Xiamen Better Silicone Rubber Co., Ltd
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Membrane Transfer Molding, also be known as Diaphragm Mould, Membrane Valve Moulding and Diaphragm Seals Mold. Membrane are used to seal and isolate enclosures, preventing unnecessary transmission of substances between two places, and are commonly used in low pressure flow control applications, such as liquids, slurries and gases, etc.
Membrane Transfer Molding's advantage is that it can produce structurally complex coated products containing metal parts or other material parts. Transfer Molding's price is much cheaper than the LSR Injection Molding, and it can also produce complex silicone rubber parts with more uniform wall thickness than the products produced by the Compression Mold.
Membrane Transfer Molding Process
1. A piece of uncured rubber is placed into a portion of the mold.
2. The mold is closed up and under hydraulic pressure, the rubber is forced through a small hole into the cavity. The mold is held closed while the rubber cures.
3. The plunger is raised up and the transfer pad material is removed.
4. Mold is opened and the part can be removed.
Membrane Transfer Molding VS. Compression Molding & LSR Injection Molding
Membrane Transfer Molding VS. Compression Molding
1. Transfer Molding takes less time to peroform.
The raw material used in compression molding does't have to be completely liquid it can be semi-solid. The semi-solid raw material can be injected or otherwise forced into the mold cavity by the plunger. This makes transfer molding faster than many other molding processes, particularly those that only support liquefied material.
2. Transfer Molding allows for higher tolerance.
This is due to the fact that transfer molding uses more pressure than compression molding. Both types of molding processes involve the use of pressurized raw material. With compression molding and transfer molding, the raw material is pressurized as it's injected into the mold cavity. Transfer molding, though, applies more pressure to the raw material, thereby allowing for higher dimensional tolerances.
Membrane Transfer Molding VS. LSR(Liquid Silicone Rubber) Injection Molding
1. Transfer Molding has high cavity count.
Transfer Molding typically has dozensof cavities, while LSR injection molding has only few cavities.
2. Transfer Molding has fewer restrictions on raw material.
The transfer molding can produce rubber and silicone productions, while the LSR injection molding can only produce silicone productions.
Membrane Transfer Molding Advantages
1. Allows for the easy integration of inserts, such as metal components of electronic parts, into the molded product.
2. Allows for intricate designs with sharper edges, providing greater design flexibility compared to other molding methods.
3. Allows for producing parts with minimal or no burr, eliminating the need for additional deburr processes.
4. Allows for higher tolerances.
5. Lower tooling and equipment costs, because simpler pot and plunger designs.
Membrane Transfer Molding Disadvantages
2. Slower production rate.
Compared to injection molding, due to the additional steps involved in material preparation and transfer.
3. Air can get trapped in the mold during the transfer process.
This can lead to defects in the final product and require additional measures to ensure air is properly evacuated.
4. Complex molds.
Since the design and mold tends to be complex, tooling can also become expensive.
5. Mold maintenance.
Inserted transfer tools require more mold maintenance than compression tools. Typically, inserts have to be taken out and reset to maintain movement overtime. Cleaning the tool can be time-comsuming, and sometimes special equipment like dry ice blasters are used to clean the intricate transfer insert.
