Plastic Mold Surface Tension for Rubber Release
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Solution Overview
Problem
Molds made of ceramic, porcelain, or aluminum used in rubber goods manufacturing often face issues such as rubber sticking, laborious removal processes, mechanical damage, and chemical degradation, leading to decreased productivity and quality, as well as environmental concerns due to strong chemicals used in the manufacturing process.
Innovation Solution
A mold made of a thermoplastic material with a surface tension ranging from 25 to 60 mJ/m², comprising a polyamide component or polyarylene sulfide, which is chemically and mechanically resistant, allowing for a gentler cleaning process and extended use without texture loss, and can be repaired by sandblasting for retexturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If molds made of ceramic, porcelain, or aluminum are used, then the mold provides structural stability and durability, but the rubber good may stick to the mold and removal becomes laborious or may damage the final product
Solution Approach 1:
The patent changes the material parameter of the mold from traditional ceramic, porcelain, or aluminum to a plastic material with specifically controlled surface tension (25-60 mJ/m²). This parameter change in surface tension prevents rubber sticking while maintaining mold durability, allowing easy removal of rubber goods without damage.
2Reliability
If strong chemicals are used in the manufacturing process to clean the mold, then the cleaning effectiveness is improved, but the mold deteriorates after several cycles and the process becomes environmentally unfriendly
Solution Approach 1:
The patent changes the surface tension parameter of the mold material to a specific range (25-60 mJ/m²) that inherently resists rubber sticking. This eliminates the need for strong chemical cleaners, thereby extending mold lifespan and removing environmental concerns associated with harsh chemicals.
3Ease of manufacture
If the mold is made of traditional materials, then the initial manufacturing cost is acceptable, but the production line has to be stopped for mold replacement due to mechanical damage or chemical degradation
Solution Approach 1:
The patent employs a plastic material with specific surface tension properties that combines the benefits of durability and chemical resistance. This composite material approach ensures the mold can withstand mechanical damage and chemical degradation without requiring production line stoppages for replacement, maintaining continuous productivity.
4Shape
If the mold texture is lost due to scratching or wear, then the mold appearance degrades, but traditional molds cannot be easily retextured
Solution Approach 1:
The patent utilizes the specific surface tension characteristics of plastic material (25-60 mJ/m²) that allows the mold to be retextured by sandblasting. This parameter-based material selection enables easy repair and restoration of mold texture, maintaining product quality without replacing the entire mold.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The plastic mold ensures smooth, regular rubber goods production with improved chemical resistance, reduced cleaning steps, and extended mold lifespan, preventing damage and environmental impact while maintaining product quality.
Implementation Method 1
the mold consisting of a plastic material having a surface tension in the range from 25 to 60 mJ/m²
Data Source
AI summary
The present invention relates to a plastic material for use in various application. Further, the present invention relates to a plastic material for an industrial former (herein also designated as a mold). Additionally, the present invention relates to a mold made of a plastic material and the method for the manufacture of said mold. Furthermore, the present invention relates to an industrial process using such mold, such as in a process for making rubber goods comprising dipping of a mold into a rubber emulsion, wherein the mold consisting of a plastic material having a surface tension in the range from 25 to 60 mJ/m2 measured according to ASTM standard D-2578/09.