Rubber production process

Rubber is an elastic material that is typically derived from the latex of rubber trees or synthetic sources.       It exhibits excellent elasticity, abrasion resistance, and aging resistance, making it widely used in various applications such as tire manufacturing, seals, pipes, rubber pads, and more.       The production process of rubber products often includes several key processing steps such as mastication, compounding, calendering, extrusion, molding, and vulcanization.       Each step plays a crucial role in determining the performance and quality of the final products.       Below is a detailed overview of the manufacturing process for rubber products.

1.      Mastication:

The raw rubber and additives are mixed and heated in the rubber crusher to soften the rubber, enhance the adhesion, and remove the impurities contained in it.

Key Factors: Control of time, temperature, mechanical force, and types/proportions of masticating agents.

2.     Compounding:

In the mixer, the rubber and various additives (such as vulcanization agents, anti-aging agents, fillers, etc.) are mixed evenly to improve the performance of rubber products.

Key Factors: Type, proportion, and sequence of additives, compounding temperature and time, mixing intensity, among others.

3.     Calendering:

The mixed rubber is pressed into thin sheets or thin strips by the calender machine for subsequent processing and molding.

Key Factors: Control of calender temperature, speed, pressure, rubber hardness, and viscosity.

4.     Extrusion:

The rubber is extruded by the extrusion machine into continuous strips of material with a specific cross-section shape, which is used to manufacture rubber products in tubes, rods or other complex shapes.

Key Factors: Control of extrusion machine temperature, pressure, speed, die head design, etc.

5.     Molding:

The rubber material is put into the mold, and under the action of heating and pressure, it fills the mold cavity and obtains the desired shape.

Key Factors: Mold design, temperature, pressure, time control, rubber fill amount, and flow properties.

6.     Vulcanization:

The formed rubber products are placed in the vulcanization furnace, and the vulcanization reaction is carried out under a certain temperature, time and pressure, so that the rubber molecules are cross-linked, thereby improving the mechanical strength, wear resistance and aging resistance of the rubber.

Key Factors: Control of vulcanization temperature, time, pressure, type/amount of vulcanizing agent, and cross-link density and structure

The detailed explanation above outlines the key processing steps in the production of rubber products, with each step's proper operation and control being crucial in determining the quality and performance of the final rubber products