CONVEYOR

BELT SPLICE CURE CALCULATION

Determining the optimum cure time for your splice

Curing of rubber compounds generates crosslinks between the molecules. The
speed/time of crosslink generation is influenced by cure temperature level and
time. In this process the properties of the compound change from a soft uncured
material to a cured elastic material.

The cure temperature will greatly affect the speed at which crosslinks are formed.
Using a low cure temperature level takes a longer reaction time for a workable
amount of crosslink density to form in comparison to higher cure temperatures.

Example, ± 50°F (10°C) increments in cure temperature nearly doubles or
nearly halves the reaction time (ref. temp. = 300°F (149°C).

Using a laboratory instrument called a Rheometer we can test at which temperature
and dwell time the best level of cure (crosslink density) is achieved.

A typical cure temperature for many sulfur cured splice compounds is 300 F (149
C). There will be some slight or slow rate of curing (crosslinking) starting at ~240 F
(melt point of sulfur in the rubber compound), as the temperature moves up to the
optimum cure temperature of 300 F (149 C) a greater degree of crosslink density is
achieved.

There is an effect known as end cure crosslinking, even after water cooling the
vulcanizer at the end of the cure time cycle some degree of crosslinks are still
forming at a slight rate. All of these factors are taken into account for the final cure
time chart.

Rheometer curve properties.

MH = Maximum torque
ML = Minimum torque

Ts2 = Time to reach a 2 unit increase in torque above minimum torque value
(ML + 2 units raise) {AKA - induction time}.

Ts5 = Time to reach a 5 unit increase in torque above minimum torque value
(ML + 5 units raise) {AKA - scorch time}.

Tc90 = Time for the torque to increase from the beginning of the test to the value
equivalent to 0.9(MH − ML)+ML. {AKA – point in time at which 90% of cure has
taken place}.

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The following illustration is a typical Rheometer curve.

Typical Cure Curve

The lab Rheometer measures torque as a function of time, this is done with an
uncured rubber sample placed between the two heated dies. Inside these dies is a
rotor that oscillates ± 3 degrees at 1.7 Hz oscillation rate. This action exerts a shear
strain on the test piece and the torque (force) required to oscillate the disc depends
upon stiffness (shear modulus) of the rubber compound. The torque is measured as
the rubber sample heats up.

Cure time calculation is based on measuring the rise (Ts2) above the minimum
torque value to the time to reach 90% of maximum torque, (Tc90). In this vicinity
the rubber viscosity contributes mainly to the torque. As crosslinking increases, the
rubber becomes more elastic and eventually maximum torque is reached.

The amount of time needed for this shift from Ts2 to Tc90 is called the rate of cure.
The rate of cure is the time scale at which crosslinking and the development of the
stiffness (modulus) of the compound occur after the scorch point (minimum torque
value).

During the curing process crosslinks are introduced, which connect the long
polymer chains of the rubber together. As more crosslinks are introduced, the

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polymer chains become more firmly connected and the stiffness or modulus of the
compound increases.

Typical modern conveyor belting is synthetic rubber based and over curing causes
an effect known as Marching Modulus (over hardening). This can easily happen
during the last stage of the cure process.

A common mistake is not water-cooling the vulcanizer. After the power to the press
is removed the belt center heat is very slow to dissipate and curing is still happening
(Marching Modulus).

As a point of reference; with most natural rubber compounds, reversion occurs with
over cure and the modulus and tensile strength decrease.

The rate of cure is an important vulcanization parameter since all splice materials /
primers / cements must have the same or similar rate of cure to crosslink together
at maximum value (ie - adhesions).

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For the cure time calculation the following information is required:

1. Determine Ts2 and Tc90 of the rubber compounds (skim & cover compounds).
This is established with the Rheometer set at 300 degree F cure temperature for
sulfur cure rubber (320 degree F cure temperature for peroxide cure EPDM rubber).

2. Determine penetration time for the overall splice gauge (OAG) using the below
gradient chart. This chart was based on an 80 degree F belt and vulcanizer start
temperature. Colder temperatures at start will slow down the rate of heat
penetration time.


To read the Rheometer curve see the Ts2 point and the Tc90 point. Subtract the
time in minutes of the Ts2 from the Tc90 time to get the cure time for each .100 of
an inch (2.54 mm).

Then multiply this by the splice thickness and add the penetration time in minutes
to that time. Penetration is the extra time needed for the center of the splice to
reach cure temperature.

Calculating cure time at 90% optimum cure from this curve.

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Since mixing splice materials is a batch process there can be a range of Ts2 and Tc90
numbers that falls within the control gate +/- points. As an example out of 10
production batches mixed, the Tc90 times ranged from 11.02 to 10.68.

So we will use the Mean Statistics Ts2 and Tc90 numbers for our calculations.
For this example,

Steel Cord Splice Material Cover Stock Ts2 – 6.56 Tc90 – 10.82

Steel Cord Splice Material Cable Gum Ts2 – 7.05 Tc90 – 11.46


Cure time calculation:

Subtract Ts2 from Tc90 and use that number for the ST Cover compound x .100 of
thickness of splice + penetration time established from chart for splice thickness.

