The reason for using rubber roller is because rubber has flexibility that no metal can provide. Metals can corrode, scratch, dent, and crack, which can easily and often happen. In addition, the texture and hardness of metals can scratch and damage any media they come in contact with. Other materials such as fiber-reinforced composites can provide better quality, but are more expensive and less readily available. They are not readily available and are usually more expensive. Rubber rollers are the most economical way to go while providing longer roller life and unique physical and psycho-mechanical properties.
a. Surfaces with a high coefficient of friction. Under clean and dry conditions, the coefficient of friction between steel surfaces is about 0.5 to 0.8. Aluminum also yields a comparable value of about 0.45 for steel. Rubber, on the other hand, has coefficients of friction ranging from 0.6 to 1.2 for various materials. The high coefficient of friction prevents items from sliding, especially when conveying items on non-horizontal surfaces.
b. No scratches and tear burrs. Metal can be easily scratched by harder materials. These scratches can form burrs on the roller surface, which can damage the product during operation. The rubber covering on the rollers protects the metal core from damage. Any damage to the rubber surface will not adversely affect operation compared to the sharp burrs created by scratching the metal.
c. Impact-resistant deformation. Rubber is known to be elastic and has good impact strength. They can easily absorb energy and dissipate it to a larger area while returning to their original shape. This prevents surface indentations and cracks from causing premature failure of the rollers.
d. Better chemical resistance. Specific rubber types can withstand different chemical exposures. Covering the roll core prevents corrosion, which can cause permanent damage to the roll. The most popular choice for chemically resistant metal rollers is stainless steel, which is much more expensive than rubber liners.
e. Replaceable liners. Since the rubber lining suffers the most damage during operation, the rigid roller core is retained without structural damage. The roller core can be easily repaired by removing and replacing the used rubber lining. This extends the service life of the roll core and the entire machine. It also avoids costly repairs, such as replacing the entire roller or rollers.
According to the scope of application and use, the first division divides rubber into two categories: general-purpose rubber and special rubber.
The second division divides rubber into three categories: general-purpose rubber, semi-general-purpose rubber, also known as large varieties of special rubber, and special rubber, also known as small varieties of special rubber.
According to the presence or absence of double bonds on the rubber molecular chain, it is divided into two categories: unsaturated rubber and saturated rubber. Unsaturated rubber, due to the double bonds on the molecular chain, is generally more chemically active, easy to react with vulcanizing agents, fast vulcanization rate, but also easy to react with oxygen, ozone, etc., bad aging resistance and low use temperature; at the same time, due to the isolation of double bonds, high molecular activity, high elasticity, and good cold resistance.
Rubber can also be divided into self-complementary rubber and self-complementary weak rubber, the former is also known as crystalline rubber (such as natural rubber, neoprene), and the latter can be divided into micro-crystalline rubber (such as butyl rubber) and non-crystalline rubber (such as styrene-butadiene rubber, etc.).
Polyurethane or urethane rolls are often considered to be the most widely used rubber rolls. Polyurethanes are known for their wide range of physical properties. A variety of blends made from different types and proportions of compounded components are possible. It can have almost any property suitable for a particular application. It can be formulated for hard, high-performance components such as wheels and rollers, or for soft, vibration-damping applications such as shock-absorbing pads and cushions. There are different formulations on the market; some are proprietary blends from large chemical manufacturers.
Polyurethane rollers are popular for their toughness, high impact resistance, shock absorption, and fatigue resistance. These properties are brought about by the reaction of different chemical substances. Its polymer system consists of four components: polyol, diisocyanate, curing agent, and additives.
The polymer of silicone roller does not have a carbon backbone but has silicone chains with methyl, vinyl, and phenyl groups. Silicone rollers have good resistance to oxygen, ozone, heat, light, and moisture, and excellent release. However, silicone rollers are more expensive and have limited mechanical properties.
Neoprene roller is a chloroprene polymer produced by the emulsion polymerization process. The presence of chlorine in the polymer chain improves resistance to ozone, oxidation, and oil. Chloroprene is a good all-around polymer, but not in any particular area. It is used in the roller industry because of its tackiness and simple workability. However, it is usually not as common as NBR due to cost.
a. The pressure between the rubber rollers increases the friction between the rubber rollers, makes the rubber rollers warm up and heat up, aggravates the squeezing expansion between the rubber rollers, accelerates the aging and deformation of the rubber rollers, and speeds up the emulsification process of the ink and water, which is very unfavorable to the transmission of the ink.
Solution: To solve this problem, the pressure between the rubber rollers should be basically the same as the pressure of the contact layout. At this point, you can use a piece of 1500 silk, 3cm wide plug piece insert test between the rubber rollers until you can feel a certain tight force on the line. After scrubbing, wipe again with a clean cloth and then put the rollers on the machine for next use.
b. The treatment of surface crystallization of rubber rollers closes the capillary pores on the surface of rubber rollers, which will make the rubber rollers lose the role of pro-ink and cause the uneven transmission of ink and easy to emulsify the ink.
Solution: Take off the rubber roller on the machine, put it on the shelf, take the cloth ball of sticky kerosene and pumice powder, rub the surface of the rubber roller evenly, wipe off the crystallized layer on the surface of the rubber roller, show the original rubber color of the rubber roller, then use the car wash water or gasoline to clean the kerosene and pumice powder left on the rubber roller, reinstall and adjust the pressure of the rubber roller.
c. The maintenance of the bearings on the rubber rollers is very obvious in the high-speed operation of the machine, especially the operator usually heaps of bearing maintenance cloth attention, that the wear is more powerful. After the bearings of the rubber roller are damaged to a certain extent, it will produce jumping friction and extrusion of the rubber roller, which will shorten the service life of the rubber roller. And will make to print out the product has "ink, water bar" phenomenon. So, the operator is required to take down the rubber rollers every week, grease the bearings and replace those bearings which are worn out and rotate badly to ensure the normal use of the rubber rollers.
d. The influence of the workshop environment pile rubber roller in the hot and humid weather and from the surrounding dusty environment production, the high-speed operation of the machine to the surface temperature of the rubber roller constantly rising, rubber roller in the heat expansion, increase the rubber roller friction, which will make the life of the rubber roller shortened.
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