阅读说明：本技术 一种橡胶膨胀节缠绕成型制造方法 (Winding forming manufacturing method for rubber expansion joint ) 是由 钟浩明 方燚 范志平 朱静 刘彬 于 2020-04-11 设计创作，主要内容包括：一种橡胶膨胀节缠绕成型制造方法,橡胶膨胀节由下述组分制成：基础生胶;补强填充剂;增容填充剂;特殊填充剂;工艺操作助剂;硫化活性剂；橡胶防护助剂；硫化剂；硫化促进剂；其制造方法如下：一、将橡胶生胶加工成橡胶混炼胶胶体；二、预成型橡胶板制取；三、预成型擦胶帘子布制取；四、内层胶板的缠绕贴合成型；五、划线隔离；六、内补强帘子布缠绕贴合成型；七、橡胶膨胀节外帘子布缠绕贴合成型；九、橡胶膨胀节外层橡胶缠绕贴合成型；十、排气、绷带定型、棉绳压紧压实；十一、最终定尺；十二、整体二段硫化。本发明提高了产品质量、使用性能和使用安全性,延长了使用寿命,适用范围广。(A winding forming manufacturing method of a rubber expansion joint comprises the following steps: base crude rubber, reinforcing filler, bulking filler, special filler, process operation auxiliary agent and vulcanization activator; a rubber protection aid; a vulcanizing agent; a vulcanization accelerator; the manufacturing method comprises the following steps: firstly, processing raw rubber into rubber compound rubber colloid; secondly, preparing a preformed rubber plate; thirdly, preparing pre-formed rubberizing cord fabric; fourthly, winding, fitting and molding the inner layer rubber plate; fifthly, scribing and isolating; sixthly, winding, fitting and molding the inner reinforcing cord fabric; seventhly, winding, fitting and molding the outer cord fabric of the rubber expansion joint; ninth, the outer layer of the rubber expansion joint is formed by winding, laminating and molding rubber; tenthly, exhausting, shaping a bandage, and compacting a cotton rope; eleven, final sizing; and twelve, integral two-stage vulcanization. The invention improves the product quality, the service performance and the use safety, prolongs the service life and has wide application range.)

1. The winding forming manufacturing method of the rubber expansion joint is characterized in that the rubber expansion joint is prepared from the following components in parts by weight: 100 parts of base raw rubber or 100-150 parts of oil-extended base raw rubber, 20-60 parts of reinforcing filler, 10-40 parts of bulking filler, 5-35 parts of special filler, 5-25 parts of process operation auxiliary agent, 2-8 parts of vulcanization activator and 0.5-4.5 parts of rubber protection auxiliary agent; 0.2-5.0 parts of a vulcanizing agent; 0.1-2.5 parts of a vulcanization accelerator; the manufacturing method comprises the following steps:

step one, adding the raw rubber into various rubber compounding agents, and mixing the raw rubber into various rubber compound colloids with processability through rubber mixing equipment

Respectively metering and adding the rubber into a rubber internal mixer according to the shaping formula proportion confirmed by the process for pressure internal mixing, and mixing to obtain various rubber compound colloids;

step two, preparing preformed rubber plate

Purifying rubber of the rubber compound processed in the step 1 by filtering rubber → extruding and bracing → cooling to 5-35C ° → long pin type cold feed extrusion → duckbill type extrusion → double-roller calender pressing → sending air cooling → four-roller cooling to 35-45C ° → tension-free coiling → preparing rubber expansion joint preformed rubber plate;

step three, preparing pre-formed rubberizing cord fabric

Preparing rubber compound colloid of rubber wiping rubber of the cord fabric according to the method and the formula proportion in the step 1, and discharging the rubber compound colloid of the cord fabric through an open mill → isolating liquid isolation → air duct conveying and cooling → slicing → feeding of a four-roll calender → tensioning of the rubber dipping cord fabric → rubber wiping on two sides of the rubber dipping cord fabric → isolating of the pad fabric → pre-tightening and rolling → pre-forming of the rubber wiping cord fabric;

step four, winding, laminating and forming of inner-layer rubber plates

1) Calculating the blanking size, the forming thickness and the forming layer number of the rubber plate 10 at the inner layer of the rubber expansion joint according to the size of the repeatedly used formed rubber mountain 13 in the rubber expansion joint forming die and the structural length of the product and the design drawing and the process construction requirements, and blanking the preformed rubber plate prepared in the second step; 2) fixing the initial part of the preformed rubber plate which is blanked in the step 1) on two sides of a reusable preformed rubber mountain 13 along two sides of the middle of the preformed rubber plate which is formed by winding by using a process exhaust needle, starting a rubber expansion joint forming machine (not shown in the schematic drawing) to rotate a rubber expansion joint forming core 1 clockwise at a low speed, stopping rotating when the initial part is rotated, coating a chemical cleaning tackifier on the outer surface of the initial part of the preformed rubber plate within the range of about 10mm, then carrying out joint lapping, carrying out rolling compaction along the lapping part by using a compression roller (not shown in the schematic drawing), and simultaneously carrying out compaction and compaction along the bottoms of two side mountain feet of the reusable preformed rubber mountain 13 by using the compression roller; starting the rubber expansion joint forming machine to rotate the rubber expansion joint forming core 1 clockwise at a medium speed or a low speed, wrapping the wound and formed preformed rubber plate outwards from the bottoms of the two mountain soles of the repeatedly used formed rubber mountain 13 by using a water-coated cloth bandage which is the same as the formed water-coated cloth bandage 11, ensuring that the next layer of bandage is pressed on the previous layer of bandage during wrapping, ensuring that the bandage is tightly pressed by force during wrapping to well form and exhaust the bandage, and stopping the rubber expansion joint forming machine after winding is finished; finishing the shaping time of 15-30 minutes according to the specification requirement, starting the rubber expansion joint forming machine to rotate the rubber expansion joint forming core 1 anticlockwise at a high speed to remove a rolling shaping bandage, wiping the surface to dry the surface, brushing a chemical reagent, cleaning to remove surface impurities and tackifying;

step five, scribing isolation

Calculating the part of the rubber expansion joint needing flanging and fitting according to the design drawing and the structural length of the product required by the construction process; marking along the circumference of the symmetrical proper parts on two sides of the molded rubber mountain 13 by using a marking pen, beating the rubber surface of the part needing flanging and jointing outside the mark by using an isolation bag to apply isolation powder, and cleaning and tackifying the part polluted by the isolation powder on the rubber surface in the marking line by using a chemical cleaning agent;

step six, winding, laminating and forming the inner reinforcing cord fabric

Calculating the blanking size of the preformed rubber-coated cord fabric prepared in the third step according to a design drawing and the structural length of a product required by a construction process, calculating the blanking cutting angle of the preformed rubber-coated cord fabric prepared in the third step by 30-60 degrees according to the rubber expansion joint rubber mountain-shaped structure, the compressive strength grade and the construction process mode, and cutting the required number of the rubber-coated cord fabrics according to the cutting angle, the perimeter size and the rubber expansion joint inner cord fabric layer 9 required by the construction process and the door width blanking of the preformed rubber-coated cord fabric prepared in the third step;

winding, laminating and forming the pre-formed rubber-wiping cord fabric after blanking according to the manufacturing process mode of the fourth step, alternately winding and laminating every two adjacent layers in a positive-negative symmetrical mode according to the cutting angle to form compression-resistant layers with warp threads densely arranged at 90 degrees, compressing and compacting the surfaces of the compression-resistant layers and the bottoms of the two side feet of the reusable formed rubber mountain 13 by using the same compression roller of the fourth step, respectively applying pretightening force to the bottom parts of the two side feet of the reusable formed rubber mountain 13 after the cord fabric in the two layers which are adjacent to the bottommost layer in the positive-negative direction is formed, and starting a rubber expansion joint forming machine to rotate clockwise at a low speed for winding, tightening and compacting;

