Polyurethane rod (PU rod) material is a thermoplastic with many versatile properties including elasticity, transparency, oil resistance and extreme abrasion resistance.PU rods are cylindrical rods of polyurethane, which can be used in the manufacturing of a variety of products, with a vast number of potential applications. PU rods are often used as an alternative to rubber, which disintegrates faster, and permanently deforms sooner than PU, and would need to be replaced. These rods are often custom made to purpose, and can be hollow or cut to make them even more versatile.
Advantages of PU Rod
Versatile
Besides durability, these rods are also highly versatile and can be used in a wide range of applications. They can be molded into a variety of shapes and sizes, making them suitable for use in a range of industrial applications. Additionally, Polyurethane rods can be customized to meet specific application requirements, making them ideal for use in custom applications.
High load-bearing capacity
Polyurethane rods have a high load-bearing capacity, which means that they can withstand heavy loads without degrading or breaking down. This makes them an excellent choice for use in applications where heavy loads are common, such as in the manufacturing of heavy machinery and equipment.
Highly resistant to chemicals
Polyurethane rods are highly resistant to chemicals, solvents, and oils. They can withstand exposure to a wide range of chemicals without degrading or breaking down, making them ideal for use in applications where chemical exposure is common. This resistance to chemicals makes Polyurethane rods an excellent choice for use in the manufacturing of chemical processing equipment and other industrial applications.
Excellent abrasion resistance
When it comes to abrasion resistance, Polyurethane rods are nonpareil. This makes them ideal for use in applications where frequent abrasion occurs. They are commonly used in the manufacturing of rollers, wheels, and other components that are subject to frequent abrasion. Additionally, Polyurethane rods can be formulated with specific levels of abrasion resistance to meet specific application requirements.
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Why Choose Us
Our Factory
Zibo Hengjiu PU Technology Co., Ltd. is a professional manufacturer which engaged in the R & D, production and sales of polyurethane prepolymer, polyester polyol and polyurethane elastomer finished products.
Advanced Equipment
The company has the most advanced production and testing equipment in China, has an annual production capacity of 30000 tons of various casting polyurethane prepolymers, polyester polyol and polyurethane elastomer finished products realizes the chain production from upstream raw materials to downstream products.
Production Market
The company's products not only spread all over the national market, but also exported to Canada, Australia, India, Turkey, Russia, Indonesia, South Korea, Malaysia and other international markets.
One-stop Solution
The company has a group of high-quality technical talents, which can provide customers with comprehensive services such as pre-sales, in-sales, after-sales and technical guidance.
Automotive industry
Polyurethane rods are often fixed to the suspension or steering of a vehicle to minimise road bumps. When these suspension bushings wear, they allow more movement in the car, such as poor handling, loose steering, or clunking or rattling noises on loose roads.
PU rods can be cut flexibly, which makes them perfect as gaskets and seals for insulating both temperature and sound, as well as shock and vibration control. For a gasket the rod can be sliced, or cast into tubes, allowing for a bigger variety of products. Its resilience against weather and the material's durability means that polyurethane can far outlast similar products made from rubber.
PU rods are also used for wheels and casters and wheels, (casters are the brackets around a wheel, often seen on office chairs). Their high load bearing capacity means that they can withstand force better than their rubber counterparts, and their abrasion resistance means that the risk of a scratch or tear is minimised.
If valve seats are cracked or damaged, valve inserts can be attached to prepare the worn or damaged areas. PU rods are ideal valve inserts, as they have good resistance to wear, and do not deform under load.
With Polyurethane's vibration absorption qualities it's no surprise that polyurethane rods also make excellent shock absorbers and noise dampers. Due to their versatility and adaptable durometer (range of hardness), they can be used for anything from keeping out the noise of the road to bumper pad applications.
Leisure & hospitality industry
Polyurethane rods are often used as supports on Roller coasters, due their high impact resistance, especially if the frames are wooden. The strength of the PU rods reinforce the rollercoaster's strength and allow them to withstand a higher impact range and force. PU rods are often used in the leisure industry for escalator wheels, due to their excellent resistance against wear and their load bearing qualities.
