Rubber Processing Technology and Compounding.ppt

Lecture # 3
RUBBER PROCESSING
TECHNOLOGY
1. Rubber Processing and Shaping
2. Manufacture of Tires and Other Rubber Products
3. Product Design Considerations

Overview of Rubber Processing
 Many of the production methods used for plastics are
also applicable to rubbers
 However, rubber processing technology is different in
certain respects, and the rubber industry is largely
separate from the plastics industry
 The rubber industry and goods made of rubber are
dominated by one product: tires
 Tires are used in large numbers on automobiles,
trucks, aircraft, and bicycles

Two Basic Steps in
Rubber Goods Production
1. Production of the rubber itself
 Natural rubber (NR) is an agricultural crop
 Synthetic rubbers is based on petroleum
2. Processing into finished goods:
 Compounding
 Mixing
 Shaping
 Vulcanizing

The Rubber Industries
 Production of raw NR is an agricultural industry
because latex, the starting ingredient, is grown on
plantations in tropical climates
 By contrast, synthetic rubbers are produced by the
petrochemical industry
 Finally, processing into tires and other products occurs
at processor (fabricator) plants, commonly known as
the rubber industry

Production of Natural Rubber
 Natural rubber is tapped from rubber trees (Hevea
brasiliensis) as latex
 In Southeast Asia and other parts of the world
 Latex is a colloidal dispersion of solid particles of the
polymer polyisoprene in water
 Polyisoprene (C5H8)n is the chemical substance
that comprises NR, and its content in the emulsion
is about 30%

Recovering the Rubber
 Preferred method to recover rubber from latex
involves coagulation - adding an acid such as formic
acid (HCOOH)
 Coagulation takes about 12 hours
 The coagulum, now soft solid slabs, is then squeezed
through rolls which drive out most of the water and
reduce thickness to about 3 mm (1/8 in)
 The sheets are then draped over wooden frames and
dried in smokehouses for several days

Grades of Natural Rubber
 The resulting rubber, now in a form called ribbed
smoked sheet, is folded into large bales for shipment
to the processor
 In some cases, the sheets are dried in hot air rather
than smokehouses, and the term air dried sheet
‑ is
used
 This is considered a better grade of rubber
 A still better grade, called pale crepe rubber, involves
two coagulation steps, followed by warm air drying

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
(non reinforcing fillers)
‑
 It is through compounding that the specific
rubber is designed to satisfy a given application
in terms of properties, cost, and processability

Carbon Black in Rubber
 The single most important reinforcing filler in rubber
is carbon black, a colloidal form of carbon obtained
by thermal decomposition of hydrocarbons (soot)
 It increases tensile strength and resistance to
abrasion and tearing of the final rubber product
 Carbon black also provides protection from
ultraviolet radiation
 Most rubber parts are black in color because of
their carbon black content

Other Fillers and Additives in
Rubber
 China clays hydrous aluminum silicates (Al
‑ 2Si2O5(OH)4)
reinforce less than carbon black but are used when the
color black is not acceptable
 Other polymers, such as styrene, PVC, and phenolics
 Recycled rubber added in some rubber products, but
usually 10% or less
 Antioxidants; fatigue and ozone protective chemicals;
‑ ‑
coloring pigments; plasticizers and softening oils;
blowing agents in the production of foamed rubber; mold
release compounds

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 150C (300F)
 If vulcanizing agents were present from the start of
mixing, premature vulcanization would result the
‑
“rubber processor's nightmare”

Mixers in Rubber Processing
 (a) Two-roll mill and
(b) Banbury-type
internal mixer

Two-Stage Mixing
To avoid premature vulcanization, a two stage mixing
‑
process is usually employed
 Stage 1 - carbon black and other non vulcanizing
‑
additives are combined with the raw rubber
 This stage 1 mixture is called the master batch
 Stage 2 - after stage 1 mixing is completed, and
cooling time has been allowed, stage 2 mixing is
carried out in which vulcanizing agents are added

Filament Reinforcement in
Rubber
 Many products require filament reinforcement to reduce
extensibility but retain the other desirable properties
 Examples: tires, conveyor belts
 Filaments include cellulose, nylon, and polyester
 Fiber glass and steel are also used (e.g.,
‑
steel belted radial tires)
‑
 Continuous fiber materials must be added during
shaping; they are not mixed like the other additives

Shaping and Related Processes
for Rubber Products
 Four basic categories of shaping processes:
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 cross linking
‑
 Die swell occurs in rubber extrudates
 The highly plastic polymer exhibits “memory”
 The rubber has not yet been vulcanized

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
Calendering

Combination of extrusion and calendering that results
in better quality product than either extrusion or
calendering alone
Roller Die Process

 Important industrial process for producing tires,
conveyor belts, inflatable rafts, and waterproof cloth
Coating or Impregnating Fabrics
with Rubber

