Production principle and process analysis of PVC rubber patches

Update time: 2024-09-27 09:47:57

PVC rubber patches are a common decorative and branding material, widely used on products such as clothing, bags, shoes, etc. They are known for their softness, durability and bright colors, and are particularly suitable for products that need to be used for a long time. The production of PVC rubber patches involves a variety of materials and processes. The following are its main production principles and processes.

The main material of PVC rubber patches is polyvinyl chloride (PVC), a commonly used synthetic plastic with good plasticity, flexibility and durability. PVC is easy to form at high temperatures and retains its shape after cooling, which makes it very suitable for producing patches with complex patterns and three-dimensional effects.

In addition to PVC itself, the following auxiliary materials may also be used when making PVC rubber patches:
Plasticizer: Increase the softness of PVC and make the patch more flexible.
Stabilizer: Improve the heat resistance and anti-aging properties of the material.
Colorant: Used to color PVC materials, which can be formulated into different colors according to customer requirements (usually using color cards to ensure accurate colors).
Filler: Fillers are sometimes added to improve material properties or reduce costs.

The production process of PVC rubber patches mainly includes the following steps:
1. Designing the mold
First, according to the needs of the customer, design a 2D or 3D pattern that meets the requirements. After the design is completed, the corresponding metal mold is made. This mold determines the shape and surface details of the patch. The mold is usually made of steel or aluminum to ensure its precision and durability.

2. Mixing colors
The color of the PVC raw material is mixed using the color card system. In order to ensure that the color of the patch meets the customer's requirements, the manufacturer will conduct a small sample test before production to confirm the color consistency. Different colors will be loaded into different injection guns to ensure that each color area can be accurately filled.

3. Injection molding process
PVC rubber patches are usually made by injection molding. Depending on the design pattern, injection molding can be divided into multi-layer injection molding (usually used for 3D effects) or single-layer injection molding (for 2D effects).

The first step of injection molding: The molten PVC material is injected into the mold through an injection device. Usually, the higher pattern part will be injected with thicker PVC material first.
Second step injection molding: After initial cooling, other colors or layers of PVC materials are injected into the corresponding areas of the mold. This step-by-step injection molding can achieve multi-color and multi-layer effects.

4. Heating and curing
The injected PVC needs to be heated to complete the curing process. The mold will be heated to a certain temperature to fully shape the PVC material. In this process, the material changes from liquid to solid, ensuring that its shape and color are fixed.

5. Cooling and demolding
After the heating and curing is completed, the mold is cooled, and then the PVC rubber patch is removed from the mold. The cooled patch is very durable and can withstand friction and washing without being easily damaged.

6. Trimming and post-processing
The PVC rubber patch removed from the mold may have some edge parts that need to be trimmed. By manual or machine trimming, the excess material is removed to make the patch more beautiful. According to customer requirements, surface coating is sometimes performed to make the patch smoother or have a special texture.

The PVC rubber patch produced by this production process has the following characteristics:
Softness: The use of plasticizers makes the patch soft and has a certain elasticity.
Durability: PVC material itself has high wear resistance and anti-aging properties, suitable for long-term use.
Waterproofness: PVC material does not absorb water, and the patch still maintains its function and appearance in a humid environment.
Bright colors: PVC can accurately present the colors required by customers and is not easy to fade.
Three-dimensional sense: Through multi-level injection molding, 3D patterns with a high sense of three-dimensionality can be produced.

PVC rubber patches are widely used in clothing, backpacks, shoes, hats and other products for decoration, brand promotion and product identification. Due to its durability and diverse design options, it is particularly suitable for sports equipment, outdoor clothing and other items that need to be washed frequently.

PVC rubber patches are transformed into actual products through the injection molding process. Its production process includes mold design, color matching, injection molding, heat curing and post-processing. The diverse characteristics of PVC materials make this patch both beautiful and practical, making it an ideal choice for various brand promotions and product decorations.