Understanding the Laboratory Press: Functions, Features, and Operation

What is a Laboratory Press?

A laboratory press is a type of machine that uses high pressure to condense and mold a variety of materials. It is commonly used in industries such as pharmaceuticals, laminating, rubber, and plastic molding. Laboratory presses are also widely used in research and development work, testing, short runs, limited production, cell manufacturing, and lean manufacturing.

Definition and main use of Laboratory Press DW5150A/DW5150B

Laboratory Press DW5150A/DW5150B is mainly used for vulcanizing flat tape and applying hot plate pressure per unit area. It offers reliable equipment operation and requires minimal maintenance.

Main function of Rubber Vulcanizing Press

The main function of a rubber vulcanizing press is to provide the necessary vulcanization pressure and temperature. The pressure is generated by the hydraulic system using a hydraulic cylinder, while the temperature is provided by a heating medium. The rubber vulcanizing press can have single or double working layers, and the hydraulic system can use either oil pressure or water pressure as the working medium.

Varieties of laboratory presses according to working layer number and hydraulic system working medium

Laboratory presses can be classified based on the number of working layers and the hydraulic system working medium. They can have single or double working layers, and the hydraulic system can use oil pressure or water pressure.

Evolution of laboratory presses in the rubber industry

In the rubber industry, laboratory presses have evolved from column structures to frame structures. The early type of laboratory press used in China was the column rubber laboratory press. However, the frame flat plate vulcanizing machine is now more commonly adopted due to its advantages over the column flat plate vulcanizing machine.

Laboratory presses are essential in the rubber industry for testing and compacting materials such as rubber. These heavy-duty machines provide the necessary precision and reliability to meet the high demands of research and industrial inquiries. With programmable controls and a wide range of pressure options, laboratory presses allow for accurate and consistent pressing of products according to specific requirements.

When choosing a laboratory press, factors to consider include the required force for a specific sample, available lab space, energy and strength requirements, and the need for mobility. Laboratory presses play a crucial role in preparing samples for a wide range of tests, such as elongation tests, Mooney viscosity, and tensile strength. Consistently well-made specimens are necessary for reliable test results and accurate analyses.

In conclusion, laboratory presses are versatile machines that play a vital role in various industries and research fields. They offer precision, durability, and consistent results, making them an integral part of laboratory operations.

Working Principle of a Laboratory Press

Process of vulcanization during laboratory press operation

In the rubber industry, a laboratory press is used for vulcanizing flat tape and applying hot plate pressure per unit area. The main function of a laboratory press is to provide the necessary vulcanization pressure and temperature. This is achieved through the hydraulic system, which generates pressure using hydraulic cylinders and provides the required temperature through heating medium. The laboratory press can have single or double points depending on the working layer number, and the hydraulic system can use oil pressure or water pressure as the working medium.

During the operation of the laboratory press, the hot plate heats up and sizes up the rubber, causing the cross-linked rubber molecules to transform from a linear structure to a mesh structure. This transformation gives the rubber a range of physical and mechanical properties. However, as the rubber is heated, it becomes soft and releases moisture and volatile matter, which gasify. To prevent the formation of air bubbles and ensure a fine and close organizational structure, sufficient pressure is applied by the hydraulic cylinder to mold the rubber model. This pressure also prevents issues such as overflow edges, lack of glue in patterns, and stoma sponge.

Impact of heat and pressure on rubber model

The combination of heat and pressure in the laboratory press plays a crucial role in the vulcanization process of rubber. The heat applied to the rubber causes it to soften, allowing for the rearrangement of molecular structure. This leads to the formation of a mesh structure, which imparts desirable physical and mechanical properties to the rubber.

The pressure exerted by the laboratory press ensures that the rubber model is properly molded. It prevents the formation of air bubbles, which can weaken the structure of the rubber and affect its properties. Additionally, the pressure helps in achieving a fine and close organizational structure, leading to a stronger and more durable end product.

Role of pressure in preventing various issues in the molding process

Pressure plays a crucial role in preventing various issues that can arise during the molding process in a laboratory press. Sufficient pressure is applied to prevent the mold from overflowing at the edges, ensuring that the desired shape is maintained. It also helps in preventing issues such as the lack of glue in patterns and the formation of stoma sponge.

