When you're tasked with producing a rubber component in an unconventional shape, platen-based molding processes offer both high quality and cost efficiency. This method works by applying heated steel platens to the rubber material, ensuring it spreads uniformly into the desired form. Despite its numerous benefits, this process can sometimes encounter challenges, such as rubber adhering to the steel surfaces, which can hinder productivity.
One of our customers specializing in rubber part manufacturing faced just such an issue. They needed a solution to prevent rubber from sticking to their steel press platens, which they used to bond two sheets of uncured rubber to steel cables forming the core of conveyor belts. The press operates at room temperature with pressures up to 560 psi, and the platens measure 84 by 39 inches. The rubber compounds they worked with were comparable to those used in tires, some containing significant amounts of natural rubber.
Every time the press was opened, it was akin to an explosion, with the rubber clinging stubbornly to the platens. This made separating them a cumbersome task, requiring the platens to be buffed after processing as few as two workpieces to eliminate the built-up residue.
To resolve these sticking problems, we applied one of our advanced surface treatments known as Plasmadize®. Plasmadize thermal spray composites are tailored with a mix of metals, ceramics, polymers, and dry lubricants to meet specific application requirements, including non-stick and release properties, wear and friction reduction, and chemical resistance. Plasmadize coatings excel in resisting acids, alkalis, chlorides, organic solvents, sulfites, thiosulfates, and chemicals used in pulp bleaching. These coatings are particularly advantageous for large surfaces or components like steel press platens due to their cost-effectiveness.
Additional features of Plasmadize include:
- A broad operating temperature range from -200°F to +1,300°F (-129°C to +704°C)
- Thicknesses ranging from 0.002 to 0.010 inches
- Hardness exceeding the Rc scale
Following the application of Plasmadize on the steel platens, the customer noticed a dramatic improvement. No longer did they experience the explosive-like scenarios or wrestle with the press. In fact, watching the first "shot" release effortlessly without any noise brought immense satisfaction to the team.
At Magnaplate, we have successfully implemented surface treatments across various industries to combat sticking issues. If your equipment's reliability and uptime are threatened by adhesion problems, our engineering experts can recommend an appropriate coating, such as Plasmadize, to enhance the non-stick characteristics of critical surfaces, ensuring even the most tenacious materials release smoothly.
For further details on Plasmadize, please visit our [product page](#).
This case highlights how innovative surface treatments can transform operational efficiency and solve longstanding industrial challenges.
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