What is rubber made from? Rubber composition and its production. What are they made of?
The range of modern car tires is very diverse. Manufacturers, in an effort to attract some buyers, are developing more and more new technological aspects that allow them to somehow highlight their product and show the best technical characteristics. However, the original composition of car tires is still unchanged and its main component is the same for almost all models. In order to find out, you need to take a closer look at what rubber is made of.
Main constituent substance
Any rubber product contains rubber - an elastic substance that can be either natural or artificial. Natural rubber is the frozen sap of rubber trees. It has great value since it is the basis from which a car tire is made. In addition to natural rubber, artificial rubber is also used, which is much cheaper to produce. Also, any car tires contain soot (carbon black).
The main purpose of soot is its strengthening properties. It affects the following characteristics of rubber: durability, strength, wear resistance. Over time, rubber always becomes dull and then tire dye is used to improve the appearance. Also, in order to reduce the cost of production, silicic acid is used, which improves the grip of wheels on wet surfaces, while reducing the overall service life of the tire.
As for the composition, all automobile rubber always contains these basic components, and the differences are provided by a variety of additives and additives, which in general improve the following characteristics:
- Reduced rolling friction and increase in speed characteristics;
- Abrasion resistance;
- Increased grip with the road surface.
Technology for creating automobile rubber
Summer and winter tires are known to be distinguished by their rigidity. To make a car tire more rigid and abrasion-resistant, artificial rubber is used. Winter tires, on the contrary, are made from natural rubber, which does not allow the tires to “tan” in the cold. Of course, you can use special resins and additives to achieve a similar effect with non-natural material, but in terms of their characteristics they will never catch up with the natural product. In addition, the tires will wear out faster.
The process of making rubber tires is quite long and labor-intensive. First, the collected sap from the rubber trees is placed in large baths of acid for several hours to harden it. The resulting material is called latex. Excess water is removed from it and passed through rollers to obtain a wide, flat strip, which is then crushed to form a light airy mass, which, after firing, is turned into blocks.
After this, the blocks are placed in a special cauldron, into which various additional components are added. They are what give car tires their different characteristics. The proportions and amount of additives are the own development of the manufacturing companies and this is where all the difference in the variety of tires lies. In this case, the manufacturer essentially made the tire from a single source material, just as a cake is essentially made from flour. However, numerous developments, research and classified elements make it possible to outperform competitors in terms of consumer characteristics at the same cost.
The mixture of rubber blocks and additives is mixed and heated, turning it into real rubber. It is rolled out again into strips and then allowed to cool.
Tire manufacturing
The main material from which tires are made is not only rubber. Inside it is a wire frame consisting of many threads. It can be textile, metal or polymer. The cord is woven according to the type of fabric, and then rubberized using an extruder. Then the frame is rolled out into strips of different widths using special machines to obtain the required tread size. The required tread pattern is also obtained by extrusion (punching).
The sidewalls of a future tire are made in a similar way: a frame is formed, layers of rubber are applied to it, then the excess wire is cut off and a ring-shaped blank of different sizes is formed (depending on the diameter of the wheels), to which rings of braces (protrusions along the edge of the sidewalls that hold the tire on the rim) are then attached ).
The finished sidewalls are then assembled together with the tread belt on a special machine. The machine connects all the parts of the tire and inflates it from the inside to give it its shape. The resulting blanks are subjected to vulcanization, as a result of which they are transformed into a single whole, and then treated with hot steam under pressure. The final stage is the application of technological inscriptions and signs to the sidewalls of the tire using a special press. After this, the finished tire is tested to ensure it meets the necessary conditions and requirements.
Thus, the production of car tires consists of several rather complex stages that require serious technological equipment. It becomes clear why high-quality processing procedures are required at each stage, because the final product depends on the characteristics of the starting materials, the proportions of added substances and components. Manufacturers do not stand still and are constantly developing new tire models, so when purchasing new products, it is worth familiarizing yourself with their characteristics in more detail and checking whether the declared parameters correspond to real indicators.
Rubber materials and combined rubber products cannot be replaced by other products. The unique combination of characteristics and performance qualities allows the use of such materials in complex work processes, complementing the design of machines, machine tools, instruments and building structures. Modern rubber production has made significant technological progress, which is reflected in the quality of the products. Technologists strive to increase the durability, strength and resistance of products to external factors.
What raw materials are rubber made from?
