As a manufacturer of rubber products, there is often a question: rubber formula, technology and other technologies are certainly important, but how much is important, how much gold he has, and how much investment in technology can get the corresponding return.

The main reason is that the technology is not mature, the heart is not bottom, in many cases only see the surface phenomenon in the process.

Rubber processing technology is also an engineering processing science. It can be said that it is broad and profound. Many chemical reaction theories are still being explored. Just like many well-known tire companies, they have passed a hundred years of history and are still constantly researching and innovating. Looking for new breakthroughs. To say simple, it is really simple enough. Many bosses of small and medium-sized enterprises can still open a factory by buying a formula or hiring a master. A technician who has not even finished reading a complete rubber professional book can still adjust the formula and spend 180 yuan's money to buy a (Xie Zhongphosphorus) rubber formula book, find a corresponding formula in it, and still make products, and with excellent marketing ability, so to market. Rubber technology seems to be such a thing, it seems to be just a layer of window paper, so it is not surprising that many bosses grind and kill donkeys.

Due to the existence of this concept, when an enterprise gets a relatively stable production process, it may feel that the survival crisis of the enterprise has been solved, so the emphasis on engineering and technical personnel or technology will be greatly reduced. The main reason is still not to realize the essence of a set of excellent rubber processing technology. In other words, we have not tasted the rich fruits backed by strong technical force.

The vulcanization process of rubber is a complex chemical reaction process. The rubber processing factory is actually a chemical plant, but there are not many factories that can manage the rubber plant according to the chemical plant standards. Why? This is a conceptual gap, because if the chemical plant does not have the correct formula, temperature, time, pressure and other effective and accurate control in the compounding process, then the products after coming out of the pot are likely to be a pile of worthless waste or inferior products with less content, and many products can easily distinguish the advantages and disadvantages of the products in terms of color, taste, specific gravity and so on. Therefore, the control and coordination of each process must be strict.

The vulcanization process of rubber can be divided into induction period, hot vulcanization period, vulcanization flat period and over vulcanization period. In the vulcanization process, if it is under-sulfur products may be found on the spot, but mild under-sulfur is not easy to find, will also affect the physical properties of the product, vulcanization over-sulfur period is a longer process, mild over-sulfur may not be found on the spot, but the same physical and mechanical properties of the product have a certain impact. The size of the pressure will make the product density, size, physical properties have a certain change. Therefore, the temperature, time and pressure in the rubber processing process are also very important factors.

Products obtained without strict technological process, even if the bad deeds of the products cannot be checked on the spot, will always be like pagodas built on quicksand, and will sink away that day. This may be one of the keys to the abnormal continuous production of many factory products and poor production flow.

The processing technology of rubber should be a fine process, which includes formula, process, mold, equipment, management, materials, product performance requirements, staff quality and other comprehensive factors. In the whole production process, there is often disharmony in all aspects, so that abnormal frequent occurrence, which not only affects the production efficiency of the product, but also seriously reduces the stability and physical properties of the product. The ideal production process should be the formula, process, equipment, materials, mold, management and other factors into one, but in fact it is very difficult to do, often in many factors to find the best balance point, if there is no broad vision, strong technical support, even such the best balance point is difficult to find.

There are many small and medium-sized rubber enterprises in China, including rubber mixing factories that only do the front part, and factories that produce products by buying rubber mixing. It is often the physical properties of the rubber compound that goes out of the rubber mixing plant are acceptable, and the processing performance is not good. The main reason is the lack of the concept of the rear section in the formulation factor. The rear section product factory does not have its own research and development strength, and the competitiveness of the product is often It has been restricted to a certain extent, and it has also affected the company's development prospects. Among many manufacturers that started by buying formulas, some factories have already reached a large scale. Due to the limitation of technical strength, they are not proud and can only rely on continuous external experts to maintain the shortage of technical strength, but this is also a good way.

It can also be said that the rubber factory's formula, process, mold, equipment, management, materials, product performance requirements, staff quality and other aspects of the mutual integration of the ability to represent the rubber enterprise technical strength of the important identification indicators. In fact, the production process and product abnormalities are largely due to the uncoordinated Peugeot factors.

How to improve the coordination of various factors is a comprehensive process, and it is also the primary task of managers and engineering and technical personnel. This is a goal that can only be approached after a long period of continuous running-in.

For rubber plants, the formulation is the core of the entire processing technology, which is not allowed to set. Formulation is also the center of the fusion of major factors. It is also a demonstration of the skills of rubber engineers.

When designing the formula, in addition to ensuring the physical properties and the balance of the five systems, the matching of the process and the constraints of other factors must also be considered.

The processing process of rubber is divided into plastication, mixing, flake-out, calendering, extrusion, vulcanization and other processes. The same formula is used in different factories. Due to different factory conditions, it is impossible to be completely applicable. Therefore, it is completely accurate to say "don't think that a formula is OK.

