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感悟LIU · 发表于 2009-3-22 16:06:51

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第一单元橡胶材质简介
一、橡胶基本知识
（一）、橡胶有关简介
橡胶工业在国民经济中占有极其重要的地位。首先，从材料学的观点来说，材料大致可以分为二类：一类是结构材料：主要使用它的强度、弹性等力学性能。
二类是功能材料：主要使用它的声、光、电磁、热等功能。
由于橡胶具有独特的高弹性能，优异的疲劳性能，极好的电绝缘性能和耐磨性等。被广泛用于制造轮胎、减震制品、密封制品、化工防腐材料和电缆绝缘材料。此外，它又可制成声学橡胶、磁性运输带、特种电热片等，因此，无论在国防工业、交通运输、机械制造方面，还是在农业、医学卫生、日常生活方面，橡胶都有着极其广泛的用途。
据统计：一架飞机需橡胶零件2000多件，耗胶560公斤。
      一辆四吨解放牌载重汽车需用橡胶制品178件，耗胶183公斤。
      一台轧钢机需用橡胶1800公斤。
      一艘万吨轮船则耗胶1万多公斤。
（二）、橡胶制品的分类
1.轮胎2.胶带（运输胶带、传动胶带）3.胶管 4.胶鞋 5.橡胶工业制品
（三）、橡胶制品生产的基本工艺过程
橡胶制品生产的基本工艺包括塑炼、混炼、压炼、压出、成型、硫化六个基本工序。
1．塑炼：使生胶弹性减小，可塑性提高。
2．混炼：为了提高橡胶的物理性能、机械性能，使加工中用的硫化剂、促进剂、补强剂、填充剂、活性剂、防老剂、软化剂、着色剂等各类化学剂均匀得分散于胶料中。
3．压延、压出、成型：即将混炼胶通过专门的设备制成各种未各种未硫化的橡胶半成品。
4．硫化：指在一定温度、压力下，经过一定的时间，使橡胶与硫化剂发生化学反应，从而制出弹性能好、强度高的橡胶制品。
5．塑炼    混炼    压出抽出存放成型    毛边品修    二烤    品检包装

（四）、橡胶的种类
                                 丁苯橡胶SBR
异戊橡胶 IR    顺丁橡胶    BR
氯丁橡胶 CR    氢化丁腈橡胶  HNBR
通用合成橡胶    乙丙橡胶 EP
丁基橡胶 IIR
                              丁腈橡胶 NBR
橡胶
                                 氟橡胶 VT 、FKM 氟硅橡胶  FSIL  硅橡胶 SIL
聚硫橡胶 T
特种合成橡胶    氯醇橡胶       丙稀酸酯橡胶ACM
聚氨酯橡胶       聚乙烯橡胶Hypalon


五）、橡胶的定义
橡胶是唯一具有高度伸缩性与极好弹性的高分子聚合物。
橡胶的独特加工工艺就是通过“硫化”将线型分子链交联成三维网状结构之高分子量聚合物。
橡胶在室温下也就是自然温度下有较好的弹性，在50度到100度之间即开始软化，产生很大的塑性变形，这时易于将配合剂混入，制成混炼胶。
这种混炼胶在高温状态下，经过一段时间（2—4min）橡胶分子之间即发生化学结合（交联），从而完成丧失塑性产生弹性成为有价值的橡胶制品。
橡胶的主要性能包括：
耐磨、耐热、耐寒、耐油、耐化学药品、耐弯曲变形、抗拉伸、抗压缩变形、耐侯、耐水、电绝缘性、气密性等。
（六）、橡胶类型及主要特性
表1-2-2生胶结构分类、特性用途及硫化交联方法
分类橡胶名称主要特性基本用途主要硫化交联方法
二
烯
系统异戊二烯类
(甲基丁二烯) 天然橡胶（NR）具有典型的橡胶弹性，并有良好的耐磨性等机械性能轮胎、胶鞋、胶管、胶带、空气弹簧等硫磺
异戊橡胶（IR）具有天然橡胶相近似的性能，质量稳定，纯净用于代替NR或并用，胶鞋、胶丝、食品卫生及医疗制品硫磺
丁二烯类丁二烯橡胶（BR）弹性、耐磨性及耐寒性比NR好轮胎胎面及胎侧等，多为并用。鞋、减震品、磨采胶辊、胶带、胶管及工业制品，塑料改性硫磺
丁笨橡胶（SBR）耐磨及耐老化性能优于NR 轿车、轻卡车轮胎等、胶鞋、胶布、文体用品、胶板、蓄电池壳、胶带等硫磺
丁腈橡胶（NBR）耐油性、耐磨性、耐老化好油封、衬垫、耐油胶管、输送带、印刷胶辊、纺织皮辊等耐油工业制品硫磺
有机物硫化
氯丁二烯类氯丁橡胶（CR）耐候性、耐臭氧性、耐热性及耐化学药品性均好轮胎内衬层、电线、电缆、输送带、减震橡胶、窗户密封条、胶粘剂、胶布、涂料金属氧化物
硫磺
烯烃系统异丁烯类丁基橡胶（IIR）耐候性、耐臭氧性、耐气透性好，并可耐极性溶剂轮胎内胎、内衬层、硫化胶囊层面防水卷材，电线电缆、蒸汽胶管、耐热输送带、药品瓶塞、密封剂等硫磺
醌肪
树脂
乙烯、丙烯类乙丙橡胶（EPM、EPDM）耐老化耐臭氧性、耐极性液体、耐电性能好轮胎胎侧，多为并用。电线电缆、汽车玻璃除水条、窗户密封条、蒸汽胶管、输送带、塑料改性等过氧化物（EPM）
硫磺（EPDM ）
聚乙烯氯磺化类氯磺化聚乙烯（CSM）耐老化性、耐臭氧性、耐候性、耐化学药品及耐磨性好防老化涂层，耐候性耐腐蚀性涂料、衬里、室外胶布，耐腐蚀性密封条，耐热耐腐蚀性胶辊等金属氧化物

乙烯-乙酸乙烯类乙烯醋酸乙烯橡胶（EVA）耐热老化性、耐候性、耐臭氧耐水蒸汽性好胶鞋、压感胶粘剂、弹性塑料成型材金属氧化物
多硫化物类聚硫橡胶（T）有高度耐油性，耐臭氧性、耐电性亦好要求高度耐油的胶管、密封件、胶辊密封剂、涂层、胶粘剂、型材等金属氧化物
氨基甲酸酯类聚氨酯橡胶（U）
聚酯型（AU）
矛醚型（EU）刚性大，机械强度特别好工业胶辊、高温密封件，联轴器及耐要高强度的工业制品，实心胎等异氰酸酯
过氧化物
硫磺
丙烯酸酯类丙烯酯橡胶（ACM、ANM）高温状态下耐油性好，并耐老化汽车上用的密封件，主要是油封、皮碗、O型圈等胺类
有机硅化合物硅橡胶（Q）有高度耐热性及耐寒性，并且也有一定耐油性皮碗、衬垫、油封、工业胶辊、减震橡胶等耐热耐寒方面用工业制品，电绝缘及医疗用品，人体制品，密封剂及热熔胶、保鲜袋等过氧化物
含氟化合物类氟橡胶（F）具有最好的耐热性、耐油性及耐化学药品性导弹、飞机、汽车等用密封件，化工厂耐腐蚀皮碗、衬垫、薄膜，油箱衬层、胶管及泵用零件等双酚
胺类
过氧化物
备注：公司目前使用的橡胶有：NBR 丁腈橡胶；EPDM 乙丙橡胶；CR 氯丁橡胶；SBR 丁苯橡胶；NR 天然橡胶；IIR 丁基橡胶；AR 丙烯酸脂橡胶 AR（ACM、AEM）；FKM、FPM、VT氟橡胶；SILICONE 硅橡胶；XNBR 羧化丁腈橡胶；  HNBR 氢化丁腈橡胶；SIL 氟硅橡胶
（七）、橡胶密封件制品概述
橡胶密封件制品一般用于防止流体介质从机械或仪表中泄漏出来，也防止外界灰尘、泥沙以及空气（对真空系统而言）进入密封机构内部，其主要特点是量大面广。除工业部门外，家用电器，如家用冰箱、洗衣机和电视机等，也大量使用橡胶密封件制品。橡胶密封件的使用条件复杂，要承受各种工作条件下的高温、高压和各种密封介质的侵蚀，并要求有良好的耐侯性、耐磨性、及高弹性、减震性及密封的稳定性等。
分类如下
      静态密封用--- O型圈、垫圈、门窗密封胶条、防尘罩、垫片等。
橡
胶                      往复运动用：O型圈、各种断面密封圈、胶碗、胶圈、隔膜等
密
封       动态密封用--- 旋转运动用：油封、气封、O型圈等
制
品                      螺旋运动用：O型圈、各种断面密封圈、密封垫圈等

      高真空用  --- O型圈、隔膜、垫圈、垫片等。
（八）、公司产品类型
O-ring (O型环)、背托环（Back-up ring）、油封、垫圈（Packing）、橡胶件客户定制品、橡胶夹铁件客户定制品、塑料件客户定制品。

第二单元  材质专业名词
一、一般橡胶配方的成分大略分为：
1. 弹性体（Elastomer ）：习惯上称生橡胶、生胶。此为橡胶配合料中的主成分，是主体材料，决定橡胶的使用性能、工艺性能和产品成本、寿命的主要因素。如：N1052 、E535（油漆胶）、WRT 、SBR1500、 NR3#  ……
2．填充剂(Filler)：包括补强填充剂与非补强填充剂。可补强OR 改变橡胶制品的物理性质，降低成本。如： N550、N774、N990、CLAY ……
3．软化剂(Softener/Plasticizer)：通常软化剂为物理增塑剂。（增塑剂包括物理增塑剂—软化剂、化学增塑剂、塑解剂），有助于混合，改善加工性，增加弹性，产生吸粘力（如：DOP、DOA、DOS、P600）。
4．硫化剂(Curatives/Vulcanizing agents)：此为硫化过程所需之原料，能使橡胶混合料发生化学的交联反应，使橡胶成为网状结构，表现其因有特性，达到和满足使用要求（SUL、ZNO、DCP）。
5．加工助剂(Processing Aids)：有助于混合时OR成型之加工性，如脱模难易，流动性等，（如：WB-212、WB-42•••）。
6．促进剂(Accelerators)：有助于提高硫化剂对胶料交联（硫化）速度以及交联程度藉以改变硫化橡胶的物理性能（如：TT、C2•••）
7．促进剂活化剂(Activators)：用于激活促进剂使其作用更为有效，以增加硫化速率（如：ZNO、MGO硬脂酸•••）。
8.老化防止剂(Antioxidants / antiozonants)：具有迟缓橡胶变坏的功能（如RD、3C …）
9．其它：着色剂 (色粉Colors/ Pigments)：如土朱、元蓝…
发泡剂(vesicant)，延迟剂(Retarders)（PVI），防霉剂(…
二、工艺专用名词
1. 塑炼（plasticization）：目的是降低生胶的弹性增加其塑性，并获得适当的流动性，以满足混炼、压延、压出、成型和硫化等各工艺加工过程的要求，便于成型加工。
塑炼促进剂又叫塑解剂（peptizing agent）：塑炼加入塑解剂可节约电力、动力。
2. 混炼（mixing）：将各种配合剂混入生胶，制成质量均匀的混炼胶的过程。
3. 压延(calendaring)：通过压延和旋转辊筒对胶料的作用制成具有一定断面形状的胶片，或实现在织物上覆盖胶层的工艺过程。
  4. 压出（挤出）(extrusion)：通过螺杆的旋转，使胶料不断向前推进，并借助于口型，可压出各种所需要形状的半成品。
压出： temperature：
℃ 机筒机头口型其它
NR 50-60 80-85 90-95
SBR 50-70 70-80 100-105
CR 50-60 60-70 80-90
NBR 50-60 70-80 70-95 螺杆50-60
IIR 80 80-85 90-120 30-40
EPDM 60-70 80-130 90-140
5、粘着（adhesion）
6、成型（prototype）
7、硫化（press cure/ Post cure）
三、各橡胶之商品名或通用名
1.  phr：Parts per hundred of rubber 以百份橡胶中所含份数计。
2.  NR ：Natural rubber 天然橡胶
SBR : Styrene – Butadiene Rubber 苯乙烯丁二烯橡胶（丁苯橡胶）
NBR : Nitrile / Bune  N /Butadiene – acrylonitrile Rubber 丙烯腈丁二烯橡胶（丁腈橡胶，耐油胶）
CR: Chloroprene Rubber /Neoprene 氯丁二烯橡胶，氯丁橡胶
EP : Ethylene Propylene Rubber 乙烯丙烯二元乙丙橡胶
EPDM: Ethylene Propylene Diene Terpolymer乙烯及丙烯为主而含少量二烯系物的三元聚合体，三元乙丙橡胶
SIL: Silicone Elastomers / MQ 硅氧橡胶/硅胶硅利光橡胶
FKM: Fluorocarbon Rubber ,Fluoro-elastomer  氟碳橡胶/ VT victon
FSIL: Fluorinated Silicone氟化硅利光橡胶，氟硅橡胶
ECO: Epichlorohydrin Rubber 环氧氯丙烷橡胶/氯醚橡胶
ACM: Polyzcrylic Rubber /ACRYL 聚丙烯酸酯橡胶
CSM: Chloro-Sulphonyl  Polyethylene /Hypalon 氯磺化聚乙烯
IIR: Butyl Rubber 丁基橡胶
T: Polysulfide Polymers 聚硫橡胶
IR: Polyisoprene Rubber 聚异戊二烯橡胶
HNBR: Hydrogenated Nitrile Rubber, Saturated Nitrile rubber, Saturated NBR 氢化丁腈橡胶
XNBR: Carboxylated acrylonitrile butadiene rubber; Carboxylated nitrile rubber羧基（化）丁腈橡胶
四、常用橡胶性能专业术语
1. PHYSICAL  PROPERTY 物理性能
2. SPECIFICATION & CALL-OUT 材料规范
3. Specific Gravity 比重
4. Tensile strength 拉伸强度
5. Elongation    伸长率
6. Compression Set  压缩永久变形
7. Heat Aged       老化
8. Ozone Resistance 耐臭氧
9. Water Resistance 耐水
10.    Fluid Resistance 耐试剂
11.    Low-temperature nonbrittle 低温脆点
第三单元混炼胶料有效存放与合理使用
标题原材料存放期限管理规范编号 MW-0003 页数 1/2
制定部门材技课制定日期 97年11月03日版本 A7
1、目的：订定公司内各种原材料、半成品及辅助材料存放期限标准，确保产品品质。
2、范围：适用于各种原材料、半成品、成品及辅助材料管制。
3、作业内容：
3.1  原物料存放场所标准情况规定：各原物料应存放在常温、通风、干燥、清洁的仓库中，且应避免包装破损及杂物混入。特殊原物料的储存还需视物料本身性质或产品说明书要求来保存。
3.2  原材料、成品及辅助材料保证期限规定如下：
品名内容保存期限
成品各种O-RING、油封产品（指油压成型后产品） 36月
原材料生胶、炭黑、软化油、药品等所有原材料 12月
辅助材料包装薄膜、打包带、标签、透明胶带等 12月
辅助材料纸箱 6月
3.3  黑烟胶存放规定如下：
品名内容保存期限
黑烟胶 NBR（丁晴橡胶）、EP（乙丙橡胶）、SBR（丁苯橡胶）、IIR（丁基橡胶） 24月
CR（氯丁橡胶）、AR（聚丙烯酸酯橡胶）、NR（天然橡胶） 3月

