Air springs have extremely high requirements for airtightness, fatigue resistance, and durability. Any mishap in the mixing, calendering, cutting, molding, and vulcanization processes directly threatens the comfort and safety of the entire vehicle. This one-page summary of six typical defects strikes at the heart of the matter.

1. Missing glue

Root cause: Insufficient filling of rubber compound + air entrapment.

Rapid repair: mold temperature at 90-110 ℃, frequent ventilation of exhaust holes, pressure maintained at 8-12 MPa, and use up the rubber sheet within 72 hours.

2. Bubbles

Root cause: Excessive air residue or glue reversion.

Rapid repair: The calender roll produces a dense sheet at 60-70℃. Before lamination, the rollers are used for compaction and needle punching. The reversion is ≤10%, the resting time is ≥8 hours, and the vulcanization pressure is ≥10 MPa.

3. Heavy skin/cracks

Root cause: Dirty interface or excessive thickness of release agent.

Quick repair: dustproof film, thin spray of atomized release agent at a ratio of 1:4, to ensure that the semi-finished product does not expire.

4. Impurities

Root cause: contamination from raw materials, on-site conditions, and operational procedures.

Quick repair: First, sift the carbon black and sulfur. After filtering the rubber compound, add sulfur. Implement 5S management to ensure that the rubber sheets and cord fabrics do not fall to the ground.

5. Capsule pleating

Root cause: Aging of the capsule or mismatch in size.

Rapid repair: design verification of thickness and mold cavity, record replacement times, and flexible mold positioning.

6. Inflation size out of tolerance

Root cause: Deviation in the cutting angle of the curtain fabric.

Quick repair: Use a dedicated cutting knife with a degree of ≥45°, measure the angle of each sheet, and simultaneously pull out the cloth pad to prevent deformation.

Four-word formula: cleanliness, reality, stability, and numbers

With clean raw materials, solid film quality, stable parameters, and accurate data tracking, the defect rate is significantly reduced, and consistency is doubled.

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