Liquid Silicone Rubber Injection Moulding

Processes Machine Technology Application

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LIQUID SILICONE RUBBER
Products from liquid silicone rubber (LSR) are
to be found in numerous applications. And its
range of uses will no doubt extend as further
and new developments come on the market.
Especially where thermoplastic elastomers no
longer meet requirements, LSR provides the
capability prole to ll the need. An added
advantage is in the fact that LSR will combine
with a host of other plastics and with metals.
Low viscosity creates high exibility
Liquid silicone rubbers belong to the group of
heat-curing rubbers. A characteristic feature is
their low viscosity during processing compared
to solid silicones or elastomers.
Two-component mixtures increasingly crosslink
by the addition process. This means that the
reaction takes place without any decomposi-
tion product forming. This is a great benet in
injection moulding because there is no concern
of deposits forming on the moulds.
In order to dene processing time until cross-
linking starts, one of the two components has
an inhibitor added, which is also referred to as
a pot-life regulator. The other component has
a catalyst added. Crosslinking better known
as curing starts due to the inuence of the
mould temperature which, depending on the

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mix, is between 160 C and 220 C. But then
the reaction proceeds fairly rapidly at approxi-
mately 5 s/mm of wall thickness. Consequently,
much shorter cycle times can be achieved with
LSRs than, for instance, with classic elastomers.
A very special material
On account of their excellent properties,
liquid silicone rubbers lend themselves to
a vast spectrum of applications.
Key features:
Physiologically acceptable
No odour or taste transfer
Unaffected by weather and ageing
High-temperature capability (continuous
working temperature up to 180 C)
Low-temperature capability
(remains exible beyond 50 C)
Sterilisable
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Basically, all Demag machines have LSR proces-
sing capability, if tted with the appropriate
additional equipment. So the processors can
take their choice. And can rely on Demags ex-
pertise to assist them in planning for the right
equipment.
Stability of the process parameters is key to as-
suring product quality at a high level. Therefo-
re, moulders should be aware of the following
pointers in processing LSR:
Melt cushion variations not to exceed 0.1 mm
Screw stop position variations not to
exceed 0.1 mm
Injection time variations not to exceed 0.02 s
Metering variations not to exceed 5 %
The range of pressure variations of the LSR in
the feed zone 5 to 10 bar maximum
Furthermore, the machine should incorporate
the following features:
Programmable back pressure
Injection by means of Smart pump
(closed loop control of speed)
Injection speed setting in extremely small in-
crements (0.1 mm/s) to avoid air entrapments
Ultrasonic stroke measuring system
Move to vacuum gap, wait for vacuum build
up, then apply clamp force and inject
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Demag machines for LSR processing
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Major elds of application
Despite their comparatively high price, liquid silicone rubbers (LSRs)
cut across almost all areas of every day life and industrial produc-
tion. Primary applications are in
Vehicle and machine building: O-rings, gaskets,
spark plug connectors
Medical devices: Mouthpieces for anaesthetic devices,
clinical nipples
Food industry: Dosing devices, covers, baby bottle teats
Kitchen and plumbing: Baking moulds, keypads,
seals and gaskets
Electricals and electronics: Mobile phone keypads,
keyboard mats
Sports and leisure: Diving masks, toys
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Demags modular system
Ranging from dummies and elastic seals to cold and high-temperature-
resistant mouldings for automobiles and aircraft the spectrum of
LSR-moulded parts and rigid/exible combinations is of an overwhelming
variety. The technology for it comes from Demag Plastics Group: a com-
plete LSR package with its helpful add-on options covers almost every
application of liquid silicone moulding.
Features included in the LSR package:
LSR plasticising unit with liquid temperature control bushes
LSR screw with non-return valve and shaft seal
Plasticising cylinder connection to mixing and metering unit
Water-cooled LSR shut-off nozzle
Programmable backpressure
Freely programmable pneumatic valve
Pneumatic cores for control of brushing equipment or demoulding
handling
Flexible vacuum program
Delayed injection with adjustable delay time
Optionally, there are additional LSR modules available:
Mould temperature controller
Pneumatic 5/2 way valve or hydraulic valves for control of cold-runner
nozzles in mould
Water lter and water monitor for cold runner cooling
Apart from the modied injection moulding machine, processing of liquid
silicones calls for a special mixing and metering plant. Here, Demag Plas-
tics Group cooperates with a number of leading manufacturers.
barrel is effected during metering at an adjust-
able, repeatable pressure.
Continuing the process, the screw feeds the
paste-like material into the space in front of the
screw. Simultaneously, the two main compo-
nents plus any pigment addition once more
undergo thorough mixing. Injection then takes
place by the screw forcing the material through
a cold runner into the mould. Once the mixture
in the mould has reached the necessary activa-
tion level >170 C, crosslinking or curing starts.
A special LSR non-return valve prevents the
mixture from owing back out of the space
in front of the screw into the forward part
of the screw. Inside the barrel, too, absolute
tightness is crucial. Therefore, Demag uses
special-purpose screws and barrels in its LSR
machines. Thanks to high-precision seals,
MACHINE TECHNOLOGY
Demag machines guarantee exceptionally clean
and effective LSR processing.
A major asset for all moulders in this context is
Demags modular injection moulding machine
concept. A exibly laid out production setup
capable of responding quickly and straightfor-
ward to new market requirements is of para-
mount importance. In fact, all Demag machines
can be used again for thermoplastics and vice
versa within a minimum of time by changing
the plasticising unit.
The mixing and metering unit delivers the two components automatically at a mixing
ratio of 1 : 1
For silicone processing, the machines are equipped with an LSR plasticising unit with cooled
shut-off nozzle
Process sequence
fully automatic and repeatable
