How are Rubber Rail Pads manufactured?
Rubber rail pads are manufactured by mixing a rubber compound, shaping it through molding (such as compression or injection molding), and then curing it under pressure to solidify. The process includes preparing the rubber mixture, adding curatives like vulcanizing agents, and then trimming the final product to meet the specific design, which may include grooves for optimal load deflection.
1. Rubber compound preparation
- Raw materials are mixed together to create a specific rubber compound.
- This mixing can be done in a single or double stage using internal mixers.
- The masterbatch, a pre-mixed compound, is then finalized on a two-roll mill by adding curatives and other agents.
- Recycled materials like crumb rubber from tires can be added to modify the stiffness.
2. Shaping and curing
- The prepared rubber compound is placed into a mold.
- Compression molding or injection molding is used to shape the pad.
- Pressure and heat are applied to cure the rubber, which causes it to vulcanize and harden.
- The mold's design is crucial, with features like grooves often incorporated to achieve the desired load-deflection characteristics.
3. Finishing
- After curing, the finished product is removed from the mold.
- Any excess rubber from the molding process is trimmed off.
- The final product is then inspected for quality and prepared for use.
| Rubber Rail Pad | ||
| Technical Parameter | Unit | Value |
| Stiffness | KN | 90-130 |
| Hardness Shore A | ℃ | 72-80 degree |
| Electronic Resistance | Ω | ≥ 106 |
| Tensile Strength before Aging | Mpa | ≥12.5 |
| Elongation before Aging | % | ≥250 |
Rail pad functions
A rail rubber pad is essential in reducing shock and vibration in a rail system. The pad laid under the rail to ensure:
- Load distribution over a larger surface
- Elimination of load concentration and the resultant fatigue stresses
- Centering of loads on the supporting element
- Absorption of uneven contact surfaces between rail and support
- Reduction of noise and vibration
- Sealing between the bottom of the rail and the top of the support
- Reduction of wear of the rail and its support
As a professional rail fastener manufacturer, GNEE RAIL can produce various types of rubber rail pads with different materials, such as natural rubber, EVA, HDPE and so on. Our EVA/HDPE/rubber rail pads are with high elasticity, applying to types for rails such as rail UIC54, UIC60, BS80lbs,BS100lbs, and sizes as ordered. The pads can be customized with or without grooves, in various possible designs, depending on customers' requirements.
