Major Processes of Manufacturing Rubber.
When providing rubber products, multiple manufacturing processes can be used. Each process is good on its way in making a certain rubber category. When you know the manufacturing processes, you can be in a position to understand the implications on costs and tradeoffs. Molding, calendaring, latex dripping and extrusion are the most common rubber processing methods.
Extrusion commences with feeding a vulcanized compound to an extruder. a dye carries the extruder upon putting it. The dye is usually a special manufacturing tool that is mean t to shape the rubber. When the compound reaches the dye, it is forced through the extruder’s opening by the pressure from the process. The extruded product is vulcanized for it to become useful. This process has a high output and a lower production cost.
Latex dripping happens when the molds that are thinly walled are immersed in latex and then withdrawn slowly. The product can be dipped again into the compound to increase its thickness. 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 includes three main manufacturing processes. They are compression molding, injection molding, and transfer molding. The oldest and cheapest method is compression molding. It is suitable for products that have a poor flow, and those that have a high viscosity. This process on the other hand, consumes a lot of time. O-rings, silicon, electrical insulators, seals, and wristbands can be made using this method.
Transfer molding limits the limitations of compression and molding. The process begins with a blank chamber that moves rubber to other chambers. Rubber is fast heated, thus easing its flow to other channels.
Injection molding is another common process in 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 results into short injection processes. This minimizes handling blanks in the process. This eliminates the chances of handling blanks in the process. This can easily fill up hard cavities as well as flow channels.
Calendaring involves forcing softened materials to the middle of rotating rollers. Rollers compress the materials. The distance between the cylinders affects the thickness of the cylinders. Of all the other processes, calendaring is the most expensive.