Top 4 Rubber Manufacturing Processes.
There are numerous processes to use when manufacturing rubber. Every manufacturing process has its advantages in making an ideal type of product. Once you know the manufacturing processes, you can be in a position to understand their effects on sale and prices. The most common rubber manufacturing processes are Extrusion, latex dipping, molding, and Calendaring.
Extrusion commences with feeding a vulcanized compound to an extruder. When it is put in the extruder, it is carried forward by a dye. The dye is important in the rubber shaping process. When the dye is put, the compound is forced by the pressure of the system through the extruder’s opening. For it to become useful, the extruded product is vulcanized. This process has a high output and a lower production cost.
Latex dripping includes dipping thinly walled molds into latex and slowly withdrawing them. To increase the thickness of the product, it can be re-dipped slowly in the latex compound. 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, compression molding, and injection 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 reduces the limitations associated with compression molding. The process commences with loading a blank in a chamber, and distributes it to various cavities. In this initial stage, pre-heating happens in the rubber, thus making the rubber to flow through the channels.
Injection molding is another form of molding. The injection and press units are two distinct units and have different controls. An extruder unit is programmed in a certain way to serve several passes. This ends up with several injection processes. This eliminates the handling of 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 rollers will then compress the materials. The thickness of the materials is a result of the thickness between the cylinders. When compared to other processes, calendaring is more expensive.