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Introduction

Rubber is one of the most used raw materials across different industries. Both natural and synthetic rubber is used extensively to make everything starting from the tiniest of home goods to massive structures used in industries. There are different types of rubber molding used in producing rubber components, and the features of the product would depend on the manufacturing process and the type of molding chosen.

Did you know that India is the fourth largest consumer of rubber? According to sources, the per capita consumption of rubber is 1.2 kg. The Indian Rubber Industry states that rubber manufacturing companies in the country produce more than 35,000 different rubber products. All these products use one of the below molding types to be manufactured.

Here are the three most popular types of rubber molding used by industries to create rubber components and products.

Rubber Injection Molding

Rubber injection molding is probably the most straightforward and commonly used type of rubber molding chosen by manufacturers across the world. As the name specifies, this type involves injecting a rubber compound into a mold and keeping the mold under high pressure for the component to get shape.

There are four sub-components of rubber injection molding.

1. Organic rubber injection

Organic rubber injection starts with prepping the rubber component by stripping and mixing it before feeding it into the screw. As a result, there is no need to preheat the rubber and the completion type reduces too.

2. LSR injection

Liquid Silicone Rubber (LSR) injection is a type of liquid injection method used specifically for silicone rubber. Parts of liquid silicone are sent into the injection unit. This is cured and injected into the mold.

3. Thermoplastic rubber injection

Thermoplastic rubber injection is a process of using thermoplastic elastomers, also known as TPEs, to create molded components in. This type of rubber molding process needs high temperatures to work and that is one challenge in using TPEs. However, with TPEs, the manufacturer can avoid the initial tasks of mixing and vulcanizing.

4. Custom rubber injection molding

This is a completely customized process where the manufacturer decides every single aspect of injection molding, starting from the raw material used, the injection molding process, and the temperature and pressure decided based on customer requirements.

Advantages of rubber injection molding

• Lower costs – injection molding is usually cheaper to achieve, and that makes it a preferred type of rubber molding.
• Easier process – rubber injection molding is a straightforward process that does not involve many complicated steps, and this is also an advantage of using this over other types of rubber molding.
• Better precision – in case smaller and more intricate parts are to be produced, the best choice in the list of different types of rubber molding is rubber injection.

Disadvantages of rubber injection molding

• Higher setup costs – while the cost of producing rubber components is lower for rubber injection molding when it comes to the setup costs, this involves more initial expenses. The cost of the production machinery is higher too.
• Generation of waste – the process of producing rubber using this type of rubber molding generates more amounts of waste that can be avoided when other types of molding processes are used.

1. Compression Molding

Compressing molding is also one of the popular types of rubber molding used in creating rubber components across different industries. As the name suggests, this process uses compression to create the structures.

Preheated materials are poured into the mold or cavity, and the mold is then closed and compressed at a certain temperature and pressure. Usually, hydraulic pressure is used to achieve the effect.

The compression is applied for a specified period of time, and then the formed structure is removed.

A compression unit usually consists of the following parts.

1. A movable top half of the mold
2. A fixed bottom half of the mold
3. An ejector pin to remove the finished product

Advantages of compression molding

• Low initial setup cost – the initial cost of setting up is quite low, compared to other types of rubber molding.
• Works for low-volume production – the cost of production does not increase, even for low-volume outputs.
• Works best for large components – large components can be easily produced using this method.

Disadvantages of compression molding

• Low dimensional tolerance – this type of rubber molding does not work well for components that are small and intricate. Precision molding may be needed for certain components where even the smallest of shape changes may be detrimental. In that case, compression molding cannot be chosen.
• High wastage production – there is high wastage produced with the production process.
• High production time – the time taken to produce components is high, as there is a considerable waiting time after compression.

2. Transfer Molding

Transfer molding is another of the popular types of rubber molding that produces rubber components of different types. There are two major halves of the mold. The upper half has a cavity where the raw material needs to be placed.

The upper half comes with a plunger that can be used to push the raw material through a narrow cavity.

The raw material goes to the heated mold through this cavity and takes shape. Once the product cools down and is vulcanized, it can be extracted through the bottom half by removing the ejector pins.

Advantages of transfer molding

• High dimensional tolerance – as long as the mold is shaped right, the final product can be designed to have high dimensional tolerance.
• Metal-rubber bonding – this technique can be used to create precise and high-quality metal rubber bonding designs.
• Easy molding process – the overall process of molding is straightforward and easy, saving time and effort.

Disadvantages of transfer molding

• High initial costs – the initial setup costs for this type of rubber molding are pretty high.
• Additional finishing processes – the final product must go through additional deflashing techniques to be completed.
• Additional prepping time – the raw material needs to be cured for a specific amount of time before it can be molded. This increases the overall cycle time of production.

3. Rubber Molding with Arvico Rubber

Arvico Rubber is your favorite rubber component manufacturer, and we specialize in using all these three types of rubber molding to create components based on your specifications.

Arvico Rubber comes with 55+ years of experience in this industry, and some of the components we specialize in are gaskets, diaphragms, seals and sleeves, expansion joints, O-Rings, and bearing bushes.