Agriculture
PU rods can be used for wear strips on ploughs.The abrasion resistance, resistance against corrosion and wear, as well as their ability to withstand high impact loads, make them perfect for this purpose.
Why Do PU Rod Need To Be Vulcanized Twice
The polyurethane products are revulcanized to improve their properties. For example, in the production process of polyurethane products, by adding vulcanizing agents and accelerators, the vulcanization reaction occurs again, and a more compact vulcanization network structure can be formed, thereby improving the wear resistance, aging resistance and chemical corrosion resistance of polyurethane products.
This secondary vulcanization treatment is very important for improving the durability and prolonging the life of polyurethane products. However, not all polyurethane products need to be revulcanized. The specific need for secondary vulcanization treatment needs to be determined according to the actual needs and uses of the product. In general, polyurethane products with high performance or harsh conditions of use must be revulcanized.
The Role Of Polyurethane Rods In Engineering And Manufacturing
In the engineering and manufacturing fields, polyurethane rods are primarily used as spacers, seals, and components. However, these are only a few of the ways these can be use.
Their ability to be shaped to a specific shape, shore hardness, and size ensures they are easy to apply in many cases, even for incredibly niche or specific parts. Furthermore, many other features of polyurethane rods also contribute to their value and efficacy as engineering and manufacturing components; these include:
Durability: Engineering and manufacturing applications demand durable and reliable parts, and fortunately, polyurethane can fit this role perfectly. Typically lasting for many years, polyurethane rods are simultaneously strong and durable, even in heavy-duty situations.
Elasticity: Despite being strong, polyurethane doesn't compromise on elasticity, making it almost rubber-like in nature. This allows PU to be utilised in many of the same ways as rubber, hence serving a key role as internal components and the like.
Shore hardness: Polyurethane rods are available in a wide range of different shore hardness ratings, allowing more flexibility in terms of hardness rating. In turn, this allows much more freedom when choosing the most appropriate hardness rating for your project.
Machinability: Thanks to its excellent properties, polyurethane is highly machinable, making it easier to work with overall. In line with this, PU rods are often easy to make to your desired size, allowing brands to find the most appropriate parts accordingly.
Resistance: Compared to some other materials, PU rods are exceptionally resistant to both chemicals and UV light exposure. As such, for parts that are prone to light or chemical exposure, polyurethane might be perfect.
The Production Process of PU Rod
Figuring Out Custom Options
Before starting on the real polyurethane manufacturing process, you need to know what type of product you're making and what specs it needs. There are countless combinations and design variables you can choose from to make exactly what you're looking for.
For instance, you might want something with a certain elasticity, hardness, tear strength, chemical resistance, flame resistance, abrasion resistance, strength—or a slew of other characteristics. Precise specifications are possible with the right mixture.
Mixing Ingredients
Diisocyanates are a group of versatile building blocks, so to speak. They're used to make a range of polyurethane products. Mixing them with other chemicals create some of the most valuable and essential polyurethanes. It's like baking—Simply mix all the ingredients together, and you get your desired end product.
It's rather incredible that polyurethane can be made into so many different types of items—something as soft as a pillow or as hard as a car bumper. Of course, it might take some trial and error with multiple rounds to find the perfect mixture required, but in the end, it will be worth it.
Insertion Into Mold
This is where the magic happens. There are different ways you can create your product in the polyurethane manufacturing process. You can use compression molding, open cast molding, spin casting, or injection molding.
For compression molding, the polyurethane will be in liquid form. You'll pour it into a mold, which is placed into a compression press. The heat thickens the liquid and the pressure completes the molding process.
Open cast molding also starts in a liquid form, but it goes into an open mold which needs heat from a special oven to finish it off.
Spin casting involves a spinning mold. You'll pour the liquid polyurethane in while this is happening to remove any air trapped inside.
