Brass-Reinforced Elastomer Composite With Low-Cobalt Cord Adhesion
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Solution Overview
Problem
Existing reinforced rubber compositions for tires face challenges in achieving good adhesion to metallic reinforcing cords while reducing the use of sulfur, zinc oxide, and cobalt salts, and minimizing environmental impact from adhesion promoters like resorcinol.
Innovation Solution
A composite comprising a reinforcing element with a copper-zinc alloy surface embedded in an elastomeric composition using a phenol/aldehyde resin with specific aromatic polyphenol and dialdehyde compounds, along with a sulfur crosslinking system, to promote adhesion without high sulfur or cobalt content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cobalt salts and high sulfur content are used in the vulcanization system, then adhesion to metallic cords is improved, but environmental impact and harmful substance content increase
Solution Approach 1:
The patent changes the chemical composition parameters of the vulcanization system by replacing cobalt salts with zinc oxide/stearic acid in specific ratios (ZnO/Stearic acid = 4:1 to 16:1 by weight) and optimizing sulfur content (1-5 phr), thereby reducing harmful substances while maintaining adhesion through alternative sulfidation mechanisms
Solution Approach 2:
The patent introduces phenol/aldehyde resin as an intermediary adhesion promoter that facilitates bonding between the rubber matrix and metallic cords without requiring cobalt salts, creating a bridge for adhesion through its chemical structure and reactivity with both rubber and metal surfaces
2Object-affected harmful factors
If phenol/aldehyde resin content is reduced, then environmental impact is minimized, but adhesion promotion capability may be compromised
Solution Approach 1:
The patent optimizes the phenol/aldehyde resin content to a specific range (1-10 phr, preferably 2-6 phr) and modifies the resin's chemical structure (using specific phenolic compounds and aldehyde ratios) to maximize adhesion efficiency at lower concentrations, thereby reducing environmental impact while maintaining effectiveness
Solution Approach 2:
The patent creates a composite adhesion system combining phenol/aldehyde resin with zinc oxide/stearic acid and sulfur, where the synergistic interaction between these components enhances adhesion promotion capability at reduced resin levels, allowing lower environmental footprint while maintaining performance
3Object-affected harmful factors
If sulfur content is reduced, then environmental impact and harmful factors are decreased, but adhesion through sulfidation is compromised
Solution Approach 1:
The patent optimizes sulfur content to a low range (1-5 phr) while compensating for reduced sulfidation capacity by increasing zinc oxide/stearic acid content and optimizing their ratio, creating an alternative adhesion mechanism that doesn't rely heavily on traditional high-sulfur sulfidation
Solution Approach 2:
The patent uses phenol/aldehyde resin as an intermediary that provides adhesion promotion functionality independent of high sulfur levels, allowing the system to achieve good adhesion with reduced sulfur content by transitioning to a different chemical bonding mechanism
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 composite achieves durable adhesion to metallic reinforcing elements with reduced sulfur and cobalt use, maintaining performance qualities like low rolling resistance and crack resistance.
Implementation Method 1
an elastomeric composition based on at least a diene elastomer, a reinforcing filler, a sulfur crosslinking system
Implementation Method 2
a composite comprising at least one reinforcing element exhibiting a surface comprising an alloy of copper and zinc, said reinforcing element being embedded in an elastomeric composition
Implementation Method 3
the adhesion between the calendering composition and the metallic cord is created via the phenomenon of sulfidation of the brass-coated surface of the cord
Data Source
AI summary
A composite comprises at least one reinforcing element exhibiting a surface comprising an alloy of copper and zinc, the reinforcing element being embedded in an elastomeric composition based on at least a diene elastomer, a reinforcing filler, a sulfur crosslinking system and a phenol/aldehyde resin based on at least one aromatic polyphenol and on at least one dialdehyde compound comprising two aldehyde functions, in which the content of phenol/aldehyde resin is less than 10 phr.