When it comes to producing rubber components with unique shapes, platen-based molding processes are a top choice due to their ability to deliver high-quality results at an economical cost per unit. This method works by applying heated steel platens to rubber material, ensuring even distribution and precise shaping. However, one common challenge with this technique is that rubber tends to adhere to the steel surfaces, which can disrupt production efficiency. Here's how a Magnaplate surface treatment resolved a sticking issue for a customer specializing in rubber part manufacturing.
This particular company needed an anti-adhesive coating for their steel press platens, which are used to bond two sheets of uncured rubber to steel cables forming the core of conveyor belts. Operating at room temperature under 560 psi pressure, these platens measure 84 by 39 inches. The rubber types involved are comparable to those used in tires, including formulations with significant amounts of natural rubber.
Every time the press was opened, it was akin to an explosion, as described by our client. The rubber would cling stubbornly to the platens, making separation a laborious task. As a result, the customer had to polish the platens after nearly every second workpiece to eliminate the accumulated rubber residue.
To tackle the adhesion problem, we applied a Plasmadize® surface treatment. Plasmadize thermal spray composites are tailored blends of metals, ceramics, polymers, and dry lubricants designed to meet specific application requirements such as non-stick functionality, wear resistance, and chemical protection. These coatings excel in resisting acids, alkalis, chlorides, organic solvents, sulfites, thiosulfates, and chemicals used in pulp bleaching. They are particularly advantageous for large surfaces like steel press platens due to their cost-effectiveness. Key attributes of Plasmadize include:
- A broad operational temperature range from -200°F to +1,300°F (-129°C to +704°C).
- Thicknesses ranging from 0.002 to 0.010 inches.
- Hardness levels exceeding the Rc scale.
Following the application of Plasmadize on the steel platens, the customer no longer faced explosions or struggled with press operations. Staff members were delighted to witness the first "cycle" where the rubber cleanly released without any sound or effort.
Magnaplate surface treatments have consistently demonstrated effectiveness in resolving sticking issues across various industries. If adhesion is affecting your equipment's performance and reliability, our team of engineers can assist in choosing the right coating—such as Plasmadize—to enhance the non-stick characteristics of essential surfaces, ensuring even the stickiest materials release effortlessly.
For further details about Plasmadize, feel free to explore our product page.
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