We understand how important dimensional tolerance and quality are to our clients, and that is why we always have prep meetings to understand the requirements completely before accepting projects.

Our design team can produce molds with 100% precision, and all finished products go through multiple levels of quality testing before reaching our clients.

Whatever type of rubber molding you want for your components, we get that done in the quickest possible time. Please get in touch with our expert consulting team to know how we can help improve the quality of your manufacturing process with our components.

Many industries prefer vulcanised rubber over traditionally processed rubber because the former is stronger, more durable, and can handle extreme temperatures much better. Vulcanisation is a relatively new process and has existed for only a few centuries.

This blog will take you through the basics of vulcanised rubber, its history, uses, types, and other useful information that will help.

What is vulcanised rubber?

Vulcanisation is a process of hardening rubber. There are two kinds of rubbers commonly used – natural and synthetic. About 70% of all rubbers used these days are synthetic. These rubbers are created using various techniques and with different additives in rubber industries, depending on what features the final product needs to have.

In their initial stages, synthetic and natural rubbers can be very sticky and with low tensile strength and may not be useful at extreme temperatures or pressures. That’s why such rubbers go through vulcanisation to improve their beneficial properties and make them durable. 

A brief history of vulcanised rubber

During the 1800s, the number of vehicles produced started slowly increasing all over the world. In really hot countries, there was one problem, though. The rubber in the tires got heated up on the road and would stick to the road and burst off after a while.

Rubber manufacturers were trying all kinds of ways to improve the life of tires, and this is when Charles Goodyear, a chemist, tried adding different chemicals to rubber and heating it to see if the physical properties changed.

It tool him a while to realize that the heating process was making beneficial changes and not the chemicals added. Over time, he created a process of adding sulfur and heating rubber to make it durable and hard.

This process was patented and was called vulcanisation. Vulcanised rubber handled high temperatures easily and was flexible, hard, and extremely durable. Right now, all rubber tires are vulcanised to improve their shelf life.

Where are vulcanised rubber used?

There are so many uses of vulcanised rubber in industries and everyday life. Some of the popular uses are mentioned below.

Did you know that about one billion tires are produced worldwide every year? Vulcanised rubber is in great demand throughout the year and will continue to be used for various purposes over the years.

Do also read our blog on rubber deterioration to understand how to prevent the failure of rubber parts.

Stages of vulcanisation

There are three basic stages in creating vulcanised rubber.

1. Induction stage
2. Curing stage
3. Optimum stage

Induction stage – This is the first stage of creating vulcanised rubber. Here, the right rubber material is chosen, and in many cases, it is shaped before it gets heated. This is because once the rubber heats and hardens, it may be impossible to shape. This stage is also called the scorching stage. The heating happens gradually, and the cross-linking begins.

Curing stage – In this stage, the rubber gets heated to up to 400 degrees Fahrenheit. At this temperature, permanent cross-links are formed, and the vulcanised rubber slowly forms.

Optimum stage – In the optimum stage, the heating process is finished, and the rubber is let to get back to its new, finished state. Beyond the optimum stage, if the rubber remains hot and keeps changing properties, it is called the over-curing stage. 

The number of crosslinks formed depends on how long the rubber was cured, the curing material used, the time given for the rubber to reach the optimum stage, and the natural properties of the type of rubber used.

The science behind vulcanised rubber

Natual rubber and SBR rubber vulcanisation

The science behind sulfur vulcanisation is based on cross-linking action. Sulfur vulcanisation is popularly applied to natural rubber and styrene-butadiene rubber (SBR). These types of rubber are first heated, and sulfur is added to them.

When the rubber is heated, some of the C-H bonds in the material are replaced by sulfur atom chains. This is called crosslinking. The more crosslinking that happens, the more changes the rubber material goes through.

Sulfur cross-linking gives the material strength, durability, and heat resistance.

Polychloroprene vulcanisation

Neoprene or polychloroprene is a type of rubber that also has several beneficial properties and hence is often vulcanised. The vulcanised rubber, in this case, comes with both the natural benefits of neoprene rubber and the strength of the vulcanisation process.

In this process, neoprene rubber is heated along with metal oxides like Zinc oxide, Magnesium oxide, and lead oxide.

What are the other additives added to vulcanised rubber?

Apart from the curing materials like sulfur or metal oxides, the following are other additives added to vulcanised rubber.

1. Accelerators that quicken the vulcanisation properties like guanidines, xanthates, thiazoles, thiurams, and dithiocarbamates
2. Anti-oxidants like phenolics, amines, and phosphites
3. Coagulants like calcium chlorides and acetic acids
4. Softeners, if needed
5. Dyes or color pigments
6. Surfactants
7. Anti-foaming agents

Benefits of vulcanised rubber

The following are some of the benefits of vulcanised rubber.

1. High resistance to temperature changes
2.  Is not affected by heat
3. Very durable and long-lasting
4. Returns to original shape quickly
5. Good insulator
6. Resistant to oxidation and UV damage
7. Resistant to abrasion

Conclusion

Vulcanised rubber is one of the most versatile materials ever found, and there have been so many industries benefit from it. vulcanization makes rubber stronger, more flexible, and extremely heat resistant.

