Rubber products are some of the most commonly used all over the world. Rubber manufacturing is many respects similar to the manufacture of plastics. However the two industries are distinctly separate. The raw material that is used to make the final product may be obtained naturally or through a synthetic process. Natural type is grown agriculturally while the main source of the synthetic type is the petrochemical industry.
Processing of rubber into finished products is done at fabricator plants. A number of processes take place in the fabricators including shaping, mixing, compounding and vulcanizing. Although the products that are produced are highly varied, the industry has been largely dominated by tires. Tires are greatly demanded due the large number of automobiles. Other industries in which they are widely used are the aviation and the manufacturing industries.
To produce natural rubber, the starting product known as latex has to be obtained from trees. The trees exist in plantations in some parts of Southeast Asia, West Africa and various other places. Latex is a colloid dispersion solid particles of a polymer known as polyisoprene in water. There is about 30% of the final product in this initial emulsion. Tapping of the latex is done in large tanks so as to get a blend from several trees.
Obtaining rubber from the latex involves several stages the first of which is coagulation. In coagulation, an acid is added to the emulsion and the two left to mix for 12 hours. The coagulum formed is then passed through a series of solid rollers to squeeze out any remaining water. The final thickness measures about 3 millimeters. The next stage is drying the product in a smoke house. This may take several days.
As drying takes place, the product turns to dark brown. The product is at this stage known as ribbed smoked sheet. It is folded into several bales and packed for transport to various processing sites. At times, drying is done by using air rather than smoke. The product in this case, which is graded highly, is referred to as dried sheet. The other technique used in improving quality is to use two stages of coagulation rather than one.
Synthetic rubber is produced by polymerization. The process that are used to form the polymers follow the same principles as those that are used to form any other polymers. The main difference here is that rather than having pellets and liquid resins, the polymers are produced as large bales. These are taken to the next stage in the process known as compounding. In compound other additives are added to the initial product to enhance certain properties.
Carbon black is one of the most important reinforcing fillers. This carbon is produced when hydrocarbons are decomposed by heat. The carbon helps to increase tensile strength and to reduce tearing of the final product. Due to its dark color, the carbon also protects the product from damage by ultraviolet rays.
Other additives that are commonly used to enhance certain properties include antioxidants, styrene, phenolics and china clay. It is important to do through mixing so as to enhance dispersion of all the ingredients used. Shaping and filament reinforcement are then done before the final product is ready for use. Filament reinforcement helps in the reduction of extensibility but all the other properties are maintained.
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