winding and forming the other inner-layer rubber-coated cord fabric layers according to the requirements until the required number of the winding and forming cord fabric layers meets the requirements of drawings and construction processes to form the rubber expansion joint inner cord fabric 9 (comprising all the inner-layer winding and forming cord fabric layers); note that multilayer layering (two adjacent layers are alternately wound and laminated in a positive and negative direction according to a cutting angle) winding, forming and laminating are adopted, the lap joint of each layer of formed cord fabric is approximately symmetrically and uniformly distributed in the circumferential direction, each layer cannot be in the same position, and the lap joint width is about 5-15 mm; compacting, shaping, exhausting and removing every two layers of cord fabric layers by using similar 11-shaping bandages (water-wrapped cloth bandages) according to the winding and compacting mode in the step 5; the winding forming layer number of the cord fabric is only even number so as to ensure that the warp of the cord fabric is densely arranged at an angle of approximately 90 degrees to form a good pressure-resistant layer

Scribing and isolating every two layers of cord fabrics according to the mode shown in the step five; after the rubber expansion joint inner curtain cloth 9 is completely wound and formed, pretightening force is respectively applied to the bottoms of the two side feet of the formed repeatedly-used formed rubber mountain 13 by using curtain wiring strips with the width of 5-30 mm, and a rubber expansion joint forming machine is started to rotate clockwise at a low speed for winding, tightening and compacting;

seventhly, mounting a flange assembly matched with the rubber expansion joint

Loosening a rubber expansion joint molding side plate 5 on a rubber expansion joint molding core 1 and a connecting bolt 4 and a nut 3 of a rubber expansion joint matching flange component 6, trying to sleeve a reinforcing insertion tube 6-2 of the rubber expansion joint matching flange component 6 on a rubber expansion joint inner layer rubber 10 and a rubber expansion joint inner cord fabric 9 layer which are qualified in winding molding, determining to use intermediate rubber (not shown in the figure) to adjust according to a matching gap so as to enable the rubber expansion joint inner layer rubber and the rubber expansion joint inner cord fabric to be in gapless matching, and carrying out fixed-length installation on the rubber expansion joint matching flange component 6 according to the requirement of the product structure length;

according to the sealing structure type and the sealing surface size of the rubber expansion joint of the flange component 6 matched with the rubber expansion joint, transition rubber of the sealing surface is jointed, the surface of tackified transition rubber and the surface of flanged cord fabric are cleaned by a chemical cleaning agent, and flanged joint of every two layers of cord fabric is respectively carried out; during the process, the surface with the isolation powder is soaked and cleaned by a chemical cleaning agent, tackified and flanged and laminated until the whole flanging and laminating of the inner cord fabric 9 and the inner layer rubber 10 of the rubber expansion joint are finished, the rubber expansion joint forming side plate 5 is tightly laminated with the flange assembly 6 matched with the rubber expansion joint after the flanging and laminating are carried out, so that the connecting bolt hole 6-1 of the flange assembly and the rubber expansion joint forming side plate 5-1 to the center of the connecting bolt hole are arranged on the same straight line, a special hole-opening mould and a hole-opening tool which are suitable for the connecting bolt hole are used for respectively opening holes of all the bolt holes to remove screw hole blocking rubber, a special perforated pipe plug is sleeved, the rubber sealing surface is prevented from being starved and the rubber is prevented from entering the screw holes and being difficult to be cleaned when the rubber flows into the screw holes during vulcanization, and the rubber is, when the bolts are fastened, rubber slightly overflows from the outer circumference of the flange assembly matched with the rubber expansion joint, so that the defect of rubber shortage cannot be generated in the vulcanization process;

step eight, winding, fitting and forming the outer cord fabric of the rubber expansion joint

Calculating the blanking size of the preformed rubber-coated cord fabric prepared in the third step according to the structural length and the construction process requirement of the product, calculating the blanking cutting angle of the preformed rubber-coated cord fabric prepared in the third step by 30-60 degrees according to the rubber expansion joint rubber mountain-shaped structure, the compressive strength grade and the construction process mode, and cutting the required number of the rubber-coated cord fabrics according to the cutting angle, the perimeter size and the rubber expansion joint outer cord fabric layer 8 required by the construction process and the door width blanking of the preformed rubber-coated cord fabric prepared in the third step;

before the outer curtain cloth of the rubber expansion joint is wound, laminated and formed, a gap formed between the reinforcing insertion tube 6-2 of the rubber expansion joint after the seventh step and the surface of the inner curtain cloth 9 of the rubber expansion joint and the mountain foot of the reusable formed rubber mountain 13 is filled with a rubber strip (not shown in the figure), and then the inner rubber layer is wound, laminated and formed according to the winding and laminating mode and procedure of the inner rubber layer in the fourth step, so that a good rubber transition layer is formed between the reinforcing insertion tube 6-2 of the flange component matched with the rubber expansion joint and the 8 layers of the outer curtain cloth of the rubber expansion joint, and the binding force between metal and the curtain cloth layer is enhanced;

winding, laminating and molding the rubber expansion joint outer curtain cloth 8 on the constructed transition rubber layer according to the sixth step;

step nine, winding, laminating and forming outer-layer rubber of the rubber expansion joint

Winding, laminating and molding the outer rubber 7 of the rubber expansion joint according to the fourth step;

step ten, exhausting, shaping a bandage, and compacting a cotton rope

The air exhaust needles are used for puncturing and exhausting air along the winding and laminating forming layer, the air exhaust needles ensure that the air exhaust holes are uniformly distributed along the surface of the rubber expansion joint forming core 1 from the outermost layer of the outer rubber 7 of the rubber expansion joint to the innermost layer of the inner rubber 10 of the rubber expansion joint, especially the distribution density of the air exhaust holes at the positions of the mountain feet at two sides of the repeatedly used forming rubber mountain is not less than 10/square decimeter, the rubber forming machine is started to rotate clockwise at a low speed, pretightening force is applied to the formed water-coated bandage 11, the water-coated bandage is wound from the positions of the mountain feet at two sides of the repeatedly used forming rubber mountain 13 to the inner side of the matched flange assembly 6 of the rubber expansion joint respectively so as to ensure that the air of the rubber and the curtain cloth is extruded and exhausted outwards in sequence, the next circle of bandage is ensured to be half pressed on the upper circle of bandage during winding so as, starting a rubber forming machine to rotate anticlockwise at a medium speed or a high speed to remove the wound bandage;

starting a rubber forming machine to rotate clockwise at a low speed, applying pretightening force to the formed water-coated cloth bandage 11, and sequentially winding the water-coated cloth formed bandage or the cotton bandage from the inner side of the rubber expansion joint matched flange assembly 6 to the other inner side of the rubber expansion joint matched flange assembly respectively, wherein the illustration only shows one layer of schematic representation, and half of the next circle of bandage is ensured to be pressed on the previous circle of bandage during winding; and the formed bandage is sequentially and tightly provided with the high-temperature resistant reusable shaped cotton ropes 12, and the winding type ensures that the cotton ropes are neatly and tightly arranged, well-distributed, well-arranged and proper in tightness;

eleven steps of final fine adjustment, sizing and fixing

A rubber expansion joint vulcanization limiting pull rod 15 is uniformly distributed along the circumference of a rubber expansion joint matching flange assembly 6, and a limiting pull rod adjusting gasket 16 and a limiting pull rod nut 17 are sequentially arranged on the rubber expansion joint vulcanization limiting pull rod 15; rotating a limit pull rod nut according to the structural length of a product required by a drawing for size fine adjustment and locking, and closely attaching a forming side plate vulcanization positioning baffle plate 14 to the outer side of a rubber expansion joint forming side plate 5 along the circumferential surface of a rubber expansion joint forming core to perform positioning and fixing;

step twelve, two-stage vulcanization of the integral vulcanizing tank

The rubber expansion joint formed by winding in the first step, the second step and the rubber expansion joint forming core enter a direct steam pressurization type vulcanizing tank together for integral vulcanization, and the method is implemented specifically as follows: heating, boosting pressure → sewage discharge → one-stage heat preservation and pressure maintaining vulcanization → sewage discharge → two-stage natural cooling and pressure reduction low-temperature long-time vulcanization → pressure release and air exhaust → cooling and tank discharge → demoulding.