Just like any other product, the way vulcanised rubber is made reflects in its quality. So make sure you pick the right manufacturer.

If you think your rubber components don’t last as long and as well as they used to, then maybe vulcanised components are what you need.

Arvico Rubber can help you choose the suitable rubber material to create components in, so their physical features can handle the internal and external factors they come in contact with. With an in-house designing team and a state-of-art manufacturing facility, we ensure the components we manufacture are precise and 100% adherent to expectations.

Rubber extrusion is the process of turning rubber into a product with a specific and intended shape and size. Depending on the end shape, different rubber extrusion profiles can be available. Arvico Rubber has many standard extrusion profiles for commonly used products and also has an in-house team to customize the profiles based on exact customer requirements.

This blog will take you through different kinds of rubber extrusion profiles, their production process, use, and benefits.

How Does Rubber Extrusion Work?

Extrusion is the process of forming a shape by pushing a material through a predesigned mold. Rubber extrusion profiles have an easy and straightforward working mechanism.

The rubber manufacturer has an extruder machine, and the specific profile-shaped die or mold is fitted in. A rubber compound is now chosen. The compound is the base material in which the profile needs to be made in.

You can create rubber extrusion profiles in any of the following rubber compounds, including the ones below.

1. Silicone
2. EDPM
3. Neoprene
4. Nitrile rubber
5. Viton
6. Butyl

Silicone extrusion profiles are very popular among our clients because of the various beneficial physical properties of silicone rubber. Silicone profiles come with the following features.

Heat resistant

Flexible and easily moldable

Fire resistant

Acid resistant

180 degrees heat aging

Oxidation resistant

UV resistant

One of the main parts of an extruder that leads to 100% of design specifications being met is the die or mold. This can be made of steel or other durable materials. When the die is designed to match client requirements 100%, the end product will have the right design too.

Not many rubber manufacturing companies have the capacity to create complex rubber extrusion profiles because their die-manufacturing capacities are limited. Arvico Rubber is different, though! We understand how vital precision is in creating these rubber extrusion profiles; that is why our design team is one of the best in the country.

Every customized extrusion profile will go through multiple levels of sample testing and quality testing before full-fledged manufacturing starts. As a result, you don’t have to worry about the parts not meeting your exact needs.

All products that we manufacture go through the below range of extensive quality testing before they are sent to the customers.

What are the Advantages of Rubber Extrusion, Rubber Extruded Products and Rubber Extrusion Profiles ?

The following are some of the advantages of rubber extrusion profiles and products made using rubber extrusion.

1. An economical way to produce rubber components.
2. Wastage is minimal in this production process.
3. It is easy to customize any type of profile by just making the appropriate die cast.
4. It is possible to automate production and create multiple pieces of rubber extrusion profiles one after the other.
5. Depending on the type of rubber used, these profiles can be resistant to aging and other external factors and be flexible and robust.
6. Rubber extrusion profiles can be created to exactly match sizing and dimension requirements. You don’t have to worry about ill fits.

What are the Common Profiles of Rubber Extruded Products?

There can be so many profiles of rubber extrusion profiles that can be created. The sky is the limit when it comes to design choices. However, the following are some of the common profiles you can see being offered by rubber manufacturers.

1. Round profiles
2. Semi-round profiles
3. Square profiles
4. Rectangle profiles
5. U channel profiles
6. D, E, J, L, P, or T-shaped profiles

Extruded Rubber Seals

When we talk about extruded products, one category that we cannot miss is extruded rubber seals. Rubber seals play an essential role in almost all industries. This humble item can save expensive equipment, quicken certain manufacturing steps, and sometimes even save the plant and people in it from hazardous leakages.

As the name specifies, seals seal surfaces so that there is no leakage in the joints. Seals can prevent solid, liquid, and gaseous leakages effectively. Depending on what kind of product flows through pipes, the right kind of rubber seals must be chosen.

Arvico Rubber’s rubber seals are commonly used in our butterfly valves, and these offer perfect sealing in three areas – pipe sealing, flanges, and operating shafts. 

Get in touch with our experts about your exact requirements and they will be able to suggest the type of rubber material to be chosen for making the seals.

 

Rubber Extrusion Profile Applications

Rubber extrusion profiles can be used for so many applications, including the following.

1. Door seals
2. Window seals
3. Angle grips
4. Silicone extrusion profile tubes
5. Rubber buffers
6. Edge protectors
7. Rubber seals
8. Expansion seals
9. Sponge cords
10. Cable protectors

How to Choose the Right Rubber Extrusion Profiles

Let’s say you have a requirement to create seals for one of your parts. The first thing for you to do is talk to a rubber component manufacturer like Arvico Rubber to understand what kind of seals may suit your need.

Our team will get all the basic information right from you before we work internally on the recommendations. The details required may include what kind of part requires the seals, if the seal would come in contact with materials that flow through the parts, what size the part and the sealing joint would be, and what external factors would affect the seal during functioning.

Based on all this, our team would come up with recommendations. You may be advised to pick up silicone extrusion profiles if we think the seal needs to be resistant to oxidation, UV rays, temperature changes, acids, and sunlight, apart from being flexible but lightweight.