Plastication is the first step in the process of rubber processing, but different kinds of rubber have different plastication processes. For example, rubber such as NR/CR/CSM must be plasticated, while rubber such as BR and Q does not need plastication. The plasticizing process is also divided into high temperature, low temperature and plasticizing agent plasticizing. In the process of using the rubber material, it is also divided into single rubber species and mixed rubber species, and the proportion of mixed rubber is also different. These processing processes are told to you in many books. Plasticizing process must also be based on the formula, mold, equipment environment and other factors, different methods will have different effects.

For example, in the NR/SBR/BR system, there are two methods, which have been promoted in production. One is to refine natural rubber and then add styrene-butadiene rubber and butadiene rubber. The second is to combine the three kinds of rubber at the same time into one. Obviously, the first method not only shortens the plasticizing processing time, but also has stable quality and excellent process performance. The second method according to the appropriate process requirements or time can also achieve the purpose, but the operation is slightly wrong, in which natural rubber is difficult to achieve the required plasticity, often there will be poor fluidity of the rubber, after molding often appear steam spots, lack of material phenomenon. If it is a new mold with patterns, this phenomenon will be even more serious. If there is a little theoretical basis, it is not surprising to think about it in detail.

Mixing is one of the most important components in the rubber processing process. Mixing can be separated from mixer and internal mixer. Mixer mixing is also divided into high temperature and low temperature, different equipment, formula, vulcanization process, production environment, the mixing process should also be different. Open mixing and close mixing have different advantages and disadvantages. Open mixing has adverse factors such as pollution, uneven dispersion and more difficult dispersion of high melting point substances. Relatively speaking, it is low temperature mixing. Therefore, it is necessary to park after the open mixing process to further spread the compounding agent, which is generally necessary. At the same time, the characteristics of low temperature mixing can be used to add small drugs including overspeed accelerator into mixing at the same time, therefore, the vulcanization T90 of the compound mixed by the opening process is sometimes more stable than that of the mixing process. Many compounding agents must be above their melting point in order to be fully dispersed evenly. For example, the commonly used additive "Gumaron" has varieties with different melting points, so only low melting point brands can be selected in the formulation of the refining process.

There are various methods of mixing process, and the most important link is the comprehensive control of temperature, time and pressure. Temperature control is the most important level. Mixing temperature can be divided into three methods: high temperature, medium temperature and low temperature. High temperature mixing is generally between 130 and 150 degrees. No accelerator or vulcanizing agent can be added to the mixing process. It is generally suitable for high-speed internal mixers. For example, SI69 is used to couple silica in tire rubber compound. The mixing temperature reaches 150 degrees and the mixing time is strictly controlled, the mechanism of SI69 coupling silica has been mature for more than 20 years. The reaction speed below 135 degrees is very slow. It is nearly suitable for high-temperature mixing. Strangely, except for some documents, there is hardly a book or teaching book in China that clearly indicates the importance of mixing temperature. The general temperature of medium temperature mixing is controlled at 110~135 degrees, and different dispensing temperatures can be selected for different formulations and processes. In fact, most small and medium-sized enterprises choose the mixing temperature at this stage, and there are several characteristics of operation at this mixing temperature stage.

The 1. is that most of the water in the compound can be evaporated.

2. is a high melting point resin, feeding bag, etc. can be fully dissolved to facilitate dispersion.

The 3. is that the general temperature rises to this stage. Most of the rubber materials have been mixed evenly and can be discharged.

The 4. is that at this stage of mixing can be added to the critical activation temperature of higher varieties of promoters mixed together will be conducive to dispersion.

The 5. is that the Mooney viscosity of the compound is easy to control. The selection of glue discharge temperature must be below the critical activation point of the accelerator, in other words, it is determined according to the variety of accelerator in the formula. Many factories use sulfur and overspeed accelerator to add them when they are released. There are also many plants that use low-temperature mixing parties and can use the same feeding procedures as open mixing.

Low-temperature mixing is generally used in a complex system that is easier to mix, has a large amount of oil, and has a low reinforcing agent structure. Mixing process is a more important process, mixing quality not only directly affects the physical properties of the compound, but also can not ensure the normal Mooney viscosity of the compound, which will also affect the vulcanization process and vulcanization speed.

Tablet process is also one of the most important processes, generally speaking, the first task is to make the sulfur dispersed evenly in the rubber material, in order to ensure uniform dispersion or speed up the dispersion time, sulfur, accelerator using pre-dispersed masterbatch is also the future direction of development. Another important part of the film is to reduce the film temperature of the rubber material, the fastest speed to speed up the heat dissipation time, because at a higher temperature sulfur, accelerator, activator easy to interact, the formation of faster curing speed of room temperature vulcanizing agent complex, the time is too long or can not effectively cool the rubber material is the most easy to scorch. The main cooling measures still depend on the condition of the equipment and the artificial process adjustment.

The phenomenon of product type expansion of extruded products and shrinkage rate of calendered products is a common problem in the process. Technologists should take into account the factors from the beginning of the product formulation design.

Although the mold belongs to the metal processing industry, many rubber processing units have their own matching. As a rubber craftsman, you should also know something about the flow and exhaust structure of the mold. There are many problems that should be taken into account before the mold design, such as the shrinkage of the rubber material, the size of the mold, the way of electroplating, etc. These factors must be provided to the mold designer in time.