3.4  加促片胶存放期限规定如下：
材质生产配方保存期限
SIL SIL胶 1年
NBR NBR60（含）-NBR70（如：N6005、N6008、N6014、N6501A、N6503B等）
NBR70（含）-NBR80（如：N7001C、N7005、N7006A、N7003C、N7200、N7301、N7507等）；NBR80（含）-NBR90（如：N8004、N8006、N8016等）；NBR90（含）以上（如：N9004、N9005、N9016等） 30天
VT及其他 V7001、V7001Q、V7008等所有VT配方及所有的过氧化物
SBR及其它如：G4001、G5001、G6001、G7505、G8003、IIR胶
NBR NBR60以下（如N4001A、N5011、N5014、N5501、N5016等） 21天
NBR 特殊N6006A-1、N7035B、N7506 14天
EP EP60（含）以上配方（如E6001A、E6005、E7001、E7007、E7501、E8003等）
EP；CR；AR；NR EP60以下（如E4004、E5011、E5501、E5010A等）；所有CR配方（如C5009C、C6014、C6015、C7004等）；所有AR配方（如A7002、A8005、A5001等）
所有NR配方（如R4004、R6016等） 7天
XNBR 如XN9001、XN7001 4天
3.5 所有回头料及重翻胶料有限期限为3.4规定期限的2/3。
3.6 原物料保管部门应按上述规定进行定期查核，对逾期原物料应以联络单方式提出，经品保部门重新检验、材技物性测试合格，再由工程部经理签核后重新确定其新的有效期限方可使用，一般重新测试合格之原料有效期限为原有效期限1/5。
3.7 对过期黑烟胶和片胶,小样抽验合格,物性测试合格,现场能正常生产,由工程部经理签核后三天内使用完。
3.8 以上若检验不合格则按不合格品进行作业。
二、有关以上ＳＯＰ详解
（一）、原理
１、混炼完的橡胶为防止橡胶粘着，在表面散布滑石粉，或将橡胶浸入有滑石粉分散的水槽中冷却，捞上后，橡胶干燥，滑石粉附着表面，防止橡胶相粘。我们公司是让胶料通过防粘剂的水溶液，后经过凉料机（用风扇吹）进行冷却。经出片（或造粒）的胶料，其下片温度仍达80-90℃。橡胶是热的不良导体，在这样的温度下存放，导致焦烧，因此必须经过强制冷却。
２、冷却后的橡胶必须经过停放熟成，以便达到以下目的：
（１）、使胶料恢复疲劳，松弛混炼时所受的机械应力；
（２）、减少胶料收缩；
（３）、使配合剂在停放过程中继续扩散，以促进均匀分散；
（４）、使橡胶与碳黑之间进一步生成结合橡胶，提高补强效果。
３、胶料停放熟成时保管要项
（１）、混炼胶料按照试样要求厚度下片，下片后必须熟成，存放于橡胶仓库，放置在平整、洁净、干燥的金属板上冷却至室温（高效率的管理方法是将炼成的橡胶堆积于台车，以便自由移动），，然后在23+/-2℃条件下，停放22-24小时，并防止吸潮。胶料需要返炼时，应按返炼的辊距、辊温和返炼时间的要求进行。
（２）、存放时混炼胶应妥善管理，否则也可能出现质量问题，如轻度焦烧等。
胶料在储存期间，必须控制温度和缩短储存时间，以避免焦烧。发收胶料，应登记入帐，按照先后次序使用。对容易发生焦烧或库存性能不稳定的胶料要区别对待，不仅要单独存放，经常翻倒，以便及时散发内部余热，而且要尽快使用。对易焦烧的胶料每隔2-3天翻动一次，对一般胶料每隔6-7天翻动一次。对返回的胶料，尤其是边角料，要分开保管，不得与原胶片互混。在计划安排上，应做到准确，减少积压，缩短周期时间。
夏季气温较高，尤其要注意管理。常用降温保管办法有：用隔离剂、冷却水制冷循环；建立地下胶库或空调胶库储存胶料；也可用水幕胶库，即胶库四壁设有喷水管，水喷到麻袋片上，以降温。
总之，储存时应注意如下几点：
ａ、胶库保持通风，胶料不受阳光直接照射，室内温度宜低些，注意夏季降温；
ｂ、胶料堆放不宜过高，并定时翻动，以利散发内部热量；
ｃ、存放时间不宜过长。
（二）、硫化曲线
1、混炼好的橡胶由于硫化剂、促进剂都已经加入。所以在混炼过程中和胶料存放的过程中，胶料有部分自硫化现象。众所周知，橡胶硫化的条件是“温度，时间，压力”。也就是说，在一定的压力和温度下，橡胶需要一定的时间可以硫化完毕。在混炼过程中，压力为空气压力，温度为胶料混炼时摩擦生热，时间为混炼时间。如果温度超过一定极限（我们的SOP规定），或混炼时间超过，都会导致橡胶在捏合机里或滚轮上直接加硫完毕而焦烧老化。
2、存放时的原理与打料过程是一样的。在存放时，在空气的压力下和存放温度下，如果时间足够长，胶料一样发生自硫，导致焦烧死料。
3、硫化曲线中体现的TS2就是焦烧时间（见硫化曲线）。所谓的焦烧时间就是橡胶从固态变为粘流态，在模具中流动的时间。为什么高硬度的橡胶流动性为什么差呢？这就因为高硬度的胶料填充量大，在混炼时，摩擦剧烈，生热高，橡胶部分硫化，焦烧时间变短，门尼粘度高。在模具中的流动时间也九短，故高硬度的胶料一定要低温长秒生产。以保证橡胶变成粘流态时能充满整个模具。并且硬度高的配方由于不能填充较多软化油，导致混炼胶的ML很高，流动性差。而低硬度的配方，为了达到其硬度要求，所以必须填充很多的软化油，软化油是降低ML的最有效的橡胶成分。同时它也会迟缓硫化。所以低硬度的硫化时间比较长，而且流动性有时会太好。
流动性和焦烧时间与加硫状况的关系。
(1)、对于低硬度，流动性越好，合模时，气体越难排出，导致产品越容易产生气泡。所以低硬度的胶料最好熟成几天后生产，对于硫化检验，必须控制ML的下限。打料时升温较慢，需要足够的时间到足够的温度，这样的胶料ML才不会太低，TS2才不会太长。对于配方需要选择高ML的生胶作为主胶，才能解决气泡。对于混料或制造，胶料需要熟成，但不是存放越久越好。因为低硬度填充油很多，存放过久，特别是存放在高温的地方（如制造的机台旁）由于油的挥发，橡胶的自硫，导致硬度上升，过高。
（2）、对于高硬度，其流动性差，焦烧时间短，很难充满整个模具。导致死料、死毛边、缺料。所以高硬度的胶料是存放熟成时间短，一般根据每个配方的经验，至少8小时，但不要超过几天。否则容易死料。
硫化检验需要管控高硬度的ML的上限和TS2的下限。对于高ML，低TS2，容易导致制造生产时死料、死毛边、缺料。而且由于条料生产时，胶料流动的回复应力太大，还有可能导致尺寸变小。对于存放较久的高硬度胶料，处理办法是少量掺到新料（合格料）中或制造用低温长秒生产。此处特别注意，绝对不能在制造课存放高硬度的料和一些容易焦烧的料（如XNBR、AR）。
（3）、橡胶最容易生产的硬度段是60-80（SHORE A/ IRHD）。但是由于存放时间和条件不一样，导致同样配方的橡胶的流动性，焦烧时间和硫化时间都不一样。最终导致生产状况和生产结果不一样。
综上，一般而言，对于同一个配方，存放越久，流动性越差，越容易缺料，越容易死料，毛边越难处理（过熟或死毛边），尺寸越不稳定，一般变小，硬度越高。

（三）、问与答
1、我们有经验，NBR70存放一个多月不会死料。为什么我们规定的胶料存放时间那么短？
答：（1）、我们是定单制的工厂，我们不应该有库存品或库存的半成品。
（2）、作为一家公司，现金流量和库存回转率是很重要的。
（3）、规定有效期限，有助于先进先出的品质管控。
（4）、协助各主管管理。有积压（胶料过期），作为品保或生产部门就知道有异常。可以及时发现处理。
（5）、从橡胶的专业知识来讲，同样的胶料，存放时间不一样，生产状况和生产结果也会不一样。导致一致性很差，出现问题，无法解决，从而浪费成本。
（6）、橡胶加工各个流程都有技术成分。目前我们制造部门主要仍依工程试模或第一次量产时抓出的时间、温度、压力范围来生产。对于存放时间不一样，特别是相差很大的，按照原来规定的条件生产，很难保证可以得到一样合格的产品或者会导致后段加工问题。
（7）、我们的品质要求高，一致性要求高。混炼是最难达到一致性高的工艺。如果再增加混炼后的不一致，势必造成我们的变异性大，一致性低。从而产品失去竞争。
2、那如何判断我们手中使用的胶料的状况？
答：硫变仪也叫硫化仪是目前橡胶业界使用最多的检验设备。通过硫化曲线大体上可以了解胶料的各种状况。因为我们的硫检标准是用混炼现场打该配方的前50手胶料的硫检数值统计制定出的，只要在硫检范围内，制造没有再过度存放或接近热源的情况下，生产没有问题的。
其中：ML----最低扭矩值。表征流动性能。
      MH---最高扭矩值。表征胶料是否可以达到配方设计硬度。
      TS2=ML+2in-1bf：早期焦烧时间
      TC90=（MH-ML）*90%+M L：硫化时间
      所以通过ML，我们可以知道这支料的流动性能，是应该降低温度，还是按上支料的温度。通过TS2，我们可以知道，这支料生产时适宜的温度。通过TC90，我们可以知道我们的加硫够不够。
3、为什么我们目前的硫化曲线没有发挥功能？
答：（1）、没有合理、正确的使用检验仪器。硫变仪属于高精密的仪器。理论上讲，要防尘、防震，要认真保养，调试和定期检修。当然生产该仪器的最清楚要怎样使用该仪器，才能让仪器的作用发挥最大，使用寿命最长。请问，现在操作人员或现场主管知不知道？这就是我们目前最大问题。从仪器设备的接收到使用，很少有全身心投入的。
（2）、我们使用的有转子的硫变仪，对于这种硫变仪，受转子的影响大。转子必须定期清洁，否则影响ML/MH。另外转子的轴与机台间有个密封圈，如果该密封圈失效，胶料或硫检完毕的产物会掉落在转子的轴套中，很大地影响ML/MH的检测结果。
（3）、另外，有转子的硫化检验，其实跟现场成型是一致的。对于硫检完以后，操作人员把转子从机台取出，如果在机台外的时间太久，势必影响下支料的检验的实际温度。因为传感器仍有些滞后，显示之数值不一定是胶料硫检加硫的实际温度。从而导致TS2/TC90/ML/MH的结果没有参考价值。
（4）、我们仪器的使用负荷与精度的影响，是否知道？重复性，再现性？我们硬度计也同样。
（5）、橡胶是热的不良导体，硫检的料的大小和厚度，多少也会影响检验的结果。
从目前来讲，混料的胶料硫化检验标准仍然制定不出来。就算现有的标准，在我们的副总和我们的客人眼里，有检验跟没有检验差不多。有时相当于只管控HD，SG。混料的一致性是较差，但不是硫检检出的那么差。
4、公司下步动作
（1）、减少回头料，绝大部分料都在混料部门已经作成预型物。但要混料能严格执行，一有边料、剩余料，及时掺入下手新料。否则，等所有的边料、剩余料合成一手料，该料对于制造生产变异性较大。
（2）、建立储藏间，用标准室温储藏预型物和胶料。
（3）、购买新的硫变仪，由品保训练合格操作人员，材技课协助，严格管控胶料品质。
5、我们已经知道混炼胶的存放方法，但是产品呢？
答：产品经过一系列的加工制备，需要一个充分的停放时间，以消除制备过程中的应力。硫化后的试样的温度逐渐下降，于是尚有一个剩余硫化过程。试验时标准温度条件下，由于橡胶导热系数大，需要一定时间，使内外温度达到平衡。因此停放处理是一个较为重要的因素。所谓停放处理是指试验之前，将橡胶试样直接暴露在标准温度和一定的相对湿度下，经过一个限定的时间，以改善试验结果的重现性。
（1）、停放
试样的试验，硫化与试验之间的间隔时间最短为16小时，最长是4周。比较试验应在相同的时间间隔内进行。产品试验在可能的情况下，试验与硫化之间的时间间隔不得超过3个月，在其它情况下，试验应在需方从收货日期算起的2个月内进行。
制成试样后，对有湿度要求的试验，试样应在标准温度和标准湿度下停放不少于16小时。只要求在标准温度下进行试验，则试样停放时间不少于30分钟。
橡胶试样停放期间，应尽可能使每个试样的整个表面都暴露出来，避免试样受到各种应力的作用和阳光的直接照射。
（2）、试验室标准条件
标准温度23+/-2℃；标准湿度为：相对湿度60-70％，很多试样只需要在标准温度下进行，则湿度为通常环境的湿度。
三、总结
所有的标准都不是放之四海而皆准的，它只能处理或管控大部分，小部分仍为特殊。因为橡胶的变异性大（富有“弹性”），所受的影响因素很多，所以要保证各个流程的一致性要高。简单说，混炼要保证每支料打的一致性，存放一致性；硫检要保证胶料检验的一致性。成型要保证机台的一致性，而后通过硫化检验在标准内设定符合这支料的生产条件。生产中，要保证人员操作的一致性。
回到主题，胶料存放的几个要素：（1）、保证一致性；（2）、先进先出；（3）、避免热源；（4）、避免阳光；（5）、适宜时间，不短不长，但不随时更改；（6）、因材而异。
            第四单元硫化曲线识别及硫变仪的正确使用

说硫化曲线
1.硫化： curing ，通常用硫化剂及促进剂在一定时间、温度、及压力下达成。
2.过早硫化： scorch，乃配合料制为最后形状准备硫化以前已部分硫化。Scorch会降低胶料之可塑性，防碍加工，其原因为模温太高或胶料储存环境温度太高。
ML= 最小扭矩，与加工性有关，ML越低，流动性佳；反之则流动性差,
MHR=从表现反原曲线获得之最大扭矩
MH=达到之最高扭矩（无恒定或最大扭矩时），与物性有关；在同样的配方下，则代表胶料之Modulus及Hardness越高。
TS2=过早硫化时间，达到H-ML高Z1b.in 所需的时间,可预知焦烧时间(Scorch time ),作为加工安全度的衡量.
TC90=最适硫化时间,达到(MH-ML)之90%所需时间;可以测得最适加硫时间,已防止
under or overcured .
RC =硫化速度,一般来说,加硫温度每增加10℃, 硫化速度增加一倍.

硫变仪的正确使用：
1、有转子硫变仪必须定期清理转子及模腔，因为曲线受转子扭距的影响；
2、无转子硫化仪一定要确保料的尺寸，大小，尤其是重量的一致，此点严重影响曲线。另外不管是
有转子或无转子，都必须保证仪器清洁和不受震动。
第五单元  原材料知识及进料检验
                                 — 公司使用之生胶与软化油
一、配合组成的多样化
现代配合组分可概括为五个体系：
主体材料：生胶、再生胶
硫化剂
促进剂
硫化体系       活性剂
                        防焦剂
         操作体系  增塑剂化学增塑剂
物理增塑剂
补强剂
防老剂
着色剂
发泡剂
芬香剂
增硬剂
增塑剂

填充剂
成本体系
增容剂
二、生胶原料选用原则
要求内容
主要使用性能如轮胎的耐疲劳生热和耐磨耗性；内胎的耐气透和耐热性能；密封件的耐油耐压缩性能；胶管、容器的耐腐蚀性能；电气材料的电纯缘性能等等。
其它兼顾性能 1．自重和负荷要求：机械强度、刚性、耐蠕变性能等
2．使用环境要求：耐热、耐寒、耐水、耐化学药品等
3．其它附加要求：透明、鲜艳、体轻、绝热、无味等
耐用性能 1．按使用条件要求：磨耗、裂口、发粘、硬化
2．按接触周围介质要求：热源、阳光、臭氧、潮湿、机械强制应力变形等
加工成型性 1．橡胶与配合材料混合的难易
2．成型方法的广窄：粘贴成型、压出压延成型、压缩成型、注射成型等
3．硫化的应用范围：高温低温、有无压力、空气、蒸汽、热油、电热
4．制品材料的二次加工方法：切削开孔、热加工、粘接、电镀、印刷等
安全性如：难燃、耐电等，贮运、保管的危险性等。
经济性材料和加工费等产品成本；维修和材料更换的生产成本；其它代替费和附加费。这三者构成综合经济性能。
社会环保责任 1．使用时有毒性和污染，对人体健康的影响；2.废弃物的处理等。

