Highlight:
60-70 Shore A Hardness Hex Rubber Ceramic Wear Plate
, ≥12MPa Tensile Strength Abrasion Resistant Alumina Ceramic Linings
, 3.6-3.8g/cm3 Density Rubber Ceramic Liners
Hex Rubber Ceramic Wear Plate Abrasion Resistant Alumina Ceramic Linings - Reparex
Product Description
In the harsh environments of industrial material handling, conveyor belt wear is a major cause of downtime and increased costs. Our wear-resistant ceramic vulcanized liners are revolutionary products designed specifically for heavy-duty applications. Through a unique vulcanization process, they perfectly combine high-wear-resistant ceramics, high-elasticity rubber, and high-strength steel plates, providing unparalleled impact resistance, wear resistance, and anti-slip performance, significantly extending the service life of conveyor belts and equipment.
Our core product—the Hex Rubber Ceramic Wear Plate —achieves a comprehensive breakthrough in impact resistance, anti-slip properties, and service life thanks to its biomimetic geometry. This product aims to completely solve the problems of wear, slippage, and material adhesion in conveyor system drive rollers, providing a permanent wear-resistant solution for heavy industries such as mines, ports, and power plants, significantly reducing overall operating and maintenance costs.
Product Feature
Structural Mechanics Advantages:
No Stress Concentration Points: The four corners of a square structure are natural stress concentration points, prone to cracking under sustained impact. The 120° angles of a hexagon distribute stress more evenly, significantly improving impact fatigue resistance.
Integral Structural Integrity: The interlocking hexagonal units form a tight "ceramic-rubber composite mesh," allowing the impact force on any single ceramic block to be shared by surrounding units, effectively preventing the spread of localized damage.
Performance Enhancement Demonstration:
Improved Anti-Slip Performance: Laboratory tests show that, with the same ceramic coverage area, the hexagonal liner, due to its unique grooved guidance, has a dynamic friction coefficient approximately 15% higher than the square liner. Especially in wet or muddy conditions, it exhibits excellent drainage and mud removal performance, resulting in a more significant anti-slip effect.
Extended Service Life: Due to the elimination of stress concentration and the strong overall structural integrity, the comprehensive service life of the hexagonal ceramic liner under the same harsh working conditions is on average 20%-30% longer than that of the traditional square liner.
Alumina ceramic technical parameters
| Technical Parameters |
Description / Value |
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Material Composition
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Alumina (Al₂O₃) content ≥ 92% (may vary depending on grade, e.g., 95% for 95-grade ceramic)
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Density
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≥ 3.7 g/cm³ (increases with higher alumina content)
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|
Hardness
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Rockwell Hardness (HRA) ≥ 82 (some sources mention ≥ 85)
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|
Flexural Strength
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≥ 290 MPa (increases with material grade)
|
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Fracture Toughness (KΙC)
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≥ 4.8 MPa·m¹/² (increases with material grade)
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Compressive Strength
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≥ 850 MPa
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Thermal Expansion Coefficient
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7.2 × 10⁻⁶ m/m·K
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Thermal Conductivity
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20 W/m·K
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Rubber Layer Properties
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- Hardness: 60 ± 5 Shore A<br>- Elongation: Over 400%<br>- Tensile Strength: ≥ 180 kgf/cm²
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Adhesion Strength
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- Ceramic/Rubber Peel Strength: ≥ 50 kg/25mm<br>- Rubber/Steel Peel Strength: ≥ 40 kg/25mm
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Safe Operating Temperature (Rubber Layer)
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90°C
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Base Steel Plate
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Q235A high-quality steel plate, thickness ranging from 3mm to 10mm
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Bolt Material
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Stainless Steel Bolts
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Special Process
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Thermosulfurization process, vulcanizing ceramic into rubber or directly onto steel plate
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| Shape & Size |
Ceramic sizes range from 10x10mm to 150x100mm, shapes include mosaic, hexagon, cylinder, etc.<br>- Rubber layer thickness: 2mm to 15mm<br>- Steel plate size can be customized |
| Application Areas |
Industries such as coal, thermal power, steel, cement, metallurgy, chemicals, machinery, mining, etc., are suitable for equipment with large material throughput, large particle sizes, and high impact forces |
Application scope
Rubber ceramic lining has a wide range of applications: it is often used in material transmission devices under normal temperature conditions. It is used as a wear-resistant inner layer and can effectively resist the impact of materials. For example, it can be installed inside the silo, the bottom of the hopper, the inside of the mixing machine, the side wall of the coal-dropping hopper, the channel of the coal-dropping pipe, the bottom of the raw coal bunker, the pipes at the inlet and outlet of the coal mill, and the surface of the material chute etc., to extend the service life of this equipment and reduce wear, thereby improving the efficiency and stability of the entire material conveying system.
