Banbury

Banana leaves Bananas Banana starch Banbury mixer Bandage lenses Banded Banded coals Band gaps Bandit... 

Fig. 39. Various mixer types for viscous pastes (a) Banbury mixer, (b) siagle-screw extmder, and (c) co-rotatiag twia-screw extmder.

R. D. Kimbrough, in P. N. Magee, ed., Banbury Report 12 Nitrosamines and Human Cancer, Cold Spring Harhon Laboratory, Cold Spring Harbor, 1982, pp. 25-34. 

In the Reclaimator, a high pressure extmder, fiber-free mbber is heated to 175—205°C with oils and other ingredients. High pressure and shear between the mbber mixture and the extmder barrel walls effectively devulcanize the mixture in one to three minutes. In the Lancaster-Banbury method, high temperature, pressure, and shear are appHed to the mbber in a batch process that is otherwise similar to the Reclaimator process. In another high pressure process, scrap mbber is devulcanized at 5.5—6.9 MPa (54—68 atm) for ca five minutes. The product is milled, baled, or pelletized as in other processes. 

The processing methods for siHcone mbber are similar to those used in the natural mbber industry (59,369—371). Polymer gum stock and fillers are compounded in a dough or Banbury-type mixer. Catalysts are added and additional compounding is completed on water-cooled roU mills. For small batches, the entire process can be carried out on a two-roU mill. Heat-cured siHcone mbber is commercially available as gum stock, reinforced gum, partially filled gum, uncatalyzed compounds, dispersions, and catalyzed compounds. The latter is ready for use without additional processing. Before being used, sihcone mbber is often freshened, ie, the compound is freshly worked on a mbber mill until it is a smooth continuous sheet. The freshening process eliminates the stmcturing problems associated with polymer—filler interactions. 

SBR mbber compounds are prepared in two stages the nonproductive and the productive phases. In the nonproductive phase the compound ingredients are mixed, usually in internal mixers (Banbury). The mixing time is usually short and the compound temperature is in the 160—195°C range. 

The productive stock, ie, the curable compound, is made up by mixing the nonproductive stock in the Banbury once more with the curative package (sulfur, accelerators, etc). This time the drop temperature is lower, in the range of 95—112°C. The productive stock is then sheeted or pelletized and coated with the dip coat, cooled, and finally stored, ready for further processing for final fabrication. 

A. W. Hsie, J. P. O NeiU, and V. K. McEUieney, eds.. Mammalian Cell Mutagenesis The Maturation of Test Systems, Banbury Report No. 2, Cold Spring Harbor Laboratory, Cold Spring Harbor, New York, 1979. 

In order to "cure" or "vulcanize" an elastomer, ie, cross-link the macromolecular chains (Fig. 2), certain chemical ingredients are mixed or compounded with the mbber, depending on its nature (4,5). The mixing process depends on the type of elastomer a high viscosity type, eg, natural mbber, requires powerhil mixers (such as the Banbury type or mbber mills), while the more Hquid polymers can be handled by ordinary rotary mixers, etc (see Rubber... 

Processing ndProperties. Neoprene has a variety of uses, both in latex and dry mbber form. The uses of the latex for dipping and coating have already been indicated. The dry mbber can be handled in the usual equipment, ie, mbber mills and Banbury mixers, to prepare various compounds. In addition to its excellent solvent resistance, polychloroprene is also much more resistant to oxidation or ozone attack than natural mbber. It is also more resistant to chemicals and has the additional property of flame resistance from the chlorine atoms. It exhibits good resiUence at room temperature, but has poor low temperature properties (crystallization). An interesting feature is its high density (1.23) resulting from the presence of chlorine in the chain this increases the price on a volume basis. 

Polymers. Studies to determine possible exposure of workers to residual epichl orohydrin and ethylene oxide monomers in the polymers have been done. Tests of warehouse air where Hydrin H and Hydrin C are stored showed epichl orohydrin levels below 0.5 ppm. Air samples taken above laboratory mixing equipment (Banbury mixer and 6" x 12" mill) when compounds of Hydrin H or C were mixed gave epichl orohydrin levels below detectable limits, and ethylene oxide levels less than 0.2 ppm, well below permissible exposure limits (46). A subacute vapor inhalation toxicity study in which animals were exposed to emission products from compounded Parel 58 suggests that no significant health effects would be expected in workers periodically exposed to these vapors (47). 