表1-2-2生胶结构分类、特性用途及硫化交联方法
分类橡胶名称主要特性基本用途主要硫化交联方法
二
烯
系统异戊二烯类
(甲基丁二烯) 天然橡胶（NR）具有典型的橡胶弹性，并有良好的耐磨性等机械性能轮胎、胶鞋、胶管、胶带、空气弹簧等硫磺
异戊橡胶（IR）具有天然橡胶相近似的性能，质量稳定，纯净用于代替NR或并用，胶鞋、胶丝、食品卫生及医疗制品硫磺
丁二烯类丁二烯橡胶（BR）弹性、耐磨性及耐寒性比NR好轮胎胎面及胎侧等，多为并用。鞋、减震品、磨采胶辊、胶带、胶管及工业制品，塑料改性硫磺
丁笨橡胶（SBR）耐磨及耐老化性能优于NR 轿车、轻卡车轮胎等、胶鞋、胶布、文体用品、胶板、蓄电池壳、胶带等硫磺
丁腈橡胶（NBR）耐油性、耐磨性、耐老化好油封、衬垫、耐油胶管、输送带、印刷胶辊、纺织皮辊等耐油工业制品硫磺
有机物硫化
氯丁二烯类氯丁橡胶（CR）耐候性、耐臭氧性、耐热性及耐化学药品性均好轮胎内衬层、电线、电缆、输送带、减震橡胶、窗户密封条、胶粘剂、胶布、涂料金属氧化物
硫磺
烯烃系统异丁烯类丁基橡胶（IIR）耐候性、耐臭氧性、耐气透性好，并可耐极性溶剂轮胎内胎、内衬层、硫化胶囊层面防水卷材，电线电缆、蒸汽胶管、耐热输送带、药品瓶塞、密封剂等硫磺
醌肪
树脂
乙烯、丙烯类乙丙橡胶（EPM、EPDM）耐老化耐臭氧性、耐极性液体、耐电性能好轮胎胎侧，多为并用。电线电缆、汽车玻璃除水条、窗户密封条、蒸汽胶管、输送带、塑料改性等过氧化物（EPM）
硫磺（EPDM ）
聚乙烯氯磺化类氯磺化聚乙烯（CSM）耐老化性、耐臭氧性、耐候性、耐化学药品及耐磨性好防老化涂层，耐候性耐腐蚀性涂料、衬里、室外胶布，耐腐蚀性密封条，耐热耐腐蚀性胶辊等金属氧化物
乙烯-乙酸乙烯类乙烯醋酸乙烯橡胶（EVA）耐热老化性、耐候性、耐臭氧耐水蒸汽性好胶鞋、压感胶粘剂、弹性塑料成型材金属氧化物
多硫化物类聚硫橡胶（T）有高度耐油性，耐臭氧性、耐电性亦好要求高度耐油的胶管、密封件、胶辊密封剂、涂层、胶粘剂、型材等金属氧化物
氨基甲酸酯类聚氨酯橡胶（U）
聚酯型（AU）
矛醚型（EU）刚性大，机械强度特别好工业胶辊、高温密封件，联轴器及耐要高强度的工业制品，实心胎等异氰酸酯
过氧化物
硫磺
丙烯酸酯类丙烯酯橡胶（ACM、ANM）高温状态下耐油性好，并耐老化汽车上用的密封件，主要是油封、皮碗、O型圈等胺类

  第六单元压缩永久变形测试压缩歪治具测试方法及步骤
1、保温压缩装置至所要求之温度。（125℃）
2、产品厚度测量：如图1用游标卡尺或厚薄规测量产品厚度（to）。
3、计算所需间隙板厚度：ts=toX(100％-35%)，压缩比率为35%，产品厚度（to）与压缩35%的厚度之差即为间隙板厚度（ts）。
4、相同规定的间隙板，中间置入产品，此时应注意产品不能接触到间隙板；产品与间隙板放入后，如图3密合压缩装置，如图4旋紧螺丝使之固定。如图5再将固定好的压缩装置放入烤箱中，加硫至所需时间。（22H）
5、到规定时间后将产品从压缩装置中取出，完全冷却后测量产品的厚度（t1）。
6、压缩变形率计算：Cs=to-t1/to-tsX100%压缩方法：将保温好的压缩装置取出，如图2在靠进螺丝两侧分别装入




第七单元  硬度计与橡胶硬度
一、定义
橡胶硬度试验，即测定橡胶试样在外力作用下橡胶对压针的抵抗能力，硬度值的大小反应了橡胶的软硬程度。橡胶硬度与其力学性能有着密切关系，如定伸应力、撕裂、弹性、压缩变形、杨氏模量等。因此在某种意义上，可以通过硬度测量了解其它性能。利用测定硬度来控制生产工艺，判定产品的达标情况和硫化情况具有重要意义。
二、试验方法的分类和原理
橡胶袖珍硬度计测量橡胶压入硬度的试验方法，包括下面两种类型：
1）邵尔硬度计；2）袖珍型橡胶国际硬度计
邵尔硬度计又分为几种：邵尔A型硬度计，适用于橡胶常规硬度范围的；邵尔D型硬度计，适用于橡胶高硬度范围的测试以及TypeB，TypeC，TypeDO，TypeO，TypeOO，TypeOOO和Type T型硬度计，比较常用的是TypeA和TypeD，以下就是它们使用的环境场合：
Durometer Scale(硬度计) Most Commonly Used ON（使用场合）
Type A 所有的O-Ring胶料
Type B（not commonly used）一定硬度的橡胶
Type C  (not commonly used) 中等硬度的橡胶和可塑性弹性体
Type D 硬橡胶；聚胺酯类；热塑性聚合体等
Type DO 高密度的织物圈
Type O 软质橡胶；中密度的织物圈
Type OO 低密度的织物圈；海绵状的橡胶和塑性弹性体
Type OOO 泡沫塑料
Type T 中密度的织物圈
测试原理：压入硬度试验是测量规定形状的压针在一定的条件下压入橡胶的深度，并换算为一定的硬度单位表示出来。
邵尔硬度计的组成：
压足：压足中间有一个直径为2.5~3.2MM的圆孔，孔心距离压足边缘至少6MM。
压针：压针由直径1.25+/-0.15MM的硬质钢棒制成。
指示机构：用于读取压针部分相对于压足地面的伸出量。
作用力：施加在压针的力和硬度计示值的关系符合下列公式：
邵尔A硬度计
F=550+75HA
式中：F---施加在压针上的力，MN
HA----邵尔A型硬度计示值
例外，公司还使用邵尔M（A）测量O-Ring，以及IRHD，JIS-A等等测试胶料或产品的硬度。
三、试样的制取
试样的厚度至少6MM，若试样的厚度小于6MM，可以用不多于3层、每层厚度不小于2MM的光滑、平行试样进行叠加。但这样所测得的结果和在整块试样上所得的硬度不能比较。（进行比较试验的试样尺寸必须大致相同）
试样必须有足够的面积，使压针和试样接触位置距离边缘至少12MM，试样的表面和压足接触的部分必须平整。（橡胶袖珍硬度计原则上不能在球形、不平整或粗糙的表面进行测量。但是在特殊情况下是允许的，比如：测量胶辊的硬度。在这种情况下，所测得的硬度与试样表面状况有关，因而和标准试样上测量的结果不同。

四、测试步骤
1）把试样放置在坚固的平面上，拿住硬度计，压足中孔的压针距离试块边缘至少12MM，平稳地把压足压在试样上，不能有任何振动，并保持压足平行于试样表面，以使压针垂直压入试样。
所施加的力刚好足以使压足和试样完全接触，除另有规定，必须在压足和试样完全接触后1S内读数，如果是其他间隔时间读数则必须说明。
2）在试样相距至少6MM的不同位置测量硬度值5次，取中位数（平均值）。O-Ring产品一般是用Shore-M或者IRHD进行测试。
3）使用邵尔硬度计时，当A型硬度计测量值超过90时推荐用D型硬度计，当D型硬度计的测量值低于20时推荐用A型硬度计，A型硬度计在测量值低于10时是不准确的，测量结果不能使用。
五、邵尔A型硬度计测定中的影响因素
1、试样厚度的影响
邵尔A型硬度值是由压针压入试样的深度来测定的，因此试样厚度直接影响测试结果。试样受到压力后产生形变，受到压力的部分变薄，硬度值增大。所以，试样厚度小硬度值大，试样厚度大硬度值小。
试样厚度 mm

试样编号 3 6 12 试样厚度
mm
试样编号 3 6 12
A001
A002 50
38 47
35 44
33 A003
A004 46
49 42
46 40
44
2、压针长度对试验结果的影响
在标准中规定邵尔A型硬度计的压针露出加压面的高度为2.5+/-0.05mm。在自由状态时指针指零点。当压针压在平滑的金属板或者玻璃板上时，仪器指针应在100度。如果指针大于或小于100度时，说明指针露出高度大于2.5mm或小于2.5mm，在这种情况下应该停止使用进行校正。当露出部分大于2.5mm时测得的硬度偏高。
压针压在玻璃板的指示值

试样编号 104 100 93
A-1
A-2
A-3
A-4 38
49
58
69 37
47
57
67 32
44
52
62
3、压针端部形试验结果的影响
邵尔A型硬度计的压针端部在长期作用下，造成磨损，使其几何尺寸改变，影响试验结果，磨损后的端部直径变大测得的结果也大，这是因为其单位面积的压强不同造成的。直径大压强小所得值偏大，反之偏小。
4、温度对试验结果的影响
橡胶为高分子材料，其硬度值随着温度的变化而变化，温度随着硬度值升高降低。胶料不同影响程度不同，如结晶速度慢的天然橡胶，温度对其影响小些，而氯丁橡胶、丁苯橡胶等影响显著。
5、读数时间的影响
邵尔A型硬度在测量时读数对试验结果的影响很大。压针与试样受压后立即读数与指针稳定后再读数值，所得的结果相差很大，前者高，后者低，两者之差可以达5到7度左右，尤其在合成橡胶测试中较为显著，这主要是胶料在受压后产生蠕变所致，所以当试样受压后立即读数。

六、优点与缺点
优点：携带方便，试验方法简单；
缺点：
1、弹簧校正不准确或因弹簧疲劳使力值变化；
2、压针尺寸的变化不易控制；
3、压针突出硬度计底面的尺寸与读数之间的不正常；
4、读数时间差异，所得值不同
七、校正
邵尔A硬度计的校正是用天平进行的。公司是实行外校。
国际橡胶硬度试验
国际橡胶硬度计是以规定的负荷和球形压头，以压头压入是样的深度差值来表示试样的硬度，单位为国际橡胶硬度，度（IRHD）。这种硬度计测量精度高，稳定性好，所以逐渐被国际标准化组织订为国际标准即ISO48（30~85IRHD），ISO1818（10~35IRHD），ISO1400（85~100IRHD）和ISO7619袖珍型（30~90IRHD）。
国际橡胶硬度计分为常规型、微型、和袖珍型三种，在常规实验法中又分低硬度硫化橡胶（10~35IRHD）测定、中硬度硫化橡胶（30~85IRHD）测定和高硬度硫化橡胶（85~100IRHD）测定。常规法多用于规范试验、仲裁试验及研究工作；微型试验法多用于测量薄型制品、O型圈、小型橡胶零件和少量橡胶品性能的测量；袖珍型试验法一般用于生产现场和厂外硬度测量。
一、国际橡胶硬度试验概述
硫化橡胶的应力-应变关系在较小的应变条件下近似于直线关系，因此，在较小的拉伸或压缩应变的条件下，杨氏弹性模量通常被定义为应力-应变曲线的斜率。国际橡胶硬度与杨氏弹性模量有较好的相关性，国际橡胶硬度是在规定条件下测量硬度计钢球压入橡胶的深度，并将该深度换算成国际橡胶硬度。国际橡胶硬度的数值确定：当IRHD等于0时，表示橡胶的杨氏弹性模量为零；当IRHD为100时，表示橡胶的杨氏模量为无限大。在通常情况下应满足以下条件：第一，国际橡胶硬度的增量，总是与杨氏弹性模量近似的成比例关系；第二，对于高弹性橡胶，国际橡胶硬度和邵尔A硬度的数值大致相同。
二、测试步骤
样品：标准样品单片（2mm）表面光滑的测试片，允许的范围1~4mm，所以也可以用两片叠加的。按照规定，为了得到所需要的厚度，允许将两块橡胶测试样品叠加在一起，但是接触面一定要光滑；GB6032规定当试样厚度小于1mm时允许亮层叠加，但是不能多于两层。试验证明，叠加都测得的硬度比相同厚度的单片测得的值要小。
将试片平放在测试台，放下压足，并把压力加大，直到显示屏上显示的压足压力为100，然后放开止动阀，让压足在胶料的弹性反作用下缓慢上升复原，当测试时间到达30S时读数，此时读数表示的就是胶料在外力作用下的残余形变，表现为压足压入橡胶的深度差值，通过一定的计算公式表示为硬度值。
它们的关系如下：
F/M=0.0038R0.65P1.35
其中：F-- 压入力，N
   M—杨氏弹性模量，Mpa
   R—钢球的半径 mm
P—压针穿透的距离 mm
测试结果：一般是在一个样品上测3到5个点，然后取中位数。
三、影响测试的几个因素
1、厚度，如前面所述，一般是单片测量，小于1mm时可以叠加，但是得到的硬度值会偏大与同等厚度的单片测试值。
2、试样表面状态对试验结果影响取决于以下三种：
1）表面粗糙，使压头与胶面的磨擦力增加，压头下降受到阻力，则测得值偏大
2）试样打磨，表面的以层硬皮被磨掉，则测得硬度值小
3）当有较明显的凹凸不平时，压头在凹处和凸处的不同位置做测定的硬度值不相同。
3、负荷作用时间的影响
各国标准试验方法均规定钢球接触力作用时间为5S，总力作用时间为30S，即在30S内读数。因为接触力对试验结果的影响较小，所以仅对于作用时间进行了实验，发现硬度值随着时间的延长而减小，30S前的影响大于30S后的影响。
4、施加的外力影响
当施加在胶料上的外力偏大时，由于胶料受到的形变大，相应的弹性形变也就多，由硬度值和应变的关系可知，它在30S内回复的形变少，以致测得的硬度值偏大。
5、同一测量点重复测量的影响
硬度试验虽属非破坏性试验，但是因为形变不能立即恢复，试样表面同一点连续重复测试是不允许的，试验表明，第二次的测量值均大于第一次的，差值随着胶料的蠕变性能不同，第二次以后的测试数据变化较小，经一定时间，试样基本可以恢复到原来的状态。
DIN53519 sheet1

第八单元    O－ring 密封设计分析
SEAL DESIGN ANALYSIS
Analysis of the seal application is crucial to the understanding of possible failure. Most seal design is performed by component suppliers and equipment manufacturers. The designs are refined as experience is gained. As quickly as process technology changes, however, the experience gained with seal design may not be relevant to the latest process technology. Vacuum applications have historically relied on high levels of compression and gland fill to reduce permeation and trapped gases. These techniques, when applied to new materials, or at higher operating temperatures, can result in premature seal failure.
The seal design and application can provide information about the cause of failure:
o Static Seals— axial and radial, confined or unconfined
o Dynamic Seals— axial (open-close) or radial (reciprocating or rotary)
o Sealing Gland Dimensions—
 shape (square, trapezoidal, etc.)
 compression
 gland fill
 stretch
Installation Procedures— stretch
COMMON SEAL FAILURES
  ABRASION

Description: The seal or parts of the seal exhibit a flat surface parallel to the direction or motion. Loose particles and scrapes may be found on the seal surface.
Contributing Factors: Rough sealing surfaces. Excessive temperature. Process environment containing abrasive particles. Dynamic motion. Poor elastomer surface finish.
Suggested Solutions: Use recommended gland surface finishes. Consider internally lubed elastomers. Eliminate abrasive components.

COMPRESSION SET

Description: The seal exhibits a flat-sided cross-section, the flat sides correspoding to the mating seal surfaces.
Contributing Factors: Excessive compression. Excessive temperature. Incompletely cured elastomer. Elastomer with high compression set. Excessive volume swell in chemical.
Suggested Solutions: Low compression set elastomer. Proper gland design for the specific elastomer. Confirm material compatibility.
CHEMICAL DEGRADATION

Description: The seal may exhibit many signs of degradation including blisters, cracks, voids or discoloration. In some cases, the degradation is observable only by measurement of physical properties.
Contributing Factors: Contributing Factors: Incompatibility with the chemical and/or thermal environment.
Suggested Solutions: Selection of more chemically resistant elastomer.
  EXPLOSIVE DECOMPRESSION

Description: The seal exhibits blisters, pits or pocks on its surface. Absorption of gas at high pressure and the subsequent rapid decrease in pressure. The absorbed gas blisters and ruptures the elastomer surface as the pressure is rapidly removed.
Contributing Factors: Rapid pressure changes. Low-modulus/hardness elastomer.
Suggested Solutions: Higher-modulus/hardness elastomer. Slower decompression (release of pressure).

