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INJECTION MOLDING

Injection molding rubber was originally an extension from the plastics industry in the early to mid 1960s. After overcoming the initial issues of temperature (plastics is cooled when molding and rubber is heated) and pressure (rubber injection molding requires significantly more pressure per square inch of cavity surface), the process has become the most efficient way to mold rubber in most cases.

Injection molding start with more efficient material preparation. The material is mixed, typically in batches, and then stripped immediately after being mixed, into continuous strips This strip is fed into a screw which charges a barrel as needed with a pre-defined amount of material. When the mold is closed, the material in the barrel is injected into the mold cavities and cured.



There are many advantages to this process:

1. Complete elimination of pre-forms, a labor-intensive step that can introduce variability in pre-form weight and shape resulting in variability of the finished product.

2. Complete elimination of operator placement of pre-forms. In many cases, the operator has to "strategically" place the pre-forms in either the cavity (compression molding) or the pot (transfer molding) to insure quality output.

3. The injection screw pre-heats the material before forcing it into the cavities. This decreases the viscosity of the material, allowing it to flow more easily into the cavities. The other advantage is the potential for decreased cure time for two reasons:

    a. more rapid cavity filling due to lower viscosity.

    b. the material is well on it's way to being cured as a result of the heat added during the screw
        charging.



COMPRESSION MOLDING

The first modern rubber product ever produced was compression molded in the home oven of Harvey Firestone in the 1890s. In many ways, not much has changed since for compression molding.

Compression molding involves taking rubber compound or mixed raw material and making "pre-forms" that are in the shape of the end product. These shapes are then loaded, typically by hand, into an open mold. The mold is closed, the rubber cured, and then demolded—typically by hand.



Compression molding can be cost effective if one or more of the following is true:

1. compression molding tooling already exists.

2. the quantity required is very low.

3. the part cross-section is very large and it requires a long cure time.


KP-Anger type Rubber Rings, for pressure pipes:

• Available range of sizes: (Nominal diameter)
   63,75,90,110,160,200,225, -250, 280, 315,
   400 and 500.

• Dimensional tolerances as per ISO 3302 M2.

• Hardness range 48 + 5 Shore A or as desired.

• Elastomer compound in all rings confirms to EN 681.

• Rings can also be supplied to confirm to other 
   standards such as ASTM/DIN etc.
 

 


KP-3S type Rubber Rings,for pressure pipes:

• Available in NR/SBR/EPDM.

• Complete range of sizes: (Nominal diameter)
   63,75,90,110,160,200,225,-250,280,
   315 and 400.

• Dimensional tolerances as per ISO 3302 M2.

• Hardness range 60 + 5 Shore A or as desired.

• Elastomer compound in all rings confirms to EN 681.

• Rings can also be supplied to confirm to other
   standards such as ASTM/DIN etc.
 

 

KP-Reka type Rubber Rings, for pressure pipes:

• Available in NR/SBR.

• Complete range of sizes: (Nominal diameter)
  200, 225, 300,350, 400,
  450 to 2500mm.

• Dimensional tolerances as per ISO 3302 M2.

• Hardness range 48 to 62 + 5 Shore A or as desired.

• Elastomer compound in all rings confirms to EN 681.

• Rings can also be supplied to confirm to other
   standards such as ASTM/DIN etc.

 


SETTING BLOCKS

Setting blocks are installed inside the window sash, between the sash material and insulated glass unit. They protect the IG from the impact of opening and closing the sash. Setting blocks provide same stress relief as windows expand and contract over varying temperature conditions.

Application:
Setting blocks work best when they are spaced and sized appropriately. The larger the pane of glass, the longer the setting block should be.Setting Blocks are basically rectangular molded components made out of Synthetic Rubbers (Neoprene, EPDM or Silicon Rubber) by a permanent Vulcanization Process.

• The Setting Blocks are normally of
   80 to 90 durometer hardness.

• The Setting Blocks are free of porosity,
   surface defects and dimensional
   irregularities that may affect serviceability.

• The Setting Blocks which are recommended
  by the manufacturer are being acceptable
  for use in the intended application of
  Non-Structural Glazing or Structural Glazing
  and these Setting Blocks have to be compatible
  with the glass and other glazing material with  
 
which they come into contact.

• These Setting Blocks not only perform well
   but they also blend well with frame. And
   of-course they are crack proof because of
   their Ozone Resistance properties.




MOLDED CORNERS

The most leak susceptible area in any gasket system is at the corners. It is a standard practice to provide some type of corner treatment to attain an acceptable level of weather tightness. When a glazing system includes extruded gasket, the corners on the exterior side of the lite are treated to effectively create a continuous gasket around the entire perimeter of the lite. Treating the corners on the interior side of the lite is often desirable.

Advantages:
The advantages of molded corners are all in the process. An inherent weakness in vulcanized corners lies in the bonding of the two pieces of rubber at the mitered corner. Any stresses placed on the corner from thermal movement, handling, installation or any other reason, are directed right at the bond line.This gives rise to premature splitting of the corner which may result in air and water infiltration position of the bond in an molded corner Molded corner allows distribution of stress away from the bond line, while a vulcanized bond directs stresses at the bond line.

 
 
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