In the development of a new polymer and a new compound, mixing equipment plays an important role. However, the properties of a compound tend to vary depending on the size and shape of the equipment used and a means to obtain the same compound by a small scale laboratory mixer as the one obtained by a large scale mixer has been longed for a long time.As a rubber compound is characterized by the physical properties, they are affected both by the dimensions and shape of the equipment and the mixing conditions. Recently, we developed a laboratory mixer generally following the designs of FH Banbury with exchangeable rotors and mixing chamber blocks which enable us to investigate the influences of the shape of equipment as well as the mixing conditions.In analysing rubber mixing, we found that the following factors should be taken into account, that is, unit-work which is the applied energy to the unit volume of the material during mixing, Mooney viscosity of the compound, bound rubber which is the amount of polymer unextractable from the compound by a solvent, and weight average molecular weight of polymer extractable by a solvent. If the values of the four factors are close enough for the two compounds obtained by different mixers of different size and shape, one may regard them as the same compounds. Furthermore, we experimentally measured the four factors for the compounds of typical formulations of three species of commercially available rubbers, that is, styrene butadiene rubber, ethylene propylene rubber and butadiene, and expressed the values of the factors as functions of mixing conditions and the parameters of rotor shapes by means of multiple regression analysis. Among the rotor parameters, the following showed significant effects: tip clearance, tip width, total bulkiness and wing overlap ratio. As for the mixing conditions, mixing time, rotor speed and mixing temperature were dominant.Using the functions obtained by the above mentioned method for the laboratory scale mixer, we tried to find the combinations of rotor shapes and mixing conditions that reproduced the compound mixed by large scale mixers. The optimum parameters of a laboratory mixer for the reproduction of the mixing of an industrial mixer were found to be larger rotor tip clearance, larger rotor tip width, larger wing overlap ratio, higher mixing temperature, and higher rotor speed than those of proportionally reduced dimensions and comparable conditions.

An attempt has been made to predict flow behavior of the rub bery material in an internal mixer by means of finite element analysis. For the convenience of analysis, a simplified model for the mixer and some assumptions were introduced. The model consists of a circular cylinder and a rotor with uniform cross sectional shape along the axis which rotates around the axis located at the center of the cylinder. Rubbery material fills the void between the cylinder and the rotor. The assumptions are: the material is a power law liquid, the material is incompressible, and the viscosity is large enough to allow laminar flow.

Internal mixers are commonly used for rubber compounding in industry. However, the relations among the designs of equipments, mixing conditions and the properties of the resulting compound are little known. In this paper we tried to reveal some manners of the relations concentrating, particularly, on rotor designs. A specially designed internal mixer (Banbury type) was developed. A number of double winged rotors of various shapes and replaceable mixing chambers were prepared. In developing the equipment, eight parameters were taken into consideration concerning the shape of rotors, that is, lengths, twist angles and overlap ratio of the wings, width and clearance at the rotor tip, angles of flow-in and flow-out at the gap area and total bulkiness of the rotor. Measured properties concerning mixing are: unit work, Mooney viscosity of dumped compound, the amount of bound rubber, weight average molecular weight of the extracted portion of the compound, and peaks in a torque curve, i.e., values of first peak torque and second peak time. In order to estimate the degree of influences of the design parameters mentioned above and mixing conditions, each measured properties were expressed as functions of these parameters by means of multiple regression analysis.

A highly sensitive thickness sensor has been developed which may be used as a continuously recording extensometer for rubbery materials. The application of the sensor for measuring volume changes in dewetting filled rubbers is also discussed. Further possible applications include the determination of Poisson's ratio on plastics.

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