We may advise you to pick up nitrile extrusion seals if they come in contact with oils or gasoline. Our recommendation would also be based on other factors like budget too.

Our plant has the ability to produce 100% precise rubber extrusion profiles in whatever shape you require. We make sure even the most complex of designs are done with expertise, and all products are quality checked in multiple stages before they reach you.

Conclusion

Rubber extrusion profiles have made the production of precise and quality rubber components easy, hassle-free, and affordable too. The fact that this rubber extrusion process does not lead to excessive wastage is something environmentally-conscious manufacturers love about it.

Arvico Rubber is your perfect partner for producing rubber seals, valves, gaskets, diaphragms, expansion joints, O-rings, and extruded rubber profiles and cords with any specifications you need. We also manufacture other kinds of rubber components needed across various industries.

Can a very simple and fuss-free product make a significant impact on several industries at the same time? Say hello to the versatile and absolutely vital part of most components and machinery – the O-rings. O-Rings or O-ring seals are loop-shaped elastomers that help seal joints or interfaces.

When two different parts are connected at a joint or an interface, the risk of leaks is high. This is especially true when there is internal pressure in the joint. An O-ring seal fits precisely in the joint grooves and ensures no solid, liquid, gas, or air passes out.

O-rings can be made using different types of rubber and can come in various sizes and shapes. Arvico Rubber has an in-house molding factory where we can custom-design molds and create O-ring seals based on exact customer specifications.

This blog will take you through the basics of O-ring seals, including their uses, properties, and types.

How do O-ring seals work?

O-ring seals are available both in pre-set standard sizes and in custom sizes; all of them work similarly. These rubber, donut-shaped components act like gaskets, creating a more leak-free and safer seal between joints. These seals can be fixed in a groove or in a channel, and they work perfectly well both ways.

Applications of O-ring seals

  There are so many applications of O-ring seals in different industries. Some of them include:

1. In transmission and fuel systems
2. In the functioning of medical equipment and tools like syringes and filters
3. In oil refineries and petrochemical industries, to prevent contamination of components
4. In the production of electronic equipment to seal the insides from dust and water
5. In drinking water production factories, to prevent water contamination
6. In chemical industries, to prevent hazardous leakages
7. In pneumatic systems, to prevent fluid loss

Static and dynamic applications of O-ring seals

In whichever industry the O-ring seals are used, they are primarily used in two kinds of environments – static and dynamic. As the name suggests, static applications are where the joints or surfaces the O-ring connects don’t move or rub against one another.

In dynamic environments, the O-ring connects two moving parts.

Static O-ring seals can be made of any material of choice, as it doesn’t go through intense wear and tear. However, dynamic O-ring seals definitely need to be made more cautiously. The constant motion will lead to the rubber material going through stress and abrasion, and unless the material is strong and flexible enough, the O-ring will break or get damaged soon.

How are O-ring seals made?

There are so many different techniques used in creating O-ring seals. Some of them include:

1. Injection molding – The molten rubber material is injected into a mold and then let to cool down. Different types of elastomers can be molded to create O-ring seals.
2. Transfer molding – The process is similar to that of injection molding, but external pressure is applied to push the molten material into the mold. As a result, the final O-ring seal is better created and is precise in shape and size.
3. Extrusion – This is a more traditional method where the elastomer is pushed through an opening in the shape of the desired mold using external pressure. As a result, the elastomer takes the shape of the mold and comes out in the desired dimensions.
4. Pressure molding – The required mold is divided into two halves here. The elastomer is poured into both these mold halves, and then the molds are joined together using pressure and heat. This helps the elastomer take the required shape.

5 basic features of O-Ring seals

You could be a client looking to create O-ring seals for your production process or a seller looking to resell these components. Either way, you should know these five basic features of O-rings, so you choose the right one for your needs.

1. Diameter

The diameter here includes both internal and external diameters. This is the first basic feature you need to be clear about while talking about O-ring seals. The interior diameter is the length between the inner ends of the O-ring, while the external diameter is the length between the extreme ends. If you are going to buy thousands of pieces of O-rings, then make sure the diameters are measured right, so they fit well.

2. Groove

Groove is used to hold the O-ring seals in place when they are fitted in a joint or inside a machine. The groove design plays a major role in deciding how well the O-ring seals. Talk to your manufacturer and understand different groove designs before picking one.

3. Hardness

Hardness is defined as how strong and durable the material of the O-Ring is. Different types of elastomers have different hardness indexes, and you need to choose the right type to fit your need. For instance, if the O-ring seals will work under extreme pressure/temperature changes, choose materials with a higher hardness index. Levels of more than 90 are usually considered hard.

The below are the hardness indexes of some of the elastomers used by Arvico Rubber.

Material	Hardness Index
Natural Rubber	30-90
Nitrile Rubber	20-100
Neoprene Rubber	30-95
Hypalon Rubber	40-95
Butyl Rubber	35-85
EPDM Rubber	40-90
Silicone Rubber	25-85
Viton Rubber	55-95
Polyurethane Rubber	60-90

4. Tensile

Tensile strength is also an important feature of O-ring seals. This talks about the kind of force or pressure that the ring can withstand without breaking. The higher the tensile strength, the stronger the material is.

