What are the disadvantages of extrusion rubber material?
As a supplier of extrusion rubber materials, I've had extensive experience with these versatile products. While extrusion rubber materials offer numerous advantages, it's crucial to be aware of their disadvantages to make informed decisions in various applications. In this blog, I'll delve into some of the key drawbacks associated with extrusion rubber materials.
1. Limited Temperature Resistance
One of the significant disadvantages of extrusion rubber materials is their limited temperature resistance. Different types of rubber have different temperature ranges within which they can function effectively. For example, natural rubber, which is commonly used in extrusion processes, starts to lose its mechanical properties at relatively low temperatures. At around 70 - 100°C, its elasticity and strength begin to decline, and it may become brittle at very low temperatures, typically below -20°C.
Synthetic rubbers, such as nitrile rubber (NBR), have better temperature resistance than natural rubber, but they still have their limitations. NBR can withstand temperatures from -40°C to about 120°C. Beyond these temperature limits, the rubber can degrade, leading to cracking, loss of flexibility, and ultimately, product failure.
In contrast, speciality rubbers like Conductive Fluorosilicone Rubber [1] have better temperature resistance. However, these speciality rubbers are often more expensive and may not be cost - effective for all applications. The Conductive Fluorosilicone Rubber can operate in a temperature range from -55°C to 200°C, but due to its complex manufacturing process and the use of specialized chemicals, it comes at a premium price.
2. Chemical Resistance Issues
Extrusion rubber materials may also face challenges when it comes to chemical resistance. Different rubbers have different levels of resistance to various chemicals. For instance, natural rubber is highly susceptible to attack by oils, solvents, and strong acids. When exposed to these chemicals, the rubber can swell, lose its shape, and lose its mechanical strength.
Even some synthetic rubbers that are known for their chemical resistance have limitations. For example, EPDM (Ethylene - Propylene - Diene Monomer) rubber has good resistance to water, steam, and many polar solvents, but it is not resistant to hydrocarbon oils. If EPDM rubber is used in an application where it comes into contact with hydrocarbon oils, it will gradually deteriorate.
Low Pressure Variable Fluorosilicone Rubber [2] offers better chemical resistance compared to many other types of rubber. It can resist a wide range of chemicals, including oils, solvents, and some acids. Nevertheless, it still may not be completely immune to all chemicals, and in highly corrosive environments, it may also require additional protection or coating.
3. Poor Weathering Resistance
Weathering can take a toll on extrusion rubber materials. Natural elements such as sunlight, rain, and ozone can cause the rubber to degrade over time. Sunlight contains ultraviolet (UV) radiation, which can break the chemical bonds in the rubber, leading to discoloration, cracking, and loss of physical properties.
Rain can also damage rubber materials, especially if they are not properly formulated. Standing water can cause the rubber to absorb moisture, which may lead to swelling and a reduction in mechanical strength. Ozone, a highly reactive gas present in the atmosphere, can react with the double bonds in the rubber chains, causing cracking and embrittlement.
Some rubbers, like neoprene, have better weathering resistance than others. However, even neoprene will eventually degrade when exposed to long - term weathering. High Resilience Fluorosilicone Rubber [3] has relatively good weathering resistance due to its chemical structure. But again, continuous exposure to harsh weather conditions can still lead to some degree of degradation over an extended period.
4. Dimensional Stability Problems
Extrusion rubber materials may experience issues with dimensional stability. During the extrusion process, the rubber is heated, shaped, and then cooled. This thermal cycle can cause the rubber to shrink or expand, leading to dimensional changes. These changes can be significant, especially in applications where precise dimensions are required.
For example, in the automotive industry, rubber seals need to fit precisely to prevent leaks. If the rubber seal undergoes dimensional changes after extrusion, it may not fit properly, leading to potential problems such as water leakage or air infiltration.
The formulation of the rubber and the extrusion process parameters play a crucial role in determining the dimensional stability of the final product. However, achieving perfect dimensional stability is often challenging, and there may be some degree of variation from batch to batch.
5. High Production Costs
Producing extrusion rubber materials can be costly. The raw materials used in rubber production can be expensive, especially for high - performance speciality rubbers. The manufacturing process also requires specialized equipment, such as extruders, which can be a significant investment.
In addition, the quality control measures necessary to ensure that the rubber products meet the required standards add to the cost. For example, testing the rubber for temperature resistance, chemical resistance, and mechanical properties is essential, but it involves additional expenses for equipment, personnel, and time.
Moreover, the lead time for producing extrusion rubber materials can be relatively long. The curing process, which is necessary to give the rubber its final properties, can take several hours or even days depending on the type of rubber and the product requirements. This long lead time can further increase the overall cost of production.
6. Environmental Impact
The production and disposal of extrusion rubber materials can have a negative environmental impact. The raw materials for rubber production often come from non - renewable resources, such as petroleum. The extraction and processing of these resources consume a large amount of energy and can cause environmental pollution.
During the manufacturing process, chemicals are used, some of which can be harmful to the environment. For example, the vulcanization process, which is used to cross - link the rubber molecules, often involves the use of sulfur and other chemicals. These chemicals can be released into the environment if not properly managed.
Disposal of rubber products also poses a challenge. Rubber is a non - biodegradable material, and it can take hundreds of years to decompose in landfills. Recycling rubber is possible, but it is a complex and costly process, and not all rubber products can be effectively recycled.
Conclusion
In conclusion, while extrusion rubber materials offer many benefits, they are not without their disadvantages. The limited temperature resistance, chemical resistance issues, poor weathering resistance, dimensional stability problems, high production costs, and environmental impact are all factors that need to be considered when choosing these materials for an application.
However, it's important to note that these disadvantages can often be mitigated through proper material selection, advanced manufacturing techniques, and appropriate quality control measures. As a supplier of extrusion rubber materials, I'm committed to helping my customers understand these drawbacks and find the best solutions for their specific needs.
If you're in the market for extrusion rubber materials and want to discuss how to overcome these challenges and make the right choice for your project, I encourage you to contact me. We can have a detailed discussion about your requirements and explore the most suitable rubber materials and production processes for your application.
References
[1] Conductive Fluorosilicone Rubber. /fluorosilicone-rubber/fluorosilicone-rubber-compound/conductive-fluorosilicone-rubber.html
[2] Low Pressure Variable Fluorosilicone Rubber. /fluorosilicone-rubber/fluorosilicone-rubber-compound/low-pressure-variable-fluorosilicone-rubber.html
[3] High Resilience Fluorosilicone Rubber. /fluorosilicone-rubber/fluorosilicone-rubber-compound/high-resilience-fluorosilicone-rubber.html