The special nitrogen generator for the rubber tire sector is suitable for nitrogen protection, molding and other fields during the vulcanization process of rubber and tire production. Especially in the production of all-steel radial tires, the new nitrogen vulcanization process has gradually replaced the steam vulcanization process. It has the characteristics of high nitrogen purity, continuous production, and high nitrogen pressure.
Key Takeaways
- The output performance indicators of tires such as: mileage, durability, uniformity, pressure penetration test, etc. are significantly better than traditional superheated water vulcanization.
- Effectively lower equipment configuration and operating expenses.
- The simplified process has changed the shortcomings of the traditional superheated water vulcanization system which is large and complex and the equipment takes up a lot of space.
In traditional processes, steel radial tires use superheated water to shape and vulcanize the tires. The so-called superheated water vulcanization refers to the use of low-pressure steam for tire shaping. During the normal vulcanization process of the tire, the bladder (similar to the role of a mold) is filled with high-pressure hot water above 170°C, and low-pressure steam is used for vulcanization at the external temperature.
Nitrogen-filled vulcanization refers to the use of low-pressure nitrogen (0.4-0.5MPa) to shape the tire. During the normal vulcanization process of the tire, the filling medium in the bladder is a mixed gas of high-pressure steam and high-pressure nitrogen (2.5MPa), and the external temperature is determined by low-pressure steam. For vulcanization, both methods use high temperatures to change the chain-like molecular structure of natural rubber into a network structure, while tightly combining the layers of belts to form patterns on the tread.
Nitrogen vulcanization, tire output performance indicators such as mileage, durability, uniformity, and puncture ability tests are all higher than those of traditional superheated water vulcanization. The purchase cost of nitrogen production equipment can basically recover the entire investment in more than one year.
Nitrogen-filled vulcanization refers to the use of low-pressure nitrogen (0.4-0.5MPa) to shape the tire. During the normal vulcanization process of the tire, the filling medium in the bladder is a mixed gas of high-pressure steam and high-pressure nitrogen (2.5MPa), and low-pressure steam is used to control the external temperature. Vulcanization uses high temperatures to change the chain-like structure of natural rubber into a network structure, while tightly combining the layers of belts to form patterns on the tread. Nitrogen vulcanization, tire output performance indicators such as mileage, durability, uniformity, and puncture ability tests are all higher than those of traditional superheated water vulcanization.
Advantages of nitrogen charging and sulfurization in nitrogen generator:
- The output performance indicators of tires such as: mileage, durability, uniformity, pressure penetration test, etc. are significantly better than traditional superheated water vulcanization.
- Effectively lower equipment configuration and operating expenses.
- The simplified process has changed the shortcomings of the traditional superheated water vulcanization system which is large and complex and the equipment takes up a lot of space.
- It solves the previous working conditions where the pressure and temperature of the steam and superheated water were difficult to adjust, making the vulcanization process stable and significantly reducing the phenomena of rubber shortage, delamination, and bubbles during tire vulcanization.
- Nitrogen has stable output performance and excellent heat insulation output performance, which greatly improves the serious heat loss of vulcanization when using superheated water and saves energy.
- High-purity nitrogen eliminates the phenomenon of early vulcanization of the vulcanization capsule and increases the average life of the capsule by 10%.
- There is no need for a large amount of steam originally used to heat superheated water, reducing the investment in public works necessary to meet the process.
- It reduces the consumption of water and electricity, and simultaneously eliminates the phenomena of running, popping, dripping, and leaking, meeting the requirements of an environmentally friendly operation.
Advantages of Nitrogen Filling in Tires with Nitrogen Generators
Compared with air-filled tires, filling with dry, low-oxygen nitrogen will stabilize the pressure inside the tire, greatly reducing the chance of tire blowout and improving the safety of high-speed driving.
A. Lower the chance of tire blowout and enhance driving safety
- Nitrogen is an inert gas that prevents oxidation of the rim and tire ply.
- The speed at which nitrogen permeates the sidewall of a tire is only 1/6 that of oxygen. For this reason, nitrogen-filled tires have a strong ability to maintain tire pressure, eliminating the need for frequent air replenishment, reducing friction and saving fuel.
- For tubeless tires, filling with dry nitrogen prevents water vapour and high oxygen content from corroding the rim.
B. Extend the working life of tires
- Nitrogen-filled tires can maintain stable pressure for a long time, extending the life of the tires.
- The inner cavity of a tire filled with ordinary air has a high content of oxygen and water. Oxygen gradually penetrates from the inner cavity of the tire to the depth of the side wall. The oxygen molecules react chemically with the unsaturated molecules in the rubber, causing the rubber to age until it is scrapped. The nitrogen concentration of nitrogen-filled tires reaches at least 95%, and the oxygen content in the tires is lower. Nitrogen can safeguard the rubber from aging and extend the working life of the tire.
- Ordinary air-filled tire pressure compressed air contains a certain amount of oil, which contaminates and gradually swells the inner tube and reduces the working life of the tire. Dry tire filling can extend the working life of the tire.
C. Lower abnormal tire deformation and save additional fuel consumption
The leakage and drop in the air pressure inside the tire will raise the additional deformation of the tire, raise the rolling resistance, and raise fuel consumption. Nitrogen-filled tires can maintain stable tire pressure for a long time, reducing abnormal tire deformation during use and reducing vehicle fuel consumption. It saves exhaust emissions and protects the environment.
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