Pressure Rubber Floor Tile Production Machine

High Output Downward - Pressure Rubber Floor Tile Production Machine , Rubber Tile Molding Machine With Can Customizable In Different Sizes
High Output Downward Pressure Rubber Floor Tile Production Machine , Rubber Tile Molding Machine Customizable In Different Sizes

Machine Introduction:

I. Equipment Structure

1. Frame Section

• Frame Structure: It is constructed with a robust metal frame, usually welded from high - quality steel. This structure provides sufficient strength and stability to withstand the substantial pressure generated during the vulcanization process. The frame design takes into account the force balance during equipment operation to ensure that no deformation occurs under long - term high - load working conditions.
• Base: The base is the foundation of the entire equipment. It typically has a large contact area to evenly distribute the equipment's weight on the ground and provides stable support for the reaction forces during vulcanization. The base is also equipped with some devices for fixing other components.

2. Downward - Pressure Device

• Hydraulic Cylinder: This is one of the key components of the downward - pressure vulcanizing machine. The hydraulic cylinder is driven by the hydraulic system and can generate powerful downward pressure. The piston of the hydraulic cylinder is connected to the upper hot plate or mold, and its stroke can be adjusted according to the thickness of the rubber floor tile and the requirements of the vulcanization process. Generally, the diameter and stroke of the hydraulic cylinder are designed according to the nominal pressure and working range of the equipment to ensure that sufficient pressure can be provided and different - sized products can be accommodated.
• Hydraulic System: It includes components such as a hydraulic pump, hydraulic valves, an oil tank, and oil pipes. The hydraulic pump is the power source that pumps hydraulic oil from the tank and pressurizes it. The hydraulic valves control the flow direction and pressure of the hydraulic oil, thereby precisely controlling the movement of the hydraulic cylinder. The hydraulic system is usually also equipped with a pressure sensor and a pressure gauge for real - time monitoring and display of the pressure value, and the operator can adjust the pressure as needed.

3. Hot Plate System

• Upper and Lower Hot Plates: The hot plates are the main components for heat transfer during vulcanization. The upper and lower hot plates are usually made of high - quality alloy steel plates, and their interiors are equipped with heating channels or heating elements. For a steam - heated vulcanizing machine, there are steam - circulation channels inside the hot plates. Steam from an external steam source is introduced into the channels, and the heat of the steam is used to heat the hot plates. In the case of electric heating, heating elements such as resistance wires are evenly distributed inside the hot plates to convert electrical energy into heat energy. The surfaces of the hot plates are precision - machined to have good flatness and smoothness to ensure that the rubber floor tiles are heated uniformly during vulcanization.
• Temperature - Control System: It can precisely control the temperature of the hot plates. A temperature sensor is installed on the hot plate to monitor the temperature of the hot plate in real - time and send the temperature signal back to the controller. The controller maintains the stability of the hot plate temperature by adjusting the power of the heating elements or the steam flow rate according to the set vulcanization temperature. The temperature - control system can achieve precise temperature adjustment, and the vulcanization temperature is generally controllable between 140 - 180°C.

4. Mold System

• Mold Design: The shape and size of the mold determine the appearance and specifications of the rubber floor tile. The mold is usually customized according to customer needs and product standards. It can be a simple square, rectangle, or a complex shape with special patterns or textures. The mold material is generally high - hardness and wear - resistant steel, and the internal surface is finely machined to ensure the molding quality of the rubber floor tile.
• Mold Installation and Fixation: The mold is installed on the upper or lower hot plate and fixed by means of bolts, clamping grooves, etc. During the vulcanization process, the mold needs to be in close contact with the hot plate to ensure that heat can be effectively transferred to the rubber raw material. At the same time, it is also necessary to ensure that the mold does not shift under pressure, thereby ensuring the dimensional accuracy of the rubber floor tile.

II. Working Principle

1. Feeding and Mold Preparation

• First, the rubber raw material, which has been mixed and added with vulcanizing agents and other additives, is placed in the mold located on the lower hot plate. The amount and distribution of the rubber raw material are controlled according to the size of the mold and the thickness requirements of the rubber floor tile. Then, the upper hot plate is lowered to close the mold, preparing for vulcanization.

2. Vulcanization Process

• Start the heating function of the hot plate system to transfer heat to the mold and rubber raw material through the upper and lower hot plates. When the hot plate temperature reaches the set vulcanization temperature (e.g., 140 - 180°C), the vulcanizing agent in the rubber raw material begins to react chemically with the rubber molecules. At the same time, start the hydraulic cylinder of the downward - pressure device to make the upper hot plate apply a certain pressure (usually between 3 - 10 MPa) to the mold and rubber raw material. Under the dual action of pressure and temperature, the cross - linking reaction between rubber molecules accelerates, and the rubber is gradually vulcanized and formed. The vulcanization time varies depending on factors such as the thickness of the rubber floor tile and the formulation, generally ranging from a few minutes to several tens of minutes.

3. Demolding and Finished - Product Removal

• After the vulcanization is completed, turn off the heating function of the hot plate system and release the pressure of the hydraulic cylinder to raise the upper hot plate. Then, the vulcanized rubber floor tile is removed from the mold. The removed rubber floor tile may require some subsequent processing, such as cooling and trimming, to obtain the final qualified product.