Specifications for soHd i7j -l,4-polyisoprenes are shown in Table 5 and include analyses for volatile matter, extractables, ash, and Mooney viscosity at 100°C. Standard method ASTM D1416 includes chemical analysis methods for volatile matter, extractables, and total ash, while ASTM D1646 includes Mooney viscosity (82). The Monsanto rheometer data for vulcanizates prepared by a standard recipe may also be specified. This formulation for vulcanizate (ASTM D3403) is mixed in a Banbury mixer in two passes with all but sulfur and accelerator added in first pass ... 

Banbury Mixer Preeminent in the field of high-intensity mixers, with power input up to 6000 kW/m (30 hp/gal), is the Banbury mixer, made by the Farrel Co. (Fig. 18-43). It is used mainly in the plastics and rubber industries. The top of the charge is confined by an air-operated ram cover mounted so that it can be forced down on the charge. The clearance between the rotors and the walls is extremely small, and it is... 

Since paste mixing is not within the scope of this section, such widely used paste mixers as the sigma blade and banbury types will not be covered here but instead are discussed in Sec. IS. 

Figure 11.16. Efficiency of mastication of rubber at different temperatures. Molecular weights (M) measured after 30-minute mastication of 200 g natural rubber in a size B laboratory Banbury...

The second path in Fig. 3 outlines the approach to a more robust tape designed by Drew [21]. Here the milled rubber and filler are combined with tackifiers and other additives/stabilizers in an intensive dispersing step, such as a Mogul or Banbury mixer. Next, a phenolic resin or an alternative crosslinker is added and allowed to react with the rubber crosslinker to a point somewhat short of crosslinking. The compounded mixture is then charged to a heavy duty chum and dissolved in a suitable solvent like mineral spirits. To prepare a masking tape. 

In order to be effective in imparting various chosen characteristics, all additives employed in a blend must be homogeneously dispersed throughout the blend. The two most commonly employed pieces of equipment for blending rubber and additives are rubber mills and a special type of mechanical mixer known as the Banbury mixer. A typical rubber mill consists of two rolls which rotate toward each... 

F Series Banbury Mixers. Parrel Corp. Bulletin No. 224-A. 

Rubber blends with cure rate mismatch is a burning issue for elastomer sandwich products. For example, in a conveyor belt composite structure there is always a combination of two to three special purpose rubbers and, depending on the rubber composition, the curatives are different. Hence, those composite rubber formulations need special processing and formulation to avoid a gross dissimilarity in their cure rate. Recent research in this area indicated that the modification of one or more rubbers with the same cure sites would be a possible solution. Thus, chlorosulfonated polyethylene (CSP) rubber was modified in laboratory scale with 10 wt% of 93% active meta-phenylene bismaleimide (BMI) and 0.5 wt% of dimethyl-di-(/ r/-butyl-peroxy) hexane (catalyst). Mixing was carried out in an oil heated Banbury-type mixer at 150-160°C. The addition of a catalyst was very critical. After 2 min high-shear dispersive melt mix-... 

Elastomer-plastic blends without vulcanization were prepared either in a two roll mill or Banbury mixer. Depending on the nature of plastic and rubber the mixing temperature was changed. Usually the plastic was fed into the two roll mill or an internal mixer after preheating the mixer to a temperature above the melting temperature of the plastic phase. The plastic phase was then added and the required melt viscosity was attained by applying a mechanical shear. The rubber phase was then added and the mixture was then melt mixed for an additional 1 to 3 min when other rubber additives, such as filler, activator, and lubricants or softeners, were added. Mixing was then carried out with controlled shear rate... 

Kneaders, Z- and sigma-blade, and Banbury mixers as shown in Figure 7.20, are generally used for the mixing of high-viscosity liquids, pastes, rubbers, doughs, and so on. The tanks are usually mounted horizontally and two impellers are often used. The impellers... 

---