The below is the tensile strengths of elastomer materials used by Arvico Rubber.

Material	Tensile Strength (PSI)
Natural Rubber	3000
Nitrile Rubber	3500
Neoprene Rubber	3000
Hypalon Rubber	2500
Butyl Rubber	2000
EPDM Rubber	3000
Silicone Rubber	1100
Viton Rubber	1800
Polyurethane Rubber	4000

5. Flash

Flash is basically excess material found in the parting line projection resulting from the molding process while creating O-ring seals. Usually, the acceptable levels of flash are the following.

Thickness of flash – 0.13 mm/ 0.005 inches

Extension of flash – 0.08 mm/ 0.003 inches

Different O-ring seal materials

As mentioned above, there are different O-ring seals depending on the material they are made out of. The properties of all these vary, and as a buyer, it is important that you know the types and their features before making a decision.

You should always be able to talk to your manufacturer and get facts right. Arvico Rubber spends the first part of any new project gathering requirements and deciding on the type of O-ring seals the customer may benefit from. We go ahead with the project only after we have a confirmation from the buyer and the buyer is satisfied. Some of the top materials in which you can get O-rings from Arvico are:

1. Natural Rubber
2. Nitrile Rubber
3. Neoprene Rubber
4. Hypalon Rubber
5. Butyl Rubber
6. EPDM Rubber
7. Silicone Rubber
8. Viton Rubber
9. Polyurethane Rubber

Conclusion

O-ring seals are, undoubtedly, one of the most commonly used rubber components across different industries. Whenever there is a need to seal gases, air, liquid, or chemicals, apart from other sealing methods used, the addition of O-ring seals becomes compulsory.

These seals may look like tiny, simple components. However, if they are not of the expected quality, they may lead to leakages, which may cause huge financial losses. At times, such leakages may also turn dangerous to people working in the plant.

That’s why make sure your O-ring seals are made by ISO-certified manufacturers like Arvico Rubber. Our designing and manufacturing teams work hand-in-hand to ensure specifications are thoroughly met and all the products from our warehouse go through multiple stages of testing to ensure they work as expected. Get in touch with us to find out the types of O-ring seals we produce.

Introduction

It is very common to expect elastomers to deteriorate over time. Both natural and manufactured rubbers deteriorate and go through aging and other kinds of changes over time, which affects their performance. However, the extent of impact and the time it takes for the deterioration to set place depends on the initial quality of the elastomer and the efficiency with which it was produced in the first place.

This blog will take you through what rubber deterioration is and what to expect when rubber deteriorates. 

What is rubber deterioration?

Deterioration is the process of gradual decline or worsening of a state. Hundreds of different kinds of small and huge rubber components are used in different industries. All these components come with a certain promised quality that facilitates seamless functioning.

With use, just like any other product, these rubber components are affected by various external and internal factors. This is called rubber deterioration. There is no way you can avoid deterioration. However, you can improve the life of your rubber components by choosing the right component manufacturer and by maintaining the components as per the manufacturer’s recommendations.

We also have a separate blog that talks about rubber quality and why it is important. Do check that, too, after you are done reading this article.

How does rubber deteriorate?

Rubber deteriorates due to physical, chemical, or biological causes. Some of the common reasons for deterioration are:

1. Radiation
2. High temperature
3. High humidity
4. Oxidation
5. Pollutant gases
6. Physical stress

Different kinds of radiation may cause different kinds of damage to elastomers. UV radiation, especially, is harmful. The more the exposure to UV radiation, the worse is the damage. Ozone affects different types of rubber in different ways.

For instance, nitrile rubber, butyl rubber, and natural rubber have poor resistance to ozone, while neoprene rubber and silicon rubber have outstanding resistance to ozone. So, when you choose nitrile rubber, you have to expect that this rubber deteriorates quicker when exposed to sunlight.

Some plastics, like nylon or polyester, absorb moisture more than others. As a result, they may swell up when exposed to damp places.

Rubber deteriorates when exposed to oxygen. Oxidation causes some damage to most kinds of rubber. Here is a list of rubbers that are affected by oxidation.

Types of Rubber	Resistance to Oxidation
Natural Rubber	Good
Nitrile Rubber	Fair-Good
Neoprene Rubber	Excellent
Hypalon Rubber	Excellent
Butyl Rubber	Fair
EPDM Rubber	Excellent
Silicone Rubber	Excellent
Viton Rubber	Outstanding
Poly urethane Rubber	Excellent

Did you know that some kinds of bacteria also degrade rubber? This is also an unavoidable factor that may cause rubber deterioration with time.

How to identify and prevent rubber deterioration?

There are different ways you can identify the quality of rubber in advance so you can predict its rate of deterioration and plan in advance. There are four different techniques to know if rubber deteriorates and plan to prevent it.

DMA Analysis

Dynamic Mechanical Analysis (DMA) is a technique that is used to analyze the characteristics of materials. Before you choose a type of material to create rubber components, it is advised to get a DMA analysis done. This will know the material’s response to stress and strain and help understand how well it would fare under different conditions.