2. The winding forming manufacturing method of the rubber expansion joint as claimed in claim 1, wherein: the base crude rubber is one or a combination of more of styrene butadiene rubber, chloroprene rubber, ethylene propylene diene monomer rubber, butyl rubber and nitrile butadiene rubber.

3. The winding forming manufacturing method of the rubber expansion joint as claimed in claim 1, wherein: the reinforcing filler is one or a combination of N330 carbon black, N550 carbon black and N660 carbon black.

4. The winding forming manufacturing method of the rubber expansion joint as claimed in claim 1, wherein: the bulking filler is one or more of calcium carbonate, calcium bicarbonate, pottery clay and bentonite.

5. The winding forming manufacturing method of the rubber expansion joint as claimed in claim 1, wherein: the special filling agent is wear-resistant filling material, anti-corrosion filling material and anti-radiation filling material.

6. The winding forming manufacturing method of the rubber expansion joint as claimed in claim 1, wherein: the process operation auxiliary agent is one or a combination of more of a dispersant, a lubricant, a plasticizer and a tackifier; the dispersing agent is peptoid T-78A and carbon black; the lubricant is paraffin; the plasticizer is dibutyl ester, dioctyl ester, naphthenic oil, engine oil and aromatic oil; the tackifier is coumarone resin, rosin and phenolic resin.

7. The winding forming manufacturing method of the rubber expansion joint as claimed in claim 1, wherein: the rubber protection auxiliary agent is one or a combination of more of an antioxidant, an antiozonant, an anti-flex cracking agent, a light stabilizer, an ultraviolet light absorber, a harmful metal inhibitor and a mildew preventive; the antioxidant is antioxidant A, antioxidant D and antioxidant DNP; the antiozonants are antioxidant 4010 and antioxidant 4010NA; the anti-flex cracking agent is an anti-aging agent 4020 and an anti-cracking agent B-10; the light stabilizer is phosphite triester GW-540; the ultraviolet light absorber is 2- (2-hydroxy-5-methylphenyl) benzotriazole and 2- (2-hydroxy-3, 5-di-tert-butylphenyl) -5-chlorobenzotriazole, the harmful metal inhibitor is antioxidant MB, antioxidant MBZ, antioxidant D and antioxidant 4010NA, and the mildew inhibitor is sodium benzoate, mildew inhibitor N- (trichloromethylthio) phthalimide and docosahexaenoic acid.

8. The winding forming manufacturing method of the rubber expansion joint as claimed in claim 1, wherein: the vulcanizing activator is one or a combination of zinc oxide, magnesium oxide, stearic acid and calcium stearate.

9. The method for manufacturing a rubber expansion joint by winding and molding as claimed in claim, wherein: the vulcanizing agent is dicumyl peroxide (DCP) or diallyl phthalate (TAIC); one or more of sulfur or insoluble sulfur.

10. The winding forming manufacturing method of the rubber expansion joint as claimed in claim 1, wherein: the vulcanization accelerator is one or a combination of more of diphenyl guanidine, dibenzothiazyl disulfide, 2-mercaptobenzothiazole, N-cyclohexyl-2-benzothiazole sulfonamide, tetramethyl thiuram disulfide and 1, 2-ethylene thiourea.

Technical Field

The invention relates to the field of rubber expansion joint manufacturing, in particular to a winding forming manufacturing method of a rubber expansion joint.

Background

Most of the rubber expansion joints in the current market adopt a mould pressing or pressurizing injection mould pressing structure, and the rubber expansion joints have the advantages of (1) short product manufacturing period and low cost, (2) beautiful and smooth appearance forming and (3) high production efficiency, but also have a plurality of defects: (1) the manufacturing technology of the mould is high in requirement and high in cost, (2) the adaptability of the mould is poor (each pressure grade, specification model, product design thickness and length, reinforcing fabric design layer number change, design mountain shape change and the like all need a special mould), (3) the product is single in structure, basically is the combination of pure rubber and reinforcing fabric, and is low in product strength grade, (4) the pressure bearing area is large due to the fact that the mountain shape span is required to be large by the mould pressing and pressure filling injection moulding processing technology, the acting force is large under the same specification and pressure grade, the compression grade strength of the rubber expansion joint is greatly reduced, the application field of the rubber expansion joint in large caliber and high pressure is limited, (5) the huge extrusion force generated by filling the rubber raw rubber into a mould cavity under the action of mould pressing or pressure filling preforming of the rubber raw rubber and the reinforcing fabric damages the arrangement density of the longitude and latitude of the reinforcing fabric, the rubber expansion joint produced by the process has poor quality consistency, low reliability, high product use failure rate and poor safety (tests show that the pressure grade in the products with the same specification, pressure grade and batch often differs by more than several times), (7) the product basically has no vacuum negative pressure resistance, and the rubber mountain-shaped is easy to deform abnormally or even shrink due to accidental negative pressure in a pipeline or a system, so that the adaptability to the application occasions (most running pipelines have the requirement) with the alternative change of the positive pressure and the negative pressure of the system is poor

The rubber expansion joint manufactured by the manufacturing method has lower compression grade per se, and the compression strength is greatly reduced and the safety risk coefficient is higher in the use process because the manufacturing method has the defects that the compression grade is unpredictable or the product quality discreteness is larger due to the fact that the reinforcing fabric is damaged by breaking the longitude and latitude arrangement density to generate the blasting breaking points, so that the use of the rubber expansion joint is greatly limited in the fields of nuclear power, chemical engineering safety, ships, offshore transportation, medium and high pressure and the fields with higher requirements on operation reliability, safety and performance.

Disclosure of Invention

The invention aims to solve the technical problems and provides a winding and forming manufacturing method of a rubber expansion joint.