The mixing and metering unit delivers the two
components, which are supplied ready for
processing, automatically and at the preset
mixing ratio from the containers rst into a res-
ervoir. Where necessary, the unit also adds pig-
ment separately from these two components.
Next, the components which have been
brought together but are still unmixed, go to a
static mixer to be thoroughly mixed by means
of ow-dividing elements. Non-return valves in
the piping prevent back ow of the paste-like
components.
In response to a metering signal from the injec-
tion moulding machine, the mixture eventually
passes through an adapter into the feed zone
of the plasticising unit. Delivery into the screw
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Temperature control
precise and zone-selective
A crucial aspect for LSR processing is precise
temperature control for the different elements
of the plant. While in the mould or rather in the
cavities, required temperatures are between
160 C and 220 C, the plasticising barrel, the
shut-off nozzles and the cold runner on the
mould should maintain a temperature between
20 C and 30 C. Failing this, the mixture would
be liable to undergo excessive and premature
heating resulting in premature curing.
Consequently, it is important to ensure exact
segregation of the temperature zones. With this
in mind, Demag uses water cooling to control
barrel temperature which as all other control
loops as well as the peripheral equipment is
integrated in the machine control system.
Demoulding
quick and reliable with brushes
Basically, demoulding of elastic, exible
moulded parts is a difcult undertaking. Ulti-
mately, it depends on the geometry of the part
as well as on the specic conditions, that is,
whether production is fully automatic or semi-
automatic. Classic type ejectors (sleeves or pins)
may be used or stripper plates, blow-off ozzles,
handling devices or brush rollers. Of great
inuence in this context is the mould concept
which is why demoulding must be given proper
consideration in the design stage.
Depending on moulded part geometry, the use of a brushing device can be practical for
demoulding
1. Silicone component A
2. Silicone component B
3. Pigment or additive addition
4. Non-return valves
5. Mixing reservoir
6. Static mixer
7. Shut-off valve
8. Non-return valve
9. Pneumatic/hydraulic shut-off
10. Temperature control
11. Mould heating
12. Vacuum pump
Key plant components of an LSR processing unit
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Design and build of a mould suitable for LSR
moulding are challenging tasks. This is because
injection moulding of a low-viscosity material
obeys its own laws. Drawing on an extensive
body of know-how, Demag Plastics Group will
assist customers for best results.
For strictly practical, qualitative and also econo-
mical reasons, fabrication of the moulded parts
should be without sprues and ashes, fully au-
tomatically and without the need for secondary
operations. These requirements alone underline
the need for precision. In order to obtain ash-
free parts, extremely close tolerances of the
order of 0.005 mm and less are mandatory. On
the other hand, it is also necessary to reliably
evacuate the cavities to avoid rejects due to
air entrapment, lling problems or so-called
white spots. Therefore, it is a good plan to have
Precision within tightest tolerances
a vacuum pump integrated in the machine to
assist mould venting.
Mould design also inuences the selection of
the machine nozzle. Possible alternatives are:
Provide a hydraulic or pneumatic shut-off
nozzle on the machine side for hot runner
moulds or moulds with an open cold runner
Provide either an open nozzle or a shut-off
nozzle on the machine side for moulds with
a cold-runner shut-off nozzle
Process variant:
Multi-component moulding
Whether for technical perfection or better
appear ance, multi-component parts using rigid/
exible combinations are gaining ground.
A com bination of liquid silicone rubber with
thermoplastics can extend moulded part
THE MOULD
properties but from the process point of view
poses a special challenge.
For instance, the thermoplastic component
must be capable of withstanding the curing
temperatures of the LSR without degradation.
Of course, the process itself must be chosen
to t to the moulded parts. Moreover, prior
testing is required to study the adhesion of
the different materials. LSR will not bond to all
thermoplastics which is why some mechanical
connection may be necessary.
Temperature distribution in a two-component mould for a thermoplastic/
LSR combination
Section of a 128-cavity mould for single-wire terminations (photo: Elmet)
Cold runner plate with 16 pneumatically operated shut-off nozzles
25 30 C 65 C 90 C 170 C 270 C
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LSR moulding solutions in practice
APPLICATIONS
The processing of liquid silicone rubber involves
vulcanisation or curing under heat. This implies
three particularities of LSR injection moulding:
metering of two different liquids by means of
a special metering unit; homogenisation and
delivery of the paste-like rubber in the injection
moulding machine; and curing in the mould at
around 160 C to 220 C.
As a single-component material, LSR is used in
many technical applications, such as keyboard
mats, plug connectors, O-rings and gaskets.
Recently, it has also found application for such
common consumer products as dummies and
dispensers in food packaging articles. Moreover,
LSR is used in medical devices, such as tubing,
respirator masks, and body electrodes. The most
dynamic growth areas today are exible baking
moulds, self-ceramifying products, e. g. sheath-
ing of cables in re-hazard areas and lift
wells and technical parts made by two-
component injection moulding for use in the
automotive and electronic industries.
Tips and tricks from LSR pros
1. In the case of thermoplastic/LSR combina-
tions, continue processing the thermoplastic
immediately whether direct by transfer into
a second injection moulding machine or by
overmoulding in a two-component mould.
This way you will be able to avoid changes in
surface tension on the thermoplastic part by
oxidation or water absorption.
2. Try out and adjust new moulds for some
time with standard LSR in order to siliconise
the surface so that zero-loss demoulding of
the parts is ensured in commercial production.
3. You can signicantly shorten the time for
adhesion build-up between the thermoplastic
and LSR by allowing a longer dwell time after
injection moulding or by post-curing. This
is the way to quickly achieve optimum nal
bonding.
www.dpg.com
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