What is ceramic rubber sheet?
The ceramic rubber sheet is a wear-resistant alumina ceramic sheet with raised particles on the surface, which is vulcanized to a wear-resistant rubber sheet according to a certain arrangement rule.
The ceramic rubber sheet greatly improves the wear resistance of the rubber sheet, which can reach 8-10 times that of the traditional wear-resistant rubber sheet. It is the best choice in high wear environments.
The rubber body of the ceramic rubber sheet is made of natural rubber, with high material purity, corrosion resistance and aging resistance, good flexibility, and can maintain good physical and chemical properties for a long time.
The surface of the ceramic block on the rubber plate has particle protrusions, which has a large grip on the belt. Under the same load, it can reduce the tension of the belt and prolong the life of the belt.
Moreover, the orderly arranged ceramic blocks are separated by a certain distance, and the grooves formed can make the foreign matter (dust, soil, rainwater, etc.) on the drum discharged in time, so that the drum has a unique self-cleaning function, which is especially suitable for humid working environments.
Advantages of ceramic rubber sheet pulley lagging:
1. The ceramic rubber sheet pulley lagging is to embed the aluminum oxide ceramic block with a content of 92% into the rubber. The high wear resistance of the ceramic on the rubber surface is used to increase the friction coefficient between it and the belt. The friction coefficient is 4-6 times that of the ordinary rubber sheet, which can significantly reduce the occurrence of belt slippage.
2.The combination of ceramics and rubber sheets greatly increases the wear resistance of the rubber sheets, which can reach 8-10 times that of ordinary wear-resistant rubber sheets.
3.The special arrangement of ceramic blocks and rubber ensures that the drum has good drainage and mud discharge performance after pulley lagging.
4.Ceramic rubber sheet with semi-vulcanized CN layer, used together with adhesive SA3000, can realize strong bonding between rubber sheet and drum.
How to do ceramic pulley lagging:
1. Disconnect the power supply.
of the conveyor and hang up the safety warning sign.
If the residual glue exceeds 0.5m², use a glue scraper to remove the residual glue.
Before shoveling glue, it must be ensured that the drum can be rotated manually. If it cannot be rotated, the connecting pin between the drum and the reducer must be removed.
If the residual glue area is less than 0.5m², there is no need to shovel glue.
Note: When shoveling glue, the angle between the flat chisel and the surface of the drum should be kept between 15-30 degrees, otherwise the steel body will be shoveled off and the flat chisel will be damaged.
Before proceeding, we need to prepare the tools for cold bonding.
2. Grinding.
Because there are a lot of dirt, dust, grease, water, rust and other organic or inorganic pollutants on the metal surface, it affects the wetting of the glue.
In order to improve the bonding strength, it is necessary to rough, clean and activate the surface of the adherend by mechanical, physical, chemical and other methods, and change the surface properties to facilitate the firm bonding of the glue, and to improve the durability and service life of the bonding.
Usually, the surface treatment of the metal surface drum is mostly carried out with a wire brush or a grinder to brush off the loose oxide layer on the surface.
At present, high-power low-speed angle grinders are mostly used with tungsten steel grinding discs for grinding, which can not only improve the grinding efficiency, but also prevent the occurrence of aging of the drum surface during grinding.
Note: When grinding, the grinding personnel must wear protective glasses and masks, hold the grinding machine tightly with both hands, and concentrate to prevent personal injury. The grinding thickness of the metal surface of the drum is preferably 30um.
3. Cleaning.
After grinding, there is a lot of dirt, dust, grease, water, rust and other organic or inorganic contaminants that affect the wetting of the adhesive. It is necessary to use the cleaning agent SK313 to remove the surface dirt and deeply clean the entire surface of the drum to prevent various impurities from affecting the glue bonding effect.
When brushing the cleaning agent, if the cleaning is not in place, you can brush it several times and wash it repeatedly until the surface of the drum is clean and free of impurities. After cleaning, there must be necessary drying time, otherwise the adhesive strength of the glue will be affected due to the residual solvent on the surface of the drum.
4. Transition.
Use a brush to apply a layer of metal primer SK363 evenly and quickly on the cleaned metal surface. It is required to apply evenly and completely without leakage, and let it dry completely for about an hour.