In order to achieve the technical purpose and achieve the technical requirements, the invention adopts the technical scheme that:

the winding forming manufacturing method of the rubber expansion joint is characterized in that the rubber expansion joint is prepared from the following components in parts by weight: 100 parts of base raw rubber or 100-150 parts of oil-extended base raw rubber, 20-60 parts of reinforcing filler, 10-40 parts of bulking filler, 5-35 parts of special filler, 5-25 parts of process operation auxiliary agent, 2-8 parts of vulcanization activator and 0.5-4.5 parts of rubber protection auxiliary agent; 0.2-5.0 parts of a vulcanizing agent; 0.1-2.5 parts of a vulcanization accelerator; the manufacturing method comprises the following steps:

step one, adding the raw rubber into various rubber compounding agents, and mixing the raw rubber into various rubber compound colloids with processability through rubber mixing equipment

Respectively metering and adding the rubber into a rubber internal mixer according to the shaping formula proportion confirmed by the process for pressure internal mixing, and mixing to obtain various rubber compound colloids;

step two, preparing preformed rubber plate

Purifying rubber of the rubber compound processed in the step 1 by filtering rubber → extruding and bracing → cooling to 5-35C ° → long pin type cold feed extrusion → duckbill type extrusion → double-roller calender pressing → sending air cooling → four-roller cooling to 35-45C ° → tension-free coiling → preparing rubber expansion joint preformed rubber plate;

step three, preparing pre-formed rubberizing cord fabric

Preparing rubber compound colloid of rubber wiping rubber of the cord fabric according to the method and the formula proportion in the step 1, and discharging the rubber compound colloid of the cord fabric through an open mill → isolating liquid isolation → air duct conveying and cooling → slicing → feeding of a four-roll calender → tensioning of the rubber dipping cord fabric → rubber wiping on two sides of the rubber dipping cord fabric → isolating of the pad fabric → pre-tightening and rolling → pre-forming of the rubber wiping cord fabric;

step four, winding, laminating and forming of inner-layer rubber plates

1) Calculating the blanking size, the forming thickness and the forming layer number of the rubber plate 10 at the inner layer of the rubber expansion joint according to the size of the repeatedly used formed rubber mountain 13 in the rubber expansion joint forming die and the structural length of the product and the design drawing and the process construction requirements, and blanking the preformed rubber plate prepared in the second step; 2) fixing the initial part of the preformed rubber plate which is blanked in the step 1) on two sides of a reusable preformed rubber mountain 13 along two sides of the middle of the preformed rubber plate which is formed by winding by using a process exhaust needle, starting a rubber expansion joint forming machine (not shown in the schematic drawing) to rotate a rubber expansion joint forming core 1 clockwise at a low speed, stopping rotating when the initial part is rotated, coating a chemical cleaning tackifier on the outer surface of the initial part of the preformed rubber plate within the range of about 10mm, then carrying out joint lapping, carrying out rolling compaction along the lapping part by using a compression roller (not shown in the schematic drawing), and simultaneously carrying out compaction and compaction along the bottoms of two side mountain feet of the reusable preformed rubber mountain 13 by using the compression roller; starting the rubber expansion joint forming machine to rotate the rubber expansion joint forming core 1 clockwise at a medium speed or a low speed, wrapping the wound and formed preformed rubber plate outwards from the bottoms of the two mountain soles of the repeatedly used formed rubber mountain 13 by using a water-coated cloth bandage which is the same as the formed water-coated cloth bandage 11, ensuring that the next layer of bandage is pressed on the previous layer of bandage during wrapping, ensuring that the bandage is tightly pressed by force during wrapping to well form and exhaust the bandage, and stopping the rubber expansion joint forming machine after winding is finished; finishing the shaping time of 15-30 minutes according to the specification requirement, starting the rubber expansion joint forming machine to rotate the rubber expansion joint forming core 1 anticlockwise at a high speed to remove a rolling shaping bandage, wiping the surface to dry the surface, brushing a chemical reagent, cleaning to remove surface impurities and tackifying;

step five, scribing isolation

Calculating the part of the rubber expansion joint needing flanging and fitting according to the design drawing and the structural length of the product required by the construction process; marking along the circumference of the symmetrical proper parts on two sides of the molded rubber mountain 13 by using a marking pen, beating the rubber surface of the part needing flanging and jointing outside the mark by using an isolation bag to apply isolation powder, and cleaning and tackifying the part polluted by the isolation powder on the rubber surface in the marking line by using a chemical cleaning agent;

step six, winding, laminating and forming the inner reinforcing cord fabric

Calculating the blanking size of the preformed rubber-coated cord fabric prepared in the third step according to a design drawing and the structural length of a product required by a construction process, calculating the blanking cutting angle of the preformed rubber-coated cord fabric prepared in the third step by 30-60 degrees according to the rubber expansion joint rubber mountain-shaped structure, the compressive strength grade and the construction process mode, and cutting the required number of the rubber-coated cord fabrics according to the cutting angle, the perimeter size and the rubber expansion joint inner cord fabric layer 9 required by the construction process and the door width blanking of the preformed rubber-coated cord fabric prepared in the third step;

winding, laminating and forming the pre-formed rubber-wiping cord fabric after blanking according to the manufacturing process mode of the fourth step, alternately winding and laminating every two adjacent layers in a positive-negative symmetrical mode according to the cutting angle to form compression-resistant layers with warp threads densely arranged at 90 degrees, compressing and compacting the surfaces of the compression-resistant layers and the bottoms of the two side feet of the reusable formed rubber mountain 13 by using the same compression roller of the fourth step, respectively applying pretightening force to the bottom parts of the two side feet of the reusable formed rubber mountain 13 after the cord fabric in the two layers which are adjacent to the bottommost layer in the positive-negative direction is formed, and starting a rubber expansion joint forming machine to rotate clockwise at a low speed for winding, tightening and compacting;

winding and forming the other inner-layer rubber-coated cord fabric layers according to the requirements until the required number of the winding and forming cord fabric layers meets the requirements of drawings and construction processes to form the rubber expansion joint inner cord fabric 9 (comprising all the inner-layer winding and forming cord fabric layers); note that multilayer layering (two adjacent layers are alternately wound and laminated in a positive and negative direction according to a cutting angle) winding, forming and laminating are adopted, the lap joint of each layer of formed cord fabric is approximately symmetrically and uniformly distributed in the circumferential direction, each layer cannot be in the same position, and the lap joint width is about 5-15 mm; compacting, shaping, exhausting and removing every two layers of cord fabric layers by using similar 11-shaping bandages (water-wrapped cloth bandages) according to the winding and compacting mode in the step 5; the winding forming layer number of the cord fabric is only even number so as to ensure that the warp of the cord fabric is densely arranged at an angle of approximately 90 degrees to form a good pressure-resistant layer

Scribing and isolating every two layers of cord fabrics according to the mode shown in the step five; after the rubber expansion joint inner curtain cloth 9 is completely wound and formed, pretightening force is respectively applied to the bottoms of the two side feet of the formed repeatedly-used formed rubber mountain 13 by using curtain wiring strips with the width of 5-30 mm, and a rubber expansion joint forming machine is started to rotate clockwise at a low speed for winding, tightening and compacting;

seventhly, mounting a flange assembly matched with the rubber expansion joint

Loosening a rubber expansion joint molding side plate 5 on a rubber expansion joint molding core 1 and a connecting bolt 4 and a nut 3 of a rubber expansion joint matching flange component 6, trying to sleeve a reinforcing insertion tube 6-2 of the rubber expansion joint matching flange component 6 on a rubber expansion joint inner layer rubber 10 and a rubber expansion joint inner cord fabric 9 layer which are qualified in winding molding, determining to use intermediate rubber (not shown in the figure) to adjust according to a matching gap so as to enable the rubber expansion joint inner layer rubber and the rubber expansion joint inner cord fabric to be in gapless matching, and carrying out fixed-length installation on the rubber expansion joint matching flange component 6 according to the requirement of the product structure length;

