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This chapter elucidates the definition of rubber sheets, their manufacturing techniques, and the diverse spectrum of their applications.
Rubber sheets are essentially flat materials crafted from rubber or fabric coated with rubber, aimed at enhancing material properties like greater tensile strength and reduced elongation.
This superior and adaptable material finds its utilization in oil and petroleum applications, such as fuel pumps and control valves, and is applicable for various uses across industries.
The creation of rubber sheets is influenced by variables such as length, width, thickness, color, size, and their intended purposes.
Prominent rubber sheets include recycled, reclaimed, synthetic, and natural rubber. Recycled rubber typically originates from crumb rubber from old tires bonded with adhesives, distinct from reclaimed rubber, which undergoes de-vulcanization and re-vulcanization. Synthetic rubber mainly consists of butadiene and styrene, derived from petroleum, and can be blended with various materials for versatile chemical and physical properties. Lastly, natural rubber comes from the latex of the Hevea brasiliensis tree, harvested mainly in South America, Africa, and Asia.
Thermoplastic polymers, like Polystyrene, Polyethylene, and Polypropylene, can be remolded several times with minimal quality loss. Blended polymers, such as PVC and ABS, may degrade during recycling, although additives can improve their stability at a higher cost.
Thermoset plastics, once processed, form a 3-dimensional network distinctly different from thermoplastics. The curing process transitions them from thermoplastic-like states to ones with permanent molecular bonds, diverging significantly from thermoplastics.
Rubbers, as a subset of thermosets, are largely thermoplastic before vulcanization, allowing for reshaping without major property loss. Vulcanization involves molecular cross-linking, but de-vulcanization remains largely unexplored. Research primarily focuses on recycling issues, with Reclaim and marketed Crumb being the primary types of recycled rubber. The challenge of de-vulcanization persists.
Polymers are optimized by compounding with mineral fillers and other polymers, enhancing capabilities and achieving varied properties, particularly in rubbers, thermosets, and PVC.
Key considerations for selecting materials for rubber sheets include:
Four crucial manufacturing techniques for producing rubber sheets include molding, extrusion, latex dipping, and calendaring.
Molding utilizes molds to shape compounds, effective for complex designs in smaller quantities and includes compression, transfer, and injection molding. Despite its cost-effectiveness for intricate designs, this method offers a slower production rate.
Products like O-rings and seals often stem from this process.
In extrusion, unvulcanized compound enters extruders, forming through dyes before vulcanization. Known for producing high volumes cost-effectively, extruded products include profiles, tubing, and gaskets.
This process involves dipping molds into latex solutions for thin-walled products, undergoing vulcanization post-dip. It's ideal for complex shapes like gloves and balloons, not feasible through extrusion.
Calendering uses rollers to flatten material, determining thickness by roller spacing. It's precise for thin, wide parts but has high operational costs.
Rubber sheets can be bonded via adhesives or vulcanization, with vulcanized joints offering superior durability. Adhesives might not perform under high pressures or temperatures.
A vulcanized joint involves carefully preparing and cutting rubber before using a bonding agent and jig for the process. While vulcanized joints offer strength, they might lack precise dimensions. This method, efficient for certain quantities, presents challenges in achieving uniformity when forming rings or profiles.
The major specifications are:
This specification addresses flexible cellular rubber products like sponge rubber but excludes ebonite cellular rubber. The products could be made from natural, synthetic, or reclaimed rubber, with polymers and additives for property enhancement.
For fabricated products, this specification requires synthetic, vulcanized, or rubber-like materials, either solo or combined, detailing inspection methods to uphold standards.
Rubber sheets are versatile materials widely used in a variety of industrial, commercial, and manufacturing applications for their insulating, sealing, and protective properties. Understanding the different types of rubber sheets and their unique characteristics is essential for selecting the best option for your specific project or industry needs. The leading types of rubber sheet materials include:
Natural rubber sheets are derived from latex harvested from rubber trees. These materials exhibit excellent dynamic and rebound characteristics, making them highly effective in applications that require flexibility and resilience. Known for their outstanding tear resistance and elasticity, natural rubber sheets are frequently used as anti-vibration pads in packaging and machinery. Their superior dynamic performance, mechanical strength, and versatility make them a top choice for general sealing, gasketing, and protective linings across industrial, automotive, and construction industries. Natural rubber is also popular in environments that do not demand specific chemical or weather resistance, offering reliable performance in a broad range of settings.
Neoprene rubber sheets (also known as polychloroprene sheets) are ideal for environments demanding corrosion-resistant, weatherproof, and flame-retardant materials. Frequently utilized in power transformers and electrical insulation, they offer outstanding resistance to petroleum products, mineral oils, greases, acids, and alkalis, making them invaluable for industrial, marine, and automotive applications. In addition to providing effective cushioning and vibration damping in external metal housings, neoprene sheets are often chosen for their sound and thermal insulating properties, ability to resist ozone and UV radiation, and performance across a wide temperature range. These attributes make them a trusted material for gaskets, seals, soundproofing barriers, and safety mats.