ASTM D573-99 Standard Test Method

ASTM D573-99 is another method that will help you understand many of the physical properties of the rubber that you choose to create components with. This standard test method evaluates the properties of a sample of rubber under laboratory conditions. If you are creating large volumes of components using a specific type of rubber, it is safer to do this test first and understand the properties of the material before creating mass volumes. This way, if rubber deteriorates, you can avoid that particular material and choose another before initiating the production process.

Ozone Testing

Ozone testing is recommended for rubber that may be constantly exposed outdoors. Controlled laboratory testing of materials is possible to identify the possible effects of ozone radiation on the material of rubber chosen.

Compound Designing

Many times, the actual material that you choose is not 100% elastomer. It is a mix of different materials and components, decided based on what physical properties you want in the final component. Since you mix different polymers, stabilizers, oils, and other fillers into rubber, this may also impact the way rubber deteriorates in the end product. Compound designing is a way of mixing the right components together so that they don’t negatively affect the component’s stability and durability.

How to stop rubber deterioration

Deterioration is an unfortunate but unavoidable part of the life of any rubber component. The simple answer to whether you can fully stop rubber deterioration is no. However, there are a few strategies you can implement to postpone the rate at which rubber deteriorates and improve its lifespan.

1. Choose the right rubber manufacturer

This is very important to improve the life of the rubber components you use. Make sure the manufacturer understands the importance of stability and durability and creates products using the right material. Arvico Rubber is your perfect component and manufacturing partner. All our products and raw materials undergo intensive testing to ensure they match our customers’ expectations.

• Understand the qualities of the rubber you choose

Arvico Rubber offers components in about nine different rubber variants. Each of these variants has different properties. That’s why it is important to understand the variations in these and pick the right variety of rubber for your needs. For instance, nitrile rubber has poor resistance against sunlight aging. If you use nitrile rubber components in machines that are run outdoors, the rubber will deteriorate quickly and lead to the malfunctioning of the machine. Instead, pick up components made of EPDM or Viton rubber, both of which have outstanding resistance to sunlight aging.

• Study the work surroundings

Sometimes, the rubber components may be exposed to harmful gases or pollutants, leading to quick deterioration. By preventing exposure to these gases or pollutants, you can increase the lifespan of the component. So study the surroundings and handle factors that may contribute to rubber deterioration.

In some cases, rubber deteriorates because the machinery with rubber components is cleaned using harsh solvents and chemicals that the rubber material cannot handle. Training the employees on the right maintenance will help prevent this from happening.

Conclusion

Rubber deteriorates due to different reasons. While all these factors cannot be eliminated, their effect can certainly be minimized with careful analysis and understanding of the type of rubber material used. Talk to your rubber manufacturer if you are confused about the type of rubber components you have. If you are ordering rubber components for your plant, understand the properties in advance so that you choose the right material.

Arvico Rubber comes with more than 50 years of experience creating high-quality rubber components for global industries. We have an in-house casting and designing team to create custom molds for individual requirements. We have created more than 50,000 individual products for clients across the world. Arvico Rubber specializes in creating diaphragms, O-Rings, Gaskets, Sleeves, Seals, Stators, PTFE components, and more such rubber components.

References

https://www.martins-rubber.co.uk/blog/what-causes-rubber-to-deteriorate/

Do You Know The Ways To Prevent Failure Of Rubber Parts ???

http://www.real-seal.com/blog/rubber-seal-deterioration-causes/#:~:text=Rubber%20Deterioration%20Defined&text=Due%20to%20the%20nature%20of,molecular%20changes%20these%20factors%20cause.

https://www.canada.ca/en/conservation-institute/services/conservation-preservation-publications/canadian-conservation-institute-notes/care-rubber-plastic.html

Introduction

Molded rubber parts are some of the most used components across industries. Molding is the process of converting natural or synthetic uncured rubber into a usable product by molding it into a shape and design of choice. In this process, a block of rubber or elastomer is pressed into a metal cavity that forms the mold.

This is then exposed to heat or pressure, which molds the block of rubber into the exact shape of the cavity it fills in. The final product is cooled down and then used.

Molded rubber has infinite uses in various industries, and the main advantage of molded rubber products is that they can be explicitly designed to meet your requirements. Some of the common molded rubber parts that you may commonly find being used are:

• O-Rings
• Diaphragms
• Bushes
• Seals
• Gaskets
• Flaps

Materials used in rubber molding

Almost all types of rubber can be used to create molded rubber parts. Depending on the properties of some of these rubbers, the best materials are listed below.

EPDM	Nitrile	Neoprene	Silicone
EPDM are excellent insulating, abrasion resistance, and vulcanizing properties Extremely resistant to ozone and UV rays Outstanding resistance to extreme heat and cold	Highly resistant to abrasion Does not absorb water Moderately resistant to acids Has high tensile strength of 3,500 PSI	Highly resistant to abrasion and acids Extremely resistant to ozone and UV rays Good resistance to extreme heat and cold High tensile strength of 3,000 PSI	Extremely durable and moldable. Greatly resistant to UV rays and ozone Does not absorb water Outstanding resistance to extreme heat and cold

Choosing the right type of rubber is very important when you want to create molded components. Make sure you talk to your rubber manufacturer to understand which material may work the best for you. This has to be decided based on the conditions the components will be exposed to.

