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1. Benefits Of Silicone Rubber Injection Molding

   April 11, 2023 5:52 am Leave a Comment

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   Plastics have become the material of choice for manufacturers using injection molding processes. Generally, plastic has strong, lightweight, and easy-to-mold characteristics suitable for molding required parts and components. However, some plastics, like thermoplastic elastomers, cannot withstand extreme heat and are more prone to distortions when exposed to very high temperatures.

   For this reason, manufacturers in a wide range of industries prefer rubber silicone to produce parts efficiently and economically. Liquid silicone rubber (LSR) is one great innovation for injection molding. The silicone’s basic structure is made up of duplicating Si-O chains (or polyatomic anions consisting of silicon and oxygen, also called silicate). LSR is highly flexible in nature, providing unique properties such as:

   • Wide temperature operating range
   • Good corrosion resistance
   • Permeability
   • Bio-inertness
   • Electrical insulation
   • Long service life

   Advantages Of Using LSR In Injection Molding

   The following are some of the benefits of using liquid silicone rubber in silicone rubber injection molding:

   Superior Heat Stability

   LSRs can withstand temperatures as high as 180℃ without melting or trickling. Due to this, they are common for heavy-duty and automotive applications such as seals and gaskets. LSR is also the preferred material for other industrial applications because of its high thermal ability.

   Low-Temperature Flexibility

   LSRs can withstand temperatures as low as -50°C. They are an excellent choice for any device that requires a low-temperature operation. This advantage is in contrast with most thermoplastics which become more rigid and brittle when exposed to low temperatures.

   Aging Resistance

   Aging resistance is critical when selecting a material for your injection molding procedure. LSR materials that have been cured are highly resistant to UV rays, weathering, and aging. They are ideal for applications that require extended outdoor exposure.

   Chemical Resistance

   LSR has low water absorption and excellent resistance to common chemicals even when exposed to extreme temperatures as compared to most thermoplastics which only offer chemical resistance in moderate temperature ranges.

   Low Compression Set

   Low compression set materials can withstand structural damage under severe stress. LSRs have a low compression set, typically between 15% and 20%. They retain their elastic properties even when compressed for extended periods of time.

   Great Shelf-Life Reliability

   The shelf life of liquid silicone rubber is one of the key factors in determining its ease of use in a production line. The majority of LSR products have a shelf life of one year.

   Electrical Resistance

   Manufacturers of electronic components must ensure that their materials can withstand corona discharge or voltage spikes. LSR has a high electrical stress resistance without affecting the final product’s conductivity.

   Precision Made Molded Rubber Parts by Jefferson Rubber

   Since the late 1970s, liquid silicone rubber injection molding has been used in various industries, including health care, medical, consumer goods, automotive, devices & electronics, and aerospace. Silicone rubber injection molding has been one of the most efficient and economical processes in molding rubber parts or components.

   Jefferson Rubber Works, Inc. manufactures high-quality molded rubber parts and offers various rubber molding capabilities, including liquid silicone injection molding, rubber-to-metal molding, compression molding, transfer molding, and more! We provide a complete solution that includes part design, prototyping, production, finishing, and assembly, all at a quick turnaround time and cost-efficient rate.

   With our 40 years of experience in the rubber manufacturing industry, we ensure to eliminate the need to work with multiple vendors. We can serve as your one-stop shop to meet all your custom rubber molding requirements and produce the high-quality products that you need.

   Contact us today to learn more about our capabilities or request a quote for your next molded-rubber parts project.

2. Clean Manufacturing With Liquid Silicone

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   Liquid silicone rubber injection molding, or LSR molding, is one of the most preferred methods for manufacturing precise and delicate components. This process is clean and highly accurate, produces high output, and offers superior strength and efficiency when integrated with the clean manufacturing technique of liquid injection molding.

   This article will discuss the properties of LSR that make it suitable for liquid injection molding and the clean manufacturing process.

   Characteristics of Liquid Silicone Rubber

   Liquid silicone rubber is a high-purity platinum-cured silicone with physical, chemical, and thermal characteristics that make it ideal for products requiring excellent productivity, durability, and efficiency. In addition, LSR has the following properties:

   Chemical Inertness

   LSR’s silicone-oxygen structure has a higher bond strength than polyethylene or carbon-based materials. It is also resistant to oxidation, UV rays, water, ozone, and radiation damage. Because of its inertness, LSR is an excellent choice for food contact, medical applications, and silicone prototyping.

