| Customization: | Available |
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| Material: | Bakelite |
| Application: | Medical, Household, Electronics, Automotive, Agricultural |
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1. Raw Material Preparation and Pretreatment
1. Main Material Selection
Select the perfect type of raw rubber based on the product's unique requirements. Natural rubber offers unmatched elasticity, nitrile rubber excels in oil resistance, and silicone rubber stands strong against high temperatures. Choose with precision for superior results.
2. Compound Agent Dispensing
Elevate performance by expertly adding vulcanizers like sulfur or peroxide, alongside promoters, anti-aging agents, and fillers such as carbon black or white carbon black. Precision is key, with an exacting error margin of just 0.1% to ensure optimal customization.
3. Treatment of Reinforcement Materials
Enhance rubber bonding strength by thoroughly pretreating skeletal materials like steel wire or fiber. Soak them in rubber and dry at 60-70°C to ensure robust reinforcement.
2. Plastic Refining Process
Refine the plasticity of the raw glue by reducing its molecular weight through mechanical extrusion with an opening machine or thermal oxidative degradation using a compacting machine. This step is crucial for improved plasticity and performance.
1. Mechanical Plastic Smelting: Maintain a steady temperature of 60°C, aiming to bring the viscosity down below 60 for optimal processing.
2. Thermoplastic Refining: A specialized approach perfect for natural rubber pretreatment, incorporating compressed air for enhanced results.
3. Mixed Refining Process
Achieve uniformity in rubber properties by thoroughly dispersing the mixture in the refining machine. The result is a consistently high-quality mixed rubber.
Key control points include maintaining a temperature not exceeding 120°C, a precise processing time of 5-15 minutes, and a roll distance carefully set between 1-3mm.
Customized adjustments:
1. To achieve high wear resistance, increase the carbon black content to 40-50 parts by weight, ensuring longevity and durability.
2. For high temperature resistance, strategically add zinc oxide (5-8 parts by weight) alongside a silane coupling agent to enhance stability under extreme conditions.
3. For the moulding process:
| Placement forming | Suitable for rubber plates and sealing strips, it is necessary to control the adhesive thickness tolerance within ± 0.1mm. |
| Extrusion and shaping | For the hose and sealing ring, the design of the mouth die directly affects the accuracy of the section. |
| Modular pressure molding | Metal-rubber composite molds should be used for complex structures. |
| Injection molding | Complex structural parts are multi-material composite components |
Rubber materials and characteristics
| native rubber(NR) | High elasticity (tensile strength 20-25MPa), wear resistance, tear resistance, but poor oil resistance and ozone resistance |
| styrene-butadiene rubber(SBR) | Excellent wear resistance (low cost), but the elasticity, tear resistance is weaker than natural rubber |
| butadiene rubber(BR) | Outstanding cold resistance (-70ºC is still elastic), wear resistance, but low strength, poor tear resistance |
| Ding eyes rubber(NBR) | Excellent oil resistance (mineral oil, lubricating oil), low compression permanent deformation, but poor low temperature resistance |
| ethylene-propylene rubber(EPDM) | Optimal weather resistance, ozone resistance, high temperature resistance (150ºC), good electrical insulation, but poor oil resistance |
| chloroprene rubber(CR) | Good aging resistance, ozone resistance and flame retardant, but poor low temperature performance (brittle below-30ºC) |
| silastic(VMQ) | Temperature resistance range (-70~300ºC), excellent biocompatibility, but low mechanical strength |
| fluorine(-containing)rubber(FKM) | High temperature resistance (250ºC), strong acid and alkali resistance, oil resistance, but poor air permeability, high processing difficulty |
| hydrogenated butadiene-acrylonitrile rubber (HNBR) | Oil resistance, high temperature resistance is better than ordinary NBR, wear resistance is strong |
| chlorosulfonated polyethylene(CSM) | Resistance to strong acid and strong alkali (such as concentrated sulfuric acid), ozone resistance, but poor oil resistance |
| urethane rubber(PU) | Excellent wear resistance (high Shaw hardness), tear resistance, but poor oil resistance, weak weather resistance |
| acrylic rubber(ACM) | High temperature resistance (200ºC), oil resistance (such as ester lubricating oil), but poor cold resistance |
Suggestions for type selection
| Oil resistance scene | Nitrile rubber (NBR) or fluorine rubber (FKM) is preferred |
| hot environment | Silicone rubber (VMQ) or fluorine rubber (FKM) |
| resistance to chemical attack | Chlorosulfated polyethylene (CSM) or fluorine rubber (FKM) |
| dynamic packing | Ethpropylene rubber (EPDM) or polyurethane rubber (PU) |
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