Moulded Rubber

Moulding
The molding of rubber and elastomeric compounds is accomplished by forcing the material into a shape using heat and pressure. Rubber and elastomers can be molded by compression, transfer and injection methods. The volume of parts and type of compound required will determine the molding method used.

IRC has four types of moulding facilities:

1. Transfer Molding
Like compression moulding is a process where the amount of molding material is measured and inserted before the molding takes place. The molding material is preheated and loaded into a chamber known as the pot. A plunger is then used to force the material from the pot through channels known as a sprue and runner system into the mold cavities. The mold remains closed as the material is inserted and is opened to release the part from the sprue and runner. The mold walls are heated to a temperature according to the cpmpound used which allows a faster flow of material through the cavities.
This process involves creating a joint between two lengths of a profile by molding uncured compound directly onto the lengths to create a molded joint. The two ends of the profile are placed such that they fill the straight section of the mold. The uncured compound is transferred from pot to the angled space in the cavity by plunger. The heat and pressure from the mold soften the compound allowing it to flow through the cavity. The part is left in the mold for a specified curing period. When the part is removed and cooled, the result is a permanent and precise joint.
2. Compression Molding
A method of moulding in which the measured qty of uncured rubber compound is directly placed in an open, heated mould cavity. The mold is closed with a top force or plug member, pressure is applied to force the material into contact with all mold areas, while heat and pressure are maintained until the molding material has cured.
3. Injection Moulding
Injection molding is a manufacturing process for producing typical items and bulk orders. In this process uncured rubber strip is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the mold cavity.
4. Hot Film Splicing
What makes film-splicing such a unique and dynamic process is that it eliminates the need for applying adhesive and requires no secondary trimming of flash (net molding). No inserts are required for splicing bulb seals, and therefore cycle times are faster versus traditional molding. Typically, an insert is placed inside the profile to be vulcanized. Once the part has been vulcanized, an incision is made to remove the mold, which must be resealed. This process can become tedious for large volumes, resulting in higher costs. Since film-splicing requires no insert, the first splice is the last splice! Having a one-step process increases productivity and eliminates the possibility for error. The result is an automotive-quality gasket. The film-splicing machine also has a unique cooling ability that allows us to splice taped profiles without compromising the adhesive ability of the tape.
Spliced joints
Splicing of extruded rubber sections show very nice results. The actual joining of the sections is made possible by a special rubber based substance during vulcanization. This method allows for joints that share the properties of the extruded sections and that are barely visible. Special moulding tools are required.
Hot Splicing
The glue used in hot splicing is rubber-based and has to be cured, or vulcanized, in place. This creates a splice that has reasonable strength, retains a lot of the properties of the seal itself and is not nearly as noticeable. The process may take longer than cold splicing depending on the cross section. This process requires some tooling costs for the curing process; therefore, it is also a little more expensive.

Moulded Products

IRC Moulded Rubber Products comprise wide range of Polymer use

IRC Moulded Rubber Products comprise wide range of Polymer use

Vulcanized EPDM Corner Jointed Gaskets and Vulcanized Picture Frame Gaskets

Elastomer EPDM Synthetic Rubber