Application of Nitrogen Generator in the Rubber Tire Industry
The nitrogen generator used in the rubber tire industry is applicable to nitrogen protection during the rubber and tire production vulcanization process, as well as in the molding field. Especially in the production of all-steel radial tires, the new nitrogen vulcanization process has gradually replaced the steam vulcanization process. It features high nitrogen purity, continuous production, and high nitrogen pressure.
In traditional manufacturing processes, steel-belted radial tires are vulcanized using hot water. The process of hot water vulcanization refers to the use of low-pressure steam to shape the tires. During normal vulcanization of the tires, the inner liner (acting like a mold) is filled with hot water at a temperature above 170°C. Under the external temperature, low-pressure steam is used for vulcanization.
Nitrogen vulcanization refers to the use of low-pressure nitrogen (0.4-0.5MPa) to shape the tires. During normal vulcanization, the filling medium in the inner liner of the tires is a mixture of high-pressure steam and high-pressure nitrogen (2.5MPa), and the external temperature is controlled by low-pressure steam. Both vulcanization methods utilize high temperatures to transform the chain-like structure of natural rubber into a network structure, while also making the carcass layer tightly bonded to form the tread pattern.
Nitrogen vulcanization has higher performance indicators for tires such as mileage, durability, uniformity, and puncture resistance compared to traditional hot water vulcanization. The cost of nitrogen equipment can be fully recovered within one year or more.
Nitrogen vulcanization refers to the use of low-pressure nitrogen (0.4-0.5MPa) to shape the tires. During normal vulcanization, the filling medium in the inner liner of the tires is a mixture of high-pressure steam and high-pressure nitrogen (2.5MPa), and the external temperature is controlled by low-pressure steam. The vulcanization process utilizes high temperatures to transform the chain-like structure of natural rubber into a network structure, while also making the carcass layer tightly bonded, forming the tread pattern on the tire surface. Nitrogen vulcanization has higher performance indicators for tires such as mileage, durability, uniformity, and puncture resistance compared to traditional hot water vulcanization.
Advantages of nitrogen generator nitrogen vulcanization:
1. The performance indicators of tires such as mileage, durability, uniformity, and puncture resistance are significantly better than traditional hot water vulcanization.
2. It effectively reduces equipment configuration and operating costs.
3. It simplifies the process flow and overcomes the shortcomings of the traditional hot water vulcanization system being large, complex, and occupying a lot of space.
4. It solves the problem of difficulty in adjusting the pressure, temperature, and steam of steam and hot water, making the vulcanization process stable and reducing phenomena such as missing glue, delamination, and bubbles during tire vulcanization.
5. Nitrogen has stable performance and excellent heat insulation properties, significantly improving the phenomenon of severe heat loss when using hot water vulcanization, and saving energy.
6. High-purity nitrogen eliminates the early vulcanization phenomenon of the vulcanization capsule, increasing the average lifespan of the capsule by 10%.
7. No longer needing the large amount of steam used for heating hot water, reducing the investment required for the necessary public engineering to meet this process.
8. Reducing water and electricity consumption, and eliminating leakage, dripping, and spilling phenomena, meeting the requirements of environmental protection operations.
Advantages of using a nitrogen generator to fill tires with nitrogen:
Compared to pneumatic tires, filling dry, low-oxygen nitrogen stabilizes the internal pressure of the tires, significantly reducing the chance of tire blowouts and improving the safety of high-speed driving.
A. Reducing the chance of tire blowouts and improving driving safety
Nitrogen is an inert gas that can prevent the oxidation of the rim and tire cord fabric.
Nitrogen permeates the sidewall of the tire at a speed of only 1/6 that of oxygen, so nitrogen-filled tires have a strong ability to maintain tire pressure and do not need frequent inflation, reducing friction and saving fuel.
For tireless, filling dry nitrogen can prevent water vapor and high oxygen content from corroding the rim.
B. Extending the lifespan of tires
Tires filled with nitrogen can maintain a stable pressure for a long time, extending the lifespan of the tires.
Filling with ordinary air in the tire cavity has a high oxygen and moisture content, and oxygen gradually permeates to the deep part of the sidewall from the tire cavity. Oxygen molecules react chemically with the unsaturated molecules in the rubber, causing the rubber to age and eventually fail. Nitrogen-filled tires have a nitrogen concentration of at least 95%, and the oxygen content in the tire is low, allowing nitrogen to protect the rubber from aging and extending the lifespan of the tires.
Pneumatic tires with air pressure contain a certain amount of oil in the cavity, which will pollute and gradually expand the inner tube, reducing the lifespan of the tire. Dry inflation can extend the service life of tires.
C. Reduce abnormal deformation of tires and save additional fuel consumption
The leakage and decrease of internal tire pressure will cause an increase in additional deformation of the tires, an increase in rolling resistance, and an increase in fuel consumption. Nitrogen-filled tires can maintain stable tire pressure for a long time, reduce abnormal deformation of tires during use, lower vehicle fuel consumption, save exhaust emissions, and protect the environment.
