Insulating rubber mat is an important safety protection product widely used in the power industry. Its core function is to prevent electric shock accidents. So, what material is insulating rubber mat made of? And how is it made? We will answer these questions one by one in the following.
I. Material Composition of Insulating Rubber Mats
1. Main Materials
-NR (Natural Rubber): It has good elasticity and physical mechanical properties, suitable for various environmental conditions for insulation needs.
-SBR (Styrene-Butadiene Rubber): It has good wear resistance and strong aging resistance, which can effectively extend the service life of the insulating mat.
2. Auxiliary Materials
In addition to the above main rubber varieties, some functional additives such as vulcanizing agents and accelerators are also added to improve the processing performance and final performance of the product. For example, by adjusting the sulfur content in the formula, the hardness and tensile strength of the rubber can be controlled; adding anti-aging agents can improve the material’s resistance to ozone and heat resistance, etc.
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II. Production Process of Insulating Rubber Mats
1. Mixing Stage
Mixing is one of the key steps in manufacturing high-quality insulating rubber mats. In this process, the appropriate proportion of raw materials is selected according to the specific application requirements of the product, and they are thoroughly mixed evenly through mixing equipment. This step directly affects the stability of the material in the subsequent processes and the overall quality of the finished product.
2. Calendering Stage
After thorough mixing, the rubber raw materials are sent to a three-roll or four-roll machine for pressing treatment. This operation aims to further remove any air bubbles inside the material and shape it into a semi-finished product of the required shape.
3. Vulcanization Treatment
Vulcanization is the process of fixing the un-crosslinked rubber molecular structure, usually accomplished with a professional vulcanizer. By precisely controlling factors such as temperature, pressure, and time, the rubber can reach its optimal state, thereby meeting the high standards of electrical insulation requirements.
4. Cutting and Quality Inspection
The final step is to cut and trim the vulcanized rubber sheet, removing excess parts and ensuring accurate dimensions. In addition, it needs to undergo strict quality inspection, including but not limited to thickness measurement, withstand voltage test, tensile strength determination, and other multiple index checks. Only when all parameters meet the relevant standards can it be recognized as a qualified product.
III. Working Principle of Insulating Rubber Mats
When a person stands on the ground covered with an insulating rubber mat and touches a live object, no circuit will be formed because the current cannot penetrate this high-resistance material and reach the ground. In this way, it effectively isolates the possible direct contact injury and provides a safe and reliable operating environment for the staff. Insulating rubber mats are mainly composed of natural rubber and other synthetic rubbers, and are made through a series of complex and meticulous processes. Correct selection of the appropriate specification and model is crucial for ensuring the safe operation of power facilities.
Jingdong Rubber Co., Ltd. is a professional rubber mat manufacturer, producing silicone rubber sheet, natural rubber sheet, fluorine rubber sheet, neoprene rubber sheet, insulating rubber sheet,EPDM rubber sheets, oil-resistant rubber sheets, anti-static rubber sheets, flame-retardant rubber sheets, conductive rubber sheets, anti-slip rubber sheets, and cowshed mats, etc. with 40 years of industry experience, are popular both at home and abroad. If you need any of our products,please send emails to sales@jingdongrubber.com.