Tag Archive for: Liquid silica gel

Manufacturing process of medical silicone wrapped circuit board?

The manufacturing process of medical grade silicone wrapped circuit boards (especially flexible circuit boards, FPC) is a special process that combines medical grade silicone materials with circuit board protection requirements. The following are the main steps and precautions of this process:

1、 Main steps

Circuit board cleaning:
Thoroughly clean the FPC circuit board to ensure that the surface is free of dust, oil stains, or other impurities. This step is crucial for the subsequent adhesion of silicone gel.

Silicone selection and blending:
Select suitable medical grade silicone materials based on the special requirements of medical products, such as biocompatibility, chemical corrosion resistance, high temperature resistance, etc.
According to the formula requirements, mix the silicone material with other additives such as colorants, viscosity modifiers, etc.

Silicone coating:
Apply the prepared silicone evenly onto the surface of the FPC using methods such as spraying, brushing, or dipping, ensuring that all circuit lines are completely wrapped.
During the coating process, pay attention to controlling the thickness and uniformity of the silicone gel to avoid the formation of bubbles or voids.

Drying and curing:
Place the FPC circuit board coated with silicone in a constant temperature oven and dry it. The drying temperature and time are adjusted according to the requirements of the silicone material.
After drying, place the FPC circuit board in a constant temperature curing box for silicone curing. The curing temperature and time are also adjusted according to the requirements of the silicone material.

Quality inspection:
Conduct a comprehensive inspection of the FPC circuit board wrapped in silicone, including visual inspection, electrical performance testing, etc., to ensure that the packaging quality meets the requirements of medical products.

Packaging and Shipping:
Wrap the silicone FPC that has passed quality inspection in an anti-static bag or box and prepare for shipment. During the packaging process, pay attention to maintaining the cleanliness and integrity of the product.

2、 Precautions

Silicone formula and selection:
Medical silicone must meet the requirements of biocompatibility, non toxicity, and non irritation.
Select the appropriate silicone type and formula based on the specific application scenario.

Coating uniformity:
Ensure that the silicone covers the entire FPC circuit board evenly and completely during the coating process.
Use appropriate coating equipment and process parameters to avoid the formation of bubbles or voids.

Drying and curing conditions:
According to the requirements of silicone material, precisely control the temperature and time of drying and curing.
Avoid the performance degradation of silicone caused by insufficient drying or incomplete curing.

Quality Inspection and Control:
Establish a comprehensive quality inspection system to conduct comprehensive testing on FPC circuit boards wrapped in silicone.
Adopting advanced detection technology and equipment to improve detection accuracy and efficiency.

Environmental Protection and Sustainability:
During the production process, emphasis is placed on environmental protection and sustainable development.
Choose silicone materials and production processes that meet environmental standards.

In summary, the production process of medical silicone wrapped circuit boards is a complex and delicate task that requires strict control over the quality and parameters of each link. By adopting advanced process technology and equipment, as well as a comprehensive quality inspection system, the quality and performance of medical silicone wrapped circuit boards can be ensured to meet the requirements of medical products.

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What are the manifestations of defects in Cato liquid silicone gel?

The defects of Cato liquid silicone may manifest in multiple aspects, and the following are some common manifestations:

1、 Incomplete solidification

Performance: The liquid silicone product has not fully solidified, resulting in insufficient hardness or softening of the product.
Possible reason: The vulcanization temperature is too low: Liquid silicone is usually platinum vulcanized, and the vulcanization temperature needs to be between 110 ℃ and 150 ℃. If the temperature is below this range, it will affect the vulcanization effect.
The vulcanization time is too short: Different silicone raw materials and product structures have different vulcanization times, and if the time is insufficient, it cannot be completely cured.
Oil and other pollutants in the injection pipeline or mold can damage the sulfurization structure of liquid silicone.
Uneven mixing of rubber materials: Liquid silicone gel is a two-component A/B agent, which needs to be thoroughly mixed before vulcanization molding.
The rubber material is too cold: the rubber material stored in refrigeration can be used directly, and the low temperature affects curing.
The temperature of embedded materials is too low (for encapsulated products), especially for products with thicker embedded materials. This problem is prone to occur when the workshop temperature is low in winter.

2、 The surface of the product is not familiar or partially unfamiliar

Performance: The surface or local area of the product is not fully matured, presenting a state of incomplete solidification.
Possible reason: Improper use of release agent: Different types of liquid silicone have different requirements for release agent, and using unsuitable release agent can affect the surface curing of the product.
There are grease pollutants on the surface of the mold, such as rust proof oil, machine lubricating oil, or sweat from workers’ fingers.
The embedded objects (plastic/hardware) are contaminated, and the dust, grease, and other dirt accumulated during the production process have not been cleaned thoroughly.
Air pollution: When using pneumatic demolding, the gas inside the air compressor is not clean, which can spray onto the mold and affect the product.