Different formulations, material shrinkage is different, in the formula is not shaped before the rash mold, often make the size of the product is not stable enough. The size of the mold must be set according to the pressure, tonnage, and the shape of the mold. If the mold is too large, the rubber material flow pressure is too small, the exhaust steam is poor, and the shrinkage rate is too large.

Plating methods include zinc plating, chrome plating, iron plating, etc. Different rubber varieties and different vulcanizing agents will decompose different by-products during vulcanization. Technologists should understand various vulcanization mechanisms in order to make correct judgments. For example, the general-purpose unsaturated rubber vulcanized by sulfur reacts to decompose aldehydes, ketones, water, etc. with less corrosion, zinc plating and chromium plating are enough, while the peroxide with carboxyl group is used to vulcanize and decompose organic acid, so it is obviously better to plate iron furlong. Some vulcanized general-purpose rubber molds can also be based on process conditions or requirements, without the need for electrical degrees.

Vulcanization is the last process in the whole process of rubber processing, and it is also the focus of reflecting the advantages and disadvantages of the previous processing process. Unvulcanized rubber material has actually determined the speed of rubber processing reaction and processing safety. Choosing the best vulcanization temperature can produce products with the best physical properties. Increasing the temperature can increase the raw rate, but at the expense of physical properties. In fact, the choice of vulcanization temperature is a comprehensive choice between physical properties and productivity. From the formula, process flow, material support control, etc. all these should be designed around the vulcanization process under the condition of ensuring physical properties. Only the stability of the vulcanization process can be regarded as the current process stability.

The stability of the product is to test the whole from the formula, management, process and other aspects of the coordination of the important Peugeot. Vulcanization temperature, time, formula coordination and support control ability is the key to stable product performance, which is the embodiment of the combination of formula and process, so the formula design should consider the process factors, the process is designed according to the formula and product requirements.

The design of the formula is designed according to the product requirements, cost, process flow, use environment and other factors. There are always such and such problems in the whole production process, which restrict the rationality of the formula. It is the responsibility of rubber technologists to continuously optimize the formula and improve the process, that is to say, to constantly find a balance point in various contradictions. Rubber Technology Network has gone through six years. It is not a difficult problem for rubber friends and netizens who have been showing their faces in this circle for a long time to make a formula. However, it is almost impossible to really get a formula that is most suitable for themselves without paying a certain price, because the formula that is most suitable for their own factories can only be designed by themselves or designed after understanding the scene, to some extent, it represents the enterprise's concept of products, which involves the level of product cost and quality, the quality of employees, the difference of management mode, and so on. The final formula and process optimization still depend on the factory itself, so it is inevitable to strengthen the technical strength of the enterprises themselves.

Raw materials are the foundation to ensure the quality of rubber products. The understanding of rubber raw materials is a necessary factor for enterprise leaders and engineering and technical personnel. After all, the factory is not a scientific research unit, and it is impossible to test and test each batch of materials. Therefore, judgment, visual inspection and testing are the main means of rubber technicians. These experiences require a long accumulation process and are also a kind of technology accumulation.

Today in the 21st century, with the progress of science and technology, a large number of rubber testing equipment has spread to small and medium-sized factories, which also gave the enterprise product quality assurance has played a huge role in promoting. At present, the product market is a buyer's market, and some additives such as vulcanizing agents and accelerators are less and less likely to be adulterated, because their quality problems have a great impact on the process flow and can be found in the first time. For example, if the content of zinc oxide, antioxidant, etc. is insufficient or adulterated, it is difficult to identify only by testing methods, and a conclusion can only be drawn after testing, while the general factory does not have these conditions, so the replacement of such materials should be more careful. Using inferior quality, insufficient content or adulterated materials for formulation research and development or optimization experiments will lead the branch technicians into misunderstandings and directly affect the progress of product development. The selection and dosage of raw materials in the process of formula design and optimization directly affect the production cost of the enterprise. An excellent rubber process formula can not only directly improve production efficiency, but also save a lot of material costs for enterprises.

In the daily production process is often affected by the production equipment, management mode, personnel quality, material funds and other factors of anti-interference, affecting the development of productivity, some places can be improved by strengthening management, etc., but some places are limited by the conditions can not be improved, then can through technical means to balance the adverse factors in all aspects.

The optimization of formula is more difficult than design and research. It requires engineers and technicians to have more broad thinking space. Such thinking space comes from the rich theoretical accomplishment and extensive practical experience of technicians. Engineering and technicians with these conditions need to accumulate and work hard for a long time, which is also a long-term technology investment of the enterprise, that is to say, the enterprise wants to cultivate an excellent rubber craftsman, must have a far-reaching vision.

With the development of science and technology and the continuous improvement of people's living standards, the rubber industry will inevitably develop in the direction of high technology and high added value. The development of enterprises will rely on technology more and more urgently. The development of enterprises must also be accompanied by technological progress. Cultivating their own technical backbone will be the primary task of enterprise development. Only with strong technical force, enterprises can be in an invincible position in the constant competition.

Therefore, technical force is the magic weapon to improve the competitiveness of rubber enterprises