When it comes to rubber products manufacturing, there are many manufacturing processes that are applied. With each procedure, it comes with its own set of benefits that make it the right choice for the manufacturing of specific product. You are going to have clearer understanding of tradeoffs and cost implications by simply learning the different manufacturing procedures.
Few of the commonly used rubber products manufacturing include extrusion, molding, latex dipping as well as calendering.
Extrusion – this process begins with unvulcanized compound that is then fed into the extruder. The moment that it’s inside the extruder, it will be carried forward to the dye, which is basically a specialized manufacturing tool used to mold the rubber. When the compound reached the dye, the pressure will be forcing it through the opening of the extruder. The extruded product will be vulcanized before it can be deemed usable.
Latex dipping – this one occurs when a thin walled mold is immersed into latex compounds and withdrawn slowly. Re-dipping the product in the latex compound will increase the thickness of the dipped product. When the dipping process has occurred, the product is now finished in vulcanization. Post treatments may be required depending on the finished dipped product.
Molding – transfer molding, injection molding and compression molding are the three main types of manufacturing processes for this. The latter is basically the least expensive and oldest method. With this process, the rubber compound is formed in a blank or chunk of rubber. For it to be shaped, the blank is positioned to the mold cavity. Because of its slow heating time, the curing time takes a while. The heating may vary from 90 seconds for thin walls to few hours for thicker walls.
Transfer molding is actually the natural progression in development in order to limit drawbacks of compression molding. The procedure begins with a blank being loaded in chamber. After that, this is distributed in multiple cavities. In the early stages, the preheating starts in rubber which will force it to flow through channels. This reduces curing time and lets the rubber to flow easier and to fill in mold cavities with higher efficiency.
For rubber products manufacturing, injection molding is the most common procedure used. With this procedure, the press units as well as injection unit function as separate entities which come with a separate control as well. With this type of molding, there is no blanks handling and processes may be automated and the difficult cavities as well as flow channels can be easily filled.
Calendering – this works by forcing a softened material to the center of a counter rotating rollers. The rollers will be compacting the materials while the product’s overall thickness is set by the gap distance between the cylinders.