3、 The product has impurities or color spots

Performance: Impurities are mixed in the product or uneven color spots appear.
Possible reasons: The rubber material or mold may be dirty, and impurities may be mixed in during the production process.
The gloves and air gun used by the operator are dirty and have contaminated the product.
The uneven mixing of rubber leads to small white transparent gel particles.
Uneven mixing of colorants or dispersion or precipitation of colorants can affect the uniformity of product color.

4、 Product deformation or shrinkage

Performance: The shape of the product changes or the size shrinks.
Possible reason: The deformation temperature of the embedded object is too low: The vulcanization molding temperature of liquid silicone is high, and if the deformation temperature of the embedded object does not meet the standard, it will deform during the vulcanization process.
Uneven pressure on embedded objects leads to deformation: The embedded objects of silicone encapsulated products are unstable in positioning within the mold, and the sealing position is subjected to uneven force.
Unreasonable product structure design: The shrinkage rate of silicone is generally higher than that of embedded objects (plastic/hardware), and the structure of the silicone part of the encapsulated product should be as uniform as possible, without being too thick or too thin locally.

5、 Product shortage and dents

Performance: There are missing materials or dents on the surface of the product.
Possible reason: Insufficient supply of liquid silicone gel and insufficient injection volume.
The injection port is too small, which affects the filling of the adhesive material.
Poor exhaust, bubbles bursting on the surface of liquid silicone products, causing material shortage.
There are dirt on the surface of the mold, which affects the filling of the rubber material.

6、 The product has bubbles (trapped gas)

Performance: Bubbles appear inside or on the surface of the product.
Possible cause: Poor exhaust: Unreasonable exhaust structure design, resulting in the inability to smoothly discharge bubbles.
Gas in the rubber material: The bubbles generated during the mixing of the rubber material have not been completely removed.
Unreasonable design of injection port: Multiple injection ports may cause bubbles to accumulate in the adhesive material.
In summary, the defects of Cato liquid silicone may involve multiple aspects such as solidification, surface curing, impurities, deformation, material shortage, and bubbles. To avoid the occurrence of these defects, it is necessary to strictly control various process parameters and raw material quality during the production process, and strengthen quality inspection and control.

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What is the typical lifespan of liquid silicone encapsulation molds?

What is the typical lifespan of liquid silicone encapsulation molds? This is a concern for many companies and individuals engaged in the production of silicone products. As a high-precision and high-efficiency production tool, the service life of liquid silicone molds directly affects production efficiency and cost.

It should be noted that the lifespan of liquid silicone encapsulation molds does not have a fixed value. It is influenced by various factors, including mold materials, mold structure, production process, usage environment, and maintenance. Therefore, it is not possible to simply provide a specific mold number as the lifespan standard for liquid silicone encapsulation molds.

We can still roughly understand the lifespan range of liquid silicone molds by analyzing their characteristics and usage. Liquid silicone material has the characteristics of low viscosity and low hardness after molding, which makes the wear of the material and product on the mold relatively small during the production process. Therefore, compared to other types of molds, the lifespan of liquid silicone molds is usually longer.

Specifically, the lifespan of liquid silicone molds can reach hundreds of thousands or even millions of mold cycles. This mainly depends on the material, design, and maintenance of the mold during use. Generally speaking, high-quality mold materials and reasonable mold design can significantly improve the lifespan of molds. Meanwhile, proper usage and good maintenance can also extend the service life of the mold.

In practical applications, the lifespan of liquid silicone encapsulation molds is often closely related to the complexity of the mold. Simple mold structures are usually easier to manufacture and maintain, resulting in a relatively longer lifespan. And complex mold structures may require more maintenance and upkeep to ensure their long-term stable operation. In addition, the pressure, temperature, and other conditions that the mold is subjected to during use can also affect its lifespan. For example, high temperature environments can accelerate the aging process of molds, thereby reducing their lifespan.

In addition to the factors of the mold itself, the production process and usage environment also have a significant impact on the lifespan of liquid silicone encapsulation molds. During the production process, improper setting of process parameters or improper operation can lead to damage or accelerated aging of the mold. Similarly, factors such as humidity and corrosive substances in the usage environment may also cause damage to the mold.

In order to extend the lifespan of liquid silicone encapsulation molds, we need to take a series of measures. Firstly, in the mold design stage, its service life and maintainability should be fully considered. By optimizing the mold structure and selecting high-quality materials, the durability and wear resistance of the mold can be improved. Secondly, in the production process, it is necessary to strictly control the process parameters and operating standards to avoid unnecessary damage to the mold. In addition, regular cleaning, lubrication, and inspection of molds are also important means to extend their lifespan.

