二氟乙烯（PVDF）基体中,制备了0—3型PZN—PZT／PVDF压电复合材料。研究了复合工艺对压电复合材料性能的影响。结果表明,采用溶液混合法能有效地改善陶瓷的分散性及复合材料的压电性,当陶瓷质量分数为90％时,压电复合材料的压电常数d33达到33．4pC·N^-1。     

“Dry latex.” A new method for the preparation of rubber-filler powders

A new method of preparing rubber powders, especially masterbatch powders, is described. It consists of the dispersion of polymer latices in highly hydrophobic fine particle-size powders such as special silicas and carbon black, followed by drying. During the whole procedure the powders never lose their pourable state. Several powder properties, e.g., particle size distribution, pourability, bulk density, and angle of repose, are dealt with for NR and SBR powders. These powders require a high shear processing stage to disperse the black and rubber chemicals into the rubber matrix. For direct extruder feeding, a highly efficient extruder mixing screw is necessary. It is shown that the powders can be sufficiently protected against aging by use of special antioxidants. The procedure is characterized by an outstanding simplicity in respect to engineering and equipment. The future outcome of the method will depend on the balance between that simplicity and the energy demand which can be tolerated.     

转子结构和工艺参数对双转子连续混炼机混合性能的影响

利用POLYFLOW软件,对聚合物熔体在双转子连续混炼机混炼段的拟稳态流场进行数值模拟,采用粒子示踪分析方法对物料所经历的流场特性进行统计学分析。得到了平均剪切应力、停留时间分布、累积最大拉伸速率等参数,通过其分析了转子结构和工艺参数对双转子连续混炼机混合性能的影响。结果表明,转子转速的提高使得物料所经受的剪切和拉伸作用增强;喂料速率的提高,使比剪切速率减小,物料在混炼段的停留时间变短;螺棱交汇区长度减小,流场中的剪切作用增强,螺棱交汇区长度和螺棱包角对停留时间分布的影响不大。最后对数值模拟的结果进行试验验证,结果基本一致。     

单螺杆挤出机中非牛顿流体层流混合停留时间表征

基于有限差分数值模拟技术,提出了计算非牛顿流体在单螺杆挤出机内停留时间分布的半解析方法,得到了不同操作参数下的停留时间分布,该分布可用来表征聚合物熔体在加工过程中的混合情况.结果表明：半解析方法能够反映由流体的非牛顿性所导致的耦合流场及压力反流对混合的影响,能更真实地反映聚合物熔体在单螺杆挤出机内的混合程度.     

单螺杆挤出过程固体输送段的数值模拟

介绍了挤出成型过程数值模拟的现状及现有通用计算流体力学(CFD)软件在模拟聚合物流动时存在的缺陷，指出自主开发CFD程序的必要性。针对单螺杆挤出过程固体输送段的数值模拟方法，讨论了传统塞流固体输送理论的缺陷，介绍了非塞流固体输送理论的优越性及相关的有限元计算方法。并针对有限元方法的复杂性，介绍了简化的三层模型方法。计算结果表明：非塞流固体输送理论的三层模型法与有限元法计算结果接近，且优于塞流固体输送理论，而三层模型法计算方法简单，便于其在工程计算中的应用。     

错位桨搅拌槽内污泥与固体颗粒混合过程的数值模拟

以直径1 m的搅拌槽为模型、含水率92%的污泥和粒径0.1 mm的固体颗粒为工作介质,采用Fluent软件对错位六叶螺旋桨搅拌下污泥与固体颗粒的混合过程进行数值模拟,通过与普通六叶螺旋桨对比,分析了2种桨型的浓度场分布、混合时间及单位体积混合能,并将计算的固体颗粒浓度分布与实验结果进行了比较. 结果表明,固体颗粒浓度分布计算结果和实验结果吻合较好,流动场分布对混合过程有一定影响,相同条件下错位桨搅拌的浓度场分布更快趋于稳定. 当转速N=4 r/s时,错位六叶螺旋桨的混合时间为27 s,比六叶螺旋桨的混合时间缩短9 s. 采用错位桨单位体积混合能仅为普通桨的79.6%,节能效果显著.     

Preparation of composite particles made from solid powders and wasted plastics by semichemical recycle method

Composite particles composed of solid powders and polymer were prepared by semichemical recycle of wasted plastics. Waste expanded polystyrene was used as raw materials of polymer matrix of composite particles. Both magnetite and silicon carbide powders were used as solid powders to give thermal and electric conductivity and magnetization, respectively. In the experiment, the oil‐phase dissolving expanded polystyrene was dispersed in fine droplets into the continuous water phase. Two kinds of powders were added at the same time or separately in the O/W dispersion. Composite particles were found to have the structure that polymer particle was covered with two kinds of solid powders. The mean diameter of composite particles and the content of each solid powder were strongly affected by the addition time when silicon carbide powder was added into the dispersion. Furthermore, it was found that the gradient adhesion layer due to two solid powders was able to be formed on the surface of polymer particle. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 483–488, 2003