Do the same for the ST Cable Gum, subtract Ts2 from Tc90 and use that number x
.100 of thickness of splice + penetration time for the established from chart for
splice thickness.

Compare the time for each and use the longer time.


Example: ST-2000 (1/4” carcass gauge) 1/2 x 1/4 cover gauge = 1” (1.00) OAG


Tc90 – Ts2; ST COVER = 4.26 CABLE GUM = 4.41


OAG DIVIDED by .100; 4.26 x 10 = 42.60 4.41 X 10 = 44.10
PENETRATION TIME; OAG = 1.00 = 17.50 OAG = 1.00 = 17.50
---------- ----------
60.10 Min 61.60 Min


TOTAL CALCULATED HEAT HISTORY NEEDED FOR SPLICE CURE = 62 Min

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The final cure time has to take into account the rubber is still slightly curing during
cooling and after you remove the splice from the press. This is the reason the
Durometer readings will creep up 3 to 5 points after 24 hrs.

The final cure also must take into account the effect of Marching Modulus (over
hardening) as seen in the Rheometer definition drawing.

FYI - Belts and vulcanizers that are very cold at start will slow down the rate of heat
penetration time. As will older vulcanizers and some lower voltage single phase
machines and of course poorly designed low quality imported vulcanizers.

Water cooling vs air cooling will greatly effect the amount of Heat History the splice
rubber sees and thus the time needed for a optimum cure.

Many use the simple rule of thumb of 5-min of cure time for every 1/16” of over all
belt gauge. The below cure time chart shows the simple rule of thumb cure
calculation is not always the right answer.

Splice Material Rate of Cure with Penetration Time

VS
5-Min Per 1/16" Over All Gauge Cure Time
200.00

180.00

160.00

140.00

120.00
Time - Mins

100.00
Splice Material Cure Plus Penetration

80.00 5-min per 1/16" Gauge Cure Time

60.00

40.00

20.00

0.00
5/16”

7/16”

9/16"

1”
1 1/16”
1 1/8"
1 3/16”
1 1/4”
1 5/16”
1 3/8”
1 7/16”
1 1/2"

1 5/8”
1 11/16”
1 3/4”
1 13/16”
1 7/8”
1 15/16”
2"
1 9/16"
11/16”

13/16”

15/16”
1/4”

3/8”

5/8”

3/4”

7/8”
1/2"

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 OUTSIDE VS CENTER PENETRATION TIME EXAMPLE CHARTS @ 300 F (149 C)

5 Min - Heat Penetration Time Offset 17.5 Min - Heat Penetration Time Offset
1/2" Belt Gauge 1" Belt Gauge
350
350
Belt Top Surface (1/2")
Belt Top Surface (1")
300
300

250
250
Belt Center - Left & Right (1/4") Belt Center - Left & Right (.5")
Temperature F

200 Belt Top Surface (1/2")

Temperature F
200 Belt Top Surface (1")
Belt Center Left (1/4")
Belt Bottom Surface (0") Belt Center Left (.5")
Belt Center Right (1/4")
Belt Bottom Surface (0")
Belt Center Right (.5")
150 150
Belt Bottom Surface (0") Belt Bottom Surface (0")

100 100

50 50

Time in Min Time in Min

0 0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140

50 Min - Heat Penetration Time Offset 95 Min - Heat Penetration Time Offset
1.5" Belt Gauge 2" Belt Gauge
350 350

Belt Top Surface (1.5") Belt Top Surface (2")

300 300

Belt Center (.750")

250 250

Belt Mid Upper (1.25") Belt Center (1")

Belt Top Surface (1.5") Belt Top Surface (2")
Temperature F

Temperature F

200 200
Belt Mid Upper (1.25") Belt Upper Mid (1.5")
Belt Mid Lower (.375")
Belt Center (.750") Belt Upper Mid (1.5") Belt Center (1")

150 Belt Mid Lower (.375") 150 Belt Lower Mid (.5")
Belt Bottom Surface (0") Belt Bottom Surface (0") Belt Bottom Surface (0")
Belt Lower Mid (.5")
100 100

Belt Bottom Surface (0")

50 50

Time in Min Time in Min

0 0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140

In Summary; I would suggest you run your own heat penetration test. Start with a
1” (25.4 mm) OAG belt splice sample, 20” x 20” (500 mm x 500 mm), placing
thermocouple wires on the top belt surface, in the center of the belt and on the
bottom belt surface.

Make a time log of the thermocouple probe wires recording the temperature in five
min increments starting room temperature and stopping after the center probe is
fully at 300 F (149 C). Use the time difference between the belt surface and center
probes.

This will determine your own heat penetration time to apply to the cure time
calculation process for the optimum splice cure.

Michael Cremeens
VP Training & Technical Support
Shaw Almex Group
(678) 477-4846
mike.cremeens@almex.com
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