Extrusion‐Molded Radially Oriented Basalt Fiber‐Reinforced Rubber Composites for High‐Performance Conveyor Belts

ABSTRACT Conveyor belts in heavy‐duty industries demand cover materials with excellent wear resistance and high tear strength, typically assessed by four core indicators: wear resistance, tear resistance, tensile properties, and fiber‐matrix interfacial adhesion. While short‐fiber reinforcement improves rubber composites, achieving controlled fiber alignment for anisotropic performance remains challenging. This study reports the extrusion molding of radially oriented basalt fiber (BF)‐reinforced rubber composites using a custom‐designed wide‐slot orientation die. The effects of BF length (1–7 mm), dosage (3–10 phr), screw speed (10–25 r/min), and extrusion temperature (70°C–85°C) were systematically investigated. Results demonstrate that radial orientation significantly enhances interfacial stress transfer and fiber‐matrix compatibility. The optimal composite, produced with 3‐mm BF at 5 parts per hundred rubber (phr), a screw speed of 15 r/min, and an extrusion temperature of 80°C, exhibits an 18.4% increase in tear strength and a 24.5% reduction in Deutsches Institut für Normung (DIN) abrasion loss compared to unoriented counterparts. These improvements enable the composite to meet high‐performance standards for heavy‐duty conveyor belts. This work establishes a feasible processing route and parameter window for manufacturing high‐performance, radially reinforced conveyor belt covers, offering practical guidance for industrial extrusion processes.