By exerting enough pressure, the laboratory press ensures that the rubber is evenly distributed within the mold, resulting in a uniform and high-quality end product. The pressure also helps in achieving proper adhesion between different layers in laminated products, ensuring their durability.

Overall, the combination of heat and pressure in a laboratory press is essential for the vulcanization process of rubber. It allows for the transformation of the rubber's molecular structure, leading to the desired physical and mechanical properties. The precise control of pressure ensures that the molding process is successful and prevents various issues that can affect the quality of the final product.

Features of the Rubber Laboratory Press

Composition and treatment of pressing plates

The pressing plates of a rubber laboratory press are made of SKD chromium-molybdenum alloy, treated with high-frequency, carburizing, chromium plating, and polishing. These plates have a hardness of up to 60HRC, ensuring durability and longevity.

Design and function of guide columns

The rubber laboratory press is equipped with four high-strength precision guide columns. These columns are designed with double layers of high-strength laminate clamping structures, ensuring stability and parallelism between the laminate plates.

Patented heating control technology and temperature distribution

The rubber laboratory press utilizes patented heating control technology. It is equipped with imported high-precision PID digital temperature control display. The heat transfer pipe, according to the heat density distribution, ensures uniform temperature distribution on the heating plate surface.

Division and functionalities of the moulded board

The rubber laboratory press has a division in the moulded board for easy fume aspiration. This feature allows for efficient and safe operation in the lab. The protection doors of the press also have a safety lock for added security.

Capabilities and features of the hydraulic system

The rubber laboratory press is equipped with a hydraulic system with a closure force of 25 tons. This system provides the necessary pressure for the pressing process. It also incorporates recovery springs for the lower plate, ensuring it is always in the ready-to-use position.

Specifications of the electrical control system

The rubber laboratory press is equipped with a user-friendly PLC controller with a Touch Screen Display. This controller allows for the free definition of the moulding cycle, including the displacements of the moving platen, thermal cycle, and pressure cycle. The press also has a cooling system for the platens during the molding cycle, ensuring the proper solidification of the material.

In summary, the rubber laboratory press offers various features that make it an essential tool in industries such as pharmaceutical, laminating, and rubber and plastic molding. Its precision, durability, and ability to meet rigorous demands make it a preferred choice for scientists and researchers. The composition and treatment of pressing plates, design and function of guide columns, patented heating control technology, division and functionalities of the moulded board, capabilities and features of the hydraulic system, and specifications of the electrical control system make the rubber laboratory press a reliable and efficient tool for various laboratory applications.

Operation of Rubber Laboratory Press

Preparation steps before use

Before using a rubber laboratory press, there are a few preparation steps that need to be taken:

1. Check the hydraulic oil quantity: Ensure that the hydraulic oil level is at least 2/3 of the height of the lower frame. If the oil quantity is insufficient, add more clean #20 hydraulic oil.

2. Lubricate the column shaft and guide frame: Check the lubrication between the column shaft and the guide frame and add lubricant if necessary. This will ensure smooth operation and maintain good lubrication.

Procedure for starting the machine

To start the rubber laboratory press, follow these steps:

1. Turn on the power supply: Move the machine to the vertical position and close the oil return port using the operating handles.

2. Start the motor: Press the motor start button to activate the oil pump. The oil will flow into the oil cylinder, causing the plunger to move up.

3. Close the hot plate: As the oil pump continues to supply oil, the oil pressure will rise to the desired rating (14.5 MPa). Once the desired pressure is reached, press the stop button to close the hot plate.

Use of plate vulcanizing machine

A rubber laboratory press, also known as a plate vulcanizing machine, is used for vulcanizing flat tape and applying pressure per unit area. Here are some key points about its usage:

• Vulcanization pressure and temperature: The main function of the press is to provide the necessary vulcanization pressure and temperature. The hydraulic system generates pressure through a hydraulic cylinder, while the temperature is provided by a heating medium.

• Types of laboratory press: Depending on the working layer number, laboratory presses can be single or double points. They can also use oil pressure or water pressure as the working medium for the hydraulic system.

