Wholesale Rubber Insert Manufacturers

What is the main production process of rubber insert?

In the production process of modern rubber inserts, raw material pretreatment, mixing and kneading, molding and vulcanization, as well as post-processing and testing are all key steps to ensure the high performance of the product. Jiangsu Topower Tyre Co., Ltd. uses advanced technology and strict process control in every link to meet the market demand for high-performance rubber inserts.
Raw material pretreatment
The main raw materials of rubber inserts include nitrile rubber (NBR) and ethylene propylene diene monomer (EPDM), supplemented by additives such as carbon black, nanofillers and vulcanizers. Jiangsu Topower Tyre Co., Ltd. introduced an intelligent proportioning system to adjust the raw material ratio in real time through online monitoring equipment to ensure that the fluctuation of key parameters such as Mooney viscosity and hardness of each batch of rubber is controlled within ±1%. When producing explosion-proof tire linings, aramid fibers and graphene nanosheets are additionally added to significantly improve the tear resistance and heat resistance of the product. Before mixing, the raw materials undergo multiple processes such as preheating, softening, crushing and screening to remove impurities and improve dispersibility, laying a solid foundation for subsequent processing.
Internal mixing and mixing
The internal mixing process is a key link in optimizing the performance of rubber inserts. Jiangsu Topower Tyre Co., Ltd. uses a German W&P internal mixer to break and re-crosslink the rubber molecular chain under a high temperature of 160°C and a high pressure of 20MPa. Through the segmented feeding process, the rubber matrix and carbon black are first added, and the vulcanizer is added after the temperature rises to 140°C to effectively avoid scorching. Subsequently, a four-roll calender is used in the mixing stage to calender the rubber compound to a uniform thickness of 0.5-2mm to ensure the uniform dispersion of the filler in the rubber matrix.
Molding and vulcanization
The accuracy of the molding process directly affects the dimensional stability and shape consistency of the lining. Jiangsu Topower Tyre Co., Ltd. uses vacuum-assisted compression molding technology to inject the rubber compound into a high-precision mold under a vacuum environment of -0.09MPa to avoid the generation of bubbles. The vulcanization stage uses a steam vulcanization tank to continuously vulcanize for 45 minutes at a high temperature of 160°C and a pressure of 10MPa, so that the rubber molecules form a three-dimensional cross-linked network. In response to the special needs of explosion-proof tire linings, Jiangsu Topower Tyre Co., Ltd. has developed a gradient vulcanization process to make the central area of ​​the lining more vulcanized, while the edge area maintains a certain degree of flexibility, thus taking into account both strength and cushioning performance.
Post-processing and testing
The vulcanized lining needs to undergo post-processing processes such as trimming, cleaning and drying to remove flash and residual vulcanizing agent. Jiangsu Topower Tyre Co., Ltd. has established a full-process quality traceability system. Each lining is printed with a unique QR code to record all production data from raw materials to finished products. The testing process covers physical performance tests (such as hardness, tensile strength, tear strength), durability tests (including high temperature aging, ozone aging) and sealing tests (such as helium leakage rate).

What factors should be paid attention to when using rubber inserts

Carrying load and stress distribution
The load-bearing capacity of the rubber insert must match the design load of the tire. Jiangsu Topower Tyre Co., Ltd. uses finite element simulation analysis technology to deeply study the stress distribution characteristics of the lining under overload conditions. Studies have shown that when the load exceeds the design standard by 20%, the temperature of the stress concentration area of ​​the liner may rise by 30°C, accelerating the breakage of the rubber molecular chain. This phenomenon has been verified in the XGC88000 crawler crane tire liner customized for XCMG Group. The liner adopts a double-layer gradient structure design, with the outer layer being high modulus rubber, which mainly bears the load; the inner layer is a low-hardness buffer layer, which effectively disperses the stress. This design significantly reduces the deformation rate of the liner under heavy load conditions and improves the service life, achieving improvements of 15% and 20% respectively. Therefore, users should avoid long-term overloading during use and regularly check the wear of the tire contact surface to ensure the normal working condition of the tire.
Temperature and thermal aging
High temperature environment is the main threat to the performance degradation of rubber inserts. Research in the laboratory of Jiangsu Topower Tyre Co., Ltd. shows that when the ambient temperature exceeds 120°C, the tensile strength of the liner decreases by 5% per week, while the ozone aging rate increases by 40%. To meet this challenge, Jiangsu Topower Tyre Co., Ltd. has developed a high-temperature resistant rubber formula, using a composite material of graphene nanosheets and organosilicon compounds, so that the lining can work continuously for 1,000 hours at a high temperature of 150°C, and the performance decay rate is controlled below 10%.
Chemical medium erosion
rubber inserts are prone to swelling or corrosion when in contact with oils, acid and alkali solutions. Jiangsu Topower Tyre Co., Ltd.'s anti-corrosion lining uses fluororubber (FKM) and nitrile rubber (NBR) blending technology. After laboratory simulation tests, it can resist immersion in 30% sulfuric acid solution for 72 hours without cracking. In addition, the company's anti-oil lining reduces the adhesion of oil stains to 80% by coating the surface with polytetrafluoroethylene (PTFE). In scenes such as chemical and oil fields, users need to clarify the medium composition, select the corresponding grade of anti-corrosion lining, and regularly clean the residue on the tire surface to extend the service life.
Mechanical stress and fatigue damage
Frequent impact and vibration can cause fatigue cracks in rubber inserts. The dynamic mechanical analysis (DMA) results of Jiangsu Topower Tyre Co., Ltd. show that at a vibration frequency of 10Hz, the hardness of the lining drops by 20% after 100,000 cycles. To this end, Jiangsu Topower Tyre Co., Ltd. has developed a self-healing rubber formula that uses the characteristics of microencapsulated repair agents to enable cracks to heal automatically within 24 hours. Users should avoid driving at high speeds on rough roads during use, and regularly check whether there are fine cracks on the tire surface, and replace problematic tires in time to ensure driving safety.
Installation and maintenance process
The performance of rubber inserts not only depends on the material itself, but also on its installation and maintenance process. Jiangsu Topower Tyre Co., Ltd. has formulated strict installation specifications, including temperature control, pressure uniformity and cleaning standards. The specific requirements are as follows: After vulcanization, the lining needs to be left at 25℃ for 48 hours to avoid residual stress; when using hydraulic equipment to vulcanize the tire, the pressure fluctuation must be controlled within ±0.5MPa; before installation, the lining surface needs to be cleaned with isopropyl alcohol to remove the release agent residue.