EXTRUSION

Description: The seal develops ragged edges (generally on the low-pressure side) which appear tattered.
Contributing Factors: Excessive clearances. Excessive pressure. Low-modulus/hardness elastomer. Excessive gland fill. Irregular clearance gaps. Sharp gland edges. Improper sizing.
Suggested Solutions: Decrease clearances. Higher-modulus/hard-ness elastomer. Proper gland design. Use of polymer backup rings.
INSTALLATION DAMAGE

Description: The seal or parts of the seal may exhibit small cuts, nicks or gashes.
Contributing Factors: Sharp edges on glands or components. Improper sizing of elastomer. Low-modulus/hardness elastomer. Elastomer surface contamination.
Suggested Solutions: Remove all sharp edges. Proper gland design. Proper elastomer sizing. Higher-modulus/hardness elastomer.
OUTGASSING / EXTRACTION

Description: This failure is often very difficult to detect from examination of the seal. The seal may exhibit a decrease in cross-sectional size.
Contributing Factors: Improper or improperly cured elastomer. High vacuum levels. Low hardness/plasticized elastomer.
Suggested Solutions: Avoid plasticized elastomers. Ensure all seals are properly post-cured to minimize outgassing.

OVERCOMPRESSION

Description: The seal exhibits parallel flat surfaces (corresponding to the contact areas) and may develop circumferential splits within the flattened surfaces.
Contributing Factors: Improper design—failure to account for thermal or chemical volume changes, or excessive compression.
Suggested Solutions: Gland design should take into account material responses to chemical and thermal environments.
PLASMA DEGRADATION

Description: The seal often exhibits discoloration, as well as powdered residue on the surface and possible erosion of elastomer in the exposed areas.
Contributing Factors: Chemical reactivity of the plasma. Ion bombardment (sputtering). Electron bombardment (heating). Improper gland design. Incompatible seal material.
Suggested Solutions: Plasma-compatible elastomer and compound. Minimize exposed area. Examine gland design.
SPIRAL FAILURE

Description: The seal exhibits cuts or marks which spiral around its circumference.
Contributing Factors: Difficult or tight installation (static). Slow reciprocating speed. Low-modulus/hardness elastomer. Irregular O-ring surface finish (including excessive parting line). Excessive gland width. Irregular or rough gland surface finish. Inadequate lubrication.
Suggested Solutions: Correct installation procedures. Higher-modulus elastomer. Internally-lubed elastomers. Proper gland design. Gland surface finish of 8–16 microinch RMS. Possible use of polymer backup rings.

THERMAL DEGRADATION

Description: The seal may exhibit radial cracks located on the highest temperature surfaces. In addition, certain elastomers may exhibit signs of softening—a shiny surface as a result of excessive temperatures.
Contributing Factors: Elastomer thermal properties. Excessive temperature excursions or cycling.
Suggested Solutions: Selection of an elastomer with improved thermal stability. Evaluation of the possibility of cooling sealing surfaces
TROUBLESHOOTING O-RING FAILURE
As most engineers and plant managers realize, O-ring failures can be critical. The ability to troubleshoot these problems can save precious time in getting production equipment back on line, or redesigning the sealing system of a company's product.
An O-ring is a "simple" device often specified or installed as an afterthought - simple that is until it fails. The apparent simplicity of an O-ring should never be confused with the complexity of its function: a device that in deformation must balance the many effects of chemical attack, friction, pressure and temperature while maintaining the fluid integrity of the system. Clearly, then, the modes of failure are case specific and varied across the range of O-ring applications.
Both mechanical and chemical causes of failure are revealed in the visual patterns of the failed O-ring. The following is a basic guide for identification of the visual evidence of O-ring failure and the interpretation of that evidence in terms of possible causes.
Seals affected by extrusion and nibbling appear as if many small bites have been taken from the O-ring on the downstream or low pressure side. These tiny bites (figure 1) are commonly found on the ring circumference and are typical of the failures that occur in high pressure systems. The biting is often caused by pressure spikes which force the elastomer into the extrusion gap and shear off small pieces of the seal wall. Materials with low tear strength and low durometer (hardness) such as silicones and fluorosilicones are more susceptible to failures of this type, while higher durometer and high tear strength materials such as carboxylated nitrile and urethane are less prone to extrusion and nibbling.

Figure 1 -- Extrusion and nibbling
Seal damage can also occur during installation. Some of the visual clues of this type of O-ring failure are short cuts, notches and a skinned or peripherally peeled surface. Causes of this type of damage are sharp edges on mating metal components of the O-ring gland, sharp threads over which the O-ring must pass during assembly, an insufficient lead in chamfer, blind grooves in multi-port valves, twisting or pitching of the O-ring during installation, an O-ring volume greater than the groove void (gland) and/or lack of lubrication during installation.
Another mode of O-ring failure is excessive abrasion. This will be seen as rough, slightly flattened surface on one side of the O-ring (figure 2). This pattern occurs primarily in dynamic seals involving reciprocating, oscillating or rotary motion. The cause may be a metal surface that is too rough or system contaminants. However, if a metal contact surface is too smooth, the lubricant will not be retained between the seal and the gland walls.

Figure 2 -- Abrasion
Flat surfaces on the bottom and top of the O-ring cross section (figure 3) indicate compression set. This condition is generally caused by the O-ring material exceeding its high temperature range. Heat hardening (figure 4) has the appearance of a pitted or cracked surface and is often accompanied by the flatness of compression set. Oxidation is similar in appearance to heat hardening.

Figure 3 -- Compression Set

Figure 4 -- Heat Hardening
In high pressure gas applications, a common problem is explosive decompression. This problem is indicated by the random short splits or ruptures going deep into the O-ring cross section. When the O-ring is first removed, the surface may also be covered by small blisters. Explosive decompression typically occurs when a gas is absorbed by an O-ring while operating in high pressure: the gas is trapped within the O-ring when the system pressure drops, causing the surface of the O-ring to blister and rupture as the trapped gas expands. In this situation, an O-ring with the smallest possible cross section should be used, as well as a rubber compound with low permeability.
O-rings used as seals on long stroke hydraulic pistons are susceptible to "spiral failure." Easily diagnosed, spiral failure exhibits a series of deep, spiral 45 degree angle cuts. Lipped seals are typically better suited to piston applications in which this failure often occurs.
Significant changes in O-ring size, such as swelling or shrinking, rapid and extreme seal deterioration and softening are all signs of incompatibility of the O-ring and the chemicals to which it is exposed. Seal volume will increase in size if it absorbs the fluid, or it may shrink if the fluid extracts the components of the O-ring compound. Plasticizer extraction frequently occurs in fuel systems in both static and dynamic applications. The obvious solution to chemically related O-ring failure is a careful material selection that matches the elastomer compatibility to the environment of the application.
The effects of the environment on an O-ring seal such as heat, friction or chemical attack may be difficult to evaluate separately. For example, extreme seal friction will generate heat which may cause thermal expansion which will make the seal more susceptible to chemical attack. Therefore the choice of the dimensional and material specifications of the O-ring is often a compromise that best balances the overall forces acting on the seal. All seals should be tested in their actual application before a final determination of O-ring size and material is made.
Seal failure prevention strategies.
Trouble-shooting seal failures through visual inspection can be very effective. However, the next step, selecting a replacement seal, involves technical decisions related to O-ring size and material selection.
Based on its customer communications, Apple Rubber estimates that nearly 60% of O-ring failures are caused by improper sizing, 30% of O-ring failures occur because a custom seal design is needed, and another 10% of failures are caused by chemical incompatibility.
While the factors leading to an O-ring failure in a given system may be numerous, it may be useful to keep in mind the following preventative guidelines.
Sizing equations typically determine the size of O-rings selected for static or dynamic applications. The most common error in sizing O-rings, however, is failure to take into account the true tolerances of the parts to be sealed by the O-ring. When 5-15% of the seals in a system leak, the problem is most often traced back to the fact that the O-rings were not matched to the actual tolerances of the system, and the gap between the machined parts was not filled by the seal.
In one example, typical of problems related to poor tolerance stack-up, the cylinders in a plastic syringe designed to add nutrients and pesticides to trees leaked when the syringe was operated and even when it was stored in the trunk of a car. When the tolerances of the syringe materials were analyzed, it was found that the expansion of the plastic syringe material at higher temperatures had not been taken into account when selecting O-rings. Apple Rubber recommended installation of thicker O-rings of a higher durometer materials, and a doubling of the wall thickness of the plastic syringe. The leaks were eliminated. More information on Understanding Tolerance Stack-Up is available in this Technical Corner.
It's also important to select O-ring materials that are appropriate to the temperature levels of the operating environment. Excessive heat, over time, degrades O-ring materials physically and sometimes chemically, rendering them non-functional as seals. Excessive heat may cause O-ring materials to swell and harden in a deformed shape. Excessive cold may affect the material properties of a seal, preventing proper sealing.
On rare occasions it may be possible for a given elastomer to sustain or exceed its maximum and minimum temperatures. However, repeated temperature spikes and drops will lead to O-ring failure.
A final caution: the most critical step in preventing O-ring failures is when plant managers and engineers pre-test O-rings in actual applications to confirm whether these "simple" devices will be trouble-free and thus cost-effective.

第九单元 VT加工工艺
一、 VT简介
1、化学名称
氟橡胶 Fluoroelastomer Rubber，Fluorocarbon Rubber，FKM
2、种类
类型化学组成氟含量 TR-10（℃）目前使用品号
Type A 偏氟乙烯-六氟丙烯 66% -17 Daikin：G716，G742，G752，G723，G731，G801（peroxide cured）
Dupont：A-401C，A-201C，A-601C，A-361C，A-500
3M：FC-2174，FC-2180
Ausimont：65BI/F，65BI/K
Type B 偏氟乙烯-四氟乙烯-六氟丙烯 68% -13  ~  -15 Daikin：G551，G621
Dupont：B-201C，B-601C

Type F 偏氟乙烯-四氟乙烯-六氟丙烯-可硫化单体 70% -6  ~  -8 Daikin：G901，G902
Dupont：GF-300，F-601C，F-605C，VTR-8600
GLT 64% -30 GLT-505，VTR-8500
GBLT 65% -26 GBLT-601
GFLT 66.5% -24 GFLT-502，VTR-8550
ETP 67% -11 ETP-900，ETP-600S
3、Dupont 的命名原则
Viton A① -4②0③1④C⑤
①:表示类型，分别是“A（F%=66%），B（F%=68%），F（F%=70%）”。
如果在A/B/F前面加上字母“G”，表示这个聚合物可以用过氧化物硫化。
如果在①处出现字母“L”，表示对于同类型的Viton有稍改善低温性能后的类型。如果在①处出现字母“LT”，表示对于同类型的Viton较多改善低温的类型。
②：表示门尼粘度，ML1+10在121℃。
③：表示预混胶中硫化剂的含量。
其中：0表示硫化剂含量最高，从9到2逐渐下降，1硫化剂含量最少。硫化剂含量越高，压缩永久变形越好，但撕裂越差。
④：表示相同类型的预混胶之间的微量区别。如A-401C与A-402C，区别在前者不含加工助剂，后者有含。
⑤：表示是否含有“硫化剂和促进剂”，如果不含“C”表示不含“硫化剂和促进剂”，反之，含有。
二、原材料的存放
VT原胶（包括生胶和预混胶），以及用于VT里的配合剂，必须密封存放在阴凉干燥处。在存放时要避免任何物质污染原材料。特别是“混料飞扬的粉尘，其它配方中的配合剂，灰尘，一些气体（煤气，酸性气体等其它），液体（水，煤油，柴油，汽油，机油等）”。
三、加工工艺
（一）、开炼机混炼
VT可以使用我们通常的橡胶生产设备进行混炼。对于橡胶，做对第一步就是要做对混炼工作。
1、开炼机混炼（Mill Mixing）
（1）、开炼机混炼是一种最古老也最基础的橡胶混炼方法。它是使用两个以不同速度对转的金属辊筒组成。辊筒间的不同速度在两个辊筒最接近的地方产生混炼所需的剪切力。生胶或预混胶通过开炼机塑炼几分钟后，变成可塑，形成有光泽的波纹状。这时，适合配合剂的加入。为了达到分散效果佳，操作者必须在混炼过程中进行割刀，打三角包，打圆卷并且薄通。
（2）、通常VT混炼建议辊温要尽可能低（23℃ or 75℉）。通常做法是使用循环的冷却水进行降温，以利于提高剪切力，防止胶料焦烧，并且提高胶料的分散度。在生胶或预混胶塑炼成有光泽的波纹壮时，配合剂要立即加入。如果有使用两种不同拈度的生胶，我们必须先把高门尼拈度的生胶进行塑炼，然后加入低门尼拈度的生胶一起塑炼。在混炼过程中进行割刀，打三角包，打圆卷并且薄通。需要注意的是，要对应于使用的开炼机的尺寸大小选择合适的批次重量。批次太大或太小，会导致混炼胶分散不均和其它异常。
Mill Roll Length Batch Weights
0.91m（36in） 13-15kg（28-33lb）
1.02m（40in） 16-18kg（35-40lb）
1.22m（48in） 21-25kg（47-55lb）
1.52m（60in） 34-41kg（75-90lb）

