ME477

Fall 2004

RUBBER PROCESSING TECHNOLOGY

1. Rubber Processing and Shaping 2. Manufacture of Tire and other Rubber Products 3. Design Consideration
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Similar to the processing of plastics But the rubber industry is quite different from the plastics industry Dominated by one product: tires Technological breakthrough
Vulcanization (cross-linking) to transform weak natural rubber into a stronger material (1839). The introduction of synthetic rubbers such as Styrene-butadiene rubber (SBR), Butadiene Rubber (BR) and Ethylene-Propylene-diene rubber (EPDM) (around WWII) Natural
strength
Synthetic

Introduction

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Rubber Processing and Shaping

Two basic steps
Production - Agricultural crop or Petroleum Shaping of rubber into finished goods
Compounding Addition of Reinforcement (R) and Nonreinforcement (NR) Mixing Two stages of mixing, masterbatch (nonvulcanizing agents) and second stage (vulcanizing agents), using two-roll mill and internal mixer Shaping Extrusion, calendering, coating, molding and casting Vulcanization A curing (cross-linking) process developed by Goodyear Rubber

Production of Natural Rubber

Latex (a colloidal dispersion (30%) of solid particles (polymer polyisoprene) in water) from Rubber trees (Hevea brasiliensis) on plantations in southeast Asia and other part
Diluted to 50% with additional water and coagulated by adding formic or acetic acids in large tanks. Coagulum (soft solid slabs) is then squeezed through a series of rollers to loose water. Drying
Ribbed smoked sheet in dark brown color - dried over wooden frames in smokehouses for several days, which are folded into large bales. Air-dried sheet - A better grade of rubber, dried in hot air rather than smokehouses. Pale crepe rubber in light tan - A even better grade involves two coagulation steps and warm air drying. 4

Internal mixer

Two-roll mill

Production of Synthetic Rubber

Most synthetic rubbers are produced from petroleum by the same polymerization techniques. Unlike shaping polymers in the form of pellets or liquid resins, synthetic rubbers start in the form of large bales.

Compounding
The specific rubber is designed by vulcanization, (adding sulfur) or fillers. Fillers to enhance the rubber's mechanical properties (reinforcing fillers) or to reduce cost (non-reinforcing fillers) Carbon black, a colloidal form of carbon, obtained by thermally decomposing hydrocarbons (soot)
to increase tensile strength and resistance to abrasion and tearing To protect from ultraviolet radiation Appear black in color
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MSU

ME477

Fall 2004

Compounding
China clays - hydrous aluminum silicates (Al2Si2O5(OH)4) for other colors but less reinforcing than carbon black. Calcium carbonate (non-reinforcing) and Silica Other polymers (styrene, PVC, and phenolics) Recycled rubber (usually 10% or less) Antioxidants (anti-aging by oxidation); fatigue- and ozone-protective chemicals; coloring pigments; plasticizers and softening oils; blowing agents in the production of foamed rubber; and mold release compounds
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Mixing
To achieve uniform dispersion of ingredients Mechanical working increases its temperature up to 150C (300F) A two-stage to avoid nightmare
Carbon black & non-vulcanizing additives (masterbatch) Vulcanizing agents after cooling

Filament reinforcement to reduce extensibility while retaining the other properties

Examples: tires, conveyor belts Filaments (cellulose, nylon, and polyester) and Fiber-glass and steel (e.g., steel-belted radial tires) Continuous fiber materials must be added during shaping; not mixed like the other additives 8

Shaping and Related Processes

Four basic categories of shaping processes :
1. Extrusion 2. Calendering 3. Coating 4. Molding and casting

Extrusion
Screw extruders are generally used The L/D ratio of the extruder barrel is less than for thermoplastics, typically in the range 10 to 15, to reduce the risk of premature cross-linking Die swell occurs in rubber extrudates due to its highly plastic condition and the memory property It is done before vulcanization.

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Calendering
Stock is passed through a series of gaps of decreasing size made by a stand of rotating rolls where final roll gap determines sheet thickness.

Roller Die Process

Combination of extrusion and calendering for better quality product.

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Kwon

MSU

ME477

Fall 2004

Coating or Impregnating Fabrics with Rubber

Used in producing automobile tires, conveyor belts, inflatable rafts, and waterproof cloth tents and rain coats

Molding
Products include shoe soles and heals, gaskets and seals, suction cups, bottle stops, tires and foamed rubber parts. (1) compression molding (tire manufacture), (2) transfer molding, and (3) injection molding Curing (vulcanizing) is accomplished in the mold in all three processes
Vulcanization -Cross-linking of elastomer molecules to make stiffer and stronger while retaining extensibility. First Goodyear invented vulcanization by sulfur at 140C for about 5 hours in 1839.

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Vulcanization
Now various other chemicals are combined with sulfur to accelerate and strengthen the 15-20 minute treatment. A variety of non-sulfur vulcanizing treatments have also been developed.
soft rubber

Tires
Functions of vehicle tires:
Support the weight of the vehicle, passengers, and cargo Transmit the motor torque Absorb road vibrations and shock

Automobiles, trucks, buses, farm tractors, earth moving equipment, military vehicles, bicycles, motorcycles, and aircraft A tire is an assembly of many parts about 50 to as many as 175 components
The internal structure, 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

hard rubber
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Manufacture of Tire and Others

Tire ( of rubber product), Footwear, Seals, Shock-absorbing parts, Conveyor belts, Hose, Foamed rubber products, Sports equipment Tire: Three basic constructions
Diagonal ply

Tire Production Sequence

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

Belted Bias

Variations in processing depending on construction, tire size, and type of vehicle

Radial ply
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Kwon

MSU

ME477

Fall 2004

Preforming of Components
The carcass consists of a number of components produced by continuous processes and then pre-cut to size and shape for subsequent assembly
Building carcass

Molding and Curing

A machine known as a building drum with a cylindrical arbor that rotates.

Tire molding: (1) uncured tire is placed over expandable diaphragm; (2) mold is closed and diaphragm is expanded to force uncured rubber against mold cavity, impressing tread pattern into rubber; mold & diaphragm are heated to cure rubber
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Other Rubber Products Rubber Belts, Hose, Footwear

Rubber belts
Widely used in conveyors and mechanical power transmission systems Rubber belt must have little or no extensibility
Reinforced with polyester or nylon fibers

Hose and
Plain hose is extruded tubing Reinforced tube:
Inner tube - extruded of a rubber compounded for particular liquid that will flow through it Reinforcement layer applied to the inner tube as a fabric, or by spiraling, knitting, braiding Outer layer compounded for environmental conditions and applied by extrusion

Footwear
Soles, heels, rubber overshoes, and certain upper parts Molded parts by injection molding, compression molding, and special molding techniques developed by the shoe industry Both solid and foamed For low volume production, manual methods are used
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Fabrics of these polymers are usually coated by calendering, assembled together, and subsequently vulcanized by continuous or batch heating processes
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Processing of Thermoplastic Elastomers (TPE)

Processed like thermoplastics, but used like elastomer Shaping processes: injection molding and extrusion. More economical and faster than the traditional processes 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
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Product Design Considerations

Rubber parts can be produced by compression molding in quantities of 1000 or less
The mold cost is relatively low

Injection molding requires higher production quantities due to more expensive mold Draft is usually unnecessary due to its flexibility to deform for removal from the mold Shallow undercuts, although undesirable, are possible

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MSU