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Yantai sunny rubber co.,ltd was established in 2005 and we are the branch company of nuclear industry yantai toncin group. We are a high-tech company of shandong province and the company covers 165 acre of land and it has 22,000m2 of factory area. Currently, the company has three main departments:Product research and development, quality control(including large product testing labs), and automation control.There are 60 skilled technical engineers with mid to high level of qualification and 230 of professional operation staffs working.

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High Quality

Our products are manufactured or executed to very high standards, using the finest materials and manufacturing processes.

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We try and respond to all concerns within 24 hours and our teams are always at your disposal in case of any emergencies.

Quality Control

We have professional personnel to monitor the production process, inspect the products and ensure that the final product meets the required quality level standards, guidelines and specifications.

Rich Experience

Dedicated to strict quality control and attentive customer service, our experienced staff is always available to discuss your requirements and ensure complete customer satisfaction.

 

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What is Rubber Coated Rollers?

 

 

A rubber coated rollers is a sophisticated machine comprising a metallic inner round shaft or tube which is covered through an exterior layer of elastomer compounds or rubber. The inner metallic shaft could be of steel or aluminum or any other industry-specific metal, depends on the rubber coated rollers manufacturer. Coming back to rubber roller layer, the outer layer is generally manufactured using a premium-quality polymer, including polyurethane, silicone, epdm, neoprene, and natural rubber.

Advantages of Rubber Coated Rollers
 

Durability

One of the biggest benefits of rubber coated rollers is their durability. Rubber is a tough material that can withstand a lot of wear and tear. This makes it ideal for applications where rollers will be used frequently or under harsh conditions.

 

 

Affordability

Rubber coated rollers are an affordable option compared to other materials. They have a lower cost per unit and can be manufactured in large quantities at once, which means less time spent on production lines and more money saved over time.

Affordability

Rubber coated rollers are an affordable option compared to other materials. They have a lower cost per unit and can be manufactured in large quantities at once, which means less time spent on production lines and more money saved over time.

 

 

Adhesive resistance

Rubber coated rollers are known to be resistant against adhesives. This feature makes them ideal for applications where they come into contact with substances like glue, paint, or other materials that could stick onto roller surfaces.

 

Application of Rubber Coated Rollers

Rubber covered rollers have found widespread use within the industrial sector. Their ability to protect and remain resistant has made them an essential part of numerous operations to aid manufacturers in the previous few decades.

 

A large reason why these rollers have emerged as such an integral tool for manufacturers is because of the durability of the rubber coatings. This material has elastic properties, i.E., it can stretch out and then return to its original size.

 

Its elasticity plays a major role in the manufacturing process and comes with various benefits, including better grip, smooth and/or delicate surfaces, resistance to industrial chemicals, and easy application. The wheels within these rollers have a large number of uses. For example, they are used for conveyor belts in civil and industrial applications, floats, tires, and numerous other products.

 

They play an integral role in paper, film, coiled metal, textiles, and sheet manufacturing processes as well. With their specific application expanding to numerous dimensions, they are also used in the packaging of fabricate equipment, producing various types of containers and packages, and making up part of the machinery that plays a large role in the grinding and sanding of steel, wood, and aluminum.

Rubber Lined Pulleys
Components of Rubber Coated Rollers

 

Roller Core
The roller core is the rigid structural member which supports the load. It is typically made of high-strength materials such as carbon steel, stainless steel, alloy tool steel, and aluminum alloys. Roller cores are designed according to their applications. They can be further broken down into several parts.

 

Roller Core Shaft
The shaft is the machine part that connects the whole roller to the motor, sprocket, or other drive units. It is solid in construction, with high strength and uniform hardness. The shaft is designed to endure bending and torsional stresses. Bending stresses are caused by the radial forces against the roller; torsional stresses are from the torque generated by rotating the roller to tangentially move loads. The shaft can be coupled to the drive unit by means of a key and keyseat or by set screws.

 

Roller Core Cylinder
The cylinder is a hollow part typically in the form of a pipe or tube. This is where the rubber lining is wrapped and bonded. It has sufficient thickness to resist deflection upon application of load. The cylinder is usually made from steel, but other rigid but light materials, such as aluminum and reinforced plastics, can be used.

 

Roller Core Flange
The flange or end plate connects the cylinder to the shaft. The shaft, cylinder, and flange are typically held together by welds. In some cases, flanges are pressed into place and held by interference fit, which is normally seen on smaller roller constructions.