Molded Rubber Products
 Molded rubber products include shoe soles and
heals, gaskets and seals, suction cups, and bottle
stops
 Also, many foamed rubber parts are produced by
molding
 In addition, molding is an important process in tire
production

Molding Processes for Rubber
 Principal molding processes for rubber are
1. Compression molding
2. Transfer molding
3. Injection molding
 Compression molding is the most important because
of its use in tire manufacture

Molding Processes for Rubber
 Curing (vulcanizing) is accomplished in the mold in all
three molding processes
 This represents a departure from previous shaping
methods
 Other shaping methods use a separate
vulcanizing step

What is Vulcanization?
The treatment that accomplishes cross linking of
‑
elastomer molecules
 Makes the rubber stiffer and stronger but retain
extensibility
 The long chain molecules become joined at certain
‑
tie points, which is reduces the ability to flow
 Soft rubber has 1 or 2 cross links per 1000 mers
‑
 As the number of cross links increases, the
‑
polymer becomes stiffer (e.g., hard rubber)

(1) raw rubber, and (2) vulcanized (cross linked) rubber:
‑
(a) soft rubber and (b) hard rubber
Effect of Vulcanization on
Rubber Molecules

Vulcanization Chemicals and
Times
 When first invented by Goodyear in 1839, vulcanization
used sulfur (about 8 parts by weight of S mixed with
100 parts of NR) at 140C (280F) for about 5 hours
 Vulcanization with sulfur alone is no longer used,
due to long curing times
 Various other chemicals (e.g., zinc oxide, stearic acid)
are combined with smaller doses of sulfur to accelerate
and strengthen the treatment
 Resulting cure time is 15 20 minutes
‑

Tires and Other Rubber Products
 Tires are about 75% of total rubber tonnage
 Other important products:
 Footwear
 Seals
 Shock absorbing parts
‑
 Conveyor belts
 Hose
 Foamed rubber products
 Sports equipment

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
 Absorb road vibrations and shock to provide a
comfortable ride
 Tires are used on automobiles, trucks, buses, farm
tractors, earth moving equipment, military vehicles,
bicycles, motorcycles, and aircraft

Tire Construction
 A tire is an assembly of many components
 About 50 for a passenger car tire
 Large earthmover tire has as many as 175
 The internal structure of the tire, known as the
carcass, consists of multiple layers of rubber-coated
cords, called plies
 The cords are strands of nylon, polyester, fiber
glass, or steel, which provide inextensibility to
reinforce the rubber in the carcass

Three Tire constructions: (a) diagonal
ply, (b) belted bias, and (c) radial ply

Tire Production Sequence
 Tire production is summarized in three steps:
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 pre cut to size and shape for
‑
subsequent assembly
 Other components include: bead coil, plies,
inner lining, belts, tread, and sidewall

 Prior to molding and curing, the carcass is
assembled on a building drum, whose main element
is a cylindrical arbor that rotates
Building the Carcass

Molding and Curing
 (1) Uncured tire placed over expandable diaphragm,
(2) split mold is closed and diaphragm is expanded
to force uncured rubber against cavity with tread
pattern; mold & diaphragm are heated to cure rubber

Other Rubber Products:
Rubber Belts
 Widely used in conveyors and pulley systems
 Rubber is ideal for these products due to its flexibility,
but the belt must have little or no extensibility
 Accordingly, it is reinforced with fibers, commonly
polyester or nylon
 Fabrics of these polymers are usually coated by
calendering, assembled together to obtain required
number of plies and thickness, and subsequently
vulcanized by continuous or batch heating processes

Hose
Two basic types:
1. Plain hose (no reinforcement) is extruded tubing
2. Reinforced tube, which consists of:
 Inner tube - extruded of a rubber compounded
for particular liquid that will flow through it
 Reinforcement layer - applied to inner tube as
fabric, or by spiraling, knitting, braiding
 Outer layer – compounded for environment and
applied by extrusion

Footwear
 Rubber components in footwear: soles, heels, rubber
overshoes, and certain upper parts
 Molded parts are produced by injection molding,
compression molding, and certain special molding
techniques developed by the shoe industry
 The rubbers include both solid and foamed
 For low volume production, manual methods are
sometimes used to cut rubber from flat stock

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

Product Design Considerations
Economic Production Quantities:
 Rubber parts produced by compression molding (the
traditional process) can often be produced in
quantities of 1000 or less
 The mold cost is relatively low compared to
other molding methods
 As with plastic parts, injection molding of rubber parts
requires higher production quantities to justify the
more expensive mold

Product Design Considerations
Draft:
 Draft is usually unnecessary for molded parts of
rubber, because its flexibility allows it to deform for
removal from the mold
 Shallow undercuts, although undesirable, are
possible with rubber molded parts for the same
reason
 The low stiffness and high elasticity of the material
permits removal from the mold

Rubber Processing Technology and Compounding.ppt

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