according to the sealing structure type and the sealing surface size of the rubber expansion joint of the flange component 6 matched with the rubber expansion joint, transition rubber of the sealing surface is jointed, the surface of tackified transition rubber and the surface of flanged cord fabric are cleaned by a chemical cleaning agent, and flanged joint of every two layers of cord fabric is respectively carried out; during the process, the surface with the isolation powder is soaked and cleaned by a chemical cleaning agent, tackified and flanged and laminated until the whole flanging and laminating of the inner cord fabric 9 and the inner layer rubber 10 of the rubber expansion joint are finished, the rubber expansion joint forming side plate 5 is tightly laminated with the flange assembly 6 matched with the rubber expansion joint after the flanging and laminating are carried out, so that the connecting bolt hole 6-1 of the flange assembly and the rubber expansion joint forming side plate 5-1 to the center of the connecting bolt hole are arranged on the same straight line, a special hole-opening mould and a hole-opening tool which are suitable for the connecting bolt hole are used for respectively opening holes of all the bolt holes to remove screw hole blocking rubber, a special perforated pipe plug is sleeved, the rubber sealing surface is prevented from being starved and the rubber is prevented from entering the screw holes and being difficult to be cleaned when the rubber flows into the screw holes during vulcanization, and the rubber is, when the bolts are fastened, rubber slightly overflows from the outer circumference of the flange assembly matched with the rubber expansion joint, so that the defect of rubber shortage cannot be generated in the vulcanization process;

step eight, winding, fitting and forming the outer cord fabric of the rubber expansion joint

Calculating the blanking size of the preformed rubber-coated cord fabric prepared in the third step according to the structural length and the construction process requirement of the product, calculating the blanking cutting angle of the preformed rubber-coated cord fabric prepared in the third step by 30-60 degrees according to the rubber expansion joint rubber mountain-shaped structure, the compressive strength grade and the construction process mode, and cutting the required number of the rubber-coated cord fabrics according to the cutting angle, the perimeter size and the rubber expansion joint outer cord fabric layer 8 required by the construction process and the door width blanking of the preformed rubber-coated cord fabric prepared in the third step;

before the outer curtain cloth of the rubber expansion joint is wound, laminated and formed, a gap formed between the reinforcing insertion tube 6-2 of the rubber expansion joint after the seventh step and the surface of the inner curtain cloth 9 of the rubber expansion joint and the mountain foot of the reusable formed rubber mountain 13 is filled with a rubber strip (not shown in the figure), and then the inner rubber layer is wound, laminated and formed according to the winding and laminating mode and procedure of the inner rubber layer in the fourth step, so that a good rubber transition layer is formed between the reinforcing insertion tube 6-2 of the flange component matched with the rubber expansion joint and the 8 layers of the outer curtain cloth of the rubber expansion joint, and the binding force between metal and the curtain cloth layer is enhanced;

winding, laminating and molding the rubber expansion joint outer curtain cloth 8 on the constructed transition rubber layer according to the sixth step;

step nine, winding, laminating and forming outer-layer rubber of the rubber expansion joint

Winding, laminating and molding the outer rubber 7 of the rubber expansion joint according to the fourth step;

step ten, exhausting, shaping a bandage, and compacting a cotton rope

The air exhaust needles are used for puncturing and exhausting air along the winding and laminating forming layer, the air exhaust needles ensure that the air exhaust holes are uniformly distributed along the surface of the rubber expansion joint forming core 1 from the outermost layer of the outer rubber 7 of the rubber expansion joint to the innermost layer of the inner rubber 10 of the rubber expansion joint, especially the distribution density of the air exhaust holes at the positions of the mountain feet at two sides of the repeatedly used forming rubber mountain is not less than 10/square decimeter, the rubber forming machine is started to rotate clockwise at a low speed, pretightening force is applied to the formed water-coated bandage 11, the water-coated bandage is wound from the positions of the mountain feet at two sides of the repeatedly used forming rubber mountain 13 to the inner side of the matched flange assembly 6 of the rubber expansion joint respectively so as to ensure that the air of the rubber and the curtain cloth is extruded and exhausted outwards in sequence, the next circle of bandage is ensured to be half pressed on the upper circle of bandage during winding so as, starting a rubber forming machine to rotate anticlockwise at a medium speed or a high speed to remove the wound bandage;

starting a rubber forming machine to rotate clockwise at a low speed, applying pretightening force to the formed water-coated cloth bandage 11, and sequentially winding the water-coated cloth formed bandage or the cotton bandage from the inner side of the rubber expansion joint matched flange assembly 6 to the other inner side of the rubber expansion joint matched flange assembly respectively, wherein the illustration only shows one layer of schematic representation, and half of the next circle of bandage is ensured to be pressed on the previous circle of bandage during winding; and the formed bandage is sequentially and tightly provided with the high-temperature resistant reusable shaped cotton ropes 12, and the winding type ensures that the cotton ropes are neatly and tightly arranged, well-distributed, well-arranged and proper in tightness;

eleven steps of final fine adjustment, sizing and fixing

A rubber expansion joint vulcanization limiting pull rod 15 is uniformly distributed along the circumference of a rubber expansion joint matching flange assembly 6, and a limiting pull rod adjusting gasket 16 and a limiting pull rod nut 17 are sequentially arranged on the rubber expansion joint vulcanization limiting pull rod 15; rotating a limit pull rod nut according to the structural length of a product required by a drawing for size fine adjustment and locking, and closely attaching a forming side plate vulcanization positioning baffle plate 14 to the outer side of a rubber expansion joint forming side plate 5 along the circumferential surface of a rubber expansion joint forming core to perform positioning and fixing;

step twelve, two-stage vulcanization of the integral vulcanizing tank

The rubber expansion joint formed by winding in the first step, the second step and the rubber expansion joint forming core enter a direct steam pressurization type vulcanizing tank together for integral vulcanization, and the method is implemented specifically as follows: heating, boosting pressure → sewage discharge → one-stage heat preservation and pressure maintaining vulcanization → sewage discharge → two-stage natural cooling and pressure reduction low-temperature long-time vulcanization → pressure release and air exhaust → cooling and tank discharge → demoulding.

Preferably: the base crude rubber is one or a combination of more of styrene butadiene rubber, chloroprene rubber, ethylene propylene diene monomer rubber, butyl rubber and nitrile butadiene rubber.

Preferably: the reinforcing filler is one or a combination of N330 carbon black, N550 carbon black and N660 carbon black.

Preferably: the bulking filler is one or more of calcium carbonate, calcium bicarbonate, pottery clay and bentonite.

Preferably: the special filling agent is wear-resistant filling material, anti-corrosion filling material and anti-radiation filling material.

Preferably: the process operation auxiliary agent is one or a combination of more of a dispersant, a lubricant, a plasticizer and a tackifier; the dispersing agent is peptoid T-78A and carbon black; the lubricant is paraffin; the plasticizer is dibutyl ester, dioctyl ester, naphthenic oil, engine oil and aromatic oil; the tackifier is coumarone resin, rosin and phenolic resin.

Preferably: the rubber protection auxiliary agent is one or a combination of more of an antioxidant, an antiozonant, an anti-flex cracking agent, a light stabilizer, an ultraviolet light absorber, a harmful metal inhibitor and a mildew preventive; the antioxidant is antioxidant A, antioxidant D and antioxidant DNP; the antiozonants are antioxidant 4010 and antioxidant 4010NA; the anti-flex cracking agent is an anti-aging agent 4020 and an anti-cracking agent B-10; the light stabilizer is phosphite triester GW-540; the ultraviolet light absorber is 2- (2-hydroxy-5-methylphenyl) benzotriazole and 2- (2-hydroxy-3, 5-di-tert-butylphenyl) -5-chlorobenzotriazole, the harmful metal inhibitor is antioxidant MB, antioxidant MBZ, antioxidant D and antioxidant 4010NA, and the mildew inhibitor is sodium benzoate, mildew inhibitor N- (trichloromethylthio) phthalimide and docosahexaenoic acid.

