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Introduction
The word rubber comes from the materials from the rubber tree
name Havea Brasiliensis
The different between raw rubber and vulcanized rubber or
elastomer:
Elastomer crosslinking
When rubber was heated the chemical reactions occur, the process
called vulcanization or curing.
Process where rubber molecules were tied together at specific place
called crosslinks
Function of crosslinks
Stretch
Retract
Rubber processing
Raw Rubber
Mastication process
Compounding
Rubber Compound
Forming process
Vulcanization process
Vulcanize rubber/
End product
Mastication Process
Compounding Process
Rubber compounding is the way of making useful products from
raw rubber
The process involved the addition of additives to change the
masticated raw rubber to rubber compound before a forming
process.
The compounding process used the two roll mill or internal mixer
Total
100
50
5
1
1
5
1
2
165
**
Parts per hundred rubber (pphr) All the ingredients used
in a compound formulation are normally given in amounts
based on a total of 100 parts of the rubber or combination of
rubber used.
Compounding Ingredients
Each ingredient has a specific function either in processing,
vulcanization or end use of the products.
The various ingredients may be classified according to their
specific functions in the following groups:
1. Fillers
As reinforcement or cost reduction. Eg. carbon black or non black
fillers
2. Plasticizers or softeners
Extenders, processing aids, special plasticizers
3. Age resistors or antidegradants
Antioxidants, antiozonants, special age resistors
4. Vulcanizing or curing ingredients
vulcanization agents , accelerators and activator
5. Special-purpose ingredients
Coloring pigments, blowing agents, flame retardants, antistatics
agents retarders, peptizers
Sulphur vulcanization
Sulfur is the oldest vulcanization agent for unsaturated rubbers
used in rubber practice
The crosslinking produced can have a monosulphide and
polysulphide or both depending on the vulcanization systems
used
Sulphur vulcanization systems can be divided into 3 systems
depending on the relative amount of sulphur & accelerator used.
The three systems can be differentiated through the types of
crosslinking produced and the main chain modification after
vulcanization
Sulphur content
(pphr)
Accelerator
contents (pphr)
Conventional vulcanization
(CV)
2.0-3.5
1.0-0.5
1.0-2.0
(or sulphur donor)
2.5-1.0
0.-1.0
(or sulphur donor)
6.0-2.0
Depends on product:
Good Strength- CV system
Good Ageing- EV
Semi EV- in between
Efficient
vulcanization
Conventional
vulcanization
In CV- there are many S-S link, EV has many C-S link. Depend on bond
energy, for ageing C-S is more difficult to break compared to S-S (thus
EV shows good ageing properties).
Peroxide vulcanization
Organic peroxides as curing agent.
Forming Process
After all the compounding ingredients have
been properly mixed the compounded green
stock is tacky and thermoplastics
In this plastic condition, the stock can be
shaped by the applications of force.
This can be accomplished for example, by
squeezing it betweens rolls (calendering) or
pushing through an orifice having the desired
shape (tubing or extruding).
Vulcanization Process
After the green stock has been formed to the desired
shape, it needs to be converted to an elastic materials
vulcanization process usually under pressure at elevated
temperature using different techniques such as
Press vulcanization
Open vulcanization/ autoclave
Continuous vulcanization
Chemically the process involves insertation of crosslinks
between the polymer macromolecules through the actions
of vulcanizing ingredients.
The crosslinking of rubber also referring as curing it a
process whereby a raw materials is converted into a useful
product.
Press Vulcanization
Press vulcanization takes place in press that
supply heat and pressure.
Examples of press vulcanization
Compression Molding
Transfer Molding
Injection Molding
Compression Moulding
Molding press
Before
After
Transfer Moulding
This is a variation on compression moulding and involves
loading a pre-formed blank of rubber in a cavity connected
to the mould cavity by a runner.
The blank is compressed when the mould closes and is
forced under pressure into the mould cavity.
Before
After
Open Vulcanization/Autoclaves
Autoclaves, known as 'curing pans' or 'vulcanisers
Its a pressure vessels filled with steam that are used to cure
rubber articles not contained in moulds (hose, extruded
section, coated cloth, retread tyres, and small cable
batches).
Most are horizontal with vertical autoclaves now rare. They
can have either quick opening doors or multi-bolted doors.
Continuous Vulcanization
Products produced on a continuous process such as rubber
covered cable and strip are continuously cured, rather than
on a batch basis.
There are various methods but each one is sited just after
the exit die of the extruder or calender.
Finishing Process
Quality Control
Example of errors
1.
2.
3.
4.
5.
Materials
Function
Elastomer/raw rubber
Fillers
Plasticier
Anti oxidant
Accelerator
Activator
Vulcanization agent
Other ingredients
Process
Function
Mastication
Compounding
Forming
Vulcanization
Final Operation
Quality Control
Latex processing
Raw Latex
Latex compounding
Compounded Latex
Latex curing
Latex processing
Vulcanize latex/
End product
Introduction
2.
Classification of latices
Latices are classified as:
1.
2.
3.
4.
The field latex contains about 33% NR and thus not economical to be
used to make a latex products
The rubber content of the field latex need to be increased before it is
used in making latex products.
This is achieved by doing concentration process to the field latex
There are few methods that can be used to concentrate natural rubber
latex:
1. Concentration by creaming
2. Concentration by centrifugation
3. Concentration by evaporation
Latex Compounding
100
0.3
0.5
0.25
0.75
0.5
15
Total
117.3
**
Parts per hundred rubber (pphr) All the ingredients used
in a compound formulation are normally given in amounts
based on a total of 100 parts of the rubber or combination of
rubber used.
Latex Curing
Curing of latex process of introducing cross-links in the rubber
molecules.
The term vulcanisation used to describe cross-linking process involving
sulphur as cross-linking agent.
Two types of vulcanisation in latex:
pre-vulcanisation when the vulcanisation is done while the latex is
still in liquid state.
post-vulcanisation if the vulcanisation is done on latex film.
Latex
Stabilisers
Depends on
formulation
Vulcanising agents +
other ingredients
Vulcanisation
55-80C
Pre-vulcanised latex
Mature for 7 days at normal
ambient temperature
to improve uniformity
Maturation
Processing
Latex film will be formed around the former and product obtained
by drying and curing the films.
2.
3.
Students Activity