（3）、开炼机混炼的实际操作建议
a、必须使用干净的开炼机，要避免其它生胶、材料、油、油脂、硫磺类的化学物质混入。因为Viton具有超强的耐油性，故与油类不相容；若是机器表面沾有油脂，则混合效果将很不理想，且混合时间将延长。一般做法是用硬度为70的丙稀腈（耐油胶）或压克力橡胶混合料来洗开炼机（此料不能含有促进剂与硫化剂）。
b、 VT是一个典型的“包后辊”的橡胶。也就是说，VT一般会包快辊。如果我们设法让它包前辊，它仍然会前后辊一直变化。
c、如有可能要使用10℃的冷却水。最大的剪切力决定最好的分散，在混炼中，橡胶的温度不断上升，门尼粘度下降，剪切力也随之下降。保证混炼胶的温度低变的特别重要，可以防止胶料粘辊，并且得到最好的分散。
d、通常，在填充剂加入后加一些配合剂，这些配合剂溶解在橡胶中比分散在橡胶中容易的多。所以这些配合剂在混炼的最后加入，此时，混炼胶温度很高，把这些物质溶解在橡胶中。
e、通常，混炼胶最好是在室温下存放12小时后在用于生产产品。在存放中，配合剂/填充系统与橡胶进一步反应和分散。经验证明存放可以改善橡胶的加工性特别是流动性能以及物理性能。
2、配方中的一些物质
（1）、酸吸收剂
在VT中，通常使用金属氧化物作为酸吸收剂。如：MgO，Ca(OH)2,ZnO,PbO,Pb3O4,等等。一些物质与填充剂混在一起加入，可以得到最好的分散。单独加这些金属氧化物，特别是MgO，会导致胶料极度粘辊并容易焦烧。所以，一般在混炼前，先把酸吸收剂与填充剂混在一起，搅拌，然后加入。
酸吸收剂必须密封保存，防止吸潮，潮解。
（2）、加工助剂
在VT中一般不能使用硬脂酸类的加工助剂，如：硬脂酸锌；这些材料对于双酚硫化的VT会降低其加工安全性，容易焦烧。
在混炼过程中加入或混炼完以后加入加工助剂。一般，加工助剂很容易分散，但是如果在混炼初期加入，因为加工助剂会降低剪切力，从而影响分散效果。]
通常加的加工助剂是：Struktol WS280，Carnauba Wax（巴西蜡），VPA1，VPA2，VPA3。一般VPA3使用不能超过1.25phr。如果VPA3用1.5或超过1.5phr会导致焦烧。
对于过氧化物硫化的VT，一般使用Struktol WS280和Armeen 18D（<1.25phr）来改善混炼和成型脱模。
（3）、混炼的注意要点
a、不要把MgO单独加入。
b、必须使冷却水进辊轮冷却。
c、对于双酚硫化的VT，建议加入0.5-1.0 phr的巴西蜡，对于过氧化物的VT，建议加入0.5-1.0phr的Struktol WS280或Armeen 18D。
d、如果可能尽可能使用高门尼粘度的聚合物。
e、尽可能的保证滚轮清洁。
f、最好使用金属氧化物的母炼胶。
g、混炼胶存放12-24小时后再进行重炼。
（4）、存放
            混炼完的VT，必须尽可能快的降温。在降温过程中与存放过程中，必须保证没有任何物质的污染。一般存放在18℃以下，不能高于32℃。存放温度过高，或时间过长，会导致胶料的焦烧状况不一样，从而影响橡胶的加工性能。存放后会增加粘度，缩短烧焦时间，尤其在热天气（如夏季时间）更为严重。Viton对湿也很敏感，热加上湿度极易造成胶料烧焦（死料），造成重大损失，应尽量避免。
            无论是任何配方，混合料若要长期储存，一定要投资置冷冻设备，因为它可以显著的减少因死料所造成之损失。
            混合料若要进一步的使用，在使用前4小时就要从冷藏库取出。在表面形成之凝结水要用强风吹干或用抹布抹干，否则水气极易造成押出物或模制品表面有微细气泡。
            若没有冷藏设备，则紧凑的混合与再加工排程显得非常重要，且要遵守标准的作业方式，才可以减少损失。一般而言在夏天时，混合料须在三天或更短的时间内使用完毕。
（二）、密炼机混炼
   1、密炼机的要求
a、要有一个能测量混炼时间的测量器。
b、要有一个能测量密炼机内胶料的温度的测量器。
c、马达转速显示器
d、上顶栓的压力
e、混炼过程中电流计
   2、VT密炼机混炼的重点
a、胶料的料温，密炼机温度显示器显示的温度比实际胶料的内部温度低10-25℃，一般情况下，VT必须在温度显示110-115℃以下卸料。
b、密炼机混炼一般为3-5min，其装料量（每批次重量）=密炼机体积*装载系数*配方的比重。VT的装载系数通常近似为70-72%。批次重量太轻，会导致混炼时间长且分散不好。太重，胶料容易焦烧且分散很差。
c、密炼机混炼时一定要对密炼机彻底的清洁以防止污染。这点是非常重要的。特别是不是VT专用的密炼机，之前有生产过硫磺系统的胶料。通常硫磺或含有硫磺的物质会破坏VT双酚硫化系统。大概0.15phr的硫磺可以让VT双酚硫化系统完全失效。同样的，芳香烃的软化油会破坏VT的过氧化物硫化系统，使之失效。所以我们在擦洗转子、密炼机内部时选择清洁油要特别的小心。为确保混炼，在混合前，须检查机械之培林（Bearing）是否紧密，能否防漏。同时事先用硬度为70的丙稀腈（耐油胶）或压克力橡胶混合料来洗车（此料不能含有促进剂与硫化剂）。
d、通常使用10℃的冷却水进行冷却可以得到最好的分散效果（配合剂的溶解温度低于100℃）。使用门尼粘度高的生胶可以得到更大的剪切力。
e、混合机械也须做定期性的检查，以确保水不会从冷却系统中渗到混合料中。此外管路，配件，防水挡板，滚轮表面与密闭式混合器转子也要定期检查是否有裂痕。只要有约1磅的水（约0.6PHR）漏入混合料中，即造成混合料之粘度提高，变成烧焦。含水的混合料所制造的模制品，通常外观不良，有气泡；尤其是在烤箱中二次加硫时更易在表面产生气泡。在生产押出制品时，混合料的水分会使押出品表面出现气泡，而且硫化物的HD会明显偏高。
f、对于高填充的VT混炼，通常有两种混炼方式，一种是“逆混法”，就是先把填充剂、酸吸收剂等加入，而后加入VT生胶。另一种是“三明治”混炼法，就是先投入一半的生胶，后投入填充剂、酸吸收剂等，最后加入剩下的生胶。
g、如果密炼机的转速可以控制，一般情况下低转速比高转速好。通常建议25-45rpm的转速。太快的转速导致胶料温度升高太快，容易焦烧，时间不够，分散效果差。但太慢的转速会导致混炼时间过长，很难达到卸料温度和一些特殊配合剂的溶解温度。
h、设定卸料温度要实际上找出密炼机显示的温度与胶料实际温度的差别。只有这样我们才能正确的设定卸料温度，而避免胶料焦烧。
i、胶料混炼完以后，通常使用翻料机进行冷却。混炼完的胶料门尼粘度相对的低，并且不能产生有效的剪切力。所以可以使用翻料机使胶料温度降到室温，并且多少对分散有进一步改善。
j、大多数的密炼机需要灌入润滑剂到转子的防尘密封内部，防止一些配方或混炼胶中的配合剂药粉进入轴承。润滑剂的选择是很重要的，否则会影响混炼的胶料。DOP是通常建议使用的润滑剂，但是如果使用太多，会导致生产的产品有瑕疵，缩水的变化，潜在的物性降低和最终产品的耐热性能降低。
k、如果使用两种门尼粘度不一样的生胶，当这两种粘度相差10以上时，先投入门尼粘度高的生胶进行塑炼，然后投入低的。当两种相差低于10或10时，可以同时投入。
l、对于过氧化物硫化的胶料，可以把硫化剂与填充剂先混均后同时加入，也可以先把促进剂先与填充剂混均后加入，硫化剂最后加入。
m、酸吸收剂必须与填充剂混均后才投入，这样的分散最好。
n、不要使用硬脂酸类的加工助剂，这类物质会导致双酚硫化系统焦烧。加工助剂必须在混炼最后加入。否则会降低剪切力，从而影响分散。

  （三）、硫化成型
      1、VT一般的缩水率是2.5-3.5%（二烤后）。较大的缩水率值不可完全归因于弹性体与其他配合药品如碳黑、填充剂等的不同热膨胀系数。有一些模具成型收缩是因为在加硫与二次加硫时挥发物的损失。Viton制品的高收缩率相信可归因于下列原因：a、高硫化温度；b、填充剂的低填充量；c、二次加硫（烘箱老化）。
2、所有的模具必须紧密性好，分模线要清楚，逃气性要好。若模具无法紧密，常会造成模制品有包空气或其他外观不良，且无法达到尺寸大小的允许范围。
      3、典型的模压加硫条件是：温度：160-190℃，压力：15-20Mpa（2175-2900psi）。并使用真空机台以利排气。加硫时间由配方，产品的尺寸大小，产品形状，模具大小决定。
      4、VT模压生产最大的问题是粘模具污染。过多的模具污物会造成混合料的流动性不良，而且会造成粘模具，影响制品外观，故需小心维护模具的良好状态，并经常清理与检查。特别是一些胺类硫化的配方。所以操作者必须特别的注意，上机前和在生产过程中密切注意模具的状况，一般上机要清模/洗模，在生产过程中发现模具污染马上要洗模/清模。另外模具必须镀上一层厚的金属铬，以降低模具的腐蚀。
      5、油压机平台需检查是否有变形，变形的平台会影响热传导性与模具的压力平均性，造成产品会有孔（加硫不足）或出现填充不足现象。若模具大小与平台大小接近时，将可减少平台的变形。
      6、一般要使用内部离型剂和外部离型剂以改善脱模状况。
      7、压注模生产特别要注意的是
         （1）、压注模成型是VT最通常的加硫方式。建议压注生产的胶料的门尼粘度至少要高于30（ML1+10在121℃）。
         （2）、预型物的重量。预型物的重量必须足够以保证每一孔都可以流到并不会缺料。通常是毛边系数是6%-10%。
         （3）、预型物的比重。也就是预型物必须是密实的，里面不能含有气体或空洞。
         （4）、压力的一致性和连续性。要保证每一孔所受的压力是一致的，在成型中，要保证机台压力不会变动。通过对机台压力的清楚，从而调整每一孔的缩水率，这是最精致的做法。
      8、转注模生产
         （1）、使用门尼粘度相对低的聚合物或胶料。对于VT，粘度一般要低于50（ML1+10在121℃）。
         （2）、用于转注模生产的胶料，必须要有足够的流动性和安全性。这样才不会出现缺料和死料的不良。所以打料和料的存放是关键。尽量避免高温打料和长时间存放料或把料存放在热源附近。
         （3）、理论上，转注孔最小是防止成型中多余的胶料往会流，和脱模时防止产品撕裂的最好方式。但是转注孔也要足够大，以保证足够的胶料能转注到每一个模腔。这个也要保证足够的压力和胶料足够长的焦烧时间。
         （4）、转注模生产的温度一般低于压注模生产的温度。一般是165-175℃。
  （四）、VT生产建议的离型剂
双酚硫化胺类硫化过氧化物硫化
内部离型剂 0.5-1.0植物蜡（如：巴西蜡）
0.5-1.0砜类混合物（如VPA No.1 或VPA No.3） 0.5低分子量的聚乙烯（LMPE）；
或是1.0植物蜡（如：巴西蜡） 0.2-0.3 硬脂酸
0.2-0.5Armeen 18D
0.2-0.5植物蜡（如：巴西蜡）

外部离型剂乳状的硅油（P-10）或乳状的聚四氟乙烯油（如Daifree-313）聚乙烯或乳状的硅油（P-10）聚四氟乙烯油（如Daifree-313）
      理想最佳的脱模时刻是在其最低硫化程度时，因胶料低程度的硫化，有较佳的离模
---如热撕裂，模数。一般还建议用压缩空气枪来取出模制品。
半永久性脱模剂（外离型剂），均匀喷洒在热模具上，并在足够的温度下发生交联反应，从；而生成一层具有强粘附力的隔离薄膜层。为使隔离薄膜层最佳地粘附到模具表面，应先对模具的表面进行彻底的清洗。只有在经过机械性清洗（如微粒体喷射、溶剂（如乙醇）去脂化、蒸汽清洗或碱清洗）后才能进行初步的涂敷。
在至少160℃的温度下，每间隔15分钟涂敷两到三层薄而均匀的涂层，可获得最为理想的隔离膜。温度越高，隔离膜的交联点密度也就越大，耐磨损度也就越高。损坏的薄膜层可以机械方法去除（微粒体喷射），也可通过浸泡在碱性溶液（乙醇中5%氢氧化钾溶液）中以化学方法除去。这种脱模剂的一个特殊优点在于硫化橡胶的表面能保持清洁，能够被印染、上清漆或粘附。摩擦系数较低，有利于硫化橡胶的脱模，也克服了一些由于热撕裂性差所导致的问题。
我们使用的STRUKTOL PERMALEASE 10是基于溶解于烃类的有机硅类聚合物的模具脱模剂。典型的成型反应条件为15分钟160℃。是属于喷洒型。（附件为我们使用STRUKTOL PERMALEASE 10 资料）
正确方法：模具要清洗干净，后至少加热到120℃，脱模剂使用前先很好的振荡，然后在距离模具20-40cm均匀喷洒两到三层薄而均匀的涂层，然后在160℃下至少保温15分钟，让脱模剂在模具表面形成一层牢固的薄膜层。此时可以排料生产。在生产中，如果发现很难脱模时，重复以上操作。注意，如果脱模剂没有有效的烤干，会粘在所排的胶料上，从而导致产品接合不良或表面有瑕疵。
（五）、二次加硫
Viton氟化橡胶经过压模成型后，通常都要经过二次加硫以得到最佳的物性，尤其是抗压缩变形。所有Viton的配合药品都含有少量的水分与挥发物，造成压模时无法完全硫化。在模具内时，水气无法从模制品内逸出，故需放在热空气循环的烘箱中，完成其硫化反应。烘箱中需要有足够的循环，以带走挥发物，而从排气孔排出。同时注意烘箱不可超负荷，且模制品需适当的支撑与分隔，不可整堆放在一起；否则，模制品会互相隔热，造成不良的特性，或者造成气泡与裂缝。为减少发生裂缝的可能性，模制品的厚度大于1/4”者，需放在121℃的烘箱中，而且其升温速度为每小时10℃，直到所需要的温度为止。


