09,11,2026 7 views
In industries such as bridge infrastructure, water conservancy engineering, rail transit, and mining machinery,rubberLining plates, shock absorbers, cushion blocks, and track shock absorbers are all core components whose performance directly determines the service life of equipment and infrastructure, and also affects operation and maintenance costs.
With the development of various heavy engineering equipment and infrastructure towards large-scale, heavy-duty, and long-life directions, the size of products and the amount of rubber used continue to increase. Traditional segmented injection molding and molding splicing processes have bottlenecks such as insufficient joint strength, uneven rubber filling, and poor vulcanization consistency, which have become key common factors restricting the performance upgrade of large rubber components.
1、 Industry difficulties
Three major bottlenecks that cannot be bypassed in the molding of large rubber parts
At the end of the day, the difficulty in forming oversized rubber parts is essentially a contradiction between the large size, thick walled structure, and the thermal sensitivity and rheological properties of rubber materials. At present, the equipment and technology in the industry are generally stuck in three issues:
1 |Large volume thick walled products: joint and filling defects with staged injection molding
Super largerubber productsThe amount of adhesive used in a single injection can often reach hundreds of kilograms, and the wall thickness can easily exceed 100mm. Traditional small capacity injection equipment cannot achieve one-time molding, and can only inject adhesive in batches. The adhesive has multiple flow frontiers in the mold cavity, and weak joints are easily formed at the joint due to adhesive burning and poor interface fusion, directly reducing the impact and tear resistance of the product by more than 30%.
In addition, uneven distribution of shear heat during thick walled mold filling and insufficient injection pressure can lead to loose pores inside, greatly reducing the wear life of the product.
2 |Multi category rubber materials: difficult to control the uniformity of plasticization and vulcanization
Rubber products used in heavy-duty engineering cover multiple systems such as natural rubber, nitrile rubber, chloroprene rubber, etc. The viscosity, thermal sensitivity, and vulcanization characteristics of different rubber materials vary greatly. If the adaptability of the screw structure of the equipment is not sufficient, it is easy to cause uneven plasticization, local over sulfurization, and fluctuations in the physical properties of the finished product can exceed 10%.
In addition, large sizemoldThe temperature field itself is difficult to control. The temperature difference between the center and edge of traditional integral heating templates can easily exceed 10 ℃. The degree of sulfurization of the same product varies at different positions, either under sulfuration or over sulfuration. Not only is the dimensional stability poor, but the aging life will also be greatly shortened when placed in complex outdoor working conditions.
3 |Continuous heavy load production: insufficient reliability, high maintenance volume, and long time consumption
Rubber parts for heavy-duty engineering usually have long production cycles, and equipment often needs to operate continuously for long periods of time. Under heavy load conditions such as high-pressure injection and large tonnage mold closing, the sealing failure of the injection unit, wear of the seal of the mold closing cylinder, and fatigue of the hydraulic system are common pain points in the industry. Once the equipment is shut down for maintenance, the entire production line will be affected.
2、 Technical breakthroughs
Core breakthrough solution for super large injection molding
In response to the common problems in the above industries, Dekemo has made technological breakthroughs in three directions: injection system, plasticizing temperature control, and structural reliability, forming a complete set of super large rubber injection molding solutions.
1 |Large volume high-pressure injection system: one-time molding of thick walled products
The most fundamental way to solve the problem of joint injection is to fill the glue all at once.
The DeKomo DKM-RV1600 rubber machine has achieved a single cylinder injection capacity of 140000 milliliters and an injection pressure of up to 200 MPa. The DKM-RV3200 rubber machine and DKM-RV10000 rubber machine have multi cylinder injection volumes of up to 220000 milliliters and 560000 milliliters, respectively. The mainstream large-scale rubber components in mining, bridge, water conservancy, high-speed rail and other fields can basically be molded in one go, eliminating the hidden danger of joints from the root.
