Troubleshooting Rubber Problems

Preface

1 TSE and TPE Materials, Compounds, Processes, and Products

1.1 Introduction

1.2 Troubleshooting Difficulties

1.3 Aids to Troubleshooting

1.4 Materials, Process, and Design Factors

1.5 Book Organization

1.6 Nature of Rubber

1.7 Training

1.8 Disclaimer

2 TSE Materials and Compounds

2.1 Introduction

2.2 Cost Reduction

2.2.1 Compounds and Compounders

2.2.2 High-Viscosity Elastomers and Compounds

2.3 Elastomer Type

2.3.1 CR (Neoprene)

2.3.2 CSM (Chloro-Sulfonyl-Polyethylene)

2.3.3 IIR (Isobutene-Isoprene)

2.3.4 EPDM (Terpolymer of Ethylene, Propylene, and a Diene)

2.3.5 SBR (Styrene-Butadiene Rubber)

2.3.6 FKM (Fluoro Rubber of the Polymethylene Type)

2.3.7 Polyisoprene (NR and IR)

2.4 Crystallization

2.5 Crosslinking Factors

2.6 Silicone Rubber

2.6.1 NBR (Acrylonitrile-Butadiene Rubber)

2.6.2 HNBR (Hydrogenated Nitrile Rubber)

2.6.3 CM (Chloro-Polyethylene)

2.6.4 CSM (Chlorosulfonated Polyethylene)

2.6.5 AEM (Ethylene Acrylic)

2.7 Elastomer Blends

2.8 Crosslinking Systems

2.9 Dispersion

2.10 Crosslinking System Effects

2.11 Retarders

2.12 Fillers

2.13 Process Aids

2.14 Plasticizers and Oils

2.15 Antidegradants

2.15.1 Discoloration and Staining

2.16 Bloom

2.17 Flame Retarders

2.18 Compound Properties

2.19 Testing

2.20 Taste

2.21 Low-Viscosity Elastomers

2.22 Silicone Rubber Viscosity

2.22.1 LSR Molding Factors

2.23 Coatings

2.24 Plastisols

3 TSE Processes and Equipment

3.1 Adhesion

3.1.1 Substrates

3.1.2 Substrate Surface Treatments

3.2 Effect of Ingredients

3.2.1 Substrate Considerations

3.2.2 Adhesive Type

3.3 Testing

3.4 Processing

3.5 Mixing

3.5.1 Mixer Type

3.6 Mills

3.7 Dispersion

3.8 Contamination

3.9 Extrusion

3.9.1 Extrusion of Specific Types of Rubber

3.9.1.1 Elastomeric Alloy (EA)

3.9.1.2 EPDM

3.9.1.3 Silicone Rubber

3.9.2 Extrusion Factors

3.9.2.1 Output Rate

3.9.2.2 Die Swell

3.9.2.3 Die Entrance

3.9.2.4 Extrudate Appearance

3.10 Equipment

3.10.1 Hot-Feed

3.10.2 Cold-Feed

3.11 Ram Extruder

3.12 Multicut Transfermix

3.13 Crosshead Extruder

3.14 Continuous Extrusion

3.15 Extruder Design

3.15.1 Vacuum Extruder

3.15.2 Cavity-Transfer Mixer (CTM)

3.15.3 Pin-Barrel Extruder

3.15.4 Roller-Head Extruder

3.16 Die Design

3.17 Feed Compound

3.18 Gear Pumps

3.19 Molding

3.19.1 Molding Methods

3.19.1.1 Compression Molding

3.19.2 Curing Presses

3.19.2.1 Four-Post Presses

3.19.3 Mold Size

3.19.4 Air Trapping

3.19.5 Flash

3.19.6 Scorch Effects

3.19.7 Shrinkage

3.20 Potential Mold Damage

3.21 Thermal Considerations

3.22 Microwave Heating

3.23 Backrinding

3.24 Mold Construction

3.25 Insulation

3.26 Mold Platens

3.27 Mold Heating

3.28 Injection-Compression

3.29 Transfer Molding

3.29.1 Cavity Filling

3.29.2 Adhesion

3.29.3 Dimensional Factors

3.29.4 Shrinkage

3.29.5 Compound Flow

3.29.6 Cold Transfer Molding

3.29.7 Sprues

3.29.8 Injection-Transfer

3.29.9 Transfer Mold Design

3.29.10 Parting Line

3.29.11 Plunger

3.29.12 Sprues

3.30 Injection Molding

3.30.1 Injection-Molding Problems

3.30.2 Injection-Molding Machines

3.31 Molds

3.31.1 Mold Materials

3.31.2 Mold Handling

3.31.3 Cavity Finish

3.31.4 Mold Heating

3.31.4.1 Heating Methods

3.31.5 Gates

3.31.6 Leader Pins

3.31.6.1 Core Pins and Bushings

3.31.7 Lands

3.32 Overflows

3.32.1 Overflow Design

3.33 Holes

3.34 Runners

3.34.1 Hot Runner

3.34.2 Cold Runner

3.35 Mold Design

3.36 Gates and Venting

3.37 Cost Factors

3.38 Fouling and Cleaning

3.38.1 Mold Fouling Factors

3.38.2 Mold Cleaning Methods

3.38.3 Fouling Sites

3.38.4 Causes of Fouling

3.38.5 Mold Cleaning

3.39 Calendering

3.39.1 Calendering Equipment

3.39.2 Feed Material

3.39.3 Calendering Factors