第十单元  Glossary for Seals, Gaskets, O-Rings, Orings, Rubber
"A"
Abrasion - Surface loss of a material due to frictional forces.
Abrasion - The wearing away of a materiel surface by friction. Particles become detached by a combined cutting, shearing and tearing action. Furnace carbon blacks are the best ingredients found for increasing the resistance of rubber compounds to abrasion.
Abrasion resistance - The resistance of a material to loss of surface particles due to friction.
Accelerated aging - A method in which an attempt is made to produce and measure the effects of natural aging in a shorter period.
Accelerator (of vulcanization) - Any substance, which hastens the vulcanization of rubber causing it to take place in shorter time or at a lower temperature. In earlier days basic oxides such as limes, litharge and magnesia were recognized as having this function. Nowadays the important accelerators are organic substances containing either nitrogen or sulfur or both. According to potency, or speed of action, accelerators are sometimes classified as slow, medium, rapid, semi-ultra and ultra-accelerators. Most accelerators enhance tensile properties, and many improve age resistance.
Accelerator Ultra - An accelerator which causes very rapid vulcanization, even at comparatively low temperatures. Tetramethylthiuram disulfide is a typical ultra-accelerator. The dislkyldithiocarbamates and xanthates are also ultra-accelerators.
Acid Resistant - Withstands the action of acids.
Acrylonitrile - Cyanoethylene, vinyl cyanide, CH2=CHCN a volatile liquid boiling at 178.50 C, prepared by dehydration of ethylene cyanhydrin and by catalytic addition or hydrogen cyanide to acetylene. Used in co-polymerization with butadiene in the manufacture of Buna N or Nitrile rubbers.
Activator - A substance, which by chemical interaction promotes a specific chemical action of a second substance. Most accelerators require activators to bring out their full effect in vulcanization, e.g., zinc oxide or other metallic oxides; some accelerators require a fat acid, especially with zinc oxide.
Adapters - A "V" shaped ring either male or female to fit together with "V" shaped rings to form a set of adjustable hydraulic packing.
Adhesion - The state in which two surfaces are held together by interfacial forces which may consist of molecular forces or interlocking action, or both.
Adhesion - The clinging or sticking of two (2) material surfaces to one another. In rubber parlance, the strength of bond or union between two (2) rubber surfaces or plies cured or uncured. The bond between a cured rubber surface and a nonrubber surface, e.g., glass, metal, wood, fabric.
Adhesion Failure - The separation of two materials at the surface interface rather than within one of the materials itself.
Aging - (1) The irreversible change of material properties after environ- mental exposure for an interval of time; (2) Exposing materials to an environment for an interval of time.
Aging - A progressive change in the chemical and physical properties or rubber, especially vulcanized rubber, usually marked by deterioration. Aging may be retarded by the use or antioxidants.
Air Checks - See Air trap below
Air trap - Surface markings or depressions due to trapping air voids in body or part due to entrapped gas between the materials being cured and the mold or press surface.
Air Curing - The vulcanization of a rubber product in air as distinguished from vulcanizing in a press or steam vulcanizer.
Aluminum Seal Rings - Sealing rings for pistons made from high grade aluminum alloy
Amines - Derivatives of ammonia in which one or more or (lie hydrogen atoms is replaced by an alkyl or aryl radical. They are called primary, secondary and tertiary amines according to the number of such substitutions. Example: RNH2, R2NH, AND R3N.
Aniline Point - The temperature in degrees Fahrenheit at which a kerosene, diesel fuel or distillate is miscible with an equal volume of aniline. Low aniline point hydrocarbons tend to swell rubbers to a greater degree than those with a high aniline point.
Anti-Extrusion Rings - Also, called back-up rings or anti-extrusion rings. Used to fit behind rubber o-ring seals to prevent extrusion into the gap between the metal pieces
Antioxidant - Usually organic and nitrogenous. A substance, which inhibits or retards oxidation and certain other kinds of aging. Some antioxidants cause staining or discoloration of the rubber compound on exposure to light and are used only in black or dark-colored goods. Others (phenolic), described as non-staining, are used in white or light-colored goods.
Anti-vibration Mounts - Rubber molded pieces used as padding between a motor and the frame to prevent vibration transfer to the machine to which it is mounted.
Apportionment - Referred to here as a part of Reliability Engineering. Synonymous with the term Reliability Apportionment, which is the assign- ment of reliability goals from system to subsystem in such a way that the whole system will have the required reliability.
AQ Seal - A special purpose hydraulic seal
Assortment Kits - Aconvenient package containing several sizes of the same seal, o-ring or retainer ring.
Autoclave - A pressure vessel into which materials or articles can be placed and exposed to steam under pressure. It is commonly used for vulcanization.
Automatic U-joints - Also called u-cups, ucups or u cups. A "U" shaped sealing ring made from a strong pliable plastic or rubber
"B"
Benchmark Data - The results of an investigation to determine how competitors and/or best-in-class companies achieve their level of performance.
Backrinding - Defect in which the rubber adjacent to the mold parting line shrinks below the level of the molded product, often leaving the parting line ragged and torn.
Backringing - Distortion at the mold parting line usually in the form of wrinkles, folds, tears or indention's. In severe cases may cause over-all dimensional changes.
Baffle Rings - A ring used to slow the flow of fluids along a shaft.
Ball Valve Seats - A teflon ring shaped to fit against the ball in a flow control valve.
Batch - The product of the one mixing operation in an intermittent process.
Bearings - A machined or molded plastic ring used as a guide ring or wear ring in a hydraulic cylinder.
Bearing Seals - A seal ring made to snap-fit into a ball, roller or spherical bearing to exclude dust, dirt or trash.
Bellows - A corrogated rubber or plastic piece which can stretch with a shaft to keep the shaft clean.
Belts - A v-belt, flat belt or drive belt made from plastic or rubber.
Bias Angle - (1) Acute angle between the direction of the cut and the diameter of the wrap in the production of wrapping for hose; (2) Acute angle between the direction of the cut and the direction of the cords in the production of fabric plies.
Bill of Material - Total list of all components/materials required to manufacture the product.
Blister - A cavity or sac that deforms the surface of a material.
Bloom - A liquid or solid material that has migrated to the surface of a rubber, thereby changing appearance. Sometimes confused with surface dust.
Bloom - The coating or efflorescence of sulfur, wax or oilier ingredients of vulcanized rubber, which may gradually appear on the surface of some rubber articles. Bloom depends on the solubility of the substance in the rubber.
Bond - The union of materials by use of adhesives, usually used in related parts vulcanized after attaching.
Bonded Seals - A flat steel washer with a rubber sealing ring molded into the center to fit over a bolt to provide a seal.
Bonding Agents - Substances or mixtures of substances that are used for attaching rubber to metal, fabrics or other substrates. Generally the rubber compound is vulcanized by heat in the process. Cyclized rubber or rubber isomers, halogenated rubber, rubber hydrochloride, reaction product of natural rubber and acrylonitrile, polymers containing diisocyanates, are all used.
Brittleness - Tendency to crack when subjected to deformation.
Bronze Piston Bearings - Guide rings or wear rings made from bronze to fit on a piston in a hydraulic cylinder.
Bumpers - A rubber or plastic part used to prevent metal-to-metal contact.
Buna N - A general term for the copolymers of butadiene and acrylonitrile. Typical commercial polymers are Hycar and Paracril.
Buna S - A general term for the copolymers of butadiene and styrene.
Bushing - A rubber or plastic spacer to provide a wear surface around a shaft.
Butadiene - CH2=CH-CH=CH2. A gaseous hydrocarbon of the diolefin series, boiling at 5~C. Also known as erythrene, divinyl, pyrollylene, Polymerizable to a synthetic rubber, polybutadiene. Butadiene is the chief raw material for making the synthetic rubbers today. Co polymerized with styrene it yields SBR or GR-S; with acrylonitrile the various Buna N or nitrile synthetic rubbers are obtained.
Butt Joint - Joining two ends of material whereby the junction is perpendicular to the ID of an O-ring.
Butyl - A synthetic rubber of the polybutene type exhibiting very low permeability to gases.
Butyl Rubber - A copolymer of isobutylene and isoprene, polymerized almost instantaneously in methyl chloride with aluminum chloride at about ñ140F. Butyl is resistant to ozone and the action of many other corrosive chemicals. Butyl rubber is resistant to permeation by gases
"C"
Canned Wipers - A wiper or scraper ring for a hydraulic cylinder which has a metal outside diameter so that it can be press-fitted into a housing.
Carbon black - Elemental carbon in finely divided form used to reinforce elastomeric compounds.
Carbon Black - Finely divided carbon formed by the incomplete combustion of natural gas or petroleum in large, closed furnaces.
Cast Iron Piston Rings - Piston sealing rings made from cast iron used in hydraulic cylinders.
Catalyst - A chemical in small quantities which accelerates a chemical reaction without itself necessarily becoming part of the final product.
Cellular Rubber - Rubber products which contain cells or small hollow receptacles. The cells may either be open or interconnecting or closed and not interconnecting.
Characteristics Matrix - An analytical technique for displaying the relationship between process para- meters and manufacturing stations.
Checking - The short, shallow cracks on the surface of a rubber product, resulting from damaging action by environmental conditions.
Checking. Sunlight - The development of minute surface fissures as a result of exposing rubber articles to sunlight, generally accelerated by bending or stretching.
Chemical Resistance - The resistance offered by elastomer products to physical or chemical reactions as a result of contact with or immersion in various solvents, acids, alkalis, salts, etc..
Chevron Packings - Also called V-Packing, Vee packing, Chevron Packing, Parachute packing or v-set packing. A complete vee packing set contains multiple "V" shaped sealing rings stacked and nested together with a male adapter on one end and a female adapter on the other end.
Chevrons - See Chevron Packing above.
Chloroprene - 2-Chloro-l, 3-butadiene, a volatile, colorless liquid which boils at 59c., synthesized from acetylene. It is used in the manufacture of neoprene, which is obtained by polymerizing chloroprene under suitable conditions.
C.I. - The abbreviation for cloth- inserted, indicating a sheet of rubber containing one or more plies of fabric covered with rubber.
Clay - Any naturally occurring mineral substance consisting preponderantly of hydrous aluminum silicates, which divided and mixed with water, yields a more or less plastic mass which can be formed and molded, and which will retain its shape on drying. Clays vary greatly in composition but in their purest forms they approach the composition of Kaolinite, A12O3.2Si2.2H20. They are used as compounding ingredients in rubber, some of them having mild reinforcing properties.
Cold Flow - Continued deformation under stress.
Coefficient of Expansion - The coefficient of linear expansion is the ratio of the change in length per degree to the length at 0 Celsius. The coefficient of surface expansion is two (2) times the linear coefficient. The coefficient of volume expansion (for solids) is three (3) times the linear coefficient. The coefficient of volume expansion for liquids is the ratio of the change in volume per degree to the volume at 0 Celsius.
Compact Seals - Multi-piece seal sets, generally used as piston seals in a hydraulic cylinder. Made to fit in a limit space, compact piston seals contain a primary sealing component, guide rings and back-up rings in one convenient set.
Compound - A term applied to either vulcanized or unvulcanized mixtures of elastomers and other ingredients necessary to make a useful rubber-like material.
Compound - 1). In chemistry, it is the material resulting from the chemical union of two or more elements in definite proportions and in which the properties of the individual elements have disappeared. - 2). In rubber manufacture, it is the composition or formula of stock, the ingredients of which, however, may not all be chemically combined and is therefore more of a physical mixture.
Compression Deflection Charateristics - The tests for compression-deflection characteristics constitute methods of compression stiffness measurement. One compression test involves the determination of a load required to case a specified deflection, and another is a compression test in which a specified weight or compressive force is placed on the specimen and the resulting deflection is measured and recorded.
Compression Set - The residual decrease in thickness of a test specimen measured 30 minutes after removal from a suitable loading device in which the specimen has been subjected for a definite time to compressive deformation under specified conditions of load application and temperature. Method A measures compression set of vulcanized rubber under constant load. Method B employs constant deflection.
Compression set - The residual deformation of a material after removal of the compressive stress.
Conductive - To conduct or transmit heat or electricity.
Contact stain - Discoloration of a product by another material or by a rubber article in the area directly touching it.
Copolymer - A polymer consisting of two different monomers chemically combined.
Copolymer - A copolymer is a high polymer consisting of molecules containing large numbers of units of two or more chemically different types in irregular sequence. Butadiene (78) and styrene (22) forms a copolymer known as GR-S.
Copper Seal Rings - Rings made from thin copper formed over fiberous filler to seal in high temperature.
Crazing - A surface effect on rubber articles characterized by many minute cracks.
Creep - The deformation, in either cured or uncured rubber under stress, which occurs with lapse of time after the immediate deformation.
Cross Section - An O-ring as viewed if cut at right angles to the axis showing internal structure.
Crush Washers - A washer made to be crushed to form a seal.
Cup Packings - Sealing devices made in the shape of a cup with outer lips curved upward usually made from rubber, fabric reinforced rubber or polyurethane.
Cure - The act of vulcanization. See Vulcanization.
Cushioning Seals - Sealing rings mounted into a cylinder to cushion the stroke or prevent metal to metal contact.
Custom Molded Products - Special shaped parts molded from rubber or plastic made to fit the machine or device it is used in.
Cut - The distance between cuts or parallel faces of articles produced by repetitive slicing or cutting of long preshaped rods or tubes such as lathe cut washers.
Cystalinity - Stretched natural rubber forms a high oriented state and shows X-ray diffraction patterns and other properties common to truly crystalline materials. The amorphous and crystalline regions are not mechanically separable phases, but the same molecule may at the same time have part of its length in a crystalline, and the remainder In an amorphous region
"D"
Design Failure Mode and Effects Analysis (DFMEA) - An analytical technique used by a design responsible engineer/team as a means to assure, to the extent possible, that potential failure modes and their associated causes/mechanisms have been considered and addressed.
Design for Manufacturability and Assembly - A simultaneous engineering process designed to optimize the relationship between design function, manufacturability; and ease of assembly.
Design Information Checklist - A mistake proofing checklist designed to assure that all important items are considered in establishing design requirements.
Design Reviews - A proactive process to prevent problems and misunderstandings.
Design Validation - Testing to ensure that product conforms to defined user needs and/or requi- rements. Design validation follows successful design verification and is normally performed on the final product under defined operating conditions. Multiple validations may be performed if there are different intended uses.
Design Verification - Testing to ensure that all design outputs meet design input requirements. Design verification may include activities such as:
Design Review - Performing Alternate Calculations - Understanding Tests and Demonstrations - Review of Design Stage Documents Before Release
Dielectric strength - The measure of a product's ability to resist passage of a disruptive discharge produced by an electric stress; the voltage that an insulating material can withstand before breakdown occurs,
Discs - Flat, round saucer shaped pieces made from rubber or plastic.
Disperse - To cause particles or molecules of matter to separate and become uniformly scattered throughout a medium. In a rubber compound, the particles of compounding ingredients are dispersed in the rubber. In latex, rubber globules are dispersed in an aqueous medium.
Distributor Seals - Sealing rings used to seal in oil and seal out dust, dirt or trash on an automobile engine electric spark distributor.
Double Acting Seals - Seal rings which seal in two direction, on the push and the pull stroke of a hydraulic or pneumatic cylinder.
Duck - A compact, firm, heavy, plain weave fabric made from cotton or synthetic fibers, or a combination of both. Duck is also known as canvas, army duck, belt duck harvester duck, hose duck and shoe duck.
Dumb-Bell (Test-Piece) - In the physical testing of rubber, a strip test-piece is used that is shaped like a dumb-bell, i.e., constricted in the middle and flaring out at the ends, as distinguished from circular or ring test-piece. The dumb-bell is the most commonly used form or test-piece. Dimensions are set by ASTM standards.
Duocone Seals - A special cone-shaped sealing ring.
Durability - The probability that an item will continue to function at customer expectation levels, at the useful life without requiring overhaul or rebuild due to wearout.
Durometer - An instrument for measuring the hardness of vulcanized rubber and plastic. See Shore
Durometer - The most common Durometer. Type A or A-2 is an instrument for determining the hardness or rubber by measuring its resistance to the penetration (without puncturing) of a blunt indentor point impressed on the rubber surface against the action of a spring; a hand and special scale indicate the resistance to penetration 01. "hardness". The scale reads from zero (0) to 100, zero (0) being very soft and 100 being very hard. The Type D durometer has a sharp indentor point and is used to measure varying degrees of hard rubber up to ebonite.
Dust Seals - Seals used to exclude dust from a machine or device
"E"
Elasticity - The property of an article which tends to return to its original shape after deformation.
Elasticity - A property of any material which makes it tend to recover its original dimensions after removal or the force which deforms it.
Elastic Modulus - The value of the load (in pounds per square inch of original cross-section) required to give an intermediate elongation, is usually called the modulus at that elongation. The expression used is "modulus at 300 percent elongation." Tensile-stress observations of this sort arc exceedingly useful in characterizing a particular compound, since by indicating the position and shape of the stress-curve. They show the relative toughness of the vulcanizate.
Elongation - Extension produced by a tensile stress.
Elongation - In the physical testing of rubber, the increase in length of a test-piece when stretched, usually expressed as a percentage of the original length; for example a 1" piece stretched (0 6" has an elongation of 500%. Elongation at break -- the elongation of a test-piece at thc moment of rupture, usually expressed as percentage of the original length.
Embrittlement - A rubber compound becoming brittle during low or high temperature exposure or in the process or aging.
Encapsulated O-rings - A rubber o-ring with a thin jacket of PTFE or Teflon surrounding the softer core material, which allows it to be used in chemical applications.
Excluders - Also called wipers or scrapers - used in a hydraulic or pneumatic cylinder to exclude and scrape the rod clean.
Expanded Rubber - Cellular rubber having closed cells made from a solid rubber compound.
