Activated Micronized Rubber Compound for Tyre Reuse
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a pressing global issue of managing end-of-life tyres in an environmentally friendly manner and maximizing their reuse, as current technologies lack effective methods to reintroduce micronized rubber powders into new tyres, thereby underutilizing their potential for CO2 reduction and circular economy principles.
Innovation Solution
A method involving the chemical activation of micronized rubber powders (MRP) using a combination of silica, silane, and functionalization components like diphenyl guanidine to enhance their performance and compatibility within rubber compounds, allowing high concentrations of activated/functionalized micronized rubber powder (FMRP) to be incorporated into natural rubber, and converting them into solid strips or slabs for efficient use in tyres.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polybutadiene rubber compound is used to provide high rolling fatigue resistance, then rolling fatigue resistance is improved, but the compound becomes unsuitable for bias-ply tyre applications requiring specific flexibility and tear resistance
Solution Approach 1:
The patent creates a composite rubber compound by blending polybutadiene rubber (providing rolling fatigue resistance) with at least one other elastomer such as natural rubber, SBR, or butyl rubber (providing flexibility and tear resistance). This composite approach allows the final compound to exhibit both high rolling fatigue resistance and the flexibility required for bias-ply tyre applications, resolving the contradiction between these two properties.
2Ease of manufacture
If conventional rubber compounds are used, then manufacturing is simple, but consistent quality control and precise property adjustment are difficult
Solution Approach 1:
The patent establishes specific parameter ranges for the rubber compound composition (e.g., polybutadiene rubber content at 20-80 parts by weight per 100 parts of total rubber, specific silica content ranges, carbon black proportions) to achieve desired properties. By controlling these compositional parameters within defined ranges, the patent enables precise adjustment of compound properties such as rolling fatigue resistance, flexibility, and tear resistance, thereby improving manufacturing precision while maintaining relative simplicity in the manufacturing process.
3Reliability
If polybutadiene rubber content is increased to improve rolling fatigue resistance, then rolling fatigue resistance improves, but the compound becomes too hard and loses the flexibility needed for modern tyre designs
Solution Approach 1:
The patent applies local quality by using different elastomers with complementary properties in specific proportions within the compound. Polybutadiene rubber (50-90 Shore A hardness) is combined with softer elastomers like natural rubber (40-60 Shore A) or SBR to create regions of varying local flexibility. This allows the compound to maintain high rolling fatigue resistance from the polybutadiene while incorporating sufficient flexibility from the other elastomers, resolving the contradiction between hardness and flexibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method significantly improves mechanical and dynamic performance of rubber compounds, enabling large-scale reuse of FMRP in tyres, enhancing properties such as tensile strength and tear resistance, and facilitating efficient transportation and reducing material costs.
Implementation Method 1
it has gradually come to light by experimentation that high silica contents in compounds based on polybutadiene rubber can improve the rolling fatigue resistance of tyres
Implementation Method 2
compounds based on polybutadiene rubber are intrinsically vulnerable to oxidation and ozone attack
Implementation Method 3
compounds based on polybutadiene rubber are intrinsically vulnerable to oxidation and ozone attack
Data Source
AI summary
The present invention relates to a rubber compound mixture comprising a matrix of a non-vulcanized rubber including micronized rubber powders and one or more auxiliaries. The present invention also relates a method for preparing such a rubber compound mixture, as well as to a rubber article. An object of the present invention is to develop a method for chemically activating/functionalizing micronized rubber powders.