III. Equipment Characteristics

1. Good Pressure Uniformity

• Due to the downward - pressure hydraulic cylinder applying pressure, the pressure can act vertically and uniformly on the mold and rubber raw material. This uniform pressure distribution helps the cross - linking reaction of rubber molecules in all parts of the rubber floor tile to occur evenly during the vulcanization process, thereby improving the product quality and making the physical properties of the rubber floor tile, such as hardness, elasticity, and wear resistance, more consistent throughout the product.

2. Precise Temperature Control

• The temperature - control system of the hot plate system can precisely control the vulcanization temperature. Precise temperature control is crucial for the vulcanization quality of rubber floor tiles because different temperatures affect the speed and extent of the vulcanization reaction. By precisely controlling the temperature, it can be ensured that the vulcanization degree of the rubber floor tile is appropriate, avoiding product - quality problems such as under - vulcanization or over - vulcanization caused by too - high or too - low temperatures.

3. High - Quality Product Molding

• The downward - pressure vulcanizing machine combines uniform pressure and precise temperature control, enabling the rubber floor tile to be precisely molded according to the design requirements in the mold. The close cooperation between the mold and the hot plate and the stable pressure environment can ensure high - dimensional accuracy and good surface flatness of the rubber floor tile, and can produce products with complex patterns and textures to meet different market demands.

What sizes are available for rubber floor tiles?
 

Imperial System Sizes

• 1x1 feet: Compact and easy to handle, suitable for small areas such as doorways, outdoor entrances, and cement slabs.
• 2x2 feet: A very popular size, easy for a single person to transport and install, and suitable for rooftops, playgrounds, home and commercial gyms, and industrial settings.
• 3x3 feet: Larger in size, often used in gyms, restaurants, horse facilities, etc., and can be interlocked and dry laid for temporary installations.
• 4x6 feet: A commercial-grade size, suitable for large-scale installations such as commercial, school, and home gyms, and can protect the subfloor under heavy equipment.

Metric System Sizes

• 300mm×300mm4: Commonly used in small areas like small indoor children's play areas or local kitchen anti-slip areas.
• 400mm×400mm and 500mm×500mm2: More often used in some commercial places or large indoor spaces, such as shopping mall aisles and school classrooms.
• 600mm×600mm2: Commonly used in office, gym and other places, with good decorative effect.
• 1000mm×1000mm2: Usually used in some large public places or high-end commercial places, but the price is relatively high.

Special Sizes

• 23x23 inches and 25x25 inches: Commonly used in gyms, commercial and retail settings.
• 37x37 inches and 39.37x39.37 inches: Suitable for large-scale installations in weight rooms, ski lodges, home gyms, golf course clubhouses, health and fitness facilities, schools, ice arenas, locker rooms, etc.

How are rubber floor tiles produced?

1. Raw Material Preparation

• Rubber Selection: The main raw material is rubber, which can be natural rubber or synthetic rubber (such as styrene - butadiene rubber, ethylene - propylene - diene monomer rubber). The choice of rubber depends on the desired properties of the floor tiles, such as flexibility, durability, and resistance to wear and tear.
• Additive Incorporation: Various additives are mixed with the rubber. These include vulcanizing agents (such as sulfur), accelerators (to speed up the vulcanization process), antioxidants (to prevent aging), fillers (such as carbon black, silica to enhance strength and other properties), and pigments (for coloring). The additives are carefully measured and added in specific proportions to achieve the desired physical and chemical characteristics of the floor tiles.

2. Mixing

• The rubber and additives are placed in a mixer, such as an internal mixer or an open mill. The mixer kneads the materials together thoroughly to ensure a homogeneous blend. This step is crucial as an uneven mixture can lead to inconsistent quality in the final product. The mixing process may occur at a specific temperature and for a set duration to optimize the dispersion of the additives within the rubber matrix.

3. Molding

• Extrusion Molding: In some cases, the rubber mixture is fed into an extruder. The extruder forces the material through a die with the shape of the cross - section of the tile (for example, square or rectangular). This forms a continuous ribbon - like shape that can then be cut into individual tiles of the desired length.
• Compression Molding: Another common method is compression molding. The rubber compound is placed into a mold cavity that has the exact shape and dimensions of the floor tile. The mold is then closed, and pressure is applied to shape the rubber into the tile. This method is often used for tiles with more complex shapes or patterns on the surface.

4. Vulcanization

• The molded rubber tiles are then subjected to vulcanization. Vulcanization is a chemical process that cross - links the rubber molecules, improving the material's elasticity, strength, and resistance to environmental factors. This process can be carried out in a vulcanizing press. The tiles are placed in the press, and heat and pressure are applied. The temperature and pressure conditions vary depending on the type of rubber and the formulation of the compound but are typically in the range of 140 - 180°C and 3 - 10 MPa. The vulcanization time also depends on factors such as the thickness of the tile and the specific rubber compound, usually ranging from a few minutes to several tens of minutes.

5. Cooling and Finishing

• After vulcanization, the tiles are removed from the press and allowed to cool. Cooling can be a natural process at room temperature or can be accelerated using cooling fans or other cooling mechanisms. Once cooled, the tiles may undergo finishing processes such as trimming any excess material from the edges, buffing the surface to achieve a smooth finish, or adding surface textures (such as grooves for anti - slip purposes).
• The finished rubber floor tiles are then inspected for quality, including checking for proper dimensions, absence of defects, and correct physical properties. After passing inspection, they are packaged and prepared for distribution and installation.