• Column vs frame structure: In the rubber industry, column rubber laboratory presses were commonly used in the past. However, the current trend is to adopt frame structure presses, which offer certain advantages over column presses.

Working principle of laboratory press

During operation, a laboratory press works by heating the hot plate and applying pressure to the rubber material. The heat causes the rubber molecules to crosslink and form a mesh structure, resulting in various physical and mechanical properties of the final product.

The hydraulic cylinder provides the necessary pressure to mold the rubber and prevent the formation of air bubbles. This ensures a fine and compact organizational structure. Additionally, the pressure helps in lamination by ensuring firm adhesion between the rubber, glue, and cloth.

It is important to apply sufficient pressure to prevent overflow, lack of glue, or sponge-like patterns. This ensures a high-quality end product with the desired properties.

Maintenance and Control of Hydraulic System

Suitable hydraulic oil and its addition process

To ensure the proper functioning of your hydraulic system, it is crucial to use the right hydraulic oil. For lab presses, it is recommended to use either 20# mechanical oil or 32# hydraulic oil. These oils provide good thermal and chemical stability, minimizing sludge formation and ensuring excellent performance.

When adding hydraulic oil, it is essential to carefully filter the oil before adding it to the system. This helps remove any impurities that can potentially damage the system. Additionally, it is recommended to check the lubrication between the column shaft and the guide frame regularly and add lubrication as needed to maintain proper operation.

Importance of lubrication and cleanliness

Keeping all parts of the hydraulic system clean is essential for its optimal performance. Regularly cleaning and lubricating the column shaft and guide frame helps maintain good lubrication operation. This prevents excessive wear and ensures smooth operation of the lab press.

Additionally, cleanliness is crucial for the longevity of the hydraulic system. Contaminants such as dirt, oil, and machining lubricants can negatively impact the system's performance. It is important to ensure that the workpieces, baskets, and fixtures loaded into the press are free of any contaminants. Inadequate cleaning can lead to staining, discoloration, and poor braze alloy flow. It may also cause vacuum loss due to the evaporation of contaminants during heating.

Procedure for dealing with abnormal noises

If you encounter any abnormal noises coming from the lab press, it is important to address them immediately. Continuing to operate the press without investigating the cause of the noise can lead to further damage. It is recommended to stop the press and inspect the source of the noise. Once the issue is identified and resolved, you can resume using the press.

Temperature control of hot plate

Proper temperature control is crucial for the effective operation of the lab press. To control the temperature of the hot plate, ensure that the rotary button SA1 is closed. This will initiate the heating process. Once the temperature of the plate reaches the preset value, the heating will automatically stop. If the temperature falls below the set value, the plate will automatically heat up to maintain a constant temperature.

Control of vulcanization motor and its cycle

The vulcanization motor plays a vital role in the lab press for pressing molded products such as rubber and plastics. It is important to follow the proper control and cycle procedures for the motor. When the machine is in the holding state (sulfide timing), and the curing time is reached, move the handle to open the mold. In case of motor overload, the power supply will automatically be cut off. The electric heating temperature control ensures precise temperature control within a range of 20-200 degrees. After reaching the set curing time, an automatic alarm will be triggered.

Remember to follow these control procedures to ensure the successful vulcanization of products and the safe operation of the lab press.

Remember, proper maintenance and control of the hydraulic system are essential for the longevity and optimal performance of your lab press. Regularly check and replace the hydraulic oil, keep the system clean and lubricated, address any abnormal noises promptly, and follow the temperature control and motor cycle procedures. By following these guidelines, you can ensure the reliable and efficient operation of your lab press for years to come.

If you are interested in our products, please visit our company website：https://kindle-tech.com/product-categories/heated-lab-press, where innovation has always been a priority. Our R&D team consists of experienced engineers and scientists who closely follow industry trends and are constantly pushing the boundaries of what is possible. Our laboratory equipment incorporates the latest technology to ensure that you can obtain accurate and repeatable results during your experiments. From high-precision instruments to intelligent control systems, our products will provide you with unlimited possibilities for your experimental work.