Product Description
Ceramic vulcanized rubber roller lagging uses advanced vulcanization technology to tightly combine high-purity, high-hardness alumina ceramic sheets with high-performance rubber, and then wraps them on the surface of the roller through professional construction technology. The lagging forms a rigid and flexible protective structure. The ceramic layer resists wear, and the rubber layer buffers impact, providing comprehensive and long-lasting protection for the roller.
Product Features
High-hardness ceramic layer: Made of special ceramic material, Mohs hardness reaches 8-9, second only to diamond, which can effectively resist the strong wear of ore, coal, and other materials.
Ceramic rubber composite structure: The ceramic sheet is combined with the rubber layer, which has both the wear resistance of ceramic and the elasticity and friction of rubber, providing excellent anti-slip performance and adapting to various complex working conditions.
Unique drainage ditch design: The grooves between the ceramic sheets help drain water and mud, keep the drum surface clean, and reduce material adhesion and belt slippage.
Product advantages
Excellent wear resistance: The wear resistance is more than 10 times that of traditional rubber rollers, and the service life is extended by at least 5 years, reducing the trouble of frequent replacement.
High friction coefficient: The convex point design on the surface of the ceramic sheet increases the friction with the belt, which can prevent the belt from slipping even in harsh conditions such as moisture and mud, ensuring stable material transportation.
High temperature resistance and corrosion resistance: It can work stably for a long time in a high temperature environment of about 200℃, and has excellent chemical stability, which can resist the erosion of various corrosive substances.
Comparison of rubber rollers, ceramic rollers, and ceramic vulcanized rubber rollers
| Comparison Items | Rubber Drum Bonding | Ceramic Drum Bonding | Ceramic Vulcanized Rubber Drum Bonding |
| Structural Composition | Single rubber layer coated on the surface of the drum | Alumina ceramic sheets were directly adhered to the drum | High-hardness alumina ceramic sheets are tightly combined with high-quality rubber through the vulcanization process, and then coated on the drum |
| Abrasion Resistance | The wear rate is relatively fast. Under the long-term erosion of hard materials, the annual wear thickness of ordinary rubber is about 2 - 3mm | Excellent abrasion resistance. The Mohs hardness of ceramic sheets is up to 9, and the annual wear thickness is less than 0.5mm | Extraordinary abrasion resistance. Combining the high hardness of ceramics and the cushioning property of rubber, the annual wear thickness is about 0.3 - 0.8mm, which is 3 - 5 times higher than that of rubber drums |
| Anti-slip Performance | The friction coefficient is 0.3 - 0.4 in a dry environment and drops to 0.1 - 0.2 in a wet environment, prone to slipping | The surface is smooth, and the friction coefficient is unstable. It is about 0.4 - 0.5 in a dry environment, and the belt is likely to slip in a wet environment | The rough texture of ceramic sheets combined with the elasticity of rubber makes the friction coefficient reach 0.6 - 0.7 in a dry environment and maintain 0.4 - 0.5 in a wet environment, with a remarkable anti-slip effect |
| Impact Resistance | The elasticity of rubber is limited. It is prone to deformation, cracking, and even peeling off under strong impact | Ceramics have high hardness but poor toughness, and are prone to cracking under impact, affecting the performance of the drum | The rubber layer can effectively absorb 60% - 70% of the impact energy, protecting the ceramic sheets and reducing damage to the drum body |
| Self-cleaning Ability | Without a self-cleaning structure, it is easy for materials to adhere and requires regular manual cleaning | Without a self-cleaning function, material adhesion is likely to cause drum imbalance | The special groove design of ceramic rubber plates can automatically discharge impurities during the rotation of the drum, reducing the cleaning frequency |
| Corrosion Resistance | Ordinary rubber is not resistant to acids and alkalis, and is prone to aging and deterioration when exposed to corrosive media | Ceramics have strong corrosion resistance, but the bonding areas are vulnerable to erosion | Both ceramics and rubber have chemical stability, which can resist corrosive media for a long time |
| Service Life | 1 - 2 years | 3 - 5 years | 5 - 8 years |
| Main Advantages | Low cost and easy installation | High abrasion resistance, suitable for working conditions with mild impact | Excellent comprehensive performance, including abrasion resistance, anti-slip, impact resistance, self-cleaning, and reducing comprehensive maintenance costs |
| Application Scenarios | Conveying scenarios with low requirements for abrasion and impact resistance, and mild materials | Environments with moderate abrasion resistance requirements and small impacts | Complex conveying systems in heavy industries such as cement, steel, and mining, with high abrasion resistance, strong impact, and harsh working conditions |
| Items | Specifications |
| Content of alumina | ≥95% |
| Density | ≥3.75 g/cm3 |
| Rockwell A hardness | ≥85HRA |
| Impact strength | ≥1500 MPA |
| Fracture toughness | ≥4.0MPa·m1/2 |
| Bending Strength | ≥330MPa |
| Thermal conductivity | 20W/m.K |
| Thermal expansion coefficient | 7.2×10-6m/m.K |
| Volume wear | ≤0.02cm3 |
Technical parameters of vulcanized rubber
Product export market
At present, our ceramic vulcanized rubber roller lagging has been exported to many countries and regions such as Southeast Asia, Europe, and America, and is widely used in local cement, steel, mining, and other industries, and has been highly recognized by international customers.