Of course, even with the above measures taken, the liquid silicone encapsulation mold will still gradually age and eventually fail during use. When the mold reaches its lifespan limit, we need to replace it with a new one in a timely manner to ensure production efficiency and product quality. When replacing the mold, we should pay attention to selecting mold materials and specifications that match the product requirements, and ensure that the installation and debugging of the new mold are correct and error free.

It is worth noting that the lifespan of liquid silicone encapsulation molds is not just a numerical issue. It is a comprehensive issue involving multiple aspects such as production efficiency, cost control, and product quality. Therefore, when evaluating the lifespan of molds, we need to consider multiple factors comprehensively and develop reasonable solutions.

In addition, with the continuous development and progress of technology, the manufacturing technology and materials of liquid silicone molds are also constantly updated and upgraded. This has significantly improved the durability, wear resistance, and production efficiency of the new mold. Therefore, when choosing and using liquid silicone encapsulation molds, we should also pay attention to the latest technological developments and product information in order to make more informed decisions.

In short, the lifespan of liquid silicone encapsulation molds is a complex and variable issue. It is influenced by multiple factors and requires comprehensive consideration of multiple aspects in order to draw accurate conclusions. By optimizing mold design, strictly controlling production processes, strengthening maintenance, and paying attention to the latest technological trends, we can effectively extend the service life of liquid silicone encapsulation molds and improve production efficiency. At the same time, timely replacement of new molds when they reach the limit of their lifespan is also an important means to ensure product quality and production efficiency

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How to choose a liquid silicone encapsulation processing plant with high production capacity?

When choosing a liquid silicone encapsulation processing plant with high production capacity, comprehensive considerations can be made from the following aspects:

1、 Factory scale and production equipment

Factory scale: Scale is the basic manifestation of production capacity. A liquid silicone encapsulation processing factory with high production capacity usually has a large production scale and a complete production line, which can ensure stable supply and timely delivery of products. Therefore, when choosing, attention can be paid to indicators such as the factory area, number of production lines, and annual production capacity of the manufacturer.

Production equipment: Advanced production equipment is an important guarantee for high-quality products. Reliable manufacturers will invest heavily in introducing advanced production equipment and technology to improve production efficiency and product quality. It is possible to investigate whether the manufacturer has automated and intelligent production equipment, as well as the accuracy and stability of these devices.

2、 Technical team and production process

Technical team: Having a professional technical team is an important indicator for evaluating a manufacturer’s production capacity. The technical team is able to provide technical support and solutions to customers, ensuring that the product meets their specific needs. When making a choice, one can understand the size of the manufacturer’s technical team, the professional background and experience level of the technical personnel.

Production process: By understanding the manufacturer’s production process and technical level, it is possible to determine whether their product quality is reliable. For example, whether advanced production processes and strict quality control procedures are adopted to ensure product stability and consistency. You can pay attention to whether the manufacturer has obtained authoritative certifications such as ISO9001 quality management system certification, which can prove the manufacturer’s emphasis on product quality and the reliability of the product.

Need to consider factory scale equipment, technical team procescustomized service levels Price cost-effectiveness and on-site

3、 Service level and customization capability

After sales service: A reliable liquid silicone encapsulation processing factory will provide a comprehensive after-sales service system, including product consultation, technical support, returns and exchanges, etc. This ensures that customers can receive timely and effective assistance when encountering problems during use.

Communication skills: The communication ability and response speed of manufacturers are also important factors in evaluating their service level. An excellent manufacturer should be able to actively communicate with customers, respond promptly to their needs and feedback, and provide personalized solutions.

Customized services: With the diversification of market demand, customized services have become an important requirement for many customers. A reliable manufacturer should be able to provide customized solutions from design to production to meet the personalized needs of customers. When choosing, you can learn about the manufacturer’s customized service capabilities and successful cases.

4、 Price and cost-effectiveness

Price comparison: There may be some differences in the prices of products from different liquid silicone encapsulation processing factories. When choosing, customers can compare their actual needs and budget to choose products with high cost-effectiveness.
Avoiding the low price trap: Price cannot be the only measure. Pursuing only low-priced liquid silicone encapsulation products may sacrifice product quality and service, thereby affecting customer performance and costs. Therefore, when making a choice, customers need to consider multiple factors such as product quality, service level, and price comprehensively.

5、 Field visits and case sharing

Field visit: If conditions permit, it is recommended to conduct a field visit to the candidate liquid silicone encapsulation processing plant. By visiting factories, understanding production lines and testing equipment, and communicating with technical personnel, the strength and reliability of manufacturers can be more intuitively evaluated.

