Rubber manufacturing

Since the first rubber product appeared on the market, continuous innovation has increased and expanded its uses.

 

Since the first rubber product appeared on the market, continuous innovation has increased and expanded its uses. The many benefits of rubber products include their durability, elasticity, extended cycle life, and flexibility to be molded and shaped into various forms and configurations. These multiple properties have made rubber a staple in several industries.

 

 

In addition to its natural properties, rubber can be combined with other materials to improve and increase its basic elasticity. These combinations yield a variety of products that are stronger, more durable and long-lasting. There are countless ways in which rubber can be deformed and molded. Some of these methods include extrusion and molding.

Extrusion processes use force to press rubber through die profiles to produce products ranging from those used in medical devices to others used as sealants and linings. As with all types of rubber processes, synthetic rubbers (such as silicone and fluoroelastomers) are used for special applications that require chemical-, heat- and weather-resistant materials.

A very common and old method of molding rubber is the use of molds in which the rubber is placed in a two-part mold to produce complex designs with intricate and irregular shapes. For the molding process, the rubber material is melted before it is placed in the mold. Diaphragms and seals are manufactured using this process, as the mold can be designed with dimensions that perfectly match its use in the final product.

One of the many uses of rubber is the manufacture of rubber rollers that are chemically resistant, shock absorbent and wear resistant. In the printing industry, rubber rollers are used to apply ink to printing presses because they are not contaminated or damaged by the ink. A major function of rubber rolls is as drive rolls for converters and web machines.

A major concern for many of them is protection against wear, friction and weathering. In some cases, rubber is bonded to metal using various forms of adhesives to create a tight and strong joint as well as excellent protection. Types of metals that are easily bonded to rubber include various grades of steel, some aluminum alloys and polyamides. Aluminum alloys have become popular materials for rubber bonding due to their light weight.

A very common use of rubber is rubber tubing, which is used in a variety of machinery and vehicles as well as in the medical and sanitary fields. Much like rubber extrusion, rubber tubing is made from rubber and its synthetic forms such as latex, neoprene, silicone, fluoroelastomer and ethylene propylene diene monomer (EDPM). The elasticity and flexibility of rubber tubing make it ideal for a variety of applications. Easy to manufacture and mold, rubber tubing is always the first choice for tubing applications.

Rubber is known to be an excellent material for absorbing and withstanding shocks and vibrations. It is used on the legs of machines that vibrate during operation and provides cushioning for other applications. Vibration absorption of rubber includes dampers, bumpers, brackets, pads and foams. Using rubber to prevent equipment vibrations extends the utility of the equipment and prevents its wear and tear.

Rubber has become a common part of a wide range of equipment, such as diaphragms used to stop flow in pipes or as a material to support car bumpers. As a recyclable material, it has become an important part of many types of equipment.

 

Rubber extrusion

The rubber extrusion process allows the molding of different rubber materials into useful products. Products such as weather stripping, rubber seals, rubber cable rings and rubber bushings are the result of the rubber extrusion process. Extrusion involves pressing the rubber through a die that molds the rubber and cuts away the material, leaving the rubber profile. Dies can be designed to produce almost any shape imaginable, so rubber extrusions can be customized to meet a variety of requirements.

The properties of an individual finished product depend on the raw rubber material used to make it, the extrusion process it undergoes, and any secondary processing. Because rubber exists in many unique forms, manufacturers can further develop their products through raw material selection. For example, natural rubber, also known as tree rubber, is sought after for its excellent acid and abrasion resistance.

On the other hand, synthetic rubbers such as silicone and fluoroelastomers are often chosen for use in the healthcare and food service industries because of their excellent heat, chemical, and weather resistance. Another synthetic rubber, nitrile, is oil resistant, while neoprene is heat resistant and butyl rubber has low permeability. In general, rubber extrusions are considered sealants and gaskets because of their excellent flexibility, impermeability and resilience. CNC Machining I butyl plugs.

 

Rubber Molding

The rubber molding process involves molding raw rubber into functional products. While some products can be manufactured through other rubber molding processes, such as cell casting and extrusion, the molding process has its own characteristics that make it unique. Products made by rubber molding are enclosed in a mold cavity rather than a mold, so they can be made into complex and irregular shapes.

Rubber molding is the operation of forming raw molten rubber inside a mold. Many complex rubber products, such as rubber diaphragms and rubber seals, are made in this way, because the rubber molding process allows to design the product precisely, so it can be perfectly installed in the equipment without any type of risk of leakage. Products manufactured to protect equipment, such as rubber gaskets and rubber washers, must also be designed with precision and are therefore manufactured by rubber molding. These products can also be produced by rubber extrusion. However, the capabilities of the extruder are much more limited. Extruders can only control the X and Y axes and are therefore better suited for the production of simpler rubber products such as rubber base plates or rubber sheets. Because the process involves a molding cavity rather than a die, rubber molding allows for design control of all three axes.

 

To learn more about our rubber molding offerings, please feel free to contact us.