Semi Automatic 2RT Rubber And Silicone Vulcanizing Press Mold Machine For Rubber

Product Specification

Semi-Automatic 2RT Rubber And Silicone Vulcanizing Press Machine / Mold Machine
 

Product Description:

Silicone vulcanizer is a piece of equipment used for processing silicone products. It is mainly used for the vulcanization and molding process of silicone.

The core working principle of the silicone vulcanizer is to vulcanize the silicone in the mold through heating and pressure. During this process, the molecular structure of silicone changes from linear to network-like, thereby significantly improving the physical properties of silicone products, such as strength, elasticity, and wear resistance.

Its structure mainly includes hot plate, pressure system and control system. The hot plate provides the temperature required for vulcanization, and its temperature control accuracy is critical to the vulcanization effect. The temperature control accuracy of a high-quality vulcanizer can reach ±1℃ - ±3℃. The pressure system is used to apply appropriate pressure to ensure that the silicone can evenly fill the mold. The pressure can be adjusted according to factors such as the shape and size of the silicone product. The control system can accurately set and automatically control vulcanization parameters such as temperature, pressure and time to ensure the consistency of each vulcanization process.

Silicone vulcanizers have many advantages. From the perspective of production efficiency, it can quickly complete the vulcanization process, effectively shorten the production cycle, and form multiple silicone products through one vulcanization, making it suitable for mass production. In terms of product quality, precise control of vulcanization conditions can ensure stable quality and excellent performance of silicone products and reduce the rate of defective products. Moreover, this machine has strong applicability and can process silicone products of various shapes and sizes, such as silicone buttons, silicone sealing rings, silicone toys and other silicone products.

When selecting a silicone vulcanizer, factors that need to be considered include the size and tonnage of the vulcanizer. Appropriate specifications should be selected based on the size of the silicone products and the quantity of each production; the temperature control range and accuracy must meet the requirements of the silicone vulcanization reaction; The stability of the pressure system and the pressure adjustment range are also important considerations; in addition, the degree of automation of the equipment, brand reputation, after-sales service, etc. must also be considered.


How it works:

The working principle of the silicone vulcanizer is mainly to apply a certain temperature and pressure to the silicone and maintain it for a certain period of time to make the silicone undergo a vulcanization reaction, thereby forming a silicone product with specific properties and shapes. The specific process is as follows:

1. Heating process:
- Principle: The silicone vulcanizer is equipped with a heating system, and common heating methods include electric heating. The heating element converts electrical energy into thermal energy to increase the temperature of the hot plate or cavity of the vulcanizer.
- Function: When the temperature reaches a certain value, the silicone molecular chain becomes more active under the action of thermal energy, and the vulcanizer begins to decompose to produce active substances such as free radicals or ions. These active substances will react with the silicone molecular chain to prepare for the subsequent vulcanization reaction.
2. Pressurization process:
- Principle: The pressure system of the vulcanizer applies pressure to the silicone through hydraulic, pneumatic or mechanical means. For example, the hydraulic system uses the pressure of the hydraulic oil to push the piston or plunger to move, thereby transmitting the pressure to the silicone; the pneumatic system provides pressure through compressed air.
- Function: Under the action of pressure, the silicone is tightly compacted in the mold. On the one hand, it can eliminate air and other gases in the silicone to avoid defects such as bubbles in the product; on the other hand, the pressure shortens the distance between the silicone molecular chains, increases the interaction between molecules, and is conducive to the vulcanization reaction.
3. Vulcanization reaction process:
- Principle: Under the conditions of heating and pressurization, the raw rubber molecules in the silicone react chemically with the vulcanizer. Taking silicone with organic peroxide as a vulcanizer as an example, the free radicals produced by the decomposition of organic peroxide will react with the double bonds or active hydrogen on the silicone molecular chain to form a cross-linked structure.
- Function: With the continuous formation and development of the cross-linked structure, the molecular structure of silicone changes from linear to mesh. This mesh structure gives silicone products higher physical properties such as strength, elasticity, heat resistance, cold resistance and wear resistance.
4. Insulation and pressure process:
- Principle: In order to ensure that the silicone can be fully vulcanized, the vulcanizer will maintain a constant temperature and pressure state for a period of time after reaching the set temperature and pressure. In this process, the vulcanization reaction continues until the cross-linking degree of the silicone reaches the expected requirements.
- Function: The length of the heat preservation and pressure holding time depends on the type of silicone, formula, thickness and shape of the product. If the heat preservation and pressure holding time is insufficient, the silicone may not be fully vulcanized, resulting in the product's performance not meeting the requirements; conversely, if the time is too long, the silicone may be over-vulcanized, causing the product's performance to deteriorate or aging.
5. Cooling and demoulding process:
- Principle: After the vulcanization reaction is completed, the vulcanizer's cooling system starts to work and cools the mold and product to a certain temperature. Cooling methods usually include natural cooling, air cooling or water cooling.
- Function: The cooled silicone product becomes harder and more stable, making it easier to remove from the mold. The demoulding process can be completed by mechanical devices or manual operation to separate the product from the mold and complete the entire vulcanization process.
 

