Rubber microwave heating vulcanization equipment

Rubber microwave heating vulcanization equipment,microwave technology significantly improves quality

Microwave Vulcanization Technology for Rubber

I. Principles of Rubber Vulcanization and Advantages of Microwave Rubber Vulcanization:

1.Raw rubber softens when heated, hardens and becomes brittle when cold, is difficult to mold, wears easily, dissolves in organic solvents like gasoline, contains double bonds that are prone to addition reactions, and is susceptible to aging. To improve the performance of rubber products, raw rubber undergoes a series of processing steps. Under certain conditions, the raw rubber in the compound reacts chemically with vulcanizing agents, transforming from a linear molecular structure to a three-dimensional network structure. This process gives the rubber compound high strength, high elasticity, high wear resistance, corrosion resistance, and other excellent properties. This process is called rubber vulcanization.

2.Traditional methods use steam or far-infrared heating for vulcanization. However, since the heating temperature slowly conducts from the outside to the inside, and rubber is a poor thermal conductor, the heat transfer from the surface to the inner layers is very slow. Most of the time is spent bringing the rubber to the vulcanization temperature. This results in long heating times, low efficiency, and poor vulcanization uniformity. In particular, the old process used magnesium silicate (talc) to prevent rubber adhesion, causing dust to permeate the rubber production workshop, with airborne dust levels far exceeding the standards set by national environmental authorities. Moreover, the overall vulcanization state of the rubber is not ideal because, under conventional heat conduction, the surface and inner layers of the rubber compound heat up at different times, leading to uneven vulcanization.

II. Microwave heating is completely different from traditional heating methods. It penetrates microwave energy into the interior of the heated medium for direct overall heating, resulting in rapid heating, high energy efficiency, significantly shortened rubber vulcanization time, better heating uniformity, and higher vulcanization quality. It allows the rubber to quickly pass through the induction stage, where adhesion is highly likely, and enter the pre-vulcanization stage in a short time. This eliminates the need for talc used in the old process, meeting environmental requirements. This production process consolidates most production steps into a single production line, with high automation, low energy consumption, labor savings, stable production, uniform product quality, and greatly improved working conditions.

III. Microwave Rubber Vulcanization Equipment and Production Process

 The microwave rubber vulcanization production line consists of an extruder, high-temperature shaping equipment, microwave vulcanization equipment, hot air vulcanization equipment, cooling section, traction machine, cutting machine, punching machine, etc. Extruder: Used to extrude rubber raw materials into the required shape and structure. The extruded rubber can be single-layer rubber (sponge or solid rubber), two-layer composite rubber (sponge and solid rubber), three-layer composite rubber (steel core, sponge, and solid rubber), four-layer composite rubber, etc. The structure and performance of the extruder vary depending on the type and specifications of the rubber.

1. Microwave vulcanization equipment: Uses microwave heating to rapidly heat the entire material to the vulcanization temperature, a process that takes only tens of seconds to one or two minutes.

2.Microwave heating equipment is the core of the entire microwave vulcanization process. The design for uniform heating is particularly important, as it is a prerequisite for uniform rubber vulcanization. Additionally, the composition ratio, color depth, and surface smoothness of the rubber compound affect microwave absorption performance and must be considered and appropriately coordinated in the microwave heating process to meet technical requirements.

IV. Technical Advantages of Microwave in Industry:

Microwave offers energy savings (high conversion efficiency to thermal energy, saving over 30% compared to traditional heating methods), environmental friendliness (no external emissions, effectively reducing harmful substances), cleanliness (materials absorb microwaves and heat themselves, with no contact or pollution, improving product quality and yield), and high efficiency (rapid heating, high energy utilization). Therefore, ZhongSheng's microwave industrial equipment can reach temperatures up to 1600°C, with kiln temperature stability within ±5°C, high automation, effectively reducing labor and improving the production environment.

V. Market Users Recognize ZhongSheng's Advantages:

Hunan ZhongSheng Thermal Energy Co., Ltd. was established in 2011 with a registered capital of 12 million yuan. It is a long-term professional company engaged in the research, development, application, and equipment integration of microwave thermal energy technology in industry, specializing in design, manufacturing, and sales. It mainly produces microwave experimental furnaces for research institutions and custom industrial microwave equipment. In the field of microwave applications, it holds 12 invention patents and 57 utility model patents. Its microwave heating kiln technology was selected for the National Development and Reform Commission's fifth batch of key energy-saving technology promotion catalogs. Compared to low-power household microwave ovens, ZhongSheng's industrial microwave equipment is designed for continuous operation, stable production, and durability in industrial settings. It is equipped with 1.5KW industrial-grade microwave sources with continuously adjustable power, ensuring uniform, adjustable, and controllable furnace temperature. It guarantees 24-hour uninterrupted use. Additionally, it uses proprietary crack antenna energy feed devices to ensure uniform microwave fields and prevent microwave reflection from damaging magnetrons, allowing magnetrons to operate 24 hours without shutdown. It also enables online replacement of wear parts without affecting normal production. The unique microwave leakage prevention device ensures microwave leakage does not exceed 1mW/cm² (national standard is 5mW/cm²), enhancing production safety, while other manufacturers typically only meet national standards. ZhongSheng's microwave drying equipment, microwave experimental furnaces, microwave high-temperature bell kilns, microwave high-temperature push plate kilns, microwave high-temperature roller kilns, and microwave garbage pyrolysis kilns all have successful application cases.

VI. Ordering/Sampling/Technical Exchange 

Inquiries for Rubber Microwave Vulcanization Equipment:ZhongSheng Manager Xu:156 7439 3491

Factory Address: Tonghai Road, Economic Development Zone, Yueyang City, Hunan Province