Neoprene rubber with a 40A durometer rating is highly compressible and ideal for applications that require maximum conformity and minimal force, such as dust seals, conformable pads, and vibration dampening solutions.
Neoprene rubber with a 50A durometer rating balances flexibility and compressibility, making it effective for shock absorption, cushioning, and gasket applications where a softer rubber sheet is preferred.
Neoprene rubber with a 60A durometer rating offers moderate hardness, providing a versatile solution suitable for oil-resistant gaskets, water seals, beverage and food processing equipment, and outdoor weather-resistant applications.
Neoprene rubber with a 70A durometer rating is more rigid and durable, delivering high resistance to compression and deformation. This makes it suitable for heavy-duty industrial gaskets, mounting pads, and equipment isolation in demanding environments.
Nitrile rubber sheets, also known as NBR (nitrile butadiene rubber), are specifically engineered for superior resistance to oils, fuels, greases, and a range of chemicals. This oil-resistant rubber material is widely used for sealing in electrical transformers, gasketing, oil-resistant flooring, automotive and food processing industries, as well as environments involving dielectric oils for electrical insulation. Due to its robust performance in contact with hydraulic fluids and hydrocarbons, nitrile rubber is the preferred solution for fuel system gaskets, hoses, and components exposed to moderate temperature variations. Nitrile sheet rubber is commonly utilized in flange joints, pipe seals, and fluid containment operations, where resistance to oil swelling and solvent degradation is critical.
Hydrogenated nitrile rubber (HNBR) represents an advanced synthetic rubber offering superior chemical and oil resistance compared to standard nitrile. Designed for demanding industrial and automotive applications, HNBR sheets can withstand elevated temperatures, aggressive fuels, synthetic oils, ozone, and steam. They provide enhanced tear strength, elongation, tensile strength, and abrasion resistance—ideal for hydraulic seals, automotive belts, hoses, and demanding environmental sealing requirements. However, HNBR's higher cost, moderate flame resistance, limited electrical insulation, and incompatibility with polar solvents or aromatic oils should be considered when selecting it for specific uses.
EPDM (ethylene propylene diene monomer) rubber sheets are highly valued for their exceptional resistance to weathering, UV radiation, ozone, harsh outdoor conditions, acids, alkalis, and ketones. This makes EPDM the preferred choice for roofing membranes, waterproof seals, weatherstripping, automotive window seals, pond liners, and outdoor gaskets. Their durability and performance across a wide temperature range also make EPDM sheets suitable for hot water and steam applications, while maintaining flexibility and resilience in extreme weather.
Silicone rubber sheets are renowned for their outstanding thermal stability, low permeability, flexibility, and chemical resistance. Capable of withstanding extreme temperature fluctuations (ranging from -60°C to 230°C), silicone rubber is preferred in cleanroom, medical, pharmaceutical, food processing, and electronic industries where hygiene, sterility, and non-toxicity are critical. Additionally, silicone sheets exhibit excellent resistance to ozone, UV, aging, and various chemicals, and are frequently used for baking mats, medical devices, gasket fabrication, and specialized industrial sealing and insulation applications.
Fabric reinforced rubber sheets are constructed from natural or synthetic rubber compounds with one or multiple embedded fabric layers (such as polyester, cotton, or nylon). The added reinforcement delivers enhanced tensile strength, dimensional stability, and resistance to deformation under pressure, making these sheets a reliable choice for high-stress gaskets, diaphragms, conveyor belts, and heavy-duty industrial sealing. This reinforced construction is especially beneficial in applications involving high pressure, vibration, or mechanical wear.
Styrene-butadiene rubber (SBR) is a cost-effective synthetic rubber prized for its abrasion resistance, impact strength, high tensile strength, and shock-absorbing capabilities. Although SBR is less resistant to ozone, ultraviolet light, oils, and hydrocarbon solvents, it remains a popular choice for automotive parts, conveyor belts, tires, shoe soles, and industrial floor coverings where wear resistance and durability are paramount. SBR rubber sheets are also used as anti-fatigue mats, protective liners, and flexible pads in commercial and heavy-duty applications.
Viton� sheets are made from high-performance fluoroelastomer materials and are highly favored in industries requiring chemical resistance and extreme temperature tolerance. This advanced fluoropolymer elastomer maintains stability over a wide operating range (-20°C to 205°C) and can handle exposure to aggressive chemicals, fluorinated solvents, and fuels. Viton� is among the most reliable elastomers for fabricating seals, O-rings, and gaskets in the chemical processing, aerospace, and automotive sectors, alongside nitrile. Developed in the 1950s for the aerospace industry, Viton� fluoroelastomers are renowned for thermal endurance—withstanding over 10,000 hours at 204°C and up to 325°C for shorter periods—as well as resistance to acids, oils, and oxidation. While Viton� offers versatile performance and exceptional durability in physically and chemically aggressive environments, it tends to be more expensive compared to general-purpose rubbers.