Technical Parameters:

Common faults of vulcanizers are mainly the following:
 

Heating system failure

- Temperature out of control:

- Cause: The temperature sensor may be damaged, resulting in the inability to accurately feedback temperature information, causing the heating equipment to continue to work or stop working; it may also be a problem with the controller, such as an error in the control program or damage to the controller component, and the temperature cannot be adjusted correctly.

- Performance: If the temperature of the vulcanizer is too high, the silicone product will be over-vulcanized, resulting in brittle surface and performance degradation; if the temperature is too low, it will cause incomplete vulcanization and insufficient product strength.

- Uneven heating:

- Cause: The main reason is that the heating element inside the heating plate is damaged or has poor contact. For example, if the electric heating rod is partially damaged, the temperature of the corresponding heating area will be lower than that of other areas.

- Performance: It will cause inconsistent vulcanization of silicone products, and different parts of the same product will have different physical properties, such as different hardness.

Pressure system failure

- Insufficient pressure:

- Cause: If it is a hydraulic system, it may be that the hydraulic pump fails and cannot provide sufficient oil pressure; it may also be that the seal of the hydraulic cylinder is damaged, resulting in hydraulic oil leakage and the pressure cannot reach the set value. If it is a pneumatic system, it may be that the output pressure of the air compressor is insufficient or the air pipeline is leaking.
- Performance: The silicone product cannot fill the mold well during the vulcanization process, and there will be problems such as lack of glue and substandard size.
- Unstable pressure:
- Reason: The pressure regulating valve fails or the pressure sensor fails, so that the pressure control system cannot accurately adjust and maintain the pressure.
- Performance: The quality of the product is unstable, and there will be uneven thickness and uneven surface.

Mechanical failure

- Unsmooth mold closing:
- Reason: Wear, deformation of the guide rod of the vulcanizer or improper installation of the mold may cause difficulty in mold closing. For example, the surface accuracy of the guide rod decreases after long-term use, which makes the upper and lower molds not well aligned.
- Performance: It will extend the vulcanization cycle, and may even damage the mold and equipment, and affect the shape accuracy of the product.
- Difficult mold opening:
- Reason: The connecting parts between the mold and the vulcanizer may be stuck, or the demolding mechanism may fail. For example, if the ejector pin of the demolding mechanism is bent and deformed, it is difficult to eject the product from the mold.
- Performance: It will not only reduce production efficiency, but also may damage the product.

Electrical system failure

- Equipment cannot start:

- Reason: Power failure, fuse in the control circuit, contactor or relay damage, etc. may cause the equipment to fail to start.

- Performance: The vulcanizer cannot work properly, affecting the production progress.

- Control system failure:

- Reason: Such as PLC (Programmable Logic Controller) program error, touch screen failure, etc., resulting in the inability to correctly set and control the parameters of the vulcanization process.

- Performance: Affects the normal progress of the vulcanization process and cannot guarantee the stability of product quality.