Case sharing: Viewing manufacturers’ successful cases and customer reviews is also an important way to evaluate their overall strength. By understanding the manufacturer’s past cooperation projects and customer feedback, we can gain a more comprehensive understanding of the manufacturer’s service level and product quality.

Choosing a liquid silicone encapsulation processing plant with high production capacity requires comprehensive consideration of multiple factors such as factory scale and production equipment, technical team and production process, service level and customization ability, price and cost-effectiveness, as well as on-site investigation and case sharing.

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What are the technical supports for the application of silicone in complex structures?

Silicone, as an important type of rubber, has demonstrated its unique advantages in multiple fields, especially in the application of complex structures. Silicone has the characteristics of heat resistance, cold resistance, ozone resistance, atmospheric aging resistance, and good electrical insulation performance, which make it irreplaceable in the design and application of complex structures.

1、 Silicone molding technology

The molding technology of silicone is the foundation for its application in complex structures. Common silicone molding techniques include injection molding, compression molding, extrusion molding, and compression molding. Injection molding is suitable for producing large quantities of small components, and precise mold design can achieve precise replication of complex structures. Compression molding is suitable for producing larger components, especially those that require high precision. Extrusion molding is mainly used for producing continuous silicone products, such as silicone tubes, silicone strips, etc. Compression molding is suitable for producing silicone components with complex shapes and structures, such as silicone buttons, seals, etc.

In the molding process of complex structures, the flowability, curing speed, and shrinkage rate of silicone are crucial for the quality of the molding. Therefore, it is necessary to strictly control the parameters such as temperature, pressure, and curing time during the molding process to ensure that the silicone can fully fill the mold and achieve the expected curing effect.

In the design of complex structures, the application of silicone needs to fully consider multiple factors. Firstly, the physical and chemical properties of silicone, such as hardness, tensile strength, tear strength, compression deformation, etc., will directly affect the service life and performance of silicone components. Next is the molding process of silicone, which has different requirements for the dimensional accuracy and surface quality of silicone components. In addition, it is necessary to consider the usage environment of silicone components, such as temperature, humidity, acidity, etc., to ensure that silicone components can operate stably for a long time.

When designing silicone components, special attention should be paid to their compatibility with other materials. For example, the bonding method, bonding strength, and possible chemical reactions between silicone and materials such as metals and plastics need to be fully evaluated and tested.

3、 Performance optimization

In order to further improve the performance of silicone in complex structures, various optimization measures can be taken. Firstly, adjusting the formula of silicone can significantly improve its mechanical properties, heat resistance, and aging resistance by changing parameters such as crosslinking degree, filler type, and content. Secondly, improving the molding process, such as adopting advanced mold design and optimizing molding parameters, can further enhance the dimensional accuracy and surface quality of silicone components. In addition, silicone components can also be subject to post-treatment, such as surface spraying, vulcanization, etc., to improve their wear resistance, corrosion resistance and aging resistance.

Silicone has unique advantages in complex structures
due to its heat and cold resistance, covering molding
technology, design considerations, performance
optimization, and application examples

4、 Specific application examples

1. Silicone button
Silicone buttons are one of the typical applications of silicone in complex structures. In the design of buttons, it is necessary to fully consider factors such as the shape, size, hardness, and coordination with other components of the buttons. Through reasonable design and molding processes, silicone buttons with excellent tactile feel, high sensitivity, and long lifespan can be produced. In addition, logo patterns and text can be added to the silicone buttons to meet customers’ personalized needs.
2. Silicone seals
Silicone seals are another common application of silicone. In complex structures, silicone seals need to have good sealing performance and aging resistance. By using high-performance silicone materials and advanced molding processes, silicone seals with excellent sealing performance and long-term service life can be produced. These seals are widely used in fields such as automobiles, aerospace, electronics, and electrical appliances, providing reliable guarantees for the normal operation of equipment.
3. Silicone medical devices
Silicone also has a wide range of applications in the field of medical devices. Due to its excellent biocompatibility and corrosion resistance, silicone is widely used in the production of various medical device components and accessories. For example, medical devices such as silicone catheters and silicone endotracheal tubes are made of silicone material. These medical devices not only have excellent performance, but also effectively reduce patients’ pain and infection risks.
4. Silicone 3D printing technology
With the continuous development of 3D printing technology, silicone 3D printing technology has gradually become a new trend in the application of silicone in complex structures. Through 3D printing technology, silicone components with complex shapes and structures can be produced, and personalized customization and rapid production can be achieved. This technology is particularly suitable for producing silicone components with complex shapes and high dimensional accuracy requirements, such as prototyping medical devices and rapid development of automotive components.