(DKM-RV1600 Rubber Injection Molding Machine)
At the same time, in response to the rheological properties of different rubber materials in heavy-duty engineering, we optimized the injection channel and designed a gradient channel to balance the shear rate in each region, reduce uneven heat generation during the filling process, and make the internal structure of thick walled products more uniform and dense. Compared with segmented molding, the wear resistance and impact resistance of the product can be improved by more than 50%.
2 |Specialized plasticizing screw+zone temperature control: ensuring consistent vulcanization
In order to adapt to different types of engineering rubber materials, we have equipped special plasticizing screws for the extra large models, optimized the structure of the screw edges and barrier mixing section according to rheology, and uniformly plasticized rubber materials of different hardness, with a plasticizing uniformity of over 95%.
In terms of temperature control, a template partition independent heating scheme is adopted, dividing large-sized templates into multiple independent temperature control zones, each with precise temperature control, to ensure synchronous vulcanization of rubber materials in various parts of the mold cavity, solving the problems of large mold temperature difference and uneven vulcanization.
3 |Heavy duty structure+servo hydraulic: supports long-term stable production
For the production demand of continuous overload, we configure everything from structural design to core components according to the overload level:
Injection sealing structure:Adopting patented multi-stage sealing and pressure adaptive design, the sealing is reliable under high pressure conditions, and the accuracy deviation of injection volume during long-term operation can be controlled within 0.3%, which not only avoids glue leakage and waste of raw materials, but also ensures stable precision of the finished product;
Optimization of mold clamping system:The clamping oil cylinder adopts a dual sealing design, and the plunger is made of alloy cast iron plated with hard chromium technology, which greatly reduces the sealing wear during reciprocating motion and eliminates oil leakage problems under heavy load conditions;
High strength hydraulic system:Equipped with a high-pressure plunger pump and high-precision hydraulic valve group, the power output is dynamically adjusted. Compared with traditional quantitative pump hydraulic systems, it can save more than 25% energy.
(DKM-RV10000 Rubber Injection Molding Machine)
3、 Application value
The dual benefits of quality and efficiency brought by technological upgrades
The practical application of Dekemote's large-scale rubber injection molding technology has solved the long-standing quality and efficiency problems in the industry from the perspective of process, bringing multidimensional value to various large-scale rubber component manufacturing enterprises
1 |Quality is more stable, and the wear-resistant life of products is extended by 20%
The one-time molding completely eliminates joint defects, significantly improves the compactness and vulcanization uniformity of the rubber material, and extends the wear resistance life of the product by more than 50%. The frequency of maintenance and replacement for end customers has decreased, and the competitive advantage of products in high-end projects will become more apparent.
2 |Efficiency improvement, overall batch production efficiency increased by 30%
Single mode production cycle can be shortened by more than 40%, and the splicing process of segmented glue injection is eliminated, resulting in an overall increase of more than 30% in batch production efficiency. With the increase in production capacity, the delivery cycle is more guaranteed when facing large orders.
3 |Cost optimization can reduce comprehensive production costs by 15%
High precision molding reduces burrs and waste, and coupled with the reduced operation and maintenance costs brought about by high equipment reliability, the overall production cost can be reduced by about 15%.
4、 Industry Outlook
Continuous innovation to support the high-quality development of heavy industry equipment
The breakthrough of Dekemote's large-scale rubber injection molding technology essentially breaks the dependence of large-scale rubber products on segmented molding processes in the past, and also enables domestic heavy-duty engineering rubber molding equipment to truly achieve independent controllability.
As a national level specialized and innovative key "little giant" enterprise, Dekemo's RV series super large rubber injection molding machine, developed through multi-dimensional technological iteration, can stably adapt to the efficient production of large rubber components in various fields such as bridge infrastructure, water conservancy engineering, rail transit, mining machinery, etc.
In the future, Dekemo will continue to deepen its cultivation and promote the development of super large rubber injection equipment towards higher precision, lower energy consumption, and more intelligence, helping China's heavy engineering equipment industry chain achieve true cost reduction, efficiency improvement, and high-quality development.