   Hypoallergenic Property

   LSR is naturally hypoallergenic and non-toxic and will not irritate or trigger allergic reactions in those with sensitive skin. Thus, it offers a safe and convenient remedy for respiratory products — such as oxygen and CPAP masks — and consumer items like earbuds, hearing aids, and portable monitoring devices worn for long periods.

   Biocompatibility

   The molecular structure of LSR also plays a role in its biocompatibility; it is odorless and tastes nothing. As a result, it is extensively used in baby products and other food and beverage-related goods because it adheres to the Food and Drug Administration (FDA) requirements.

   Versatility

   The mechanical and thermal stability characteristics of LSR are exceptional, resulting in it being preferred over other elastomeric polymers. In addition, it retains its properties at wide temperature ranges — high and low — varying from -40 ℃ to 200 ℃, depending on the grade.

   Clean Manufacturing Process

   The most consistent and stable materials utilized in the liquid silicone rubber injection molding process are platinum-cured polymerics. The vulcanization or curing process employs a two-part silicone compound (composed of A and B parts in different containers) attached to the pumping system and delivered to a static mixer at a predetermined ratio. Compound A is usually the base-forming material, whereas Compound B is a catalyst.

   The mixture is combined with a platinum cure system before being injected into the mixing chamber. Next, it is added into the closed mold via a runner and gate system. Once cured, the components are removed from the mold cavities, and the process is repeated for the next batch.

   Following that, the products may be subjected to post-molding, which includes the following processes:

   • Deflashing: This method eliminates the residual rubber material used in injection molding. This is done via a centrifugal barrel finishing machine, a quick and cost-effective equipment to deflash multiple components.
   • Post curing: This process is subject to high temperatures to accelerate curing and optimize some of the material’s physical parameters. This will also speed up the cross-linking process and ensure that the polymer molecules are correctly aligned.
   • Inspecting: This process generates precise and prompt dimensional data and performance test results for molded parts.
   • Packaging: This is the final step in preparing the molded parts for shipping after a thorough inspection.

   Only the Best and Highest-Quality Molded Parts From Jefferson Rubber Works

   Jefferson Rubber Works produces high-quality molded rubber parts and provides a wide range of rubber molding services, including liquid silicone injection molding, rubber-to-metal molding, compression molding, transfer molding, and more. We also offer a complete solution with part design, prototyping, production, finishing, and assembly — all with a quick turnaround and low cost!

   Get in touch with us today to learn more about our capabilities or request a quote for your next project!

3. Protect Your Water Well Pump With a Diaphragm Water Pressure Tank

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   Water well pumps extract water from wells to supply residential, commercial, industrial, and agricultural applications. These are important components of well systems, so they need protection to avoid costly replacement and repair. Doing so can prevent excessive wear and tear on the well pump and avoid water supply interruption.

   A diaphragm water pressure tank is a low-cost and effective way to safeguard your water well pump. Utilizing and maintaining the tank effectively will provide a consistent water supply and save you money in the long run.

   This article provides a detailed guide on protecting your water well pump with a diaphragm water pressure tank.

   Maximizing Well Pump Lifespan With a Diaphragm Water Pressure Tank

   A diaphragm water pressure tank will prevent unnecessary damage to a well pump by letting it rest between cycles. However, properly installing, using, and maintaining the tank is still important to take advantage of its full benefits.

   Here are four things to remember and follow when using a diaphragm water pressure tank for your well pump:

   1. Correctly Install the Diaphragm Water Pressure Tank

   The rubber diaphragm in the water pressure tank is a barrier between the pressurized air and water. Then, it allows the air to compress and expand as the water level in the well changes. Thus, installing the tank according to the manufacturer’s instructions is crucial. For instance, it should be connected to the pump with the correct pipe size and fittings.

   2. Adequately Adjust Air Pressure

   The air pressure in the tank is used to regulate the water pressure. It also prevents short cycling of the well pump, which can cause excessive wear and tear and shorten its lifespan. Therefore, you must adjust the air pressure to the correct levels to maintain and protect the well pump.