Preferably: the vulcanizing activator is one or a combination of zinc oxide, magnesium oxide, stearic acid and calcium stearate.

Preferably: the vulcanizing agent is dicumyl peroxide (DCP) or diallyl phthalate (TAIC); one or more of sulfur or insoluble sulfur.

Preferably: the vulcanization accelerator is one or a combination of more of diphenyl guanidine, dibenzothiazyl disulfide, 2-mercaptobenzothiazole, N-cyclohexyl-2-benzothiazole sulfonamide, tetramethyl thiuram disulfide and 1, 2-ethylene thiourea.

The invention greatly improves the product quality, the service performance and the use safety, prolongs the service life and has wide application range.

Drawings

FIG. 1 is a schematic structural view of a rubber expansion joint winding mold according to the present invention;

FIG. 2 is an enlarged view of FIG. 1 at A;

in the figure: 1. a rubber expansion joint forming core, 1-1, a tailstock centre hole of the rubber expansion joint forming core, 1-2, a claw support column of the rubber expansion joint forming core, 2, an adjusting gasket, 3, a nut, 4, a connecting bolt, 5, a rubber expansion joint forming side plate, 5-1 a connecting bolt hole of the rubber expansion joint forming side plate, 5-2 a sealing surface forming groove of the rubber expansion joint forming side plate, 6, a rubber expansion joint matching flange component, 6-1, a flange component connecting bolt hole, 6-2, a reinforcing insertion pipe of the rubber expansion joint matching flange component, 6-3 a limiting lug plate of the rubber expansion joint matching flange component, 6-4 a limiting lug plate bolt connecting hole, 7, rubber expansion joint outer layer rubber, 8, rubber expansion joint outer curtain cloth, 9, rubber expansion joint inner curtain cloth, 10. the rubber expansion joint comprises rubber expansion joint inner layer rubber, 11, a shaping bandage, 12, a high temperature resistant reusable shaping cotton rope, 13, a reusable shaping rubber mountain, 14, a shaping side plate vulcanization positioning baffle, 15, a rubber expansion joint vulcanization limiting pull rod, 16, a limiting pull rod adjusting gasket, 17 and a limiting pull rod nut.

Detailed Description

The invention will be further explained with reference to the drawings.

The winding forming manufacturing method of the rubber expansion joint is characterized in that the rubber expansion joint is prepared from the following components in parts by weight: 100 parts of base raw rubber or 100-150 parts of oil-extended base raw rubber, 20-60 parts of reinforcing filler, 10-40 parts of bulking filler, 5-35 parts of special filler, 5-25 parts of process operation auxiliary agent, 2-8 parts of vulcanization activator and 0.5-4.5 parts of rubber protection auxiliary agent; 0.2-5.0 parts of a vulcanizing agent; 0.1-2.5 parts of a vulcanization accelerator; the manufacturing method comprises the following steps:

step one, adding the raw rubber into various rubber compounding agents, and mixing the raw rubber into various rubber compound colloids with processability through rubber mixing equipment

Respectively metering and adding the rubber into a rubber internal mixer according to the shaping formula proportion confirmed by the process for pressure internal mixing, and mixing to obtain various rubber compound colloids;

step two, preparing preformed rubber plate

Purifying rubber of the rubber compound processed in the step 1 by filtering rubber → extruding and bracing → cooling to 5-35C ° → long pin type cold feed extrusion → duckbill type extrusion → double-roller calender pressing → sending air cooling → four-roller cooling to 35-45C ° → tension-free coiling → preparing rubber expansion joint preformed rubber plate;

step three, preparing pre-formed rubberizing cord fabric

Preparing rubber compound colloid of rubber wiping rubber of the cord fabric according to the method and the formula proportion in the step 1, and discharging the rubber compound colloid of the cord fabric through an open mill → isolating liquid isolation → air duct conveying and cooling → slicing → feeding of a four-roll calender → tensioning of the rubber dipping cord fabric → rubber wiping on two sides of the rubber dipping cord fabric → isolating of the pad fabric → pre-tightening and rolling → pre-forming of the rubber wiping cord fabric;

step four, winding, laminating and forming of inner-layer rubber plates

1) Calculating the blanking size, the forming thickness and the forming layer number of the rubber plate 10 at the inner layer of the rubber expansion joint according to the size of the repeatedly used formed rubber mountain 13 in the rubber expansion joint forming die and the structural length of the product and the design drawing and the process construction requirements, and blanking the preformed rubber plate prepared in the second step; 2) fixing the initial part of the preformed rubber plate which is blanked in the step 1) on two sides of a reusable preformed rubber mountain 13 along two sides of the middle of the preformed rubber plate which is formed by winding by using a process exhaust needle, starting a rubber expansion joint forming machine (not shown in the schematic drawing) to rotate a rubber expansion joint forming core 1 clockwise at a low speed, stopping rotating when the initial part is rotated, coating a chemical cleaning tackifier on the outer surface of the initial part of the preformed rubber plate within the range of about 10mm, then carrying out joint lapping, carrying out rolling compaction along the lapping part by using a compression roller (not shown in the schematic drawing), and simultaneously carrying out compaction and compaction along the bottoms of two side mountain feet of the reusable preformed rubber mountain 13 by using the compression roller; starting the rubber expansion joint forming machine to rotate the rubber expansion joint forming core 1 clockwise at a medium speed or a low speed, wrapping the wound and formed preformed rubber plate outwards from the bottoms of the two mountain soles of the repeatedly used formed rubber mountain 13 by using a water-coated cloth bandage which is the same as the formed water-coated cloth bandage 11, ensuring that the next layer of bandage is pressed on the previous layer of bandage during wrapping, ensuring that the bandage is tightly pressed by force during wrapping to well form and exhaust the bandage, and stopping the rubber expansion joint forming machine after winding is finished; finishing the shaping time of 15-30 minutes according to the specification requirement, starting the rubber expansion joint forming machine to rotate the rubber expansion joint forming core 1 anticlockwise at a high speed to remove a rolling shaping bandage, wiping the surface to dry the surface, brushing a chemical reagent, cleaning to remove surface impurities and tackifying; multilayer layered winding forming and laminating forming are adopted, the lap joint position of each layer of formed rubber plate is approximately symmetrically and uniformly distributed in the circumferential direction, each layer of lap joint can not be at the same position, and the lap joint width is about 5-15 mm;

step five, scribing isolation

Calculating the part of the rubber expansion joint needing flanging and fitting according to the design drawing and the structural length of the product required by the construction process; marking along the circumference of the symmetrical proper parts on two sides of the molded rubber mountain 13 by using a marking pen, beating the rubber surface of the part needing flanging and jointing outside the mark by using an isolation bag to apply isolation powder, and cleaning and tackifying the part polluted by the isolation powder on the rubber surface in the marking line by using a chemical cleaning agent;

step six, winding, laminating and forming the inner reinforcing cord fabric

Calculating the blanking size of the preformed rubber-coated cord fabric prepared in the third step according to a design drawing and the structural length of a product required by a construction process, calculating the blanking cutting angle of the preformed rubber-coated cord fabric prepared in the third step by 30-60 degrees according to the rubber expansion joint rubber mountain-shaped structure, the compressive strength grade and the construction process mode, and cutting the required number of the rubber-coated cord fabrics according to the cutting angle, the perimeter size and the rubber expansion joint inner cord fabric layer 9 required by the construction process and the door width blanking of the preformed rubber-coated cord fabric prepared in the third step;