Finally, with low-pressure injection molding, you'll inject the liquid form of the substance into a mostly closed mold. The mold has openings that allow air to slowly escape.
Final Touches and Product Inspection
After the product cools down and comes through the molding process, it's shaved down to the required size. It's shaved down farther when excess pieces of polyurethane parts get caught outside the mold and need to be touched up for consistency. Once the product is almost ready to go, it moves through an inspection for quality control.
Packaging
Last, but not least: When the product has been approved, it goes onto the packaging phase. The facility you use for your polyurethane manufacturing process may or may not do this for you, so this step can depend on your situation.
Precautions When Using PU Rod
Fire Prevention
Polyurethanes rod may be flammable, especially during processing where vapours or aerosols are present. Make sure to work in a safe area free from sources of ignition or sparks. Keep fire extinguishers on hand and know fire safety procedures.
Ventilation
Ensure that the work area is well ventilated to reduce exposure to vapours and fumes from processing polyurethanes rod. Use adequate ventilation systems, such as fume hoods or fans, to maintain adequate air circulation.
Safe handling
Handle polyurethanes rod in accordance with the manufacturer's instructions and local regulations. Avoid direct contact with skin, eyes or respiratory tract. Avoid eating, drinking or smoking when handling polyurethanes.
Personal Protection
Wear appropriate protective clothing, such as gloves, goggles, face masks or respirators, and chemical-resistant clothing, according to the specific recommendations for the type of polyurethane used.
Chemical handling
Follow good chemical handling practices, such as proper labelling, safe storage, waste management and cleaning of equipment used.
Training and information
Ensure that operators are properly trained on safety procedures, including the correct handling of polyurethanes, the use of personal protective equipment and the actions to be taken in case of emergencies.
Do You Know The Main Points Of Operation In The Process Of PU Rod Processing
Temperature Control
When synthesizing the prepolymer, the temperature is controlled between 75-82℃. If it is too high, the performance of the synthesized prepolymer will decrease, and if it is too low, the polymerization time will be prolonged. The temperature of the prepolymer when mixed with MOCA is controlled between 90-110℃. If it is too high, it will reduce the hardness and strength of the product, and if it is too low, it will increase the viscosity of the polymer, which is not conducive to the pouring operation. For polyurethane elastomer equipment, the vulcanization time is controlled at 130℃. If it is too high, it will decompose MOCA, which is not conducive to cross-linking reaction, and will increase other side reactions; if it is too low, it will prolong the molding time. The melting temperature of MOCA should be controlled as soon as it melts into a liquid, and the heating cannot be continued, otherwise the color of the liquid MOCA will become darker and decompose, which will affect the performance of the product.
Time Control
Synthesis reaction 2h, intermittent vacuuming 2h. Then seal it and store it at room temperature. The prepolymer synthesis should not exceed 4 hours at 75℃, let alone 2 hours at a high temperature of 100℃, otherwise the performance of the product will be reduced. The pouring should be completed within 1-2 minutes, because the stability period of the prepolymer and MOCA is very short after mixing, generally only 4-5 minutes, otherwise the mixture will solidify and cannot be poured. Molding vulcanization time depends on the shape and size of the product, generally between 15-30 minutes, to ensure that the product is molded. For large products, it takes longer, 2-3 hours.
Degassing Of Prepolymer
The quality of degassing is the key to the failure of casting polyurethane elastomer. Generally, two steps need to be controlled. After the prepolymer is synthesized, when it is standing still, vacuum degassing at 75℃ to remove most of the gas in the prepolymer; before the prepolymer is mixed with MOCA, it needs to be heated to 100-110℃, high temperature Degassing; at the same time, vacuum (-0.095mpa) degassing for 10 minutes, then take it out and stir to turn the bottom air bubbles to the top, then vacuum and degass for 10 minutes, and then discharge the gas in the prepolymer before mixing it with the vulcanizing agent to cast the product.
FAQ
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