Application range
It is suitable for belt conveyor rollers in many industries such as cement, steel, thermal power, ports, chemicals, mineral processing, coal, smelting, and engineering machinery. Whether it is handling hard ores and powdery materials, or dealing with harsh environments such as humidity, acid, and alkali, it can play a stable role.
Company Introduction
As an enterprise focusing on the research, development, production, and sales of industrial wear-resistant materials, we have many years of industry experience and technical accumulation. The company adheres to the concept of "quality first, innovation-driven, customer satisfaction", and is committed to providing more efficient and reliable wear-resistant solutions for global industrial users. Our products are widely used in cement, steel, coal, mining, ports, chemicals, and other industries, and have won wide recognition and praise from customers.
Workshop Introduction
The production workshop operates strictly by standardized processes and is divided into multiple functional areas, such as the raw material pretreatment area, ceramic processing area, the rubber mixing area, the vulcanization molding area, the quality inspection area, etc., to ensure the orderly production process.
Starting from the selection of raw materials, the ceramic raw materials are formed and sintered into ceramic sheets; the rubber raw materials are mixed and vulcanized, and then the ceramic sheets and rubber are compounded through a hot vulcanization process, and finally cutting, grinding and other finishing processes are carried out, and after multiple strict quality inspection processes, the product quality is ensured, and the internationally leading ceramic press, high-temperature sintering furnace, rubber mixer, large-scale vulcanization equipment and various precision testing instruments are introduced to ensure the high precision and high quality of product production.
FAQ:
Q1:What is Conveyor Drum Pulley Ceramic Embedded in Rubber?
A1:Rubber Embedded Ceramic Conveyor Roller is an advanced industrial component. It is made by bonding high-hardness alumina ceramic sheets to high-quality rubber by vulcanization and then coating the roller. It has excellent wear resistance and strong anti-skid performance, which solves the slipping problem under wet/abrasive conditions (such as coal, ore), and has a service life 5-8 times longer than rubber lagging and 3 times higher traction, making it an ideal choice for heavy industrial conveyors.
Q2:How much better is the wear resistance of ceramic pulley lagging than ordinary rubber lagging?
The wear resistance of ceramic pulley lagging is extremely outstanding, with an annual wear thickness of about 0.3-0.8mm, while the annual wear thickness of ordinary rubber lagging is about 2-3mm under long-term erosion of high-hardness materials. In comparison, the wear resistance of ceramic pulley lagging is 3-5 times that of ordinary rubber lagging, and the service life can be extended to 5-8 years, greatly reducing the replacement frequency and downtime maintenance time.
Q3:Will the ceramic roller fall off during use?
A3:Ceramic rollers generally do not fall off under normal use. We use high-quality ceramic materials and adhesives, and use a special process to firmly stick the ceramic sheet to the roller surface, which can withstand long-term impact and friction.
Q4:Can the size of the ceramic roller be customized according to customer needs?
A4: Yes, we provide customized services. We have a professional R&D team and advanced production equipment, and can customize ceramic rollers for customers according to their specific needs, such as the diameter, width, length, and other size requirements of the roller, as well as special use environments and working conditions.
If you have customized needs, just provide detailed product specifications and requirements, and we will serve you wholeheartedly to meet your personalized needs.
Q5:What is the reason for the debonding of ceramic pulley lagging? How to avoid it?
A5:Debonding may be caused by many reasons, such as inadequate cleaning of the pulley surface during installation, uneven application of adhesive, improper control of vulcanization process parameters, or long-term impact force beyond the design range during use. To avoid debonding, it is necessary to strictly follow the standard process for installation, ensure that the pulley surface is dry and clean; select high-quality adhesive and apply it evenly, accurately control the vulcanization temperature, pressure and time. At the same time, during use, try to avoid overloading the equipment and reduce abnormal impact.
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