Extrusion - 1) Distortion, under pressure, of portion of seal into clearance between mating metal parts. 2) Material, under pressure, which is forced through the opening of a die in order to obtain a desired cross sectional shape
"F"
Face Seals - Rubber rings used like a gasket between two flat pieces of metal.
Failure Modes Analysis (FMA) - A formal, structured procedure used to analyze failure mode data from both current and prior processes to prevent occurrence of those failure modes in the future.
Fastener Seals - See Bonded Seals.
Feasibility - A determination that a process, design, procedure, or plan can be successfully accom- plished in the required time frame.
Fibre Seal Rings - Aa gasket or other die cut, water-jet cut or formed ring used to seal between two surfaces.
Filler - Any compounding material, usually in powder form, added to rubber in a substantial volume to improve quality or lower cost. The most important reinforcing filler is carbon black. The most important inert filler, diluent or extender is whiting.
Finish, Mold - The quality or appearance of the machined surface of a mold.
Finish, Product - The quality or appearance of the surface of a rubber product.
Finite Element Analysis - A technique for modeling a complex structure. When the mathematical model is subjected to known loads, the displacement of the structure may be determined.
Flange Packings - A pipe flange gasket.
Flange Seals - A seal used on the bolt-up flange on a hydraulic systems - usually on the hose fitting or pipe flanges.
Flash - Excess rubber on a molded product resulting from cavity overflow at the parting lines where the mold sections are separated.
Flex cracking - A cracking condition of the surface of rubber articles such as tires and footwear, resulting from constantly repeated bending or flexing in service.
Flow Marks - Surface imper- fections due to improper flow and failure of stock to knit or blend with itself during the molding operation.
Friction - Resistance to motion due to the contact of surfaces
"G"
Gap Seals - A seal ring used to seal between the gaps of metal or plastic.
Gasket - A flat, non-moving, compressible rubber-like device squeezed between two flat sufaces forming a static seal. Gaskets can be made from homogeneous rubber, fabric reinforced rubber, fiberous materials with rubber binders, flexible graphite, PTFE and many other materials. Some gaskets are made from a combination of metal and fiberous materials and some are all metal. An o-ring, while not flat is also referred to as a gasket at times. (See: http://www.epm.com/ptfe_parts.htm and http://www.epm.com/ptfe_gaskets.htm and http://www.epm.com/pg1314.htm for gasket types)
Gate - (rubber injection or transfer mold) - The orifice used to control the flow of rubber, and through which a shaped cavity in a mold is filled with rubber.
Gland Bearing Rings - Also called guide rings or wear rings used as a bearing surface for the rod of a hydraulic ram or cylinder.
Gland Seals - Seals or packings used a the main sealing device in a ram or cylinder.
Glandsele - The brandname of a type of rod seal.
Glass Temperature (Tg) - The temperature at which a rubber becomes glass-like. a more recent name for Second Order Transition point.
Glass transition point - Temp- erature at which a material loses its glass-like properties and becomes a semi-liquid.
Globe Valve Discs - Teflon rings used to seal in a globe valve.
Glyd Ring - Also known as wear rings or guide rings - made from plastic, teflon or soft metal to act as a bearing surface for a cylinder rod.
Grain - The unidirectional orientation of rubber or filler particles occurring during pro- cessing (extrusion, milling, calen- dering) resulting in anisotropy of a rubber vulcanizate.
Grease Seals - Also called oil seals, rotary seals or shaft seals. Made of rubber to seal grease in a housing with a rotating shaft.
Green strength - (1) The resistance to deformation of a rubber stock in the uncured state. (2) Uncured adhesion between plied or spliced surfaces.
Grommets - A rubber ring used to fit into a hole in sheet metal aloow wires, shafts or rod to exit the housing without touching the metal.
Guiding Elements - Wear rings, guide rings, guiding rings, bearing rings for hydraulic cylinder rods.
Guide Rings - See also wear rings, guide rings or bearing rings. Usually made from a form of Teflon or PTFE
"H"
H-ring - Also called H-Wiper. An "H" shaped rod wiper ring made from NBR or polyurethane for a hydraulic or pneumatic cylinder.
Hardness - The relative resistance of rubber to the penetration (without puncturing) of a blunt point impressed on its surface.
Hat Packings - Usually made from leather, it is ised as a rod seal or ram seal in a hydraulic cyinder.
Heat history - The accumulated amount of heat a rubber stock has been subjected to during process- ing operations, usually after incorporation of the vulcanizing agents. Incipient cure or scorch can take place if heat history has been excessive.
HiClean - A brand name for rod wipers.
High Pressure Seals - Seals to be used in high pressure hydraulic applications made from teflon, urethane or fabric reinformced material.
Hydraulic Cylinder Kits - A selection of seals used to completely repair a cylinder or ram.
Hydraulic Packings - Packing rings used in a hydraulic ram or cylinder,
Hydrolysis - Chemical decom- position of a substance involving the addition of water.
Hysteresis (a) - The heat generated by rapid deformation of a vulcanized rubber part. It is the difference between the energy of the deforming stress and the energy of the recovery cycle.
Hysteresis (b) - Hysteresis or energy loss is the difference between the work input and the work output as measured under the curves or extension and retraction (stress and elongation curves). The difference becomes heat build-up
"I"
Insert - A part, usually metal, which is placed in a mold and appears as an integral part of the molded product.
Internal Mixer - An enclosed mixing machine for rubber or other suitable material, inside or which are two (2) heavy mixing rotors which revolve in opposite directions with a small clearance between themselves and tine enclosing walls. The mixing chamber is jacketed or otherwise arranged for water-cooling, and is provided with a feeding hopper which can be closed by means of a pneumatically operated, vertical ram. Leading examples are the Banbury, the Boiling and the Shaw mixers.
IRHD (International Rubber Hardness) - For complete definition see ASTM D 1415-68 Standard Method of Test for International Hardness of Vulcanized Natural And Synthetic Rubbers.
Isolators - A term used to describe a bearing seal - which replcases an oil seal providing more reliable sealing
"K"
Kaizen - Taken from the Japanese words kai and zen where kai means change and zen means good. The popular meaning is continual improvement of all areas of a company not just quality.
Kantseal - A brandname of a special seal.
Knit mark - Where raw stock did not unite into a homogeneous mass during the vulcanization. This is also called poor knitting. See Flow marks
K-Type Fluid Seals - A "K" shaped sealing ring used in a hydraulic or pneumatic cylinder
"L"
Labyrinth Seals - A non-contacting, rotary seal with a series of internal grooves to divert the flow and lubricating fluids in the direct of its source used on a shaft.
Lantern Rings - A spacer ring with grooves and port holes used in the stuuffing box of a pump or other rotating equipment utilizing braided packings, to allow an outside source of lubrication.
Lathe Cut Seals - A seal or gasket ring cut square on a lathe.
Lip Packing & Rings - Could be the description of a u-cup or of an oil seals. A seal with a lip design to provide sealing.
Lip Seals - Seal rings having lips to provide a flexible, dynamic sealing against a shaft.
Loaded Lip Seals - A hydraulic u-cup which has an o-ring or quad ring fitted into the u-shaped groove to assure good low pressure sealing on a reciprocating shaft.
Loaded U-Cups - Same as loaded lip seals.
Low Film - A thin film of oil on the shaft of a hydraulic cylinder.
Low temperature flexibility - The ability of a rubber product to be flexed, bent, or bowed at specified low temperature without loss of serviceability
"M"
Magnesia - (a) Heavy calcined: Magnesium oxide by calcination of magnesite (natural magnesium carbonate), and then ground for use as a compounding ingredient for molded goods and hard rubber. (b)Light calcined: Magnesium oxide by calcination of purified magnesium carbonate and/or magnesium hydroxide. It has a fine particle size and a bulk factor of 10 to 30 pds. per cubic ft. Used chiefly in neoprene stocks. (c)Extra light calcined: Prepared similarly by calcination of magnesium carbonate, but with a bulk factor of 4 to 6 pds. per cubic ft. Used chiefly in neoprene stocks.
Maintainability - The probability that a failed system can be made operable in a specified interval or downtime.
Mandrel - A bar, serving as a core, around which rubber is extruded, forming a center hole.
Masterbatch - A preliminary mixture of rubber and one or more compound ingredients for such purposes as more thorough dispersion or better processing, and which will later become part of the final compound in a subsequent mixing operation.
Master Batch - A mixture of rubber with one (1) or more ingredients in definite but higher concentrations than those in which they normally occur in a complete rubber mix. Used for efficiency in compounding, and also to avoid the handling of small quantities of accelerators, antioxidants, color, etc...
Masticate - To work rubber on a mixing mill or in an internal mixer till it becomes soft and plastic. To break down. MASTICATOR - A machine for plasticizing rubber by mechanical work.
Metal O-rings - An o-ring usually made from hollow stainless steel tubing, with a small vent hole.
Mill - A machine with two horizontal rolls revolving in opposite directions used for the mastication or mixing of rubber.
Mill - A machine consisting of two (2) adjacent, heavy, chilled iron rolls set horizontally, and which revolve in opposite directions (i.e., upper surfaces rotate), used for the mechanical working of rubber Mills are of different types. For masticating, and mixing compounds the rolls are smooth and revolve with differential speed. For crepeing and washing rubber, mills have scored or fluted rolls and differential speeds and may be equipped to spray the rubber with water. Mills with even-speed rolls are occasionally used for different purposes. Mills are corridor hollow and equipped for internal heating with steam or cooling with water.
Mixing - The process of incorporating the ingredients or a rubber compound into the rubber, usually done on a mixing mill or in an internal mixer. The mixing process consists in (1) breaking down the rubber, (2) gradual incorporation or compounding ingredients, (3) final working of the rubber after all ingredients are in, and (4) removing the mixed compound from the mill in sheets.
Modulus - The ratio of stress to strain. In the physical testing of rubber, the load necessary to produce stated percentage of elongation, compression or shear.
Modulus - (See Elastic Modulus) In the physical testing of rubber, the ratio of stress to strain, i.e., the load in pounds per square inch or kilos. per square cm. of initial cross-sectional area necessary to produce a stated percentage-elongation. It is a measure of toughness, is influenced by pigmentation, state of cure, quality or rubber and other factors.
Mold Register - Means used to align the parts of a mold.
Mooney scorch - A measure of the incipient curing characteristics of a rubber compound using the Mooney viscometer.
Mooney Viscometer - A laboratory testing machine for measuring the plasticity of raw rubber or unvulcanized rubber compounds. A knurled steel rotor disc winch is centrally embedded iii the heated rubber specimen firmly held in a cavity under pressure is caused to rotate at a low speed (2 rpm). The resistance offered by the plastic rubber mass to the rotation of the rotor disc is the measure of the plasticity of the rubber. The machine is also used to determine the scorch characteristics of rubber mixes.
Mooney viscosity - A measure of the viscosity of a rubber or rubber com- pound determined in a Mooney shearing disc viscometer.
Mounts - A rubber molded part used as a motor mount or to mount device against a frame without allowing vibration to pass through the mounting
"N"
Nebar - A special type of gasket material used in electrical transformers.
Neoprene - Synthetic rubber made by polymerizing 2-chlor-1, 3-butadiene. Neoprene compounds are rioted for their resistance to oil, sunlight and ozone. There are various types, most of which are vulcanizable without the use or sulfur.
Nerve - The elastic resistance of unvulcanized rubber or rubber compounds to permanent defor- mation during processing.
Nilos Rings - A special seal ring.
Nitrile Rubber - A generic term comprising the various copolymers of butadiene and acrylonitrile. the copolymers vary essentially in butadiene-acrylonitrile ratios, Mooey values and staining properties. They are resistant to solvents, oils, and greases and to bent and abrasion. Some trade names are Chemigum, Krynac, Nipol, Hycar, and Paracril. The Germans first produced the nitrile rubbers and called them Buna N and Perbunan.
Non-Blooming - The absence of a bloom.
Novathan - A name for a type of polyurethane sealing material
"O"
Oil Resistance - Ability to withstand swelling by a specified oily liquid for specified time and temperature, expressed as percentage swelling or volume increase of specimen. Oil Resistance - as applied to vulcanized elastomer compositions: resistance to change in size and shape and resistance to loss in physical (mechanical) properties due to contacts with or immersion in an oil.
Oil Resistant - Ability of a vulcan- ized rubber to resist the swelling and deteriorating effects of various type of oils.
Oil Seals - Also called grease seals, rotary seals or shaft seals. Made of rubber to seal grease in a housing with a rotating shaft.
Open Cell - A cell not totally enclosed by its walls and hence interconnecting with other cells.
Open Steam Cure - A vulcanization process that takes place under direct steam pressure in an autoclave. It is used where direct pressure molding is not possible. In -the case of vulcanization of sheeting, or coated fabrics, rolls of product are wound onto steel drums (with suitable interleaf) which are placed in the autoclave for cure. Some tubing arid shaped products are placed on pans for extra curing.
Optimum Cure - State of vulcan- ization at which maximum desired property is attained.
Optimum Cure -The physical properties of a rubber compound vulcanized at a given temperature for increasing periods of time undergo continuous change. For example, tensile strength may rise to a maximum, continue on a plateau, and then decline; whereas breaking elongation may continuously decrease. Therefore it is impossible to choose any one time of cure at which every property will be at its optimum, hence optimum cure is a compromise and may be considered as that time required to obtain the combination of properties most desirable for the article under consideration.
Opti-Seal - A special seal ring to provide optimum sealing.
O-rings - O-ring seals are circular rings of various cross-sectional configurations installed in a gland to close off a passageway and prevent escape or loss of a fluid or gas. An oring is specified by three of its features: its dimensions, material, and hardness. Material and hardness specify the elastomeric compound and Shore A (durometer) hardness of the compound that is used to manufacture the o-ring. An O-ring's dimensions are described by stating its inside diameter (I.D.) and its cross-section. Designing for o-rings depends on three major and interrelated variables: the operating conditions or environment the seal will experience, the gland geometry into which the seal will be installed and the three variables account for the fact that there are so many different types of seals and applications.
Overcure - A state of excessive vulcanization resulting from overstepping the optimum cure, i.e., vulcanizing longer than necessary to attain full development of physical strength. Manifested by softness or brittleness, and impaired age resisting quality of the vulcanizate.
Oxidation - Active oxygen organic materials. This is called oxidation. Rate of degradation will increase with rising temperatures.
Ozone - An allotropic from oxygen, (03), produced by (he action of electrical discharges in air. It is a gas with a characteristic odor, and Is a powerful oxidizing agent. Rubber compounds in a stretched condition are susceptible to the deteriorating action of ozone in the atmosphere, which results in a cracked condition.
Ozone cracking - The surface cracks, checks, or crazing caused by exposure to an atmosphere contain- ing ozone
"P"
Packaging - A unit that provides protection and containment of items plus ease of handling by manual or mechanical means.
Packing - An adjustable sealing device on a ram, valve stem or pump shaft --- old technology and leakage is required for lubrication. If packing leaks, it is simply tightened slightly to 'control' the leakage. For pumps and valves, packings can be rope-like, braided into continuous lengths and then cut to size to fit a shaft. For hydraulic applications, v-shaped fabric reinforced rubber rings are used. Early hydraulic packings were made from leather. For a rubber o-ring, that particular item can be found called a seal, a gasket and a packing ring - even in U.S. government technical specifications dating back 50 years. (See: http://www.epm.com/pg7.htm and http://www.epm.com/hydraulic_materials.htm)
Pads - A rubber part used as an anti-vibration device.
Parachute Packings - Also called V-Packing, Vee packing, Chevron Packing, Parachute packing or v-set packing. A complete vee packing set contains multiple "V" shaped sealing rings stacked and nested together with a male adapter on one end and a female adapter on the other end.
Parbacks - A back-up ring with a concave shape on one side, used as an anti-extrusion ring for an o-ring.
Permanent set - The amount by which an elastic material fails to return to its original form after deformation.
Permanent Set - The amount by which an elastic material fails to return to its original form after a deformation. in the case of elongation, the difference between the length after retraction and the original length, expressed as a percentage of the original length, is called the permanent set. Permanent set is dependent on quality and type of rubber, degree and type of filler loading, state of vulcanization, and amount of deformation.
Permeability - To permit passage of gas through the molecular structure of a given material.
Piston Bearing Rings - Also called guide rings, wear rings, piston guide rings.
Piston Guide Rings - Also called guide rings, wear rings, piston rings usually made from nylon or POM.
Piston Rings - Any ring used on the piston of a hydraulic or pneumatic cylinder.
Piston Seals & Packings - Any seal or packing ring used on the piston of a hydraulic or pneumatic cylinder.
Piston T-Seals - A "T" shaped rubber seal, with back-up rings of a harder material on each side, used as a piston seal.
Plasticity - (1) A measure of the resistance to shear of an unvulcanized elastomer; (2) A tendency of a material to remain deformed after reduction of the deforming stress to or below its yield stress.
Plasticizer - A substance that softens or plasticizes another substance through its solvent action.
Plunger Pump Seals - Packing seal rings used to seal the plunger of a reciprocating pump.
Plunger Seals - Sealing rings used on a plunger.
Plugs - A cone shaped rubber part used to be forced into a tube end or hole to make a complete seal.
Pneumatic Seals - Any seal or packing ring, usually flexible rubber, used to seal against compressed air instead of hydraulic fluid or other liquid.
Pock marks - Uneven blister-like elevations, depressions, or pimpled appearance.
Poisson's Ratio - The ratio of lateral concentration per unit of diameter to longitudinal extension per unit of length in a bar of material longitudinally stressed. For a body which does not change its volume on deformation, it is 0.5. For metals, the ratio is usually considerably less than 0.5. In the case of vulcanized rubber, pure gum, having practically no volume change on extension, shows a ratio of approximately 0.5 for small deformations; compounded rubber may increase in volume on extension, consequently the ratio drops below 0.5. For rubber the ratio is constant only for small extensions.
Polymer (a) - A material formed by the joining together of many (poly) individual units (mar) of a monomer.
Polymer (b) - A polymer is a very long chain of units of monomers prepared by means of an addition and/or a condensation polymerization. The units may be the same or different. There are copolymers, dipolymers, tri- or terpolymers, quadripolymers, high polymers, etc...
Porosity - The presence of numer- ous small holes or voids.
Post cure - Heat or radiation treatment, or both, to which a cured or partially cured thermosetting plastic or rubber composition is subjected to enhanced the level of one or more properties.