5、 Conclusion

In summary, the application technology support of silicone in complex structures covers multiple aspects such as molding technology, design considerations, performance optimization, and specific application examples. Through continuous technological innovation and practical exploration, we can further improve the performance and application level of silicone in complex structures, providing more reliable and efficient solutions for the development of various fields.
In the future development, we can foresee that the application of silicone gel in complex structures will be more extensive and in-depth. With the continuous improvement of people’s requirements for product performance and quality, silicone as a high-performance material will play a more important role.
In short, the technical support for the application of silicone in complex structures is a complex and important issue. We need to continuously conduct in-depth research and practical exploration, constantly improve the performance and application level of silicone in complex structures, and provide more reliable and efficient solutions for the development of various fields. At the same time, we also need to pay attention to the environmental friendliness and sustainable development of silicone materials, and contribute to the future sustainable development.

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What are the advantages of liquid silicone encapsulation in smart wearables?

The application of liquid silicone rubber (LSR) in smart wearable devices is becoming increasingly widespread, mainly due to its unique material properties and processing technology. The following are the main advantages of liquid silicone encapsulation in smart wearable devices:

1. Biocompatibility and safety

Food grade material: Liquid silicone meets food grade standards, is non-toxic and odorless, and will not cause harm to the human body. It is particularly suitable for smart wearable devices that come into direct contact with the skin, such as smart watches, health monitoring bracelets, etc.
Biocompatibility: Liquid silicone has good biocompatibility and will not cause skin allergies or irritation, making it suitable for long-term wear.

2. Temperature resistance and weather resistance

High temperature resistance: Liquid silicone can maintain its physical and chemical properties in high temperature environments, making it suitable for smart wearable devices used in high temperature environments.
Low temperature resistance: Liquid silicone can maintain good elasticity and flexibility even in low temperature environments, making it suitable for smart wearable devices used in cold environments.
Weather resistance: Liquid silicone has excellent weather resistance, which can resist ultraviolet rays, oxidation, and aging, ensuring stable performance of smart wearable devices during long-term use.

3. Elasticity and Flexibility

High elasticity: Liquid silicone has extremely high elasticity and can recover to its original shape after multiple bending and stretching, ensuring that smart wearable devices are not easily deformed during use.
Flexibility: Liquid silicone has good flexibility and can adapt to smart wearable devices of different shapes and sizes, providing a comfortable wearing experience.

Liquid silicone is widely used in smart wearable devices
and has become an indispensable material for smart wearable devices.

4. Waterproof and dustproof properties

Waterproof: Liquid silicone has excellent waterproof performance, which can effectively prevent moisture infiltration and ensure the normal operation of smart wearable devices in humid environments.
Dustproof: Liquid silicone has good dustproof performance, which can effectively prevent dust and particulate matter from entering the interior of the equipment, extending the service life of the equipment.

5. Chemical resistance and corrosion resistance

Chemical resistance: Liquid silicone can resist the erosion of various chemicals, ensuring that smart wearable devices will not corrode or deteriorate when in contact with chemicals.
Corrosion resistance: Liquid silicone has good corrosion resistance, which can resist the erosion of corrosive substances such as acid and alkali, ensuring the long-term stability of smart wearable devices.

6. Advantages of processing technology

Injection molding: Liquid silicone adopts injection molding technology, which can achieve the processing of complex shapes and fine structures, ensuring the appearance and functionality of smart wearable devices.
Automated production: The liquid silicone injection molding process is suitable for automated production, which can improve production efficiency and product consistency, and reduce production costs.

7. Antibacterial performance

Antibacterial agent addition: Adding antibacterial agents to liquid silicone can effectively inhibit bacterial growth, improve the hygiene performance of smart wearable devices, and is particularly suitable for health monitoring devices.

8. Comfort and aesthetics

Comfort: Liquid silicone has a soft touch and good breathability, providing a comfortable wearing experience, especially suitable for smart wearable devices that can be worn for a long time.
Aesthetics: Liquid silicone can achieve multiple color and transparency choices by adding colorants, meeting the aesthetic needs of smart wearable devices.
In summary, liquid silicone encapsulation has multiple advantages in the field of smart wearables, including water and dust resistance, good biocompatibility, excellent weather resistance and stability, efficient processing performance, and environmental sustainability. These advantages make liquid silicone encapsulation an indispensable and important material in smart wearable devices.

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What are the molding processes for liquid silicone products?

The molding process of liquid silicone products mainly includes the following:

1、 Liquid Injection Molding (LIM)

Liquid injection molding is the process of injecting liquid silicone into a closed mold for solidification molding. This process has efficient production speed, precise product size and detail control ability, making it very suitable for mass production of complex shaped silicone products. For example, in fields such as automotive components and electronic product casings, the application of LIM technology has greatly improved production efficiency and product quality.

