When it comes to rubber products manufacturing, there are many manufacturing processes that are applied. Every procedure has certain benefits, which makes it the perfect choice for the manufacturing of certain kinds of product. Being able to make yourself aware of different manufacturing processes help to understand tradeoffs and cost implications.
Some of the frequently used rubber products manufacturing are extrusion, molding, latex dipping as well as calendaring.
Extrusion -for this procedure, it begins with unvulcanized compound which is later fed to the extruder. After it’s inside the extruder, it’ll be carried forward to the day; a specialized manufacturing tool 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 then has to be vulcanized before it can be considered usable.
Latex dipping – this occurs when thin walled mold is dipped into latex compounds and gradually withdrawn. The thickness of the dipped product could be increased by simply re-dipping the product in latex compound. As soon as the dipping process occurred, the product is finished by vulcanization. Depending on finished dipped product, it may require post treatments.
Molding – this composed of three primary manufacturing processes including transfer molding, injection molding and compression molding. For the latter, it’s the least expensive and at the same time, the oldest technique. A blank or chunk of rubber is used in this procedure to form the rubber compound. The blank is placed into the mold cavity in order for it to be shaped. There’s a slow heating time leading to long curing time. Heating might vary from 90 seconds for thin walls and can last for several hours for thicker walls.
Transfer molding is actually the natural progression in development in order to limit drawbacks of compression molding. This procedure starts with blank being loaded in chamber. Once done, it’s scattered in several cavities. From the early phase of it, preheating will begin in rubber which is going to force the rubber to flow through channels. Through this, the curing time is reduced and the rubber can flow easier to fill in mold cavities with improved efficiency.
Injection molding is the most common process for rubber products manufacturing. With this kind of procedure, the press units and the injection unit serve as separate entities which come with individual controls too. With such kind of molding, blanks handling is eliminated and processes could be automated and difficult cavities as well as flow channels can be filled easily.
Calendering – this works by forcing a softened material to the center of a counter rotating rollers. The rollers are compacting the material and the overall thickness of product is set by the gap distance between cylinders.