winding and laminating the blanked pre-formed rubber-wiping cord fabric according to the manufacturing process of the fourth step, alternately winding and laminating every two adjacent layers in a positive-negative symmetry mode according to the cutting angle to form a compression-resistant layer with warp threads densely arranged at 90 degrees, compressing and compacting the surface and the bottoms of two mountain feet of the repeatedly used formed rubber mountain 13 by using the same compression roller of the fourth step, the bottom parts of the two side feet of the repeatedly used molded rubber mountain 13 after the forming of the cord fabric in the two layers which are adjacent to each other on the front and back sides of the bottommost layer are respectively applied with pretightening force by using cord fabric wiring strips with the width of 2.5-25 mm, and a rubber expansion joint molding machine is started to rotate clockwise at a low speed for winding, tightening and compacting, the process operation is important, and the process has two main process advantages, firstly, tightening and compacting the inner rubber layer and the inner curtain cloth layer to enable the bottoms of the inner rubber layer and the inner curtain cloth layer to be tight and discharge mixed gas formed by contact; secondly, the inner rubber layer and the inner curtain cloth layer are vulcanized and adhered at the bottoms of the mountain feet well, and the defects of layering, peeling, unshelling, air bubbles and the like are avoided

Winding and forming the other inner-layer rubber-coated cord fabric layers according to the requirements until the required number of the winding and forming cord fabric layers meets the requirements of drawings and construction processes to form the rubber expansion joint inner cord fabric 9 (comprising all the inner-layer winding and forming cord fabric layers); note that multilayer layering (two adjacent layers are alternately wound and laminated in a positive and negative direction according to a cutting angle) winding, forming and laminating are adopted, the lap joint of each layer of formed cord fabric is approximately symmetrically and uniformly distributed in the circumferential direction, each layer cannot be in the same position, and the lap joint width is about 5-15 mm; compacting, shaping, exhausting and removing every two layers of cord fabric layers by using similar 11-shaping bandages (water-wrapped cloth bandages) according to the winding and compacting mode in the step 5; the winding forming layer number of the cord fabric is only even number so as to ensure that the warp of the cord fabric is densely arranged at an angle of approximately 90 degrees to form a good pressure-resistant layer

Scribing and isolating every two layers of cord fabrics according to the mode shown in the step five; after the rubber expansion joint inner curtain cloth 9 is completely wound and formed, pretightening force is respectively applied to the bottoms of the two side feet of the formed repeatedly-used formed rubber mountain 13 by using curtain wiring strips with the width of 5-30 mm, and a rubber expansion joint forming machine is started to rotate clockwise at a low speed for winding, tightening and compacting;

seventhly, mounting a flange assembly matched with the rubber expansion joint

Loosening a rubber expansion joint molding side plate 5 on a rubber expansion joint molding core 1 and a connecting bolt 4 and a nut 3 of a rubber expansion joint matching flange component 6, trying to sleeve a reinforcing insertion tube 6-2 of the rubber expansion joint matching flange component 6 on a rubber expansion joint inner layer rubber 10 and a rubber expansion joint inner cord fabric 9 layer which are qualified in winding molding, determining to use intermediate rubber (not shown in the figure) to adjust according to a matching gap so as to enable the rubber expansion joint inner layer rubber and the rubber expansion joint inner cord fabric to be in gapless matching, and carrying out fixed-length installation on the rubber expansion joint matching flange component 6 according to the requirement of the product structure length;

according to the sealing structure type and the sealing surface size of the rubber expansion joint of the flange component 6 matched with the rubber expansion joint, transition rubber of the sealing surface is jointed, the surface of tackified transition rubber and the surface of flanged cord fabric are cleaned by a chemical cleaning agent, and flanged joint of every two layers of cord fabric is respectively carried out; during the process, the surface with the isolation powder is soaked and cleaned by a chemical cleaning agent, tackified and flanged and laminated until the whole flanging and laminating of the inner cord fabric 9 and the inner layer rubber 10 of the rubber expansion joint are finished, the rubber expansion joint forming side plate 5 is tightly laminated with the flange assembly 6 matched with the rubber expansion joint after the flanging and laminating are carried out, so that the connecting bolt hole 6-1 of the flange assembly and the rubber expansion joint forming side plate 5-1 to the center of the connecting bolt hole are arranged on the same straight line, a special hole-opening mould and a hole-opening tool which are suitable for the connecting bolt hole are used for respectively opening holes of all the bolt holes to remove screw hole blocking rubber, a special perforated pipe plug is sleeved, the rubber sealing surface is prevented from being starved and the rubber is prevented from entering the screw holes and being difficult to be cleaned when the rubber flows into the screw holes during vulcanization, and the rubber is, when the bolts are fastened, rubber slightly overflows from the outer circumference of the flange assembly matched with the rubber expansion joint, so that the defect of rubber shortage cannot be generated in the vulcanization process;

step eight, winding, fitting and forming the outer cord fabric of the rubber expansion joint

Calculating the blanking size of the preformed rubber-coated cord fabric prepared in the third step according to the structural length and the construction process requirement of the product, calculating the blanking cutting angle of the preformed rubber-coated cord fabric prepared in the third step by 30-60 degrees according to the rubber expansion joint rubber mountain-shaped structure, the compressive strength grade and the construction process mode, and cutting the required number of the rubber-coated cord fabrics according to the cutting angle, the perimeter size and the rubber expansion joint outer cord fabric layer 8 required by the construction process and the door width blanking of the preformed rubber-coated cord fabric prepared in the third step;

before the outer curtain cloth of the rubber expansion joint is wound, laminated and formed, a gap formed between the reinforcing insertion tube 6-2 of the rubber expansion joint after the seventh step and the surface of the inner curtain cloth 9 of the rubber expansion joint and the mountain foot of the reusable formed rubber mountain 13 is filled with a rubber strip (not shown in the figure), and then the inner rubber layer is wound, laminated and formed according to the winding and laminating mode and procedure of the inner rubber layer in the fourth step, so that a good rubber transition layer is formed between the reinforcing insertion tube 6-2 of the flange component matched with the rubber expansion joint and the 8 layers of the outer curtain cloth of the rubber expansion joint, and the binding force between metal and the curtain cloth layer is enhanced;

winding, laminating and molding the rubber expansion joint outer curtain cloth 8 on the constructed transition rubber layer according to the sixth step;

step nine, winding, laminating and forming outer-layer rubber of the rubber expansion joint