We have a blog that talks extensively about rubber quality and how to choose the right kind of rubber. Do read this next.

Methods of creating molded rubber parts

There are three common methods used to create molded rubber parts. The manufacturer will decide the right method based on product specifications, available budget, and the required precision.

1. Compression Molding

In compression molding, compressive force is used to mold rubber into the shape of choice. Compared to the other methods, compression molding is cheaper, simpler, and has easy prototyping stages. Here, rubber is placed in the molding cavity, and compression heat is applied to mold it into the shape and size of choice. The molded rubber parts are usually perfect in size and dimensions and require no or minimal reworking later on.

2. Transfer Molding

In transfer rubber molding, the rubber is transferred from one mold or cavity to another and hence the name. Initially, the rubber is placed in a heating mold. Once it is heated to the required temperature, it passes from here through sprue holes into the actual molding cavity. Once the molded end-product cools down, the mold is opened, and the component is removed.

This is a perfect method to use when the production volume is low or when there is less lead time to get the finished product.

3. Injection Molding

Molded rubber parts can also be produced through the injection molding method. Here, the raw material is initially heated to very high temperatures until it reaches a plastic-like consistency. This is now injected into the molding cavity and undergoes high pressure and temperature here. The raw material goes through a vulcanization process inside the cavity, and this helps achieve really high precision and quality.

Injection molding is definitely more expensive than the other two methods but is used when the output quality cannot be compromised. This is also perfect for high-volume molding requirements.

How can rubber molded parts solve industrial challenges?

Handling Rattling and Vibration

When a large machine with hundreds of smaller parts works at full speed, it is normal to expect rattling or shaking. However, rattling can lead to friction and cause damage to the internal components. In such large machines, replacing even a single part is going to be an expensive affair.

Rubber components are the easiest solutions to handle the rattling issue. Good quality molded rubber products can be used to dampen the vibrations and rattling effects and protect expensive parts.

Noise Cancellation

In really large industries, handling noise pollution can be really challenging. Machines make a lot of noise when they work and when humans are constantly exposed to such high decibels of noise, it can be harmful. Molded rubber parts are also excellent noise cancellation components when used strategically.

Get in touch with Arvico Rubber to know how best to use our molded components to reduce noise within your plant.

Re-Tweaking Existing Product Design

Let’s say you want to re-tweak an existing product and want to make it more expansive or inclusive to a new client requirement. Instead of trashing the existing design and trying something new, make use of rubber moulding processes to re-tweak existing product designs. The fact that rubber is extremely moldable and flexible makes it a great choice to design at your will.

Improving Efficiency of a Machine or a Product

Problems like friction, vibrations, leaks, or choice of material can lead to a product performing inefficiently. Industries can smartly make use of molded rubber parts to improve the efficiency of a machine or a product easily. This saves the industry time and money.

Handling sealing challenges

In certain industries that use harmful gases or liquids in their production process, 100% sealing is a requirement and not a choice. Rubber molding is one of the most trusted methods to pick seals or valves that fit your machine perfectly. Buying ready-to-use seals may not give you the results that you are looking for.

Rapid Prototyping – can this be used?

This is becoming a very common question that most rubber manufacturers are being asked when the clients come for prototyping. Rapid prototyping is a newer trend in the molded rubber parts industry.

Prototyping is the act of creating a sample to check its quality, sizing, and dimensions before the full-fledged production process starts. Ideally, whatever method has been chosen to mold rubber in (compression, transfer, or injection) will be used to create prototypes.

These days, the trend of using 3D printing is on the rise. 3D printers create prototypes, and the process is rapid and really cheap.

However, it is to be noted that 3D printing is still an evolving technology. We would suggest clients create prototypes with both 3D printing and the traditional methods to see how different they turn out and then make a decision. Relying only on 3D printed prototypes may cause slight deviations in the size and shape of products you actually wanted.

Why choose Arvico Rubber to manufacture your custom molded rubber parts?

Arvico Rubber has 55+ years of working experience creating rubber molded parts. We have created more than 50,000 products based on specific customer requirements. Our in-house die casting and designing team will be able to create custom molds in the exact design specifications you want. Our prototypes are made after detailed analysis, and the final components go through a variety of internal and third-party quality tests.

We have produced molded rubber products for varied industries, including pharmaceuticals, petroleum and natural gas, food and dairy processing, electrical and electronics, packaging, automotive, textile, and more.

Molded rubber parts are integral for larger appliances, machines, and tools to function seamlessly. The quality of these smaller parts you choose determines the overall efficiency of these machines. Make sure you pick the right rubber component manufacturer. Arvico Rubber believes in creating long-lasting relationships with all our clients, and we deliver what we promise.

Introduction

There are two basic types of rubber – natural and artificial (synthetic). Natural rubber is derived from the latex of the rubber tree and is flexible, moldable, strong, and has a high stretch ratio. All these features have made it one of the most sought-out materials for making all kinds of consumer products. Synthetic rubber is a type of rubber created to imitate natural rubber and is created artificially end-to-end. Synthetic rubber is more affordable, can be produced limitlessly, and can be created with properties to match requirements exactly.