2、 Injection molding

Injection molding is the process of placing liquid silicone gel in an open mold and curing it into shape through heating and pressure. This process is relatively simple, with low equipment costs, and is suitable for small and medium-sized batch production. Pressure injection molding is particularly suitable for producing products of different shapes and sizes, such as silicone seals, buttons, etc. Although its production speed is slow, it has certain advantages in cost control and flexibility.

3、 Transfer molding

Transfer molding is the process of injecting liquid silicone into a mold cavity, filling the entire mold with pressure, and then heating and solidifying it. This process is particularly suitable for producing products with complex shapes and multi cavity molds. Transfer molding can reduce waste and improve material utilization, while ensuring the dimensional accuracy and surface quality of the product. The application of transfer molding technology is becoming increasingly widespread in fields such as medical devices and precision instruments.

Molding process of liquid silicone products

4、 Injection molding

Injection molding is the process of pouring liquid silicone directly into an open mold and forming it through natural curing or heating curing. This process is simple and easy to implement, with low mold costs, making it very suitable for small-scale production and prototype making. Injection molding plays an important role in the early stages of product design, as it can quickly verify the feasibility of design schemes and adjust and optimize them.

5、 In Mold Injection Molding

In mold injection molding is the process of injecting liquid silicone into a mold and combining it with other materials such as plastic and metal to form a mold. This process enables the perfect combination of different materials to produce composite products with unique properties and appearance. The application of in mold injection molding technology has greatly enriched the types and functions of products in fields such as consumer electronics and smart homes.

6、 Extrusion molding

Extrusion molding is the process of extruding liquid silicone into a specific shape (such as a long round tube) through an extruder. The extruded silicone products can be cut arbitrarily, with flexible and versatile shapes, and are widely used in medical, video equipment and other fields. For example, medical supplies such as silicone catheters and infusion tubes are often produced using extrusion molding technology.

7、 Dropping molding

Dropping molding is the process of solidifying liquid silicone gel into a mold through a dropper device. This process is suitable for producing products with small batches, complex shapes, and fine structures. Dropping molding can achieve high-precision material control, but the production speed is slow.

In summary, there are various molding processes for liquid silicone products, each with its unique advantages and applicable scenarios. Choosing the appropriate molding process is crucial for improving production efficiency and product quality.

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How to control the product size of liquid silicone sealing rings?

In the manufacturing industry, liquid silicone sealing rings are widely used as high-performance sealing materials in various fields such as electronics, medical, automotive, aerospace, etc. Its excellent high and low temperature resistance, aging resistance, chemical corrosion resistance, and good elastic recovery ability make it a key component to ensure equipment sealing and reliability. However, in the production process of liquid silicone sealing rings, how to accurately control product size to ensure product consistency and meet strict customer requirements is a major challenge faced by manufacturers.

1、 Mold Design: Foundation and Key

The mold is the basis for forming liquid silicone sealing rings, and its design directly affects the dimensional accuracy, appearance quality, and production efficiency of the product. Firstly, the selection of mold materials is crucial, requiring good heat resistance, wear resistance, and corrosion resistance to ensure the stability and accuracy of the mold under long-term high-temperature and high-pressure operations. Secondly, the design of the mold structure needs to consider the flow characteristics of liquid silicone, reasonably set the gate position, quantity, and size, as well as the exhaust system, to ensure uniform material filling and avoid adverse phenomena such as bubbles and material shortages.

In order to accurately control product dimensions, molds also need to be equipped with high-precision measurement and adjustment systems, such as precision cavity size measurement tools, temperature control systems, etc. The mold temperature has a significant impact on the flowability, curing speed, and final product size of liquid silicone. Therefore, through precise temperature control, the injection molding process can be optimized and the stability of product size can be improved.

2、 Injection molding process: details determine success or failure

The injection molding process is the core link in the production of liquid silicone sealing rings, which directly affects the dimensional accuracy and intrinsic quality of the product. During the injection molding process, parameters such as injection pressure, injection speed, holding time, and cooling time must be strictly controlled. Excessive injection pressure may cause product deformation or mold damage, while insufficient pressure may result in incomplete filling; Injecting too quickly may cause turbulence, affecting the surface quality of the product, while injecting too slowly may prolong the production cycle.

The pressure holding stage is particularly crucial for preventing product shrinkage and ensuring dimensional stability. By adjusting the holding time and pressure, the solidification process of liquid silicone in the mold can be effectively controlled, reducing dimensional deviations caused by uneven shrinkage. In addition, the reasonable setting of cooling time is also an important factor in ensuring the stability of product size. Too fast or too slow cooling speed may affect the final size and performance of the product.