3.39.4 Blisters

3.39.5 Tack

3.40 Laser Engraving

4 TSE Products

4.1 Product Considerations

4.2 Effect of Aging

4.3 Composites

4.4 Belts

4.5 Rubber Lining

4.6 Balloons

4.7 O-Rings

4.8 Rubber Mirror

4.9 Cow-Related Applications

4.10 Regenerative Brake Systems

4.11 Rubber-Covered Horseshoes

4.12 Rubber Bullets

4.13 Bungees

4.14 Rubber Band Ligation

4.15 Rubber Bands

4.16 Floor Mats

4.17 Mounts

4.18 Stress Concentration

4.19 Roofing

4.20 Finite Element Analysis

4.21 Air Springs

4.22 Keyboard Springs

4.23 Gloves

4.24 Inflatable Dam

4.25 Inflatable Traffic Hump

4.26 Tennis Balls

4.27 Tires

4.27.1 Tire Manufacturing Systems

4.27.2 Modular Integrated Robotized System

4.27.3 Bridgestone Innovative and Rational Development

4.27.4 Modular Tire Manufacturing

4.27.5 Advanced Tire Operation Module

4.27.6 Automated Production Unit System

4.27.7 Integrated Manufacturing Precision Assembled Cellular Technology

4.27.8 Components

4.27.9 Tire Molds

4.27.10 Venting Tire Molds

4.27.11 Run-Flat Tires

4.27.12 Semi-pneumatic Tires

4.27.13 Tire Aging and Safety

4.27.14 Tire Recycling

4.28 Nontire Products

4.28.1 General Design Considerations

4.29 Bridge Bearings

4.30 Earthquake Mounts

4.31 Expansion Joints

4.32 Seals

4.32.1 Automobile Sunroof Seals

4.32.2 Radial Lip Seals

4.32.3 O-Ring Seals

4.32.4 Gaskets

4.32.5 Wine Bottle Corks

4.32.6 Casket Seals

4.32.7 Aircraft Runway Seals

4.32.8 TPU Seals

4.33 Inner Tubes

4.34 Windshield Wiper Blades

4.35 Friction Drive

4.36 Baby Bottle Nipples

4.37 Belts

4.37.1 Serpentine Belts

4.37.2 Aircraft Recorder Belts

4.37.3 O-Ring Belts

4.37.4 Conveyor Belts

4.37.5 Timing Belts

4.38 Mountings, Bearings, and Bushings

4.38.1 Engine Mounts

4.39 Hose and Tubing

4.39.1 Self-Sealing Fuel Cells

4.39.2 Radiator Hose

4.39.3 Fuel Hose

4.39.4 Turbocharger Hose

4.39.5 Refrigerant Hose

4.39.6 Heating Hose

4.39.7 Brake Hose

4.39.8 Power-Steering Hose

4.39.9 Hose Design

4.39.10 Hose Manufacture

4.39.11 Hose Failure

4.39.12 Hose Abrasion

4.39.13 Medical Hose

4.39.14 Hose Identification Technology

4.40 Expansion Joints

4.41 Color

4.42 Rubber-Covered Rolls

4.43 Wire and Cable Coating

4.44 Cellular Rubber

4.45 Hard Rubber

4.46 Rocket Insulation

4.47 O-Rings

4.48 Earplugs

4.49 Testing

4.50 Dip Molding

4.50.1 Latex

4.50.2 Plastisol

4.50.3 Materials

4.50.4 Processing

4.50.5 Design, Products, and Applications

5 TPE Materials and Compounds

5.1 Introduction

5.2 TPE Types

5.2.1 TPV (Thermoplastic Vulcanizate)

5.2.2 SBC (Styrenic Block Copolymer)

5.2.3 SEBS (Styrene Ethylene Butylene Styrene)

5.2.4 TPU (Thermoplastic Polyurethane)

5.2.5 TPO (Thermoplastic Polyolefins)

5.2.6 COP (Copolyester)

5.3 Drying

5.4 Cost

5.5 Service Temperature

5.6 Color

5.6.1 Painting

6 TPE Processes and Equipment

6.1 Injection Molding

6.1.1 Injection Molding Machines

6.1.1.1 Specialized Machines and Techniques

6.1.2 Machine Operation

6.1.3 Drying

6.1.4 Barrel and Screw

6.1.5 Injection Rate

6.1.6 Injection Pressure and Mold Packing

6.1.7 Clamp Pressure

6.1.8 Nonreturn Valve

6.1.9 Mold Temperature and Cooling Time

6.1.10 Heat Transfer

6.1.11 Mold Fouling

6.1.12 Regrind

6.1.13 Injection Molds

6.1.13.1 Mold Material

6.1.13.2 Mold Surface Treatments

6.1.13.3 Mold Maintenance

6.1.14 Mold Design

6.2 Blow Molding

6.3 Extrusion

6.3.1 Extrusion Equipment

6.3.2 General Design Guidelines for Extrusion

7 TPE Products

7.1 Athletic Products

7.2 Hood Stops

7.3 Food Trays

7.4 Rollers

7.5 Seals

7.5.1 Seal Design

7.6 Hose

7.7 Prosthetics

7.8 CVJ Boots

7.9 Fish Lures

7.10 Design

7.11 Appearance

7.12 Conductive SEBS

7.13 Safety

Appendix I

Abbreviations

Appendix II

Definitions

Index