高粘度ゴム (HCR) or Heat Cured Rubber (HCR) is an injection molding technique used to create equipment with high consistency polymeric silicone that is resilient and elastic.
The Strong Consistency Rubber (HCR) is a flow plate with a high resistance to flow and little elasticization. 高粘度ゴム (HCR) is suitable for tough environmental circumstances because it has excellent shock absorption, heat and cold resistance, and electrical conductivity.
What is High Consistency Rubber（HCR）？
ソリッドシリコーンゴム (高粘度シリコーンゴムと呼ばれることもあります, またはHCR), 有機過酸化物または白金触媒を使用して高温で硬化します。. HCRは分子量の高い長いポリマー鎖で構成されているため、堅固な粘稠度を持っています。. HCR は、その優れた機械的品質により、さまざまな静的および動的用途に採用されています。, 含む:
- 自動車
- 航空宇宙
- 送電および配電
- ワイヤーとケーブル
- 食品加工
- ゴム成型品
HCR により優れた耐老化性と温度耐性が提供されます。. 押出成形などの従来技術, カレンダー加工, 圧縮, 射出成形を使用して加工することができます.
The HCR Injection Molding Process
Solid silicone rubber is produced in bulk by rubber producers, who combine the ingredients in an uniform mixture at high temperatures. The curing process is facilitated by the inclusion of peroxide catalyst. Fabricators start the cross-linking of the molecules, but roll out the sheets of rubber materials before the vulcanization process is finished for storage or transportation.
The actual silicone rubber manufacturing process entails six steps:
- 触媒作用とミル軟化
この最初のプロセスは、すべてを元に戻します。 "クレープ硬化" これは材料がサプライヤーまたは製造業者に保管されている結果として発生し、押出および成形の両方の用途に必要です。. さらに, some procedures employ milling to combine the two components of an extra cure elastomer before processing or to add peroxide catalysts as needed to a free radical elastomer. A two-roll mill is required for this time-consuming procedure since the elastomer must go through the mill more than once to combine the complex material into a homogenous final result. The sheet might need to be processed further once it has been taken out of the mold.
- プリフォームの構築
The preparation of a performance comes next, which entails a lot of work, especially in high-volume production settings that run continuously. トランスファープレスのトランスファーリザーバーに適合するプラグは、トランスファー成形手順の一部として、ダイカッターでプリフォームから切り取られる必要があります。. Due to the requirement that the preform be cut into the same shape as the finished component, the compression molding application involves a more involved procedure. The elastomer sheet is cut into strips and fed into the extruder to prepare the preform for the extrusion and injection molding applications.
- 押し出し
HCR用押出プレスには単軸押出機が使用されています. オペレーターはローラーフィードホイールを使用して、プレハブストリップを押出機に供給します。. The elastomer material is extruded through a die and mandrel assembly, which equips the extruder with a crosshead assembly to form the required profile. The "support extrude" processing option uses a crosshead assembly that is mounted on the extruder to pass the supporting geometry through it and extrude a layer of silicone rubber over it.
- 成形
さまざまな高粘度シリコーン用途にはさまざまな成形ツールが必要です. Personnel are needed to load the elastomer into the machinery and to de-mold the completed components during both transfer and injection molding manufacture. In order to complete the compression molding process, employees must insert preforms into each mold's cavity. Due to the long cure cycles of high consistency rubber, the molds may have several holes.
- 加硫
Extruded goods are vulcanized by fabricators using hot-air vulcanizing ovens (HAVs). By creating molecular cross-links, this process makes the material stronger and more resilient. 押し出されたプロファイルは、縦型オーブン内のオーブンを通して引き上げられます。, 縦型と横型の両方で利用可能です. Radiant heat or a steam autoclave oven are used in some vulcanization procedures.
- 仕上げ
The application determines how much finishing is done. The finishing procedure for extrusion profiles involves a visual examination and cutting the tubes into predetermined lengths. The profile has to go through a post-cured procedure to get rid of the peroxide byproducts for extrusion components that are peroxide cured. Trimming or de-flashing of molded components is another step in the injection molding process. The employee cuts the components off the huge, molded sheet using a die-cutting tool. The component can need post-curing in specific circumstances.
Material is wasted during the production of high-consistency rubber, and labor is expensive. さらに, physical labor and other tools and equipment are needed. しかし, the equipment is less costly than the molds needed to make items made of LSR (液状シリコーンゴム).
高粘度ゴムはいつ使用されるのか (HCR) 最善の選択?
高粘度ゴム (HCR) 自動車用の機器や材料部品を製造する場合、射出成形がよく選ばれる方法です。, 電気, 生物医学的, および製薬産業. 高粘度ゴム (HCR) 高い温度耐性を示します, 優れたショックアブソーバーです, 優れた電気伝導体です.
高粘度ゴム (HCR) ケーブル製造のための最良のオプションです, スパークプラグブーツ, 電気絶縁体, チューブ, 航空機器, 耐熱性に優れているため、その他の密閉機器にも使用できます。, 耐火性, 煙の排出量が少ない.
この手順は、大量生産の実行に必要な自動複製に十分適応できないためです。, 高粘度ゴム (HCR) モールド法は大規模な製造の場合に最適なオプションです.