Solid silicone raw material is essentially an amorphous, semi-transparent solid – commonly known as solid silicone. The initial step involves mixing it in a refining machine, ensuring an even blend of added curing agents and color compounds. This meticulous process yields the desired color, and the resulting mixture is then rolled into thin sheets using silicone release paper and fed into a cutting machine. Each silicone product maintains relative stability in weight, ensuring consistent material distribution during the cutting process.
Silicone products created through silicone mixing boast excellent high and low-temperature resistance, electrical performance, and thermal stability. They can operate reliably at fixed temperatures, exhibiting remarkable resistance to ozone, weathering, corona discharge, arcs, and sparks.
How to silicone mixing？
1. Silicone Mixing Preparation
For refining, the preparation of raw materials is vital. Collect all necessary materials for organic silicone mixing, including solid raw silicone materials, pigments, and curing agents. Clean the mixing area thoroughly, ensuring no contaminants or debris that could interfere with the organic silicone mixing process. Staff continuously provides different colors and shapes of silicone for each machine in our shaping workshop.
Selecting Raw Materials for Silicone Mixing
The staff responsible for refining tirelessly provides different colors and shapes of silicone for each machine in our shaping workshop. The preparation of raw materials for refining is crucial. Different materials are chosen based on the hardness, utility, and tensile strength required for various products.
Requirements for Silicone Refining
The hardness of general solid silicone rubber raw materials ranges between 30 to 90 degrees. During the allocation of color compounds, the amount of color compound is distributed according to the color concentration of the product and the usage and tensile strength of the raw material. The allocated color compound is placed on the refining machine for mixing with a curing agent, allowing the molding machine to produce products under high-temperature compression molding.
Requirements for Silicone Curing Agents
Curing agents are one of the most critical additives in silicone materials. Without curing agents, products made will be unvulcanized. Many silicone product manufacturers encounter issues such as product shrinkage or unvulcanized phenomena due to problems with vulcanization – either too much or too little, expired vulcanization time, among other reasons.
2. Ingredient Measurement
Measure the required amounts of organic silicone base and catalyst according to the recommended mixing ratio provided by the organic silicone manufacturer.
3. Component Combination
Pour the measured components into a clean mixing container. Pour the base component first and then add the catalyst. Following this order ensures a uniform mixing process and reduces the risk of incomplete mixing.
4. Start Mixing
Thoroughly mix the organic silicone components using a mixing spatula or stick. Scrape the sides and bottom of the container while mixing to ensure all materials are well blended. Continue mixing until all components are thoroughly mixed and a uniform mixture is obtained. Mixing time may vary depending on the organic silicone formula but is generally 1 to 5 minutes.
5. Check Consistency
During mixing, observe the texture and consistency of the silicone mixture. Ensure uniformity throughout the entire mixture, removing any lumps.
6. Additives or Pigments
If your organic silicone formula requires additives or pigments, add them at this stage. Follow recommended guidelines for the quantity and timing of additive additions. Thoroughly mix to ensure an even distribution.
7. Degassing
If necessary, degas the organic silicone mixture to remove bubbles or residual gas. Place the mixed silicone in a vacuum chamber and maintain a vacuum for the specified time. This helps improve the quality and performance of the final organic silicone product. Note that not all organic silicone formulas require degassing.
8. Cutting
Before the refining process is complete, cut the silicone material to the desired thickness and dimensions. This ensures efficient use of raw materials and prevents material waste and shortages during the shaping process.
Troubleshooting Common Issues
Some common problems may disrupt the mixing of silicone rubber. Uneven dispersion of additives, visible stripes, or color changes in materials may indicate potential issues. Inconsistent material characteristics, such as different hardness or elongation rates, can compromise the material’s applicability to the intended use. A thorough analysis and adjustment of mixing parameters such as speed and time can mitigate these concerns.
Incomplete Mixing: A frequent issue in silicone rubber refining is the uneven dispersion of additives. This can lead to deviations in material characteristics from specifications and hinder achieving the expected results. Various factors, from improper mixing techniques to insufficient tool design, can contribute to this problem. In-depth analysis and fine-tuning parameters like speed and time can alleviate this concern.
Inconsistent Color: Variations in material color between different batches may indicate underlying issues. Minor changes in the dispersion of pigment particles or differences in mixing parameters can result in noticeable color differences. The solution involves meticulous tracking of pigment incorporation, consistent temperature control, and regular cleaning of mixing tools to prevent cross-contamination.
Quality Control Measures: Quality control is the cornerstone of ensuring uniformity and reliability in silicone rubber mixing. Real-time monitoring of parameters such as temperature and mixing speed allows for immediate adjustments in case of deviations. Regular sample testing throughout the mixing process helps identify any anomalies in material characteristics, enabling timely corrections. Additionally, post-mixing tests, including tensile strength and elongation rate assessments, validate whether the material meets specified standards.
Conclusion
The silicone refining process follows this basic procedure, but seemingly simple steps involve various technical challenges. Therefore, a comprehensive understanding is necessary to grasp how silicone rubber products are processed.