 

Roller Core Bearings
Bearings are used to reduce friction against the static and rotating parts. The configuration, mounting, and type of bearing can vary depending on the design of the roller. The configuration described previously has the shaft installed together with the roller cylinder. In other designs, the bearing can be installed on the roller while the shaft is static on the main equipment.

 
The Production Process of Rubber Coated Rollers
 

Roller Core Fabrication And Preparation
The cylinder or hollow tube is formed through sheet rolling and welding. This can be done by the rubber roller manufacturer or by a separate plant that supplies steel tubes. The ends of this tube can be machined to receive bearings. If required, flanges or support discs are cut that are sized to fit inside the cylinder. A shaft is fabricated by turning a metal stock in a lathe machine producing a cylindrical core. This shaft can either be welded to the flanges as stated above, or be slid into the bearings on each end of the tube. All dimensions must be accurate to attain the roller's required diameter, roundness, and balance. The flanges are then welded to the ends of the cylinder with the shaft. After fabrication, the roller core is subjected to secondary processes such as blasting and cleaning to remove any traces of corrosion and contaminants on its surface.

 
 

Rubber Compounding
Rubber compounding is the formulation process where certain chemicals are added to the raw rubber to modify its final mechanical and chemical properties, lower its cost, and aid its processability and vulcanization. This process involves heating and masticating, which breaks down the rubber‘s polymer chain, making it receptive to the compounding ingredients. It is done through roll mills, banbury mixers, or screw kneaders (extruders). Common compounding ingredients are filler systems (carbon black, silica, calcium carbonate), plasticizers (for softening and processing), stabilizer systems (antioxidants, antiozonants), and vulcanizing agents (sulfur, peroxide).

 
 

Bonding And Building
Bonding is the process that involves adhering the rubber cover to the surface of the roller core using a chemical bonding agent or ebonite base layer. Once the bonding components are applied, the rubber building process can begin. Rubber building is the process of covering or lining the rigid roller core with the rubber compound. Some of the general methods for rubber building are explained below.

 
 

Plying Process
Plying is the most common method, involving rotating the roller core while feeding calendered rubber sheets or strips. The rubber sheets wind or wrap around the roller until the required diameter is acquired. The roller core can be pressed against two or three rollers to provide pressure to tightly wrap the rubber cover.

 
 

Extrusion Process
In this process, instead of using calendered rubber strips, rubber from an extrusion machine is bonded to the surface of a rotating roller core. This process is more suitable for large rollers such as those used in big paper mills.

 
 

Casting Or Molding
This process involves placing the roller core into a mold or die where rubber resin is transferred or injected. The resin covers the roller core and is introduced to high heat to cure the rubber.

 
 

Vulcanization And Cooling
Vulcanization or curing is the process of creating crosslinks between the elastomer chains or the rubber compound. This makes the rubber more stable, enabling it to resist the effects of heat, cold, and solvents. Vulcanization is done by applying heat to the system, which initiates the bonding of curative agents such as sulfur and peroxide. After heating, the rubber is allowed to cure for several minutes or hours. After which, the rubber roller is cooled for the next stages.

 

What is Rubber Lined Pulleys？

 

 

A rubber lining conveyor pulley is a mechanical contraption, like a conveyor belt, used to adjust the route of the belt in a conveyor system, or to move the belt, or to apply strain to the belt.Pulleys are a lot heavier than belts and are utilized at one or the flip side of the transport or close to the drive/motor.

Advantages of Rubber Lined Pulleys
 

Shock and noise reduction

Rubber wheels have good buffering effects and shock-absorbing capabilities, which can effectively reduce vibration and noise when the vehicle is driving and improve driving comfort. At the same time, the shock-absorbing properties of rubber wheels can also extend the service life of vehicle components.

Wear-resistant and durable

The rubber wheel has moderate hardness and a certain degree of elasticity and toughness, so it can resist friction and wear well and extend its service life. In addition, rubber wheels also have good weather resistance and corrosion resistance, and can be used in various harsh environments.

Strong crack resistance

The material of the rubber wheel has good strength and toughness, so it has a certain resistance to various external force impacts and deformations. Even if it is crushed or hit by heavy objects, it is not easy to crack or crack.

Application scenarios

Rubber wheels are widely used in various vehicles and mechanical equipment, such as automobiles, railway cars, ships, loaders, forklifts, etc. In these scenarios, the advantages of rubber wheels are brought into play, ensuring the normal driving of the vehicle and the long-term use of the equipment.