Rubber is used in a variety of industrial applications and is one of the inevitable materials in today’s world. Did you know that different rubber materials are available for different purposes these days? Each of these comes with its own features and advantages, and when you want to design a rubber component, knowing the pros and cons of each type of rubber will definitely help you.

Properties of rubber

While there are so many different properties of rubber, there are three major ones that you should know about.

1. Elasticity – Elasticity is the stretch ratio of the material. The molecular structure of rubber makes it easy to stretch them, allows them to come back to their original shape, and makes it possible to mold them into shapes of choice. That’s why in 2020 alone, the world produced 13 million metric tons of natural rubber and 14.3 million metric tons of synthetic rubber for human use.
2. Thermal contraction – Thermal contraction is the behavior of rubber to contract or shrink when thermal pressure is applied. Thermal contraction makes the rubber molecules twisted and tangled, and this causes their shape disintegration. Thermal contraction is an important property that helps mold rubber into different shapes, and this also depends on the type of rubber you choose.
3. Durability – This is one property that experts love about rubber. Rubber has a relatively slow heat-buildup rate and is also extremely resilient to oxidizing agents, UV radiation, water, environmental agents, corrosion, and other factors that can damage the material. Also, when it comes to synthetic rubber, the durability can be improved drastically by mixing the right materials together.

Ten Common Types of Rubber

There are ten common types of rubbers, and they all come with their own distinct properties. Out of these, only one is produced naturally, from the latex of certain plants. Others are all synthetically produced in manufacturing facilities.

Natural Rubber – This is the only type of rubber obtained from natural sources. Natural rubber is derived naturally from the bark of the Hevea brasiliensis tree. Incisions are made on the barks of the tree and a sticky, white milky fluid called latex is drawn. This process is called tapping and the latex is further processed to create natural rubber. Industrialization led to excessive demand for rubber and this was the basis for the creation of synthetic rubber during the early 1900s.

Did you know that natural rubber is a raw material used in the production of more than thousands of products, including surgical gloves, aircraft and automobile parts, and even clothes? While there are about 25,000 types of plants that produce latex, rubber can be extracted from only 2000 of these species.               

Styrene-Butadiene Rubber – Styrene-butadiene rubber (SBR) is widely used in the production of tires and other automotive parts. Because of its high tensile strength and resilience, it is also used in the production of moving mechanical parts. This type of rubber is one of the most commonly produced types of synthetic rubber on the market right now.

Silicone Rubber – Silicone rubber is a relatively new entrant that has become an extremely preferred choice in the last few decades. Silicone is known for its malleability and biocompatibility. Biocompatibility is being non-toxic and insoluble in body fluids. It is also extremely resilient to UV, ozone, fire, and other environmental damages. This type of rubber is one of the common choices of materials used to create products in the food and beverage, healthcare, and electronics industries.

EPDM Rubber – Ethylene Propylene Diene Monomer rubber comes with many great properties like low conductivity, ozone, UV, weathering resistance, and age resistance. Because of this, the material can be used outdoors in products like roofs, sealants, hoses, and seals. EPDM rubber is also used in manufacturing certain automotive parts.

Neoprene Rubber – Another very popular type of rubber is neoprene. Did you know that it is one of the oldest synthetic rubbers on the market right now? It handles corrosion, degradation, and flames very well and hence is used in the production of high-pressure accessories like gaskets, belts, and seals.

Butyl Rubber – Isobutylene isoprene rubber or butyl rubber is chosen for its extremely high gas impermeability feature. Gas impermeability is the ability of the rubber to stay unaffected by most kinds of gases. This is why this type of rubber is a great material to use as a sealant in vacuum applications.

Nitrile Rubber – Nitrile Butadiene Rubber, or simply nitrile rubber, is derived from acrylonitrile and butadiene. It is resistant to most oils, fuels, and chemicals, and this makes it a great choice to be used in the aeronautical and automotive industries. Thanks to its high moldability, it is also used in making footwear, floor mats, sponges, and rubber foams.

Hydrogenated Nitrile (HNBR) – HNBR is better than nitrile in a way that it is more chemical and oil resistant. It can also handle higher temperature extremes than regular nitrile rubber. This type of rubber finds extensive usage in the automotive industry.

Hypalon Rubber – Hypalon rubber is a type of chlorosulfonated polyethylene (CSPE) rubber that was originally created by DuPont Performance Elastomers. The formula of the rubber was slightly changed over time, and it is largely used in the marine industry.

Viton Rubber – Viton is not a generic rubber type. It is a trademarked product of DuPont and is a fluoropolymer elastomer. This type of rubber was first introduced under the brand name Viton, and hence, right now, the brand name has become more or less a generic usage of any rubber made of fluoropolymers. Viton is chemical and oil resistant and can withstand high temperatures. It is the best choice to use when handling oxygenated automotive fuels. Viton is most commonly used in making O-Rings, seals, and gaskets.

Conclusion

Picking the right type of rubber and good quality of rubber is the most vital step in creating products of your choice, in the specifications you need. It would always help to talk to an expert to understand what rubber choices would suit you. Get in touch with Arvico Rubber experts for any questions you may have about natural and synthetic rubbers and their types and usage.