All about the rubber extrusion processes

Rubber extrusion is a manufacturing process used to create continuous lengths of rubber with a consistent cross-sectional profile. It involves forcing uncured rubber through a shaped die under pressure to produce a desired shape. Here's a comprehensive overview of the rubber extrusion process:

Process Steps:

1. Material Preparation: Raw rubber material, often in the form of pellets, strips, or sheets, is prepared and compounded with additives like vulcanizing agents, plasticizers, fillers, and pigments to achieve the desired properties.

2. Extruder: The rubber compound is fed into the extruder—a machine that consists of a hopper, a rotating screw, and a barrel. The screw rotates and applies heat and pressure to soften and homogenize the rubber material.

3. Die Design: A die or tooling, which determines the final shape of the extruded rubber, is designed according to the product specifications. Dies can be simple or complex, depending on the profile needed (solid, hollow, complex shapes, etc.).

4. Extrusion Process: The softened rubber material is pushed through the die cavity by the rotating screw, applying pressure to force it through the shaped opening. The material takes the die's shape as it exits, forming a continuous length of rubber.

5. Cooling and Vulcanization: The extruded rubber is cooled using various methods (e.g., water baths, cooling tanks) to maintain its shape. Additionally, vulcanization takes place, a process where the rubber compound undergoes chemical cross-linking, improving its strength, elasticity, and durability.

6. Cutting and Finishing: Once the rubber is fully cured, it is cut to the desired lengths or wound onto spools. Further finishing processes like curing, surface treatments, or additional shaping may be performed based on the final product requirements.

Factors Influencing Rubber Extrusion:

• Material Selection: Different rubber compounds (e.g., natural rubber, EPDM, silicone) have distinct

   properties that suit specific applications.

• Die Design: The die's shape and dimensions determine the cross-sectional profile of the extruded   

   rubber. Complex shapes may require specialized tooling.

• Temperature and Pressure: Control of temperature and pressure within the extruder affects the

   material's flow characteristics and final properties.

• Speed and Pulling Force: The rate at which the material is extruded and pulled through the die

   impacts the dimensions and surface finish of the extruded rubber.

 

 

 

 

Applications of Rubber Extrusion:

• Seals and Gaskets: Commonly used in automotive, aerospace, and industrial applications.

• Tubing and Hoses: For fluid transfer in various industries like medical, automotive, and construction.

• Profiles and Moldings: Used in construction, weatherstripping, and other applications requiring specific shapes.

 

Benefits of Rubber Extrusion

Most benefits to using the rubber extrusion process for produce rubber. Not only is the process more effective in terms of decreased waste volumes, but the process is highly economical, with manufacturing costs being lower than other manufacturing methods.

Moreover, the extruded rubber products themselves have their own beneficial assets. These products are extensively durable and long-term and are mostly durable to heat, chemicals, abrasion and cold, for making them ideal for usage in harsh or extreme situations.

The rubber extrusion can be used to manufacture a large number of products that vary in shapes and sizes, which assists the team at Seashorerubber Rubber produce custom products that meet our clients’ needs. The rubber extrusion process is generally used to produce the following rubber products, angle extrusions, marine fenders, side skirts, T and P profile extrusions, and a variety of seals.

Extrudable Rubber Materials

The Rubber Extrusion process can used for a large number of natural and synthetic rubber compounds, as well as EPDM, synthetic polyisoprene, neoprene, nitrile SBR, Viton, and silicone. We release a majority of rubber compounds to meet the needs of our clients.

Extrusion Die for Extruded Rubber

An extrusion die is a definite and specific tool made by cutting an opening via a blank of steel. The structure of the opening will match the ended rubber cross section long for an extruded part. Once in place, the rubber material will be compelled through this die via the pressure that grows up from the revolving screw of the extruder.

Many rubber compounds likely to swell when going through the extrusion die, causing them to experience an increase in dimensions. Thus, every die is made according to every particular part and material to make sure that all patience are met for the finished extruded rubber part.

 

Custom Rubber Extrusion Specifications

At Seashorerubber Rubber, we offer a bespoke service to help our clients decide which rubber quality meet their best requirements, We will check the operating environment the product will be used in to recognize the required properties of the rubber. All our products are available in a large number of materials suitable for any environment.

 

Extruded Rubber Products

Seashorerubber can also cut custom rubber extrusions in a range of shapes, lengths, and rubber compounds to meet different weather, temperature, and technical specifications. Some of them, such as neoprene or EPDM, can be extruded like or dense rubber, sponge rubber. Common extruded rubber products include:

•             Connectors

•             Tubing

•             Mandrel formed hoses

•             Door, cabinet and window seals

•             Vibration reducers

•             Gaskets

•             Spliced gaskets

•             Window seals for mass transit

•             Pressure switch square tubing

 

Rubber extrusion is a versatile process widely used to manufacture various rubber products, offering customization in shapes, sizes, and properties to meet diverse industrial needs.