Transfer Mold of Membrane Materials
NBR Membrane | Hardness: 40~90 Shore A |
Normal service temperature: -35℃~100℃ Low temperature resistance type: -55℃~100℃ High temperature resistance type: -30℃~125℃( in the air); -30℃~150℃(in the oil) | |
| Advantages: excellent resistance to oil and non-polar solevents, excellent bonding properties, good mechanical properties and air tightness. | |
| Disadvantages: weather resistance and ozone resistance is not strong. |
EPDM Membrane | Hardness: 30~90 Shore A |
| Service temperature: -45℃~100℃ | |
| Advantages: excellent heat resistance, weather resistance and ozone resistance. Good water resistance, electrical insulation resilience, low temperature resistance | |
| Disadvantages: poor air tightness, self-viscosity and mutual viscosity, not resistant to non-polar solutions. |
Neoprene Membrane | Hardness: 40~95 Shore A |
| Service temperature: -45℃~135℃ | |
| Advantages: great resistance to exposure to the ozone, sunlight, oxidation, weather, oils, solvents, and several other material. It is also tear resistant, is durable, and easily adheres to metals and fabrics. | |
| Disadvantages: poor resistance to strong oxidising acids, esters, ketone and certain hydrocarbons. |
FKM Membrane | Hardness: 50~90 Shore A |
Service temperature in Static Seal: -26℃~232℃ Service temperature in Dynamic Seal: -15℃~200℃ | |
| Advantages: flame retardant, gas penetration resistance, ozone resistance, weather resistance, good aging resistance and resistance to chemical media. | |
| Disadvantages: can not be used with molten or gaseous alkali metals. |
Membrane Transfer Molding Surface Treatment
Sand blasting adopts compressed air as the power to form a high-speed jet beam to spray the material (copper ore, quartz sand, emery, iron sand) to the surface of the mold to be treated at high speed, remove the residual burrs and rust, and make the surface of the mold smoother. The surface requirements of the different products are different, and sand of different thickness is used. At the same time, the mechanical properties of the workpiece surface are improved, the fatigue resistance of the workpiece is improved, the adhesion between it and the coating are also beneficial.
The sand blasting method is simple, so the cost is low. However, if the mold surface is sandblasted twice or multiple times, the tool edge of the mold will be damaged, resulting in more rough and thicker parting lines.
In the process of using chemical liquid to corrode the mesh, the liquid soaks the mold for afixed time chemical reaction, wich is not affected by the surrounding environment. However, when the liquid corrodes the mesh, it needs to cover the non-texture area, which is difficult to operate. Moreover, the mesh life in the corrosion area of the liquid is relativley short, which can easily lead to the rapid scrapping of the mold core.
For the small mesh area that needs to be treated, there will be dividing line between the mesh in different areas, so that the surface pattern of the products is inconsistent. In this case, chenmical corrosion is suitable for products that need to form a large area of mesh.
EDM treatment is easy to operate, short precision, suitable for small area of mesh processing. And the electrical spark hit out of the mesh is harder. Usually 5 Axis Machine is used for processing, so the cost of EDM is the highest.
Membrane Transfer Molding, also be known as Diaphragm Mould, Membrane Valve Moulding and Diaphragm Seals Mold. Membrane are used to seal and isolate enclosures, preventing unnecessary transmission of substances between two places, and are commonly used in low pressure flow control applications, such as liquids, slurries and gases, etc.
Membrane Transfer Molding's advantage is that it can produce structurally complex coated products containing metal parts or other material parts. Transfer Molding's price is much cheaper than the LSR Injection Molding, and it can also produce complex silicone rubber parts with more uniform wall thickness than the products produced by the Compression Mold.
Membrane Transfer Molding Process
1. A piece of uncured rubber is placed into a portion of the mold.
2. The mold is closed up and under hydraulic pressure, the rubber is forced through a small hole into the cavity. The mold is held closed while the rubber cures.
3. The plunger is raised up and the transfer pad material is removed.
4. Mold is opened and the part can be removed.
Membrane Transfer Molding VS. Compression Molding & LSR Injection Molding
Membrane Transfer Molding VS. Compression Molding
1. Transfer Molding takes less time to peroform.
The raw material used in compression molding does't have to be completely liquid it can be semi-solid. The semi-solid raw material can be injected or otherwise forced into the mold cavity by the plunger. This makes transfer molding faster than many other molding processes, particularly those that only support liquefied material.
2. Transfer Molding allows for higher tolerance.
This is due to the fact that transfer molding uses more pressure than compression molding. Both types of molding processes involve the use of pressurized raw material. With compression molding and transfer molding, the raw material is pressurized as it's injected into the mold cavity. Transfer molding, though, applies more pressure to the raw material, thereby allowing for higher dimensional tolerances.
Membrane Transfer Molding VS. LSR(Liquid Silicone Rubber) Injection Molding
1. Transfer Molding has high cavity count.
Transfer Molding typically has dozensof cavities, while LSR injection molding has only few cavities.
2. Transfer Molding has fewer restrictions on raw material.
The transfer molding can produce rubber and silicone productions, while the LSR injection molding can only produce silicone productions.