Our Production and Quality Control System
Pre-treatment Process
Ceramic Treatment: Ceramic blocks are treated with sandblasting and a special cleaning agent to achieve optimal surface energy, ensuring wettability with rubber.
Steel Plate Treatment: Steel plates undergo shot blasting to remove rust and are then coated with a high-performance metal adhesive to eliminate the risk of later corrosion and delamination.
Core Vulcanization Process
We employ a high-temperature, high-pressure, one-stage vulcanization technology. Under specific temperature (150°C-160°C), pressure (≥20MPa), and time conditions, the rubber undergoes a vulcanization reaction. Its long-chain molecules chemically bond with the treatment agents on the ceramic and steel plate surfaces, achieving a permanent and irreversible molecular-level bond between the three. This is far superior to ordinary cold bonding processes.
Full-Process Quality Inspection
Incoming Material Inspection: Physical and chemical property testing is performed on each batch of ceramic and rubber raw materials.
In-Process Inspection: During the vulcanization process, temperature and pressure curves are monitored in real time to ensure consistent process parameters for each batch of products.
Finished Product Inspection:
Ceramic Peel Strength Test: Using a universal tensile testing machine, ensure the bond strength between ceramic and rubber is ≥5 MPa (significantly higher than the industry average).
Shore Hardness Test: Ensure the rubber hardness is within the preset range (e.g., ±5 HA).
Drop Ball Impact Test: Simulates the impact of large materials to test the product's impact resistance.
Global Market Applications and Customer Value Report
Our products have been exported to over 30 countries and regions worldwide, establishing an excellent reputation in the following key markets.
Australian Iron Ore: Facing highly abrasive iron ore, our hexagonal three-in-one liners have achieved over 3 years of stable operation on large stacker-reclaimer drive rollers.
Chilean Copper Ore: In long-distance, high-drop conveying systems in mountainous areas, our products effectively solve the problem of premature failure caused by the impact of traditional liners, reducing customers' overall maintenance costs by 40%.
Southeast Asian Port Terminals: In high-temperature, high-salinity, and humid environments, our products exhibit excellent anti-slip and anti-aging properties, ensuring the safety and efficiency of continuous port operations.
FAQ
Q1: What are the specific data for your ceramic-rubber bond strength? How do you guarantee it won't detach over the long term?
A1: We promise a ceramic-rubber peel strength ≥5 MPa. This is thanks to our unique ceramic surface treatment technology and high-temperature vulcanization process, which creates a chemical reaction between the rubber and ceramic, rather than a physical bond. Even under long-term alternating hot and cold temperatures and stress cycles, the bond strength will not weaken.
Q2: How do you ensure the flatness of your liners for worn roller surfaces?
A2: For two-in-one flexible liners, their inherent elasticity can compensate for slight unevenness. For three-in-one steel plate liners, we have a professional on-site measurement team that can provide pre-bending line customization services. This means that during production, we create liners that perfectly match the roller's designed curvature, ensuring 100% fit after installation and eliminating vibration and noise caused by poor fit.
Q3: Besides standard sizes, can you provide customized solutions for extreme working conditions?
A3: Of course. This reflects our core competitiveness. We can reverse engineer the dimensions, thickness, and packing density of ceramics and the formulation of rubber based on your material characteristics (such as particle size, humidity, acidity, and alkalinity), drop, belt speed, and other parameters, to provide you with a "tailor-made" solution.
Q4: What are the installation methods for the hexagonal ceramic liner?
A4: We support three installation methods: bolt fixing, welding fixing, and adhesive fixing. For different equipment, our technical team will provide detailed installation drawings, indicating the bolt hole locations, welding points, or adhesive process requirements. We also provide specialized installation tools and adhesives.
Q5: What is the product's lifespan?
A5: It varies depending on the working conditions. In scenarios with moderate impact and material hardness ≤8, the lifespan of a two-in-one liner is approximately 3-4 years, and that of a three-in-one liner is approximately 4-5 years. In high-intensity impact scenarios, the lifespan can still reach 1.5-2 years, far exceeding that of traditional materials.
Q6: Is sample testing supported?
A6: Yes! We can provide 1-2 samples free of charge for customers to conduct abrasion resistance and impact tests. Customers can also send samples to a third-party testing agency for verification. Bulk orders will be placed only after the samples pass the tests.
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