Need to optimize mold design, precise injection molding proces

3、 Post processing: optimization and improvement

After injection molding of liquid silicone sealing rings, a series of post-treatment processes are required, including demolding, trimming, cleaning, inspection, etc. Although these processes may seem simple, the final control of product size is equally important. When demolding, it is necessary to ensure that the product is smoothly and undamaged removed from the mold, avoiding dimensional changes caused by external forces. During the trimming process, excess burrs and burrs should be removed to maintain a clean appearance of the product, while avoiding excessive trimming that may affect dimensional accuracy.

The cleaning steps are not only to remove stains and residual release agents from the surface of the product, but more importantly, to maintain the cleanliness of the product surface and prepare for subsequent inspection and packaging. The inspection process is the last line of defense for product quality control, ensuring that every product meets design requirements through measures such as size measurement and appearance inspection. For products that do not meet the standards, they should be promptly identified, isolated, and reworked or scrapped.

4、 Quality Control: Continuous Improvement and Enhancement

In the production process of liquid silicone sealing rings, quality control is a continuous process aimed at improving the stability and consistency of product dimensions through data analysis, problem tracking, and continuous improvement. Firstly, establish a sound quality management system, clarify the quality standards and inspection processes for each link, and ensure that every step of the operation is systematic.

Secondly, advanced measurement techniques and equipment such as coordinate measuring instruments and laser scanners are utilized to perform high-precision and high-efficiency dimensional measurements on products, promptly detecting and correcting dimensional deviations. At the same time, collect quality data during the production process, use statistical process control (SPC) and other methods for analysis, identify potential quality issues, and take corresponding preventive measures.

In addition, strengthening employee training and improving their quality awareness and operational skills are also important ways to enhance product quality. Through regular skill training, quality awareness education, and quality case analysis, we aim to enhance employees’ awareness of product size control and stimulate their enthusiasm for participating in quality improvement.

silicone injection molding

silicone injection molding

epilogue

The product size control of liquid silicone sealing rings is a complex system engineering involving multiple aspects such as mold design, injection molding process, post-treatment, and quality control. By continuously optimizing mold design, precisely controlling injection molding process parameters, strictly implementing post-processing standards, and establishing a sound quality control system, the stability and consistency of product dimensions can be effectively improved, meeting customers’ strict requirements, and enhancing the market competitiveness of enterprises. In the future, with the continuous development of materials science, manufacturing technology, and information technology, the production of liquid silicone seals will become more intelligent and precise, providing more reliable and efficient sealing solutions for various industries.

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What are the defects of liquid silicone encapsulation? How to solve it?

The liquid silicone encapsulation process may encounter some defects in practical applications. Here are some common defects and their solutions:Common defects and solutions

Bubbles and voids:

Defect description: During the encapsulation process, bubbles or voids appear inside or on the surface of the silicone gel.
Solution: Vacuum defoaming: Perform vacuum defoaming treatment before injection to remove air from the silicone gel. Control the glue injection speed: Inject glue slowly and evenly to avoid the formation of bubbles during rapid injection. Choose the appropriate silicone: use low viscosity, easy to flow silicone material.

Poor adhesion:

Defect description: The adhesion between silicone and substrate (such as metal, plastic) is insufficient, making it easy to peel off.
Solution: Surface treatment: Polish, clean or use primer on the surface of the substrate to increase surface roughness and activity. Choose the appropriate silicone: Use silicone materials with good adhesion properties. Control vulcanization conditions: Ensure appropriate vulcanization temperature and time to enhance adhesion.

Inconsistent size:

Defect description: The size of the encapsulated product is inconsistent with the design requirements, and may be too large or too small.
Solution: Precise control of the mold: Ensure accurate mold size, regularly inspect and maintain the mold. Control the amount of glue injected: Accurately control the amount of glue injected each time to avoid too much or too little. Optimize vulcanization process: Ensure stable vulcanization process and avoid size changes caused by uneven vulcanization.

Customized processing factory for liquid silicone encapsulatio

Surface defects:

Defect description: There are defects on the surface of the encapsulated product, such as scratches, unevenness, flow marks, etc.
Solution: Optimize the gluing process: Ensure a smooth gluing process and avoid the formation of flow marks or scratches. Mold surface treatment: Ensure a smooth mold surface, regularly clean and maintain the mold. Control vulcanization conditions: Ensure appropriate vulcanization temperature and time to avoid surface defects caused by uneven vulcanization.

Silicone discoloration or deterioration:

Defect description: Silicone gel may discolor or deteriorate during vulcanization or use.
Solution: Choose the appropriate silicone: Use silicone materials with good high temperature resistance and aging resistance. Control vulcanization conditions: Ensure that the vulcanization temperature and time are appropriate to avoid excessive temperature that may cause silicone gel to deteriorate. Storage conditions: Ensure that the silicone material is stored in a dry and cool environment, avoiding direct sunlight and high temperatures.

