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READ MOREIn the production process of household appliance rubber accessories, the precise design of the formula is crucial, which is directly related to the final performance of the product, including wear resistance, high temperature resistance, aging resistance, elasticity and shape stability. As a company with a strong R&D team and advanced testing equipment, we are well aware of the importance of determining the dosage of various compounding agents (such as vulcanizers, accelerators, fillers, etc.) in the formula. This is not only a science, but also a combination of art and experience.
In the formulation design stage, the basic principle we follow is ""performance first, reasonable cost, and environmental protection standards"". This means that we must first ensure that rubber accessories can meet the stringent requirements of household appliance products, such as wear resistance, high temperature resistance, aging resistance, etc.; secondly, under the premise of ensuring performance, try to optimize costs and improve market competitiveness; finally, the selection and dosage of all raw materials must meet environmental protection standards to ensure the green and sustainable production process.
Selection and dosage of compounding agents
1. Vulcanizing agent
Vulcanizing agent is a key ingredient in rubber formula, which determines the degree of cross-linking of rubber and directly affects the strength, hardness and heat resistance of the product. We use highly efficient and low-toxic vulcanizing agents such as peroxides and sulfur, and determine the optimal dosage through precise experiments. This process involves a large number of laboratory tests, including vulcanization curve analysis, to determine the optimal vulcanization time and temperature, as well as the dosage of vulcanizing agent. Our chemical analysis laboratory is equipped with advanced vulcanizers that can monitor various parameters in the vulcanization process in real time to ensure the accuracy and stability of the formula.
2. Accelerator
Accelerators are used to accelerate the vulcanization reaction, shorten the vulcanization cycle, and improve production efficiency. Different types of accelerators have different effects on the vulcanization rate and cross-linking structure. We select the most suitable accelerator combination according to the type of rubber substrate and the target performance, and accurately adjust its dosage through small-scale and pilot-scale amplification steps. Using the most advanced testing equipment in the industry, such as infrared spectrometers and electron microscopes, we can deeply analyze the structural changes of rubber molecules to ensure that the amount of accelerator can meet production needs without causing problems of over-vulcanization or under-vulcanization.
3. Fillers
Fillers can not only reduce production costs, but also improve the physical properties of rubber, such as hardness, wear resistance and thermal stability. We select inorganic or organic fillers with high dispersibility and low oil absorption, such as calcium carbonate, diatomaceous earth, carbon black, etc., and evenly disperse them in the rubber matrix through advanced mixing technology. The amount of filler must be strictly calculated and optimized to ensure sufficient filling amount to improve performance, while avoiding excessive filling amount that causes processing difficulties or performance degradation. Our R&D team uses computer simulation technology to predict material properties under different filling amounts, combined with experimental verification to ensure the scientific nature of the formula design.
After preliminarily determining the amount of each compounding agent, we conduct multiple rounds of formula optimization experiments. By changing the amount of a single or multiple compounding agents, observe their specific effects on rubber properties, such as hardness changes, tensile strength, tear strength, thermal aging properties, etc. Our laboratory is equipped with comprehensive physical performance testing equipment, such as universal material testing machines, thermal aging chambers, etc., which can comprehensively evaluate the various performance indicators of rubber accessories.
We also focus on the verification of practical applications. The optimized formula is made into samples and simulated tests of home appliance products are carried out, such as durability test, temperature resistance test, waterproof test, etc. of switch buttons, to ensure that the products can meet the strict requirements of customers in actual use. Our annual production capacity reaches 200 million pieces, which can quickly respond to customer needs and conduct final verification before large-scale production to ensure that the formula is stable and reliable.
In the process of formula design and compounding agent selection, we always put environmental protection and sustainable development first. Non-toxic, recyclable or biodegradable raw materials are preferred to reduce the impact on the environment. At the same time, we continue to optimize the production process, reduce energy consumption and waste emissions, and strive to achieve green production.
The determination of the amount of compounding agents in the formula of home appliance rubber parts is a complex and delicate process, which relies on scientific experimental design, advanced testing technology and rich practical experience. As a company with a strong R&D team and advanced testing equipment, we rely on our deep technical accumulation and innovative spirit to continuously break through technical barriers and provide customers with high-performance, environmentally friendly and reliable home appliance rubber accessories solutions.