Injection Molding of Rubber
Injection Molding of Rubber
Injection Molding of Rubber
Contents
1. Production Processes Compounds and Requirements 2. Processing Additives Introduction + Function
3. How to choose the right Process Additive 4. Example Case Studies problems and their solution 5. Conclusion
Requirements
Must have high level of dispersion Need to have excellent flow properties A fast cure rate is required Must release easily from the mould Should be low in mould fouling
Injection Moulding
High precision components
Seals, O rings, Gaskets and bellows, Metal bonded parts Rubber compounds must be well mixed
Injection Moulding
Highly automated process
Short production cycles are used Robotised demoulding High uniformity of produced parts
Raw Materials
Compounding
Rubber Compound
Processing
Rubber Compound
Processing
Viscosity reduction Easier mixing release Better batch homogenity Shorter cycles, more efficient mixing Better filler dispersion
8
Raw Materials
Compounding
Rubber Compound
Processing
Improved compound flow Reduced compound stickiness Better demoulding / Less fouling Improved article appearance Higher productivity 9 Less scrap rate
Problem Details?
Problem?!
Formulation analysis: filler dosage? curing system? plasticiser type? stearic acid level? etc.
Know-How Experience
Suited, most efficient process additive is choosen
10
Compound 1
175 95 10 10 1 1
Compound 2
175 95 10 10 1 1 2 8 2,5 304,5
Process Additive Struktol WS 180 - Process lubricant (organosilicone based) - efficient at low dosage 0,5 - 2 phr - well compatible with EPDM (low peroxide demand) - pelletised product
Vistalon 3666 N-550 Statex Sunpar 2280 ZnO Vulkanox HS/LG Vulkanox MB2/MG-C Struktol WS 180 (flakes) Perkadox 14-40 Sartomer 206 Sum :
8 2,5 302,5
Occuring Problems: a) insufficient compound flow b) stickiness of parts to mould surface c) quick mould fouling
11
Mould cleaning: Struktol MC-I mould cleaning compound injected after Compound 1 and Compound 2 cycles
14
15
Note: 8
Note: 6
Process Additive
50 50 70 5 2 0,5 2
Compound 1
50 50 70 5 2 0,5 2
Compound 2
Struktol WB 222
Process lubricant
1,25 4 184,75
1,25 4 184,25
Occuring Problems: a) insufficient compound flow b) stickiness of parts to mould surface c) mould fouling
17
18
Mould cleaning: Struktol MC-I mould cleaning compound injected after compound 1 + compound 2 cycles
19
21
uncoated
Permalease coated
Friction Modus AFM microscope view of coated steel plate in friction mode
22
5. Conclusion
It is important to choose the best suited process additive for concerned process / occured problem
Use of little process additive helps to solve production problems in an easy way Injection moulding problems can be resolved by using e.g. Struktol WS 180 or Struktol WB 222 (better flow, lower mould fouling, improved article appearance)
26
Struktol HT Products
A new range of products developed to offer added advantages
Several products have improved dispersing nature Easier dispersibility at lower temperatures Can be mixed into soft compounds or at end of mixing
HT Product HT 202 HT 204 HT 266 HT 105 Standard Product A 50P WB 16 EF 44 A86
27
HT Product offers improved safety for use in soft compounds or low viscosity compounds when added at the end of mixing or in mill mixing. HT product will disperse at temperatures above 60 C 60C
Ingredient CR (Type W) ODPA AFD N-990 Struktol KW 400 Struktol Zimag 29/43 Struktol WB 16 Flake Struktol WB 16 Microb. Struktol HT 204
DOTG CBS Sulphur
Control
WB 16 Fl
WB 16 Beads
HT 204
100 2 1 35 30 8
100 2 1 35 30 8
3
100 2 1 35 30 8
3
100 2 1 35 30 8
3 1 1 1 1 1 1 1 1 0.5
7 6
power (kW)
Mixing energy is reduced due to presence of WB 16 types. Rotor slippage occurs due to insufficient WB 16 dispersion. Low temperature generation
5 4 3 2 1 0 0 60 120 180
time ( sec )
torque (dNm)
Cure curves show reduced max torque with WB 16 variants. Probably this is due to rotor slippage as undispersed WB 16 melts at 180C during curing
6 5 4 3 2 1 0
10
15
20
25
30
time (min)
30
Rheological behaviour:
Control dump temperature (C) energy consumption (kj) Sample temperature (C) 59 478 73 WB 16 Fl 53 339 56 WB 16 Beads 51 339 55 HT 204 53 408 65
13
180/30 0,2 6,1 1,3 7,6 0,03
7
180C/30 0,2 5,5 1,4 8,9 0,04
10
180C/30 0,2 5,5 1,4 8 0,04
12
180C/30 0,2 6 1,3 7,8 0,03
31
Physical properties:
Control Cure time for 2 mm (min) 180C cure time for 6 mm (min) 180C 30 30 31 WB 16 Fl 30 30 31 WB 16 Beads 30 30 31 HT 204 30 30 31
32
Control
WB 16 Microbead
WB16 Flakes
HT 204 (Microbead)
33
Tensile Strength
MPa 14 12 10 8 6 4 2 0 Control WB 16 Flake WB 16 Microbead HT 204
34
Conclusion
In a soft / low temperature mixing compound for injection moulding Struktol WB 16 flake did not disperse Struktol WB 16 microbead was borderline Struktol HT 204 was fully OK
35
Ingredient CR (Type W) ODPA AFD N-220 Silica (VN3) Struktol KW 400 Struktol Zimag 29/43 Struktol HT 204 (added early) Struktol HT 204 (added late)
DOTG CBS Sulphur
Control
HT 204 early
HT 204 late
100 2 1 30 10 10 8
100 2 1 30 10 10 8
3
100 2 1 30 10 10 8
3
1 1 0.5
1 1 0.5
1 1 0.5
Single stage mixing in laboratory Banbury. HT 204 added early after 30 seconds together with silica HT 204 added late after 2 30 - together with curatives Dump at 3 30
36
Spider Mouldings
Control
37
Conclusion
The point of addition has an influence
Late addition resulted in increased flow properties for the same loading Struktol HT 204 dispersed OK when added late in mixing
38
39