Preliminary Bill of Material - An initial Bill of Material completed prior to design and print release.
Preliminary Process Flow Chart - An early depiction of the anticipated manufacturing process for a product.
Press-in Wipers - A wiper or scraper ring for a hydraulic cylinder which has a metal outside diameter so that it can be press-fitted into a housing.
Pressure - (No, Low, Poor) - May refer to inadequate pressure in mold/press, oven heater or autoclave during Cure. Symptoms may be porosity, unfills, blister, low adhesions, etc...
Process Failure Mode and Effects Analysis (PFMEA) - An analytical technique used by a manufacturing responsible engineer/ team as a means to assure that, to the extent possible, potential failure modes and their associated causes/mechanisms have been considered and addressed.
Processing Aids - Waxes, low molecular weight polyethylene, metal soaps, petroleum oils, and other agents which dissolve or lubricate rubbers, soften them and act as processing aids.
Product Assurance Plan - A part of the Product Quality Plan. It is a prevention-oriented management tool that addresses product design, process design, and when applicable software design.
Production Trial Run - Product made using all production tools, processes, equipment, environment, facility; and cycle time.
Protectors - A rubber or plastic cap or cup shaped ring used to protect threads or fragile items during shipping or assembly.
Proto-Types - A part that is made during the design process to determine the feasibilty or suitability of a project.
Proto Types - See proto-types
Pusher Rings - A ring that fits against another sealing device to push it in order to activate it or enegize it in the absence of pressure or in low pressure applications
"Q"
Quality Planning Sign-Off - A review and commitment by the Product Quality Planning Team that all planned controls and processes are being followed
"R"
Radial Shaft Seals - Also called grease seals, rotary seals or shaft seals. Made of rubber to seal grease in a housing with a rotating shaft.
Rebound - Rebound is a measure of the resilience, usually as the percent- age of vertical return of a body which has fallen and bounced.
Rebound test - Method of deter- mining the resilient properties of vulcanized rubber, by measuring rebound of a steel ball or pendulum falling from a definite height onto a rubber sample.
Register - The accurate matching of the plates of a mold.
Reinforcing Agent - In rubber compounding, a finely-divided substance or filler which, when properly dispersed in rubber, produces improved physical properties in the vulcanized product, i.e., greater energy of resilience, greater resistance to abrasion, higher modules of elasticity and tensile strength Certain grades of furnace blacks are the most important reinforcing agents for black stocks. For light-colored stocks, calcium silicate, precipitated calcium carbonates, silica and clay are the most commonly used.
Reliability - The probability that an item will continue to function at customer expectation levels at a measurement point, under specified environmental and duty cycle conditions.
Reliability Apportionment - See Apportionment.
Reproducibility - The variation in the average of measurements made by different operators using the same gage when measuring identical characteristics of the same parts.
Resilience - The property of a material that enables it to return to its original size and shape after removal of the stress which causes the deformation.
Resilience - The energy returned by vulcanized rubber when it is suddenly released from a state of strain or deformation. The returned energy, expressed as a percentage of the original potential energy, is a measure of the resilience. Various rebound testers are used to measure rebound (Bashore, Lupke).
Retarder - Any substance whose presence ill relatively small proportion retard a chemical reaction. Specifically, a substance which when added in small proportion to a rubber compound, retards the rate of vulcanization. An anti-scorching agent; examples, phthalic anydride, salicylic acid.
Reversion - (1) A deterioration of physical properties that may occur upon excessive vulcanization of some elastomers, evidenced by a decrease in hardness and tensile strength, and an increase in elonga- tion; (2) A similar change in proper- ties after air aging at elevated temperatures. Natural rubber, butyl, polysulfides and epichlorobydrin polymers exhibit this effect (extreme reversion may result in tackiness). Most other polymers will harden and suffer loss of elongation on hot air aging.
Reversion - The softening of some vulcanized rubbers when they are heated too long. Usually accompanied by an increase in extensibility, a decrease in tensile strength and a lowering of the stress required to produce a given elongation. Extreme reversion may result in tackiness; the rubbers "revert" to an unvulcanized then to a non-polymeric condition.
Rheology - The science of deformation and flow of matter. Deals with the laws of plasticity, elasticity and viscosity and their connections with paints, plastics, rubber, oils, glass, cement, etc...
Rheometer (Monsanto) - An oscillating disk cure meter used for determining vulcanization charac- teristics of a rubber compound.
Rimseal - A sealing device used on the rim of round plate or rim of a wheel.
Rings - Round sealing devices.
RMS - Root Mean Square - The measure of surface roughness, obtained as the square root of the sum of the squares of micro-inch deviation from true flat.
Rod Seals - Any seal used on the rod of a hydraulic or pneumatic cylinder made from rubber or plastic.
Rollers - A round, flat ring used as a wheel or guide.
Rotary Seals - Seals used on rotating shafts - see lips seals, grease seals, oil seals.
Rotocure - Rotory press.
Roto Glyd - A flat plastic, PTFE or Teflon ring used on a rotatinfg shaft.
Rubber - A material that exhibits elastic properties that allow recovery from large deformations quickly and forcibly. A tough, waterproof substance obtained through polyme- ric synthesis or in natural form from the sap of various species of plants or trees.
Rubber Latex - Colloidal aqueous emulsion of an elastomer
"S"
Scorch - Premature vulcanization of a rubber compound, generally due to excessive heat history. Also see Mooney Scorch;
Scorching - A term frequently used to denote premature vulcanization of a rubber compound, occurring on a mill or calender, or in an extruder. Same as burning or "setting up".
Scraper Rings - A ring which rides tight against a rod, with a sharp lip to scrape or wipe off excess oil, dirt or dust in a hydraulic or pneumatic cylinder.
Scrapers - Also, called a wiper ring - A ring which rides tight against a rod, with a sharp lip to scrape or wipe off excess oil, dirt or dust in a hydraulic or pneumatic cylinder.
Seal - An elastomeric ring-shaped component used in a constantly moving, dynamic application - either reciprocating or rotating shaft - providing a near positive no leak mode in a hydraulic cylinder, ram, mixer or gear box - as examples. (Note: no sealing device is absolutely 100% positive). Seal rings can be u-shaped, v-shaped, o-shaped, metal inserted, radial lipped, multiple lipped or a simple flat ring. (See: http://www.epm.com/additional_types.htm and http://www.epm.com/additional_types2.htm for other types of seals)
Seal Cages - A special device used to assist a seal ring.
Seal Kits - Any group of seals, o-rings, wiper rings and back-up rings used to repair a specific hydraulic cylinder.
Seal-Master Machine Instant Seal Making Machine - A special CNC controlled machine for making seals instantly (See: www.epm.com/sealmaster.html)
Seats - A stationary ring which is pressed into a housing and acts as the matching face of a mechanical seal.
Shaft Repair Kits - A package of seals which includes all seals needed to repair the rod end of a hydraulic or pneumatic cylinder.
Shaft Seal & Packings - Any seal ring used on the rod of a hydraulic ram.
Shallex - A brand name for vee packings, chevron or parachute packings.
Sheet Materials - Rubber or fiberous material used to make gaskets.
Shims - Flat, thin metal gasket-like parts used as spacers to position machiery or align equipment.
Shore A Hardness - An indentation method of rating the hardness of rubber using a Shore Durometer with the A scale from 0 to 100.
Shrinkage - Contraction of molded rubber upon cooling.
Skin - A relatively dense layer at the surface of a cellular material.
Simulation - The practice of mimick- ing some or all of the behavior of one system with a different, dissimilar system.
Simultaneous Engineering - A way of simultaneously designing products, and the processes for manufacturing those products, through the use of cross functional teams to assure manufacturability and to reduce cycle time.
Single Acting Seals - Rings which are designed to seal only in one axial direction.
Slip O-rings - A type of ring which fits over an o-ring to relieve friction.
Smoke sheets - Plantation natural rubber sheets that, after passing through a mill that puts the conven- tional ribbing design on them, are washed and hung on racks in a smoke house where they undergo a combined smoking and drying process.
Snap-in Wipers - A rod wiper which is made from one homogeneous material, either rubber or polyurethane, which is designed to snap-fit into a matching machined groove.
Solosele - The brand name of a particular single acting u-cup seals.
Spacers - A ring with flat sides to provide specific dimensional spacing between two components.
Special Characteristics - Product and process characteristics designated by the customer including govern- mental regulatory and safety; and/or selected by the supplier through knowledge of the product and process.
Specific gravity - The ratio of the mass of a unit volume of a material to that of the same volume of water at a specified temperature.
Speedi Sleeves - The name of a thin, round tube which slips over a rotating shaft to provide a new, clean sealing surface for a rubber lip oil or grease seal.
Splice - A joint or junction made by lapping or butting edges, straight or on a bias, and held together through vulcanization or mechanical means.
Spring Energized Seals - Any sealing ring that utilizes a metal garter spring or finger spring to assist in energizing the seal when there is not sufficient pressure.
Spring Loaded Seals - See spring energized seals above.
Sprue - (1) The primary feed channel that runs from the outer face of an injection or transfer mold to mold gate in a single cavity mold or to runners in a multiple cavity mold; (2) The piece of material formed or partially cured in the primary feed channel.
Sprue mark - A mark, usually elevated, left on the surface of an injection or transfer molded part, after removal of the sprue.
Squeeze - Cross section diametrical compression of O-ring between bottom surface of the groove and surface of other mating metal part in the gland assembly.
State of cure - The cure condition of a vulcanizate relative to that at which optimum physical properties are obtained.
Stat-O-Seals - See bonded seals.
Stem Packing - A type of homogeneous or multi-braided packing used on the stem of a valve to stop leakage.
Stepseal - A seal ring with a step cut groove to match up against a housing machine to fit.
Stoppers - See plugs.
Stress - Force per unit of original cross sectional area required to stretch a specimen to a stated elongation.
Stress relaxation - The decrease in stress after a given time of constant strain.
Substrate - A material upon the surface of which an adhesive promo- ter is applied for any purpose such as bonding or coating.
Subsystem - A major part of a system which itself has the charac- teristics of a system, usually consisting of several components.
Swelling - The increase in volume or linear dimensions of a specimen immersed in a liquid or exposed to a vapor.
Swelling - The property of raw or unvulcanized rubber absorbing organic liquids such as benzene, gasoline, etc., arid swelling to many times its original volume. in a general sense, it may be any increase in volume of a solid substance caused by the absorption of a liquid.
Switch Seals - Seals used in electrical switching devices to keep moisture out.
System - A combination of several components or pieces of equipment integrated to perform a specific function
"T"
Tack - The ability to adhere to itself; a sticky or adhesive quality.
Team Feasibility Commitment - A commitment by the Product Quality Planning Team that the design can be manufactured, assembled, tested, packaged, and shipped in sufficient quantity at an acceptable cost, and on schedule.
Tear Resistance - Resistance to tearing, measured as the force required to tear completely across a specially-designed nicked rubber test piece or right-angled test piece by elongating it at a specified rate. Express in lbs. per inch of thickness of specimen.
Tear Strength - The maximum load required to tear apart a specified specimen, the load acting substan- tially parallel to the major axis of the test specimen.
Telescopic Packing - Packing sets used on telescopic cylinders, each stage having a different diameter.
Temperature Range - Lowest temperature at which rubber remains flexible and highest temperature at which it will function.
Tensile Strength - Force in pounds per square inch required to cause the rupture of a specimen of a rubber material.
Tensile Strength - The capacity of a materiel to resist a force tending to stretch it. Ordinarily the term is used to denote the force required to stretch a material to rupture, and is known as "breaking load", "breaking stress "ultimate tensile strength". lit rubber testing, it is the load in lbs. per square inch or kilos per square centimeter of original cross-sectional area, supported at the moment of rupture by a piece of rubber being elongated at a constant rate.
Tensile Stress - The applied force per unit of original cross sectional area of a specimen.
Tensile Stress at Given Elongation - The tensile stress required to stretch a uniform section of a specimen to a given elongation.
Tension Set - The extension remaining after a specimen has been stretched and allowed to retract.
Thermal Deterioration - The elongation at the moment of rupture.
Thermoplastic Rubber - Rubber that does not require chemical vulcanization and will repeatedly soften when heated and stiffen when cooled; and which will exhibit only slight loss of its original charac- teristics.
Thermosetting Rubber - Chemi- cally vulcanized rubber that cannot be remelted or remolded without destroying its original characteristics.
Thorseals - A brand name for a polyurethane hydraulic u-cup seal.
Timing Plan - A plan that lists tasks, assignments, events, and timing required to provide a product that meets customer needs and expec- tations.
Tips - A rubber cup-shaped part used on the end of a rod or shaft to provide shock resistance or cushioning.
Trim - The process Involving removal of mold flash.
T-Seals - A "T" shaped rubber sealing ring with harder back-up rings on each side for rod or piston sealing.
Tube Springs - A rubber or plastic cushioning device used to assist spring or cover the outer portion of a coil spring
"U"
U-Cup - a type of seal used in a hydraulic or pneumatic cylinder. It's cross section is U-shaped to allow oil to energize the seal body to properly block oils and seal correctly.
U-cups - A "U" shape cup sealing ring designed to seal in one direction along a shaft or rod in a hydraulic or pneumatic cylinder.
Undercure - Degree of cure less titan optimum. May be evidenced by tackiness, loginess (lack of snap or resilience), or inferior physical properties.
Ultimate Elongation - The maxi- mum elongation prior to rupture.
Undercure - State of vulcanization less than optimum. It may be evidenced by tackiness or inferior physical properties.
U-Packings - A "U" shape cup sealing ring designed to seal in one direction along a shaft or rod in a hydraulic or pneumatic cylinder
"V"
V-Packing - Also known as Vee Packing, Vee Sets, Chevron Packing, Parachute Packing. A multiple ring set of packings whose center rings or sealing rings are V-shaped to form sealing lips. The V-rings stack on top of each other and have a male and female adaptor on each end to make the set flat. This packing type is adjustable.
Valve Discs - A PTFE or Teflon disc used on a valve as a seat to provide positive sealing whn shut off.
Value Engineering (Value Analy- sis) - A planned, clean sheet approach to problem solving, focusing on specific product design and process characteristics. Where value analysis is employed to improve value after production has begun, value engineering is employed to maximize value prior to expend- itures of facilities and tooling money.
Valve Packing - Braided packing used in the stuffing box of a valve stem to make a positive seal.
Valve Seats - A PTFE or Teflon disc or ring used on a valve as a seat to provide positive sealing whn shut off.
Valve Stem Packing - Braided packing used in the stuffing box of a valve stem to make a positive seal.
Vee Packing - Also called V-Packing, Vee packing, Chevron Packing, Parachute packing or v-set packing. A complete vee packing set contains multiple "V" shaped sealing rings stacked and nested together with a male adapter on one end and a female adapter on the other end.
Vibration Mounts - A rubber piece used to eliminate vibration between to components.
Viscosity - The resistance of a material to flow under stress.
Voice of the Customer - Customer feedback both positive and negative including likes, dislikes, problems and suggestions.
Voice of the Process - Statistical data that is feedback to the people in the process to make decisions about the process stability and/or capability as a tool for continual improvement.
Voids - The absence of material or an area devoid of materials where not intended.
V-Packings - Also called V-Packing, Vee packing, Chevron Packing, Parachute packing or v-set packing. A complete vee packing set contains multiple "V" shaped sealing rings stacked and nested together with a male adapter on one end and a female adapter on the other end.
V-Rings - Also called V-Packing, Vee packing, Chevron Packing, Parachute packing or v-set packing. A complete vee packing set contains multiple "V" shaped sealing rings stacked and nested together with a male adapter on one end and a female adapter on the other end.
Vulcanizate - Rubber in its cured or vulcanized state.
Vulcanizating Agent - Any material which can produce in rubber the change in physical properties known as vulcanization, such as sulfur, polysulfides, organic polynitro derivatives, peroxides arid quinone dioximes.
Vulcanization - An irreversible process during which a rubber compound through a change in its chemical structure (for example, cross-linking) becomes less plastic and more resistant to swelling by organic liquids and elastic properties are conferred, improved, or extend- ed over a greater range of temper- ature
"W"
Washers - Round, flat rings used as spacers, gaskets or slip devices under the head of a bolt.
Water Absorption - The increase in weight and volume after immersion in water.
Water resistance - The ability to withstand swelling by water for a specified time and temperature.
Wear Rings - Wear rings, guide rings, guiding rings, bearing rings for hydraulic cylinder rods.
Wear Sleeves - Wear rings, guide rings, guiding rings, bearing rings for hydraulic cylinder rods.
Wear Strips - Strips of abrassion resistant plastic, PTFE or Teflon material - Wear rings, guide rings, guiding rings, bearing rings for hydraulic cylinder rods.
Wetting - Completeness of contact between particles dispersed in a medium, such as carbon black rubber.
Wheels - Round rollers to provide easy movement of a machine or component.
Wiper Rings - Also, called a wiper ring - A ring which rides tight against a rod, with a sharp lip to scrape or wipe off excess oil, dirt or dust in a hydraulic or pneumatic cylinder
"X"
X-Rings - Also called quad rings or quatro rings, rubber rings of a special shape ised to replace o-rings and eliminate the rolling found when using o-rings
"Y"
Young's modulus - The ratio of normal stress to corresponding stress or compressive stresses below the proportional limit of the material
"Z"
Zinc Oxide, Activator - Accelerators of vulcanization do not always exert their full influence unless the rubber mixture contains substances known as activators. Zinc oxide is an activator and gives its best activity in the presence of an organic acid like stearic acid with which it forms a rubber-soluble soap.
Zurcon - A type of material used to make guide rings, wear rings, bearings or selas

julun · 发表于 2009-3-22 16:52:48

楼主辛苦了，英文部份有中文吗

zdzlw2004 · 发表于 2009-3-22 17:11:47

楼主辛苦了，要是有个WORD版本就好了

黑色金子 · 发表于 2009-3-22 17:22:51

楼上，word文档是可以用网页编辑的，很简单也是，一般的在菜单行都有个word编辑的，你可以试试

楼主发的资料好像都是咱们这个网站上的，我似乎见过。。。可以找找

rubber猎人 · 发表于 2009-3-22 17:27:29

辛苦了楼主，要是附件就更好了！

yunhuali · 发表于 2009-3-22 17:28:04

楼主今天确实很辛苦啊发了这么多的帖子
而且都是资料呵呵

qdwangbo · 发表于 2009-3-22 20:29:22

楼主今天确实是辛苦啊。。。。。。。。。

lhf1325 · 发表于 2009-3-23 09:37:27

精神可嘉，楼主很辛苦啊，呵呵~~~~~~~~~~

桐河 · 发表于 2009-3-23 16:17:26

表示哈子，楼主你辛苦了

tianshen · 发表于 2009-3-31 09:47:05

楼主，上传一个ＷＯＲＤ附件多好啊，从页面复制下来都乱了啊！

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