Rubber Roller The Spare Parts Of Vacuum Filter

Types of Rubber Lined Pulleys

 

Pulley lagging is an essential part of every belt conveyor system, ensuring that there is proper traction between the pulley and the conveyor belt. Properly lagged pulleys reduce belt slippage and wear on belts. Other benefits include high service life, resistance to corrosion, ensuring maintenance savings, less downtime, and more productivity.

 

Rubber lagging: The most common type of pulley lagging is rubber lagging, which comes in two forms: Plain rubber lagging and grooved rubber lagging (including diamond, herringbone, and chevron grooves). Rubber is a versatile material that can be changed in thickness, hardness, and the type of grooves it has.

 

Ceramic lagging is great for places that are rough and need materials that are strong and last a long time. It can have dimple or smooth ceramic tiles, and it can cover different areas.

How to Choose Rubber Lined Pulleys

 

 

Belt Type And Running Speed
The run speed of the belt has a significant impact on lagging. However, because belts are more expensive to replace, they should always take precedence. Consider how much speed will wear out the lagging and affect the operating temperature when selecting a pulley lagging.

 

Pulley Type
Because drive and tail pulleys have different responsibilities, you can choose two different types of lagging for them even if they are on the same conveyor. When a head pulley lags, more grip is required than when a tail pulley lags.

 

The Operating Environment And Conditions
Climate, wet or dry conditions, and chemical contact all influence the type of pulley lagging used. Conveyor experts, such as can recommend the best type of pulley lagging for your specific operating conditions.

 

The Type Of Material Being Processed
Product abrasion is an important factor to consider when processing different materials. The abrasiveness of the belting material influences belting requirements, which in turn influences the type of pulley lagging to be used.

Components of Rubber Lined Pulleys

 

Drum/shell
The drum is the pulley area in direct contact with the belt. The tray has a certain surface width and diameter, which is determined by the conveyor belt type.

 

Shaft
Stepped shafts of different diameters are used in the conveyor pulley to cover all the stresses exerted by the belt with minimal distortion. The shaft is locked between the diaphragm hubs by a locking mechanism. The shaft and pulley assembly is supported by a bearing kit located in a plummer block. Variable shaft diameter offers high torsional resistance to applied loads.

 

Diaphragm Plate
Both ends of the drum are covered with thick round steel discs. This disc is called a diaphragm plate. They are welded to the shells to provide additional strength to the drum.

 

Locking Element
The locking components are precisely engineered elements that are mounted over the shaft and on the hub of the pulley via the end plate. The locking element works on the principle of friction, in which tightening a number of screws secures the element to the shaft and hub at the same time.

 

Hub
The hub is the machine lodging welded to the endplate. The elements of the hub are related to the size of the pulley, the breadth of the shaft, and the size of the locking elements, which are significant for each errand.

 
Why You Need Rubber Lined Pulleys
 
01/

Strength
Many people consider rubber to be flimsy and bouncy, like a typical rubber band. However, rubber can also be incredibly strong and firm. The hardness of rubber is measured in durometer, and the average durometer for rubber is between 20-90. Because of its considerable strength, rubber works as an ideal liner to reduce impact in a variety of applications; drive rollers, pulleys, impact bins/pads, and skirt boarding.

02/

Durability
You need a solution to protect your equipment from the daily wear-and-tear and abrasion that comes along with daily use. The durability of rubber makes the perfect abrasion-resistant barrier that will keep your equipment running more smoothly - even with high-abrasion industries like sand or aggregate mining. Protect tanks, fan housings, impellers, containers, and ducts from abrasion problems.

03/

Flexibility
We can cover pretty much anything in rubber- so your options are endless! Rubber liners can be applied to new or existing equipment, in a wide variety of compounds. You can even select your color! Because there are so many options, you can rely on our team of rubber experts to help you select the right type of rubber to best suit your situation.

04/

Protection
Soft natural rubber offers excellent protection from many corrosive materials, like chemicals. Chemical handling systems, scrubbers, reactors, vapor collecting systems, and blower systems can all be protected with rubber.

FAQ

Q: What is rubber roller used for?

A: Rubber rollers are used in a many manufacturing processes to accomplish various mechanical functions and create a uniform pressure zone. Some rollers are used to apply paint or printing inks. The furniture industry uses rollers in sanding and pressing operations.

Q: What are polyurethane rollers used for?

A: Many industries can benefit from the use of these rollers. This is because they're made to automate repetitive movements along assembly lines and eliminate the need for manual handling. If there's heavy lifting, pressing, or assembling needed in an industry, they will likely need urethane rollers.

Q: What is a rubber roller also called?

A: Urethane rollers urethane rollers or rubber rollers, also known as rubber rolls, are chemically resistant, shock absorbent cylindrical tubes that service many essential manufacturing applications.

