Lecture 3 Rubber Processing Ch14
Lecture 3 Rubber Processing Ch14
Lecture 3 Rubber Processing Ch14
RUBBER PROCESSING
TECHNOLOGY
1. Rubber Processing and Shaping
2. Manufacture of Tires and Other Rubber Products
3. Product Design Considerations
Synthetic Rubber
Most synthetic rubbers are produced from petroleum
by the same polymerization techniques used to
synthesize other polymers
Unlike thermoplastic and thermosetting polymers,
which are normally supplied to the fabricator as
pellets or liquid resins, synthetic rubbers are supplied
to rubber processors in the form of large bales
The rubber industry has a long tradition of
handling NR in these unit loads
Compounding
Rubber is always compounded with additives
Compounding adds chemicals for vulcanization,
such as sulfur
Additives include fillers that either enhance the
rubber's mechanical properties (reinforcing
fillers) or extend the rubber to reduce cost
(nonreinforcing fillers)
It is through compounding that the specific
rubber is designed to satisfy a given application
in terms of properties, cost, and processability
Mixing
The additives must be thoroughly mixed with the
base rubber to achieve uniform dispersion of
ingredients
Uncured rubbers have high viscosity so mechanical
working of the rubber can increase its temperature up
to 150C (300F)
If vulcanizing agents were present from the start of
mixing, premature vulcanization would result the
rubber processor's nightmare
Two-Stage Mixing
To avoid premature vulcanization, a twostage mixing
process is usually employed
Stage 1 - carbon black and other nonvulcanizing
additives are combined with the raw rubber
This stage 1 mixture is called the master batch
Filament Reinforcement in
Rubber
Many products require filament reinforcement to reduce
extensibility but retain the other desirable properties
Examples: tires, conveyor belts
1. Extrusion
2. Calendering
3. Coating
4. Molding and casting
Some products require several basic processes plus
assembly work (e.g., tires)
Extrusion
Screw extruders are generally used
The L/D ratio of the extruder barrel is less than for
thermoplastics
Typical range 10 to 15
Reduces risk of premature crosslinking
Die swell occurs in rubber extrudates
The highly plastic polymer exhibits memory
The rubber has not yet been vulcanized
Calendering
Rubber stock is passed
through a series of gaps
of decreasing size by a
stand of rotating rolls
Rubber sheet thickness
is slightly greater than
final roll gap due to die
swell
1. Compression molding
2. Transfer molding
3. Injection molding
Compression molding is the most important because
of its use in tire manufacture
What is Vulcanization?
The treatment that accomplishes crosslinking of
elastomer molecules
Makes the rubber stiffer and stronger but retain
extensibility
The longchain molecules become joined at certain
tie points, which is reduces the ability to flow
Soft rubber has 1 or 2 crosslinks per 1000 mers
As the number of crosslinks increases, the
polymer becomes stiffer (e.g., hard rubber)
Effect of Vulcanization on
Rubber Molecules
(1) raw rubber, and (2) vulcanized (crosslinked) rubber:
(a) soft rubber and (b) hard rubber
Pneumatic Tires
Functions of pneumatic tires on vehicle :
Support the weight of the vehicle, passengers,
and cargo
Transmit the motor torque to propel the vehicle
Tire Construction
A tire is an assembly of many components
About 50 for a passenger car tire
1. Preforming of components
2. Building the carcass and adding rubber strips to
form the sidewalls and treads
3. Molding and curing the components into one
integral piece
Variations exist in processing depending on
construction, tire size, and type of vehicle
Preforming of Components
Carcass consists of multiple components, most of
which are rubber or reinforced rubber
These components and others are produced by
continuous processes
They are then precut to size and shape for
subsequent assembly
Other components include: bead coil, plies,
inner lining, belts, tread, and sidewall
Processing of Thermoplastic
Elastomers
A thermoplastic elastomer (TPE) is a thermoplastic
polymer that possesses the properties of a rubber
TPEs are processed like thermoplastics, but their
applications are those of an elastomer
Most common shaping processes are injection
molding and extrusion
Generally more economical and faster than the
traditional processes for rubbers that must be
vulcanized
TPE Products
Molded products: shoe soles, athletic footwear, and
automotive components such as fender extensions
and corner panels
Extruded items: insulation coating for electrical wire,
tubing for medical applications, conveyor belts, sheet
and film stock
No tires of TPE