Poor fluidity of silicone gel:

Defect description: Silicone has poor fluidity during the injection process, making it difficult to fill the mold.
Solution: Choose low viscosity silicone: Use silicone material with good fluidity. Heating silicone: Heat the silicone appropriately before injection to reduce its viscosity. Optimize the glue injection equipment: Ensure that the glue injection equipment works properly, with appropriate pressure and speed.

summary

The defects of liquid silicone encapsulation technology mainly focus on bubbles, poor adhesion, inconsistent size, surface defects, discoloration or deterioration of silicone, and poor fluidity of silicone. The key to solving these defects lies in optimizing process parameters, selecting suitable materials, precise control of molds and equipment, and regular maintenance and inspection.
If you encounter specific problems or have specific needs in practical operation, please provide more details, and I will do my best to provide you with more detailed solutions.

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What is the tolerance control for the secondary molding of liquid silicone encapsulation? Can we seal the glue?

Liquid Silicone Rubber (LSR) encapsulation secondary molding is a precision manufacturing process that involves injecting liquid silicone rubber onto a pre formed plastic part or other substrate. Tolerance control is crucial for ensuring product quality and performance. Here are some general guidelines on tolerances:

During the encapsulation process, liquid silicone gel is injected or poured onto the substrate that needs to be encapsulated, and after curing, it forms a protective layer or connecting layer. Secondary molding, on the other hand, refers to the injection or casting of liquid silicone gel on top of the existing layer of silicone gel on the substrate to achieve more complex structures or functions.

In this process, tolerance control has become a crucial factor. Excessive tolerance may result in liquid silicone not being able to fully cover the corners or gaps of the substrate, leaving a hidden risk of adhesive leakage; The tolerance is too small, and it may also be difficult to form or cause product deformation due to insufficient fluidity of silicone.

So, what is the tolerance control range for the secondary molding of liquid silicone encapsulation? This actually depends on multiple factors, including the viscosity of silicone, injection or casting pressure, shape and size of the substrate, ambient temperature, etc. But generally speaking, we can consider the following aspects:

1、 Viscosity of silicone gel
The viscosity of silicone directly affects its fluidity. Silicone with low viscosity has good fluidity and is easy to fill the corners and gaps of the substrate, but it is also prone to overflow due to excessive fluidity. Therefore, when choosing silicone, it is necessary to select the appropriate viscosity based on the specific application scenario and requirements.

2、 Pressure for injection or pouring
The pressure of injection or pouring is a key factor affecting the filling effect of silicone gel. If the pressure is too low, silicone may not be able to completely fill the gaps in the substrate; Excessive pressure may lead to silicone overflow or product deformation. Therefore, in practical operation, it is necessary to adjust the injection or pouring pressure reasonably according to factors such as the shape and size of the substrate, the viscosity of the silicone gel, etc.

3、 Shape and size of substrate
The shape and size of the substrate have a direct impact on tolerance control. For substrates with complex shapes and high dimensional accuracy requirements, tolerance control needs to be more stringent. In this case, it may be necessary to use higher precision molds and stricter process control to ensure the filling effect of silicone.

4、 Environmental temperature
The ambient temperature has a significant impact on the curing speed and flowability of silicone gel. In high temperature environments, the curing speed of silicone increases and its flowability decreases, so it is necessary to increase the tolerance appropriately to ensure that silicone can completely fill the substrate. On the contrary, in low-temperature environments, the curing speed of silicone gel slows down and its flowability increases, so it is necessary to reduce the tolerance appropriately to prevent silicone gel from overflowing.
Based on the comprehensive consideration of the above factors, we can derive a rough tolerance control range. However, it should be noted that this is only a reference range and not an absolute standard. In practical operation, flexible adjustments need to be made according to specific situations.
To ensure proper tolerance control of the secondary molding of liquid silicone encapsulation, we can take the following measures:
1. Strengthen raw material testing to ensure that the silicone used meets quality requirements;
2. Regularly maintain and upkeep the mold to ensure its accuracy and stability;
3. Strictly control the pressure and time of injection or pouring to ensure that the silicone can evenly and fully fill the substrate;
4. Strictly control the production environment to ensure that parameters such as temperature and humidity meet production requirements;

5. Strengthen product quality testing, promptly handle and provide feedback on non-conforming products.
Please note that these are only general guiding principles. In the actual production process, adjustments and optimizations should be made based on specific product design, material characteristics, and production processes to achieve the best results. If you need detailed recommendations for specific products, please provide more information for more accurate assistance.

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