To ensure the optimal density of rubber and plastic insulation products, strict control is required during the production process: raw material control, process parameters, equipment accuracy, and quality inspection. The details are as follows:
1. Strictly control raw material quality and ratio
A. Select base materials (such as nitrile rubber and polyvinyl chloride) that meet purity standards and have stable performance to prevent impurities from affecting foaming uniformity.
B. Accurately proportion auxiliary materials such as foaming agents and stabilizers: The amount of foaming agent must match the base material (too little results in higher density, too much results in lower density), and ensure uniform mixing. Automatic mixing equipment can achieve precise metering. Kingflex’s advanced production equipment enables more precise mixing.
2. Optimize foaming process parameters
A. Foaming temperature: Set a constant temperature based on the raw material characteristics (usually between 180-220°C, but adjusted depending on the recipe) to avoid temperature fluctuations that can lead to inadequate or excessive foaming (low temperature = higher density, high temperature = lower density). Kingflex uses multi-zone temperature control to ensure more uniform and complete foaming.
B. Foaming Time: Control the length of time the insulation material foams in the mold to ensure bubbles are fully formed and do not burst. Too short a time will result in high density, while too long a time may cause bubbles to coalesce and result in low density.
C. Pressure Control: The pressure in the mold must be stable to avoid sudden pressure fluctuations that damage the bubble structure and affect density uniformity.
3. Ensuring Production Equipment Accuracy
A. Regularly calibrate the metering systems of the mixer and foaming machine (such as the raw material feed scale and temperature sensor) to ensure that the raw material feed and temperature control errors are within ±1%. All Kingflex production equipment is staffed by professional equipment engineers for regular calibration and maintenance to ensure equipment accuracy.
B. Maintain the tightness of the foaming mold to prevent material or air leaks that may cause localized density abnormalities.
4. Strengthen Process and Finished Product Inspection
A. During production, sample samples from each batch and test the sample density using the “water displacement method” (or a standard density meter) and compare it to the optimal density standard (typically, the optimal density for rubber and plastic insulation products is 40-60 kg/m³, adjusted depending on the application).
C. If the detected density deviates from the standard, the process will be adjusted in the opposite direction in a timely manner (if the density is too high, the amount of foaming agent should be appropriately increased or the foaming temperature should be raised; if the density is too low, the foaming agent should be reduced or the temperature should be lowered) to form a closed-loop control.
Post time: Sep-15-2025
