1.

Induction region
*Cross
* All

linking starts at this stage * Scorch time is taken as two units above minimum viscosity

processing and shaping operations are done before scorch time

2.Curing
*

region

Permanent cross links are formed, Dependent upon-Amount of vulcanizing agent,Activity,Reaction time,

Temperature,Nature
*

of rubber,Presence of other ingredients

Optimum cure time is the time for attaining 90% torque

* Amount
*3.

of cross links formed decide the physical properties of the vulcanizate

Overcure region Desides the stability of the network towards heat

Vulcanization of thick articles

* Upto 6 mm thickness cure time from Rheometer is
sufficient

*For thick articles 5 min extra is added for every

additional 6mm

*For industrial products cure input requirement for

vulcanization is obtained using programmed
temperature profile curometer

Vulcanization Different methods

Moulding
( Shaping and curing
within the mould)
* Compression

moulding
* Transfer moulding
* Injection moulding
* Blow moulding
* Vacuum moulding

Methods other than moulding

(Curing of previously shaped compound/composites)
Batch curing
Continuous curing
Autoclave or steam pan High pressure steam tube
Hot air oven
Hot air tunnel
Water curing
Fluidized bed
Lead curing
Liquid curing method
Continuous drum cure
Microwave vulcanization

Batch curing methods

1.Autoclave or steam pan
cylindrical pressure vessel
Used for curing

1.Extrusions, sheeting and other items which are

unsuitable for mould curing

Unjaketed Autoclave

Admits steam directly

Chance of partial degradation
Imparts condensation markings

Jacketed Autoclave

Curing in inert atmosphere

Produces bright coloured items

Advantages
Large number of components can be cured at a time
Improves press and mould utilization by using it for the
secondary vulcanization of large mouldings

2.Hot air oven

Mainly used for post curing of heat resistant polymers like silicone and
fluorocarbon
Advantages of post curing
1.Improves the state of cure of the product, there by the physical properties
2. Drives off volatile materials from components intended to serve at high
temperatures

3.Water curing
Uses autoclaves as pressure vessels heating by steam jacket or
steam injection
Load the vessel fill waterapply heat for the prescribed period
Applications
vulcanization of very large hand built rubber lined machinery such as
pump, pipes and chemical tanks

4.Lead curing
Used for the vulcanization of hoses. Cover hose with lead
using T-head extruder or presswound on large drum
fill the hose with water, seal the endsplace the
assembly in autoclave and cure. Super heated warer exert
presdsure on the inner side against the outer cover.

5.Sulphur chloride curing

Thin walled rubber articles can be cured by dipping in the
solution of sulphur chloride in carbon di sulphide or
exposure to its vapours

Continuous vulcanization
shaping, curing and finishing are continuous
Major componets are
EXTRUDER /CALLENDER
VULCANIZER
DOWN STREAM EQUIPMENTS

1. High pressure steam vulcanization

Major applications:- Reinforced hoses, wires and cables
The extrudate is un supported and is subjected to tension. So that this
technique is suitable only for composite products having continuous non
rubber reinforcement
Vulcanization is carried out in steel tubes of long length(75 m), sealed one end
to the extruder and the other end with rubber/water seals. Steam at 15 kg/cm 2
( 216 kg/cm2 )is used for heating

2.Hot air tunnel

For the vulcanization of cellular and carpet underlay
which do not have to meet tight dimensional
tolerences
*Conveyor belts are used to carry the extrudate
* Gas heated or electrically heated
Temperature at the exit point is 250 300 oC
Drawbaks: Poor heat transfer
Very long line(360 m)

3.Liquid Curing Method

Thermally isolated metal chamber contains a heating
medium * eutectic salt
*glycol
*silicone oil
eg:- NaNO2-40%,KNO3 -53%, and NaNO3-7%

Operating temperature 120 280oC

Advantages:- 1.Excellent heat transfer
2.High line speed

4.Fluidized bed
*A metal chamber containing glass beads(0.1-0.2mm) with
perforation at the bottom
*Steam from the bottom initially
*compressed air replaces steam once the temperature is attained
* glass beads behaves just like a fluid and the rubber section is
drawn through the medium
o Good heat transfer
o Chemically inert
o Non wetting
o Requires no guides or supporting rollers

5.Continuous drum cure

For vulcanization of * Sheet materials
* flooring
* belting

Important parts-heating drum,reversing rolls and pressure belt

Drum dia-600 3000mm, pressure 4.6 15.3 kg/cm2
(155 216 oC )

Emerging Methods of Vulcanization

Conventional methods Heat is supplied from out side
* Steam
* Electrical heating
* Gas heating
* Oil heating
Modern Methods * Heat is generated within the bulk of the polymer by
irradiating with microwaves or ultrasonic waves
* No need of curing agents for high energy radiating systems
like Co60
& Electron beam

Microwave curing
*Electromagnetic radiations of
Freq. 915-2450 MHz for domestic and industrial purposes

* Heat is generated in the bulk of the polymer

* The poloymer should be polar or other wise made polar by incorporation with
polar polymer/ingredients

The Unit consists of

1.Microwave section
2.High temperature heating section
3. Conveyor belt
Applications

* Production of Automobile profiles(water strips, tubing,seals,sponge etc)

* Construction profiles(Highway seals, gaskets expansion joints foe bridges
etc)

Ultrasonic Vulcanization
Elastic waves produced by cyclic vibrating
movement of ultrasonic transmitter when
come in contact with viscoelastic material,
the ultrasonic energy is converted into heat

High energy radiation system

Co60 or Electron beams of 1021-1018Hz is
used
High penetrating power (fast curing of
thick articles)
No need of conventional curing agents
Free radicals are formed by high energy
radiation which joins at reactive sites to
form the cross linking

Thank you