| Customization: | Available |
|---|---|
| Material: | Bakelite |
| Application: | Medical, Household, Electronics, Automotive, Agricultural |
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1. Raw Material Preparation and Pretreatment
1. Main Material Selection
Choose the perfect type of raw rubber based on the product's purpose. For unparalleled elasticity, opt for natural rubber; for supreme oil resistance, select nitrile rubber; for exceptional high-temperature resilience, silicone rubber is the ultimate choice.
2. Compound Agent Dispensing
Achieve customized performance by meticulously adding vulcanizers (sulfur or peroxide), promoters, anti-aging agents, and fillers (either carbon black or white carbon black). Precision is key—ensure weighing accuracy within 0.1%.
3. Treatment of Reinforcement Materials
Enhance the binding strength of skeletal materials (such as steel wire or fiber) with rubber. Pre-treat by soaking and drying at a controlled temperature of 60-70°C.
2. Plastic Refining Process
Elevate the plasticity of raw glue by reducing its molecular weight. Employ mechanical extrusion (via an opening machine) or thermal oxidative degradation (using a compacting machine).
1. Mechanical Plastic Smelting: Maintain a temperature of 60°C and achieve a viscosity below 60 for optimal results.
2. Thermoplastic Refining: Perfect for natural rubber pretreatment, this method introduces compressed air for enhanced results.
3. Mixed Refining Process
Achieve a harmonious blend by uniformly dispersing the mixture in a rubber refining machine, resulting in a mixed rubber of consistent quality and excellence.
Key control points to ensure excellence: regulate temperature to not exceed 120°C, maintain processing time between 5-15 minutes, and adjust roll distance to 1-3mm.
Customized adjustments:
1. For products demanding high wear resistance: elevate carbon black content to 40-50 parts by weight.
2. For superior high-temperature resistance: incorporate zinc oxide (5-8 parts by weight) and a silane coupling agent for optimal performance.
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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