Major Processes of Manufacturing Rubber.
When providing rubber products, multiple manufacturing processes can be used. Every manufacturing process has its advantages in making an ideal type of product. Knowing the processes can assist you in knowing their prices and tradeoff effects. The most common rubber manufacturing processes are Extrusion, latex dipping, molding, and Calendaring.
Extrusion starts by putting a vulcanized compound in an extruder. When it is put in the extruder, it is carried forward by a dye. 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. Before becoming usable, the extruded product is vulcanized. Every rubber compound ought to have a cure package that is usually blended before vulcanization.
Latex dripping happens when the molds that are thinly walled are immersed in latex and then withdrawn slowly. To increase the thickness of the product, it can be re-dipped slowly in the latex compound. After the dipping process occurs, the product is then vulcanized. 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. The least expensive and oldest method is compression molding. It is suitable for products that have a poor flow, and those that have a high viscosity. The process might however be time consuming and with a low rate of production. Some of the products that result from this method are wristbands, electrical insulators, seals, silicon, and O-rings.
Transfer molding helps in minimizing the limitations of compression molding. The process starts with a loading chamber that is blank, and distributes to other cavities. In the starting stage, rubber is heated, therefore making it possible to move to other channels.
Finally, there is injection molding. The injection unit and the press unit acts as two distinct entities with separate controls. An extruder unit serves several passes by moving in a certain programmed way. This ends up with several injection processes. This minimizes handling blanks in the process. This eliminates the chances of handling blanks in the process. Flow channels and hard cavities can be filled by this easily.
Calendaring works by forcing the softened material to the middle of rollers that are counter-rotating. Rollers compress the materials. The thickness of the materials is a result of the thickness between the cylinders. Of all the other processes, calendaring is the most expensive.