The Most Common Rubber Manufacturing Processes.
There are various methods of manufacturing rubber. Each process is good on its way in making a certain rubber category. When you know the manufacturing processes, you can be in a position to understand the implications on costs and tradeoffs. Among the most common rubber manufacturing processes are latex dripping, extrusions, calendaring and molding.
Extrusion commences with feeding a vulcanized compound to an extruder. A dye carries the extruder forward. The dye is special in manufacturing and assists in shaping the rubber. When the dye is put, the compound is forced by the pressure of the system through the extruder’s opening. The extruded product is vulcanized for it to become useful. Every rubber compound ought to have a cure package that is usually blended before vulcanization.
Latex dripping happens when molds that are thinly walled are put into latex molds and later withdrawn slowly. The product can be dipped again into the compound to increase its thickness. Vulcanization happens when the product is through with the dipping process. The need of post treatments is determined by the nature of the dipped product. The products that result from this method include grips, bladders, rubber gloves, tubing, and balloons among others.
Molding is comprised of three processes. These are transferred molding, injection molding and compression molding. Compression is the oldest and least expensive. It is suitable for products that have a poor flow, and those that have a high viscosity. This process on the other hand, consumes a lot of time. This method can make electrical insulators, wristbands, O-rings, silicon, and seals.
Transfer molding reduces the limitations associated with compression molding. The process commences with loading a blank in a chamber, and distributes it to various cavities. In the starting stage, rubber is heated, therefore making it possible to move to other channels.
Finally, there is injection molding. Both the press and injection units have different controls, and are two separate entities. An extruder unit is programmed in a certain way to serve several passes. This ends up with several injection processes. This minimizes handling blanks in the process. This eliminates the chances of handling blanks in the process. This can easily fill up hard cavities as well as flow channels.
By calendaring, the softened materials are forced into the middle of rotating rollers. The materials are compressed by the rollers. The product’s thickness thus becomes determined by the gap between the cylinders. Of all the other processes, calendaring is the most expensive.