In addition to effectively preventing the surface of the drum from contamination, the metal primer can prolong the storage period of the treated metal, ensure the wetting performance of the adhesive, and increase its adhesive strength and durability.
5. Glue painting.
Mix and stir the two-component cold vulcanization adhesive glue SA3000. According to the needs, you can take an appropriate amount of glue and mix it in the container according to the ratio of 100:4. After the preparation is completed, the glue must be used in time and cannot be stored for a long time.
Apply the mixed SA3000 evenly on the surface of the drum, let it dry completely, and no longer stick to the back of the fingers. The drying time is about 15-45 minutes.
After the first layer of glue is completely dry, apply the second layer of SA3000. When the second layer is slightly sticky to the back of the finger, it can be finally bonded (the second layer needs to be painted again if it is too dry).
If the rubber sheet is an ordinary ceramic rubber sheet, it is necessary to polish and clean the bonding surface of the rubber sheet, and then apply the glue twice.
If the rubber sheet is a RIT ceramic rubber sheet (with a semi-vulcanized CN layer on the bonding surface), it is only necessary to paint the bonding surface of the rubber sheet with glue once, and there is no need to polish the bonding surface of the ceramic rubber sheet.
6. Paste the rubber sheet.
Determine the bonding reference line on the drum: After brushing the glue for the second time, find the reference for the ceramic glue board on the surface of the drum.
Line drawing method: Take the two sides of the drum as the benchmark, and draw the benchmark line with a square ruler, a steel ruler and a knife.
Cover the semi-vulcanized surface of the rubber sheet with a clean plastic film. Based on the reference line found on the drum, tear the plastic film about 50mm wide and start pasting the ceramic rubber sheet on the surface of the drum (Note: Do not tear too much, otherwise After sticking, it is very firm and cannot be peeled off), after confirming that the position is correct, start to tear off the plastic film, and stick it down with your hands while tearing it off.s
If the sticking is skewed and the sticking area is not large, you can drop the cleaning agent between the ceramic rubber plate and the drum, and slowly tear it off. Then apply SA3000 to the place where the rubber plate and the drum are pasted, and then paste it after it dries for a while.
Note: When pasting the ceramic rubber sheet, make sure that the margins on both sides of the ceramic rubber sheet and the drum are basically the same, and the edge of the ceramic rubber sheet is as consistent as possible with the reference line drawn on the drum.
Press down with a flat roller and tap with a rubber mallet. Bai-Ott reminds that any pressing and knocking must be done from the middle of the drum to both sides, and it is forbidden to do it from both sides to the middle, otherwise the air will be wrapped in the rubber sheet, which will affect the bonding.
The two sides of the drum and the joints of the ceramic rubber sheets are the key tapping positions, and it is necessary to ensure that all the adhesives are in place.
7. Rubber sheet sealing.
For the joint part, use a knife to cut a V shape at the joint of the ceramic rubber sheet, and the outer width is 15mm.
Polish the V-shaped part with a wire grinding brush, then brush it with a clean brush, mix the rubber repair agent according to the ratio of 1:1 and fill it with the rubber repair agent, and press it with a falt roller while filling.
What are the precautions for pulley lagging?
1. The temperature is higher than 10°C, the relative humidity is less than 90%, there should be no water spray, and there is relatively no dust on the site. Measures such as blocking the wind on the downwind side and installing an awning can be taken;
2. Grinding and polishing should be thorough, without leaving glue residue, rust spots, pits and flash;
3. Brush the metal primer evenly and dry it thoroughly. If it does not dry, use hot air blowing and drying measures;
4. Brush the glue twice, to be even, and to brush from one direction to the other in one direction to avoid the generation of air bubbles and cause the failure of the glue coating. After each brush, you must wait for it to dry before brushing.
5. When pulley lagging the compaction and beating should be from the middle to both sides, so as to avoid bubbles and lead to failure;
6. For sealing, the size should be calculated, and there should be no gaps and bulging bubbles;
7. It is best to cure for 8 to 24 hours after pulley lagging.
After seeing this, you must have a new understanding of ceramic rubber sheets. If the drum you maintain is running in a muddy, wet, and high-wear environment, you may try to use ceramic rubber sheets for lagging. Maybe you will be long-term. Maybe your long-standing problem will be solved.