Winding, laminating and molding the outer rubber 7 of the rubber expansion joint according to the fourth step;

step ten, exhausting, shaping a bandage, and compacting a cotton rope

The air exhaust needles are used for puncturing and exhausting air along the winding and laminating forming layer, the air exhaust needles ensure that the air exhaust holes are uniformly distributed along the surface of the rubber expansion joint forming core 1 from the outermost layer of the outer rubber 7 of the rubber expansion joint to the innermost layer of the inner rubber 10 of the rubber expansion joint, especially the distribution density of the air exhaust holes at the positions of the mountain feet at two sides of the repeatedly used forming rubber mountain is not less than 10/square decimeter, the rubber forming machine is started to rotate clockwise at a low speed, pretightening force is applied to the formed water-coated bandage 11, the water-coated bandage is wound from the positions of the mountain feet at two sides of the repeatedly used forming rubber mountain 13 to the inner side of the matched flange assembly 6 of the rubber expansion joint respectively so as to ensure that the air of the rubber and the curtain cloth is extruded and exhausted outwards in sequence, the next circle of bandage is ensured to be half pressed on the upper circle of bandage during winding so as, starting a rubber forming machine to rotate anticlockwise at a medium speed or a high speed to remove the wound bandage;

starting a rubber forming machine to rotate clockwise at a low speed, applying pretightening force to the formed water-coated cloth bandage 11, and sequentially winding the water-coated cloth formed bandage or the cotton bandage from the inner side of the rubber expansion joint matched flange assembly 6 to the other inner side of the rubber expansion joint matched flange assembly respectively, wherein the illustration only shows one layer of schematic representation, and half of the next circle of bandage is ensured to be pressed on the previous circle of bandage during winding; and the formed bandage is sequentially and tightly provided with the high-temperature resistant reusable shaped cotton ropes 12, and the winding type ensures that the cotton ropes are neatly and tightly arranged, well-distributed, well-arranged and proper in tightness;

eleven steps of final fine adjustment, sizing and fixing

A rubber expansion joint vulcanization limiting pull rod 15 is uniformly distributed along the circumference of a rubber expansion joint matching flange assembly 6, and a limiting pull rod adjusting gasket 16 and a limiting pull rod nut 17 are sequentially arranged on the rubber expansion joint vulcanization limiting pull rod 15; rotating a limit pull rod nut according to the structural length of a product required by a drawing for size fine adjustment and locking, and closely attaching a forming side plate vulcanization positioning baffle plate 14 to the outer side of a rubber expansion joint forming side plate 5 along the circumferential surface of a rubber expansion joint forming core to perform positioning and fixing;

step twelve, two-stage vulcanization of the integral vulcanizing tank

The rubber expansion joint formed by winding in the first step, the second step and the rubber expansion joint forming core enter a direct steam pressurization type vulcanizing tank together for integral vulcanization, and the method is implemented specifically as follows: heating, boosting pressure → sewage discharge → one-stage heat preservation and pressure maintaining vulcanization → sewage discharge → two-stage natural cooling and pressure reduction low-temperature long-time vulcanization → pressure relief and air exhaust → cooling tank discharge → demoulding;

temperature rise and pressure rise embodiments: according to the requirements of a vulcanization process, filling high-temperature superheated or supersaturated steam into a vulcanizing tank according to the rubber type and variety specification of a vulcanized product, the equipment specification of the vulcanizing tank, the vulcanizing agent matching mode and the like, and heating and boosting the tank body and the product to 133-170 ℃ and 0.36-0.7 MPa according to a set heating speed or heating curve;

the phenomenon that the temperature and the pressure are too violent or too slow in temperature rise and pressure rise is forbidden, the products are impacted and damaged due to the violent condition, the rubber material flows too fast to generate larger extrusion force to damage the arrangement density of the cord fabric, blasting through points are generated, and the compression resistance grade and the use safety of the cord fabric are reduced; over-slow can reduce the compounding vulcanization of rubber, and make the activity of vulcanization accelerator not be completely released, and affect the final vulcanization depth, and make the service performance of rubber expansion joint be reduced and deviate from its designed performance

One-stage heat preservation and pressure maintaining vulcanization implementation mode: keeping the temperature and the pressure for 2-6 hours at the vulcanization temperature and the vulcanization pressure according to the designed vulcanization process standard, so that the vulcanization temperature and the vulcanization pressure are kept stable and unchanged in the time period of keeping the temperature and the pressure;

the excessively high vulcanization temperature, the excessively high vulcanization pressure, the excessively long heat preservation and pressure maintaining time and the like can cause rubber flowing overspeed or excessively large extrusion to damage the arrangement density of the cord fabric to generate blasting breaking points, rubber expansion joints generate oversulfur to reduce the physical performance of the cord fabric, and the excessively high temperature can cause the shrinkage deformation or performance reduction of the cord fabric with not very high temperature resistance grade; similarly, the external pressing force of rubber vulcanization expansion is insufficient due to too low vulcanization temperature, too low vulcanization pressure, too short heat preservation and pressure maintaining time and the like, so that the surface of the rubber vulcanization expansion joint has the defects of material shortage, rubber shortage, air bubbles and the like, the rubber expansion joint cannot reach a positive vulcanization point (namely, the rubber is called as sulfur shortage), so that the performance of the rubber expansion joint cannot reach the designed performance, and the compression resistance grade and the use safety of the rubber expansion joint are influenced due to the reduction of the use performance;

the two-stage natural cooling, pressure reduction and low-temperature long-time vulcanization implementation mode comprises the following steps: after the first-stage heat preservation and pressure maintaining vulcanization is finished, slowly cooling to 90 ℃ according to a set cooling vulcanization curve, and reducing the pressure to be below 0.1 MPa; the time is along with the compounding mode of the vulcanizing agent, and the main purpose of the vulcanization in the section is to completely release the vulcanizing agent, the cross-linking agent, the coupling agent, the accelerator, the activator and the like in the rubber compounding to generate obvious combined action, so that the rubber is completely vulcanized, and the phenomenon that the compounding agent which is not completely decomposed in the using or storing process generates self-vulcanization to influence the service life of the rubber is prevented.

The base crude rubber is one or a combination of more of styrene butadiene rubber, chloroprene rubber, ethylene propylene diene monomer rubber, butyl rubber and nitrile butadiene rubber.

The reinforcing filler is one or a combination of N330 carbon black, N550 carbon black and N660 carbon black.

The bulking filler is one or more of calcium carbonate, calcium bicarbonate, pottery clay and bentonite.

The special filling agent is wear-resistant filling material, anti-corrosion filling material and anti-radiation filling material.

The process operation auxiliary agent is one or a combination of more of a dispersant, a lubricant, a plasticizer and a tackifier; the dispersing agent is peptoid T-78A and carbon black; the lubricant is paraffin; the plasticizer is dibutyl ester, dioctyl ester, naphthenic oil, engine oil and aromatic oil; the tackifier is coumarone resin, rosin and phenolic resin.

The rubber protection auxiliary agent is one or a combination of more of an antioxidant, an antiozonant, an anti-flex cracking agent, a light stabilizer, an ultraviolet light absorber, a harmful metal inhibitor and a mildew preventive; the antioxidant is antioxidant A, antioxidant D and antioxidant DNP; the antiozonants are antioxidant 4010 and antioxidant 4010NA; the anti-flex cracking agent is an anti-aging agent 4020 and an anti-cracking agent B-10; the light stabilizer is phosphite triester GW-540; the ultraviolet light absorber is 2- (2-hydroxy-5-methylphenyl) benzotriazole and 2- (2-hydroxy-3, 5-di-tert-butylphenyl) -5-chlorobenzotriazole, the harmful metal inhibitor is antioxidant MB, antioxidant MBZ, antioxidant D and antioxidant 4010NA, and the mildew inhibitor is sodium benzoate, mildew inhibitor N- (trichloromethylthio) phthalimide and docosahexaenoic acid.

The vulcanizing activator is one or a combination of zinc oxide, magnesium oxide, stearic acid and calcium stearate.

The vulcanizing agent is dicumyl peroxide (DCP) or diallyl phthalate (TAIC); one or more of sulfur or insoluble sulfur.

The vulcanization accelerator is one or a combination of more of diphenyl guanidine, dibenzothiazyl disulfide, 2-mercaptobenzothiazole, N-cyclohexyl-2-benzothiazole sulfonamide, tetramethyl thiuram disulfide and 1, 2-ethylene thiourea.