Most rubber materials are obtained from the industrial processing of synthetic and natural rubber mixtures. This treatment is achieved by cross-linking rubber molecules with chemical bonds. Recently, powdered raw materials have been used for the production of rubber, the characteristics of which are specifically designed for the formation of injection molds. These are ready-made compositions based on liquid rubber, from which ebonite products are also produced. The vulcanization process itself is not complete without special activators or agents - these are chemicals that help maintain optimal working qualities of the mixture. Typically, sulfur is used for this task. These are the components that form the basis of the kit required to make rubber. But, depending on the required performance qualities and purpose of the product, technologists introduce production stages at which the structure of the product is enriched with modifying elements.
Additives for modifying rubber compounds
During the manufacturing process, the rubber mixture can be filled with accelerators, activators, vulcanization agents, softeners and other components. Therefore, the question of what rubber is made of is largely determined by auxiliary additives. For example, regenerates are used to preserve the structure of the material. With the help of this filler, the rubber product can be subjected to secondary vulcanization. A considerable part of modifiers does not affect the final technical and operational properties, but plays a significant role directly in the manufacturing process. The same vulcanization process is corrected by accelerators and retarders of chemical reactions.
A separate group of additives are plasticizers, that is, softeners. They are used to lower the temperature during vulcanization and disperse other ingredients in the composition. And here another question may arise - how much do additives and the rubber itself affect the chemical safety of the mixture being formed? That is, what is rubber made from from an environmental point of view? In part, these are truly hazardous mixtures that include sulfur, bitumen and dibutyl phthalates, stearic acids, etc. But some of the ingredients are natural substances - natural resins, rubber, vegetable oils and wax components. Another thing is that in different mixtures the ratio of harmful synthetics and natural ingredients may change.
Stages of the rubber product manufacturing process
The industrial production of rubber begins with the process of plasticization of raw materials, that is, rubber. At this stage, the main quality of future rubber is acquired - plasticity. Through mechanical and thermal treatment, rubber is softened to a certain extent. From the resulting base, rubber will be subsequently produced, but before that, the plasticized mixture is subject to modification with the additives discussed above. At this stage, a rubber compound is formed, to which sulfur and other active components are added to improve the characteristics of the compound.
An important step before vulcanization is calendering. Essentially, this is the molding of a raw rubber mixture that has been enriched with additives. The choice of calendering method is determined by the specific technology. Rubber production at this stage may also involve extrusion. While conventional calendering aims to create simple rubber forms, extrusion makes it possible to produce complex products in the form of hoses, O-rings, tire treads, etc.
Vulcanization as the final stage of production
During the vulcanization process, the workpiece undergoes final processing, due to which the product receives characteristics sufficient for operation. The essence of the operation is to apply pressure and high temperature to a modified rubber mixture enclosed in a metal mold. The molds themselves are installed in a special autoclave connected to a steam heater. In some areas, rubber production may also involve pouring hot water, which stimulates the process of distributing pressure through the fluid. Modern enterprises are also striving to automate this stage. More and more new molds are appearing that interact with steam and water supply nozzles based on computer programs.
How are rubber products produced?
These are combined products that are obtained by combining fabric materials with a rubber mixture. In the process of manufacturing rubber products, paronite is often used - a hybrid material obtained by combining heat-resistant rubber and inorganic fillers. Next, the workpiece undergoes rolling processing and vulcanization. Rubber products are also produced using syringe machines. In them, the workpieces are subjected to thermal effects, after which they are passed through the profiling head.
Equipment for rubber manufacturing processes
The full production cycle is carried out by a whole group of machines and units that perform different tasks. The vulcanization process alone is served by boilers, presses, autoclaves, formers and other devices that provide intermediate operations. A separate unit is used for plasticization - a typical machine of this type consists of a spiked rotor and a cylinder. The rotation of the rotor part is carried out by means of a manual drive. Rubber production is not complete without cooking chambers and calender units, which roll out rubber mixtures and apply thermal effects.
Conclusion
The manufacturing processes of rubber products are largely standardized both in terms of mechanical processing and chemical exposure. But even if the same production equipment is used, the characteristics of the resulting products may be different. This is also proven by domestically produced rubber, which offers different sets of performance properties. The largest share of rubber products in the Russian segment of the industry is occupied by automobile tires. And in this niche, the ability of technologists to flexibly modify compositions in accordance with stringent requirements for the final product is especially clearly demonstrated.