The material’s robust chemical compatibility and long service life make it ideal for gaskets, valve linings, fuel system seals, and industrial applications subjected to elevated temperatures and harsh chemicals.
Butyl rubber, also known as isobutylene isoprene rubber (IIR), is highly regarded for its superior shock absorption, low permeability to gases, and exceptional resistance to moisture, ozone, UV, oxidation, aging, and chemicals. Its ability to dampen vibrations and form airtight seals makes it ideal for vacuum sealing, tank liner, industrial dampers, and sound insulation panels. Butyl rubber is also compatible with ester-based phosphate hydraulic fluids and provides excellent electrical insulation for specialized components in the automotive and HVAC industries. While manufacturing may present challenges such as blistering, creeping, and air entrapment, the advantages of butyl rubber, including its flexibility and longevity, outweigh its drawbacks for demanding sealing, dampening, and protective applications.
This chapter will explore the various applications and advantages of rubber sheets.
Flooring and roofing applications are the most popular uses of rubber sheets in the industry. Rubber provides good resistance to substances like oil and petroleum, ultra violet lights, and oxidizing elements. Furthermore, it has the capacity to maintain flexibility even in cold temperatures. It is elastic and that even makes it suitable for various kinds of shock absorbers and for specialized machinery mountings designed to reduce vibration.
Rubber sheets are utilized across a wide range of applications, including industrial buildings, agricultural machinery, and Original Equipment Manufacturer (OEM) parts. They are also commonly used in commercial and residential settings such as storerooms, gyms, dance studios, garages, under shower pans, in drainage systems, and for weather stripping, as well as various construction and remodeling projects.
These sheets find applications in virtually every industry, including scientific, footwear, medical, engineering, railways, automotive, defense, aerospace, and marine sectors. Examples include their use in railroad tank cars, as linings for storage tanks, and in the creation of floor mats, gaskets, bearing pads, horse stall mats, sandblasting equipment, orthopedic footwear, and heavy-duty curtains. Rubber sheets are also used in wet areas like under showerheads and in washrooms to enhance slip resistance.
As the use of rubber sheets continues to expand, their demand is expected to grow significantly. Rubber sheets offer a cost-effective alternative to other materials and their versatility in combining with various products further enhances their appeal in the industrial market.
The benefits of rubber sheets are:
Protection of Work Surfaces � Rubber sheets provide excellent cushioning and impact absorption, making them effective at safeguarding work surfaces in industrial environments from damage.
Safety � Rubber is known for its safety benefits, being user-friendly and suitable for public areas. Its non-slip and shock-absorbing properties contribute to a safer environment for both users and staff.
Protection of Equipment � Rubber is an ideal material for protecting machinery due to its shock-absorbing qualities, helping to reduce wear and tear on equipment.
Anti-Vibration � Rubber effectively dampens vibrations from machinery, which helps prevent annoyance and reduces the risk of damage from excessive vibrations.
Resistance � Rubber is resistant to electricity, discoloration, and rust, enhancing its durability and longevity in various applications.
Versatility � Rubber sheets can be cut into a variety of shapes and sizes, including pads, washers, and gaskets, making them highly adaptable to different needs.
Availability � Rubber sheets come in various materials and colors, making them suitable for numerous settings, including retail and commercial applications. They can be customized into various forms, such as gaskets, washers, and pads.
Natural rubber has limited resistance to hydrocarbons, fats, oils, and greases, which can lead to swelling or dissolution upon contact with these substances. Ethylene propylene rubber (EPDM) sheets are unsuitable for food applications or exposure to aromatic hydrocarbons. They are commonly used for high-temperature water vapor seals, bathroom equipment seals, brake system components, and radiator seals in automotive applications. Silicone rubber sheets, though effective, are generally more expensive. Additionally, some rubber sheets can be affected by moisture and may not have a long lifespan. They may expand with temperature fluctuations, so they should be used in environments where these properties can be managed appropriately.
Rubber sheets can have a long service life with proper care and maintenance. This includes initial cleaning, regular upkeep, and the application of suitable finishes. It is advisable to use doormats at main entry points and to perform daily cleaning with a wet vacuum to remove dirt particles from the grooves of the sheet.
Avoid using chemicals on rubber sheets as they may cause adverse reactions. In healthcare settings, such as labor rooms and neonatal units, rubber sheets should be washed with running water and treated with an antiseptic solution. After cleaning, they should be hung to dry, then powdered before being rolled and stored.
If cracks, scratches, or thinning are observed on the rubber sheet, it may no longer maintain its insulation properties and should be replaced promptly. To prevent aging and deterioration, avoid exposing the sheets to direct sunlight, sharp metal objects, or excessive heat. Additionally, keep them dry and clean, and prevent contact with acids, alkalis, and other corrosive substances to avoid damage and maintain effective insulation performance.
Therefore, rubber sheets are basically material that is made from rubber. They are cost effective and safe for use by the public. Manufacturing rubber sheets is a lucrative business as they have immense and various uses in every industry worldwide (chemical, biological, commercial, environmental, and physical). They can be molded into various shapes and in various colors.
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