When you're tasked with creating a rubber component in a unique shape, platen-based molding is often the go-to method due to its ability to deliver high-quality outcomes at an affordable cost per unit. This process involves pressing heated steel platens against rubber material, ensuring the substance spreads evenly to match the desired form. Despite its numerous benefits, one common challenge is that rubber tends to adhere to the steel surfaces, which can disrupt production efficiency. Here's how a Magnaplate surface treatment assisted one of our customers in maintaining smooth operations.
This particular company needed an anti-stick coating for their steel press platens, which are used to bond two sheets of uncured rubber material to a set of steel cables forming the core of a conveyor belt. The press operates at room temperature under 560 psi, with each platen measuring 84 by 39 inches. The rubber materials involved are comparable to those used in tires, including a variety that contains a significant amount of natural rubber.
Our customer described the situation as resembling an "explosion" whenever the press was opened, as the rubber consistently stuck to the platens. This necessitated frequent maintenance, requiring the platens to be buffed after processing every two workpieces to eliminate the accumulated rubber residue.
To resolve these adhesion issues, we applied one of our Plasmadize® surface treatments. Plasmadize thermal spray composites are tailored with combinations of metals, ceramics, polymers, and dry lubricants to meet specific application requirements such as non-stick and release capabilities, wear or friction reduction, and chemical resistance. Notably, Plasmadize coatings can withstand exposure to acids, alkalis, chlorides, most organic solvents, sulfites, thiosulfates, and chemicals used in pulp bleaching. These coatings are particularly advantageous and cost-effective for large-scale applications like steel press platens. Additional features and specifications include:
- A broad operational temperature range of -200 to +1,300°F (-129 to +704°C)
- Thicknesses ranging from 0.002 to 0.010 inches
- Hardness levels exceeding the Rc scale
Following the application of the Plasmadize coating on the steel platens, the customer no longer faced the previous sticking issues or had to exert significant effort to separate the components. The team was delighted to witness the first "shot" releasing effortlessly without any accompanying noise.
Magnaplate surface treatments have demonstrated success in resolving adhesion problems across various industries. If sticking is impacting your equipment's performance and reliability, our engineering team can assist in selecting an appropriate coating—such as Plasmadize—to enhance the non-stick qualities of essential surfaces, ensuring even the most stubborn materials release smoothly.
For additional details about Plasmadize, feel free to explore our product page.
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