Membrane Transfer Molding Advantages
1. Allows for the easy integration of inserts, such as metal components of electronic parts, into the molded product.
2. Allows for intricate designs with sharper edges, providing greater design flexibility compared to other molding methods.
3. Allows for producing parts with minimal or no burr, eliminating the need for additional deburr processes.
4. Allows for higher tolerances.
5. Lower tooling and equipment costs, because simpler pot and plunger designs.
Membrane Transfer Molding Disadvantages
2. Slower production rate.
Compared to injection molding, due to the additional steps involved in material preparation and transfer.
3. Air can get trapped in the mold during the transfer process.
This can lead to defects in the final product and require additional measures to ensure air is properly evacuated.
4. Complex molds.
Since the design and mold tends to be complex, tooling can also become expensive.
5. Mold maintenance.
Inserted transfer tools require more mold maintenance than compression tools. Typically, inserts have to be taken out and reset to maintain movement overtime. Cleaning the tool can be time-comsuming, and sometimes special equipment like dry ice blasters are used to clean the intricate transfer insert.
Transfer Mold of Membrane Materials
NBR Membrane | Hardness: 40~90 Shore A |
Normal service temperature: -35℃~100℃ Low temperature resistance type: -55℃~100℃ High temperature resistance type: -30℃~125℃( in the air); -30℃~150℃(in the oil) | |
| Advantages: excellent resistance to oil and non-polar solevents, excellent bonding properties, good mechanical properties and air tightness. | |
| Disadvantages: weather resistance and ozone resistance is not strong. |
EPDM Membrane | Hardness: 30~90 Shore A |
| Service temperature: -45℃~100℃ | |
| Advantages: excellent heat resistance, weather resistance and ozone resistance. Good water resistance, electrical insulation resilience, low temperature resistance | |
| Disadvantages: poor air tightness, self-viscosity and mutual viscosity, not resistant to non-polar solutions. |
Neoprene Membrane | Hardness: 40~95 Shore A |
| Service temperature: -45℃~135℃ | |
| Advantages: great resistance to exposure to the ozone, sunlight, oxidation, weather, oils, solvents, and several other material. It is also tear resistant, is durable, and easily adheres to metals and fabrics. | |
| Disadvantages: poor resistance to strong oxidising acids, esters, ketone and certain hydrocarbons. |
FKM Membrane | Hardness: 50~90 Shore A |
Service temperature in Static Seal: -26℃~232℃ Service temperature in Dynamic Seal: -15℃~200℃ | |
| Advantages: flame retardant, gas penetration resistance, ozone resistance, weather resistance, good aging resistance and resistance to chemical media. | |
| Disadvantages: can not be used with molten or gaseous alkali metals. |
Membrane Transfer Molding Surface Treatment
Sand blasting adopts compressed air as the power to form a high-speed jet beam to spray the material (copper ore, quartz sand, emery, iron sand) to the surface of the mold to be treated at high speed, remove the residual burrs and rust, and make the surface of the mold smoother. The surface requirements of the different products are different, and sand of different thickness is used. At the same time, the mechanical properties of the workpiece surface are improved, the fatigue resistance of the workpiece is improved, the adhesion between it and the coating are also beneficial.
The sand blasting method is simple, so the cost is low. However, if the mold surface is sandblasted twice or multiple times, the tool edge of the mold will be damaged, resulting in more rough and thicker parting lines.
In the process of using chemical liquid to corrode the mesh, the liquid soaks the mold for afixed time chemical reaction, wich is not affected by the surrounding environment. However, when the liquid corrodes the mesh, it needs to cover the non-texture area, which is difficult to operate. Moreover, the mesh life in the corrosion area of the liquid is relativley short, which can easily lead to the rapid scrapping of the mold core.
For the small mesh area that needs to be treated, there will be dividing line between the mesh in different areas, so that the surface pattern of the products is inconsistent. In this case, chenmical corrosion is suitable for products that need to form a large area of mesh.
EDM treatment is easy to operate, short precision, suitable for small area of mesh processing. And the electrical spark hit out of the mesh is harder. Usually 5 Axis Machine is used for processing, so the cost of EDM is the highest.