We'll tell you what car tires are made of and what components they use. Despite the fact that the preparation recipes for the production of some tires are kept secret, the main components of the composition are known.
Chemical composition
The main material is rubber. It comes in different forms and can be made from either synthetic or natural rubber. The most common are tires made from synthetic rubber, since it is easy to develop and much cheaper and is not inferior in quality to natural rubber.Second in terms of quantitative indicators – carbon technical(soot). It accounts for approximately 30% of the entire mixture. What is carbon used for? Essentially, it is a binding component of the mixture, acting at the molecular level. Without the use of carbon black, tires would be short-lived, fragile and subject to increased wear.
Sulfur is used instead of carbon black. But the choice of one or another component is rather a matter of economic feasibility. From a technological point of view, the difference is small.
Another alternative to carbon black is silicic acid. It is used as a replacement for soot because the latter is constantly becoming more expensive. However, this decision causes some controversy among professionals, and they are related to the fact that silicic acid, with low strength, has a higher ability to adhere to a wet road surface. That is, while losing wear resistance, we gain better grip.
Various oils and resins are used as additives for the preparation of compounds. They perform a softening function, which is especially important in the production of winter tires.
The fact that rubber contains silicic acid, corn starch or other additives on which advertising is made means nothing. It is important to invent and then follow a recipe that, using these components, would provide excellent tire performance. But not all manufacturers succeed in this.
It can be summed up that car tires are made either from rubber or from other materials, but with the addition of rubber. Manufacturers have their own optimal chemical composition, which determines various characteristics. One manufacturer focuses on service life, another on speed performance, and a third on wet performance. These characteristics determine the price and quality of the tire.
Many car owners have a general understanding of the structure of car tires, but few can tell you how tires are made. The most common idea is that rubber is poured into a certain mold, from which the finished product is then pressed out.
In fact, this is not so, and the production of car tires is a complex, high-tech process that requires sophisticated specialized equipment, careful automated control and the participation of highly qualified specialists.
A little history
The first rubber tire was created back in 1846 by Robert William Thomson. At that time, no one was interested in his invention, and they returned to the idea of a pneumatic tire only 40 years later, when in 1887 the Scotsman John Dunlop came up with the idea of making hoops from a sprinkler hose, putting them on the wheels of his son’s bicycle and inflating them with air.
Three years later, Charles Kingston Welch proposed separating the tube and tire, inserting wire rings into the edges of the tire and placing them on the rim, which then received a recess towards the center. At the same time, rational methods for mounting and dismantling tires were proposed, which made it possible to use rubber tires on cars.
Tire production process
What are they made of?
The main material used in the production of tires is rubber, made from natural or artificial rubber. 
Depending on the proportions and what kind of rubber is added, the end result is summer or winter car tires.
- Thus, mainly artificial rubber is added to the rubber mixture for summer tires, so the rubber is more rigid, wear-resistant, it does not “float” at high temperatures and provides reliable grip on the road surface. To make winter tires, natural rubber is added, which makes the rubber softer and more elastic. Thanks to this, winter tires do not “tan” even in very severe frosts.
- In addition to rubber, many other components are added to the rubber mixture, such as plasticizers, fillers, carbon black, and vulcanizing additives.
A tire consists of several elements combined into one: carcass or cord, belt layers, tread, bead and side part.
How to make a frame
The cord of a future tire is made from metal, textile or polymer threads on a special machine - a “creel”. From many spools of wire, the threads converge in one place. In general terms, the design resembles a loom. Next, the woven cord enters the extruder, where it is rubberized.
The finished carcass is subsequently cut into strips of different widths to produce tires of different sizes. And it is wound into reels for storage and transportation. Since unvulcanized rubber is very sticky, spacers are inserted between the layers to prevent damage to the carcass.
How to make a protector
The next stage of production is the creation of the tread. A strip of rubberized cord is threaded into a machine, which turns it into a tread using extrusion. So that workers can visually quickly determine the size of the future tire, colored lines are drawn onto the tread with paint.
Side part
The tire bead consists of a bead ring and a layer of viscous airtight rubber. The production of tire beads begins with rubber-coated metal wire, after which it is twisted to the required radius of the wheel rim and cut into circles. After this, assembly is carried out on the machine. You can watch this process in more detail in the video.