Q: What is the difference between steel and rubber rollers?

A: The difference between rubber and steel rollers lies in their crimping method for the stem. Steel rollers (chevron) conditioner rolls break the stem at specific points while causing minimal damage to the leaves. In contrast, rubber rollers handle crops more gently, crimping the stem without crushing the entire plant.

Q: What is a roller coating?

A: Roller coating is a process of coating a surface with a brazing paste using a roller. It is an automated, cost-effective process best used for large tolerance non-flat surfaces and hard to control joint gaps. With minimal labor needed, parts go through the roller coating machine at the adjusted speed.

Q: What are silicone rollers?

A: Silicone rollers are well suited for “tipping” or decoration of raised artwork as well as application to flat, curved and contoured surfaces. Silicone rollers are ideal for non-decorating applications requiring a non-slip surface for feeding/pulling films through a variety of machine applications.

Q: What is a neoprene roller?

A: It is a historic synthetic rubber that has been used extensively in many industries but often times the physical properties can be surpassed by more modern roller compounds.

Q: Which is better rubber or steel?

A: When the same amount of pressure is applied on both ends of the steel, the strain created is very less compared to rubber. This means that steel has a larger value than young's modulus of elasticity and can withstand a high amount of stress comparable to rubber.

Q: Is rubber more durable than steel?

A: Steel's role in construction and manufacturing is pivotal due to its strong, durable, and resilient nature. Rubber, on the other hand, is flexible, can stretch and absorb impact with ease.

Q: What is the difference between rubber and epdm?

A: Epdm or ethylene propylene diene monomer is rubber made from the properties within its name: Ethylene, propylene, diene, and monomers are all put together into a single bond structure, giving you epdm rubber. Epdm is a less expensive type of rubber, but it's resistant to heat, cold, ozone, water and weathering.

Q: What is the purpose of rubber lining?

A: Rubber lining is an application method used to protect multiple types of systems by lining corrosion and abrasion-resistant rubber upon the surface or inside of pipes and tanks. 2. Where is rubber lining used? Rubber linings are mainly used for protection against corrosion and/or erosion damage.

Q: What is rubber pulley?

A: Rubber pulley lagging sheets are known for their excellent wear resistance, providing a protective layer that extends the pulley's life. They offer high tensile strength, tear resistance, and can withstand harsh mining conditions.

Q: What are the materials used in rubber lining?

A: Epdm (ethylene propylene diene monomer) rubber is a popular choice for many applications because it is very versatile. It can resist ozone and sunlight, oxidizing chemicals, non-flammable hydraulic fluids, pure aniline, fire extinguisher liquids, acids, hot water, and steam.

Q: What is rubber lined steel pipe?

A: The proper rubber-lined pipe can withstand years of abrasive and corrosive service conditions. Our rubber compounds are engineered for chemical resistance to protect your pipe from the effects of abrasion, impact, acids and oxidizing agents.

Q: What is the hardness of rubber lining?

A: Soft rubber linings normally have a hardness range of 40º to 80º irhd and are intended specifically for conditions which are corrosive or abrasive. Hard rubber lining and ebonites have a hardness range of 25º to 80º on the shore d scale.

Q: Who is a rubber liner?

A: Rubber liners use a variety of tools to perform their duties, including buffing and trimming materials with air and electrical tools. They also install new rubber linings inside rail cars that carry chemicals, such as hydrochloric acid.

Q: Where does rubber material come from?

A: Natural rubber is made by extracting latex – the liquid sap – from certain types of trees and other plants. While most latex is sourced from the hevea brasiliensis tree, aka the rubber tree, over 2,500 varieties of trees and plants (including dandelions) produce the right kind of sap.

Q: How is pipe rubber lined?

A: The rubber lining is a process of application of liner material (normally in the form of rubber sheets or extruded tubes) over the internal surface of the steel piping followed by vulcanizing at the required temperature to attain the desired degree of hardness.

Q: Why rubber lining?

A: Rubber lining of equipment can significantly increase its wear life as it is highly resistant to both fine and abrasive materials, and can be applied to a wide variety of industrial equipment. At weir minerals, we are specialists in lining pumps, hydrocyclones, hoses, pipes, valves and other processing equipment.

Q: What is the function of rubber liner?

A: Rubber linings are essential for adding corrosion resistance to pipes, tanks, and other similar vessels. It also protects metals from ignition, explosion, and substance contamination. The process of successfully applying rubber lining requires skill and accuracy to provide maximum corrosion resistance.

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