   3. Regularly Check for Leaks

   A diaphragm water pressure tank with leaks will not function as intended and might cause damage to the well pump. Therefore, regular upkeep and inspection are important to ensure its performance and condition. This will also help keep the air pressure in the tank at the proper level to strengthen the durability of the water well pump.

   4. Maintain the Tank

   Regular maintenance of the pressure tank helps to prevent the build-up of rust, corrosion, and sediment in the tank. This prolongs the life of the well and reduces the need for costly repairs. Neglected pressure tanks can also leak dirt, rust, and other contaminants into the water source and disrupt the supply.

   Jefferson Rubber Works: A Reliable Supplier of Rubber Diaphragms for the Water Tank Industry

   A rubber diaphragm in a water pressure tank can protect a well pump and improve its performance. By consulting with an expert in rubber diaphragm manufacturing, you can get a guaranteed high-quality product tailored to your specific needs.

   Jefferson Rubber Works is a trusted manufacturer of custom rubber products! Aside from pressure tanks, our rubber diaphragms have applications ranging from actuators and flow control valves to switches and turbochargers.

   Contact us to learn more about our rubber manufacturing capabilities, or request a quote today!

4. Understanding the Rubber Injection Molding Process

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   Rubber injection molding is an efficient technique for manufacturing precise rubber parts and rubber-to-metal bonded components. It creates products with faster cycle times than transfer or compression molding. In addition, due to its advantageous qualities, it is widely used in various industries, such as the automotive, food and beverage, medical, electronic, and agricultural sectors.

   The rubber injection molding process started in the mid-1960s after the successful modification of the plastics method. This procedure involves heating the rubber and exerting greater pressure per square inch on the cavity surface.

   In this article, we will elaborate on the basics of the rubber injection molding process and how it works.

   What Is Rubber Injection Molding?

   The rubber injection molding process molds uncured rubber by injecting the raw material into a metal mold chamber. It provides precision and efficiency not typically observed in other rubber manufacturing processes. It is also suited for applications utilizing compounds with quicker curing durations.

   Here are some of the common applications and uses of rubber injection molding:

   • Bumpers
   • Bushings
   • Diaphragms
   • Grommets
   • Isolators
   • Mounts
   • O-Rings
   • Pads
   • Plugs
   • Seals
   • Suction cups
   • Washers

   What Are the Components of the Rubber Injection Molding Process?

   Like any other methodologies, the procedure begins with material preparation. One advantage of rubber injection molding is that it allows the use of different varieties of rubbers.

   The following are the most frequently utilized materials in the manufacturing industry:

   • Butyl
   • EPDM
   • Fluorocarbon
   • Fluorosilicone
   • Hydrogenated nitrile butadiene
   • Natural rubber
   • Neoprene
   • Nitrile
   • Silicone
   • Styrene-butadiene
   • Urethane

   In addition to the raw rubber material, an injection molding machine or press is required. Common components include an injection ram, a heating system, and a hopper. Also called platens, they support the molds used to shape the components.

   Injection molding machines or presses are graded by their tonnage, indicating the amount of clamping force the machine can exert. Tonnage can range from less than 5 tons to more than 9,000 tons, with very few manufacturing operations employing the higher amounts.

   How Does the Rubber Injection Molding Process Work?

   Rubber injection molding starts with the bulk mixing of raw rubber, followed by its stripping into continuous lengths. Next, they are fed through a screw into a barrel containing a predetermined quantity of rubber material. The screw then preheats the material before being injected into the cavities. This reduces the substance’s viscosity, allowing it to flow freely into the cavities.

   The rubber stock plasticizes to the desired temperature while heating. Then, the plasticized rubber material is injected into a heated, high-pressure mold chamber. Using a runner and a gate system, heat and pressure initiate the curing of the rubber compound, ultimately vulcanizing it. Once the required level of cure is achieved, the rubber is allowed to cool and harden in the mold. Lastly, the pieces are ejected from the mold in preparation for the next cycle.

   Jefferson Rubber Works for High-Quality Rubber Injection Molding Solutions

   At Jefferson Rubber Works, we combine industry experience with cutting-edge technology to provide customized solutions and services at affordable costs and unmatched speed and precision. We can also assist you with component design, prototype, manufacture, finishing, and assembly, so you do not need to collaborate with many companies for a single project.

   Contact us today to find out more about our services and solutions. You can also request a quote, and we will be happy to assist you with your needs!