Assembly
The first one hangs the bead rings, and the second one inserts the spools with components. After this, the machine does everything automatically: it connects the parts together and inflates the workpiece with air under the tread with breaker. The almost finished tire is weighed and inspected for defects. This process can also be watched on video.
Curing
The last stage of production is vulcanization. The tire is treated with hot steam under a pressure of 15 bar and at a temperature of about 200 degrees Celsius. As a result, rubber, soot and various additives are sintered, and a tread pattern and inscriptions are applied to the surface of the tire using molds. Finished tires are checked to ensure they meet all required specifications.
Rubber is a widely known material that is used in almost all areas of human life. Medicine, agriculture, and industry cannot do without this polymer. Rubber is also used in many manufacturing processes. What this material is made of and what its features are is described in the article.
What is rubber
Rubber is a highly elastic polymer. Its structure is represented by chaotically arranged carbon chains held together by sulfur atoms.
In their normal state, carbon chains have a twisted appearance. If the rubber is stretched, the carbon chains will unwind. The ability to stretch and quickly return to its previous shape has made material such as rubber indispensable in many areas.
What is it made of? Typically, rubber is made by mixing rubber with a vulcanizing agent. After heating to the desired temperature, the mixture thickens.
The difference between rubber and rubber
Rubber and rubber are high-molecular polymers obtained naturally or synthetically. These materials differ in physical and chemical properties and production methods. Natural rubber is a substance made from the sap of tropical trees - latex. It flows out of the bark when it is damaged. Synthetic rubber is obtained by polymerization of styrene, neoprene, butadiene, isobutylene, chloroprene, nitrile. When synthetic rubber is vulcanized, rubber is formed.
What are the different types of rubbers made from? For certain types of synthetic materials, organic substances are used to obtain a material identical to natural rubber.
Rubber properties
Rubber is a universal material that has the following properties:
- High elasticity - the ability to undergo large reverse deformations over a wide temperature range.
- Elasticity and stability of shapes at small deformations.
- Amorphous - easily deformed with slight pressure.
- Relative softness.
- Poorly absorbs water.
- Strength and wear resistance.
- Depending on the type of rubber, rubber can be characterized by water, oil, gasoline, heat resistance and resistance to chemicals, ionizing and light radiation.
Over time, rubber loses its properties and loses its shape, which is manifested by destruction and a decrease in strength. The service life of rubber products depends on the conditions of use and can range from several days to several years. Even with long-term storage, rubber ages and becomes unusable.
Rubber production
Rubber is produced by vulcanization of rubber with the addition of mixtures. Typically 20-60% of the processed mass is rubber. Other components of the rubber mixture are fillers, vulcanizing agents, accelerators, plasticizers, antioxidants. Dyes, fragrances, modifiers, fire retardants and other components can also be added to the composition of the mass. The set of components is determined by the required properties, operating conditions, technology for using the finished rubber product and economic calculations. In this way, high-quality rubber is created.
What are semi-finished rubber products made from? For this purpose, production uses the technology of mixing rubber with other components in special mixers or rollers intended for the production of semi-finished products, followed by cutting and cutting. The production cycle uses presses, autoclaves, drum and tunnel vulcanizers. The rubber mixture is given high plasticity, thanks to which the future product takes on the required shape.
Rubber products
Today, rubber is used in sports, medicine, construction, agriculture, and manufacturing. The total number of products made from rubber exceeds more than 60 thousand varieties. The most popular of them are seals, shock absorbers, tubes, seals, sealants, rubberized coatings, and facing materials.
Rubber products are widely used in production processes. This material is also indispensable in the production of gloves, shoes, belts, waterproof fabric, and transport belts.
Most of the rubber produced is used to make tires.
Rubber in tire production
Rubber is the main material in the production of car tires. This process begins with the preparation of a rubber mixture of natural and synthetic rubber. Then silica, soot and other chemical components are added to the rubber mass. After thorough mixing, the mixture is sent to the oven. The output is rubber bands of a certain length.
At the next stage, the cord is rubberized. Textile and metal cords are filled with hot rubber mass. This method produces the inner, textile and belt layers of the tire.
What is rubber for tires made from? All car tire manufacturers use different rubber formulations and technologies. To give the finished product strength and reliability, various plasticizers and reinforcing fillers can be added.
Natural rubber is used to produce tires. Its addition to the rubber mixture reduces the heating of the tire. The majority of the rubber mixture is synthetic rubber. This component gives tires elasticity and the ability to withstand heavy loads.
