Conveyor Belt Rubber Composition Low-Temperature Power Consumption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conveyor belts for cold regions face challenges in achieving sufficient reductions in power consumption at low temperatures due to high tan δ values after vulcanization, which is not adequately addressed by existing rubber compositions.
Innovation Solution
A rubber composition for conveyor belts comprising butadiene rubber, styrene butadiene rubber, carbon black, sulfur, and a vulcanization accelerator, with specific mass ratios and properties such as glass transition temperature and nitrogen adsorption specific surface area, to achieve reduced power consumption and improved stress dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional rubber composition is used, then the conveyor belt structure is simple, but power consumption reduction at low temperatures is insufficient due to high tan δ values
Solution Approach 1:
The patent applies parameter changes by precisely controlling the glass transition temperature of butadiene rubber at -65°C or lower, the nitrogen adsorption specific surface area of carbon black at 90 m²/g or less, and the sulfur-to-vulcanization accelerator mass ratio at 1.5 or less. These parameter optimizations reduce tan δ at low temperatures, thereby reducing power consumption while maintaining composition simplicity
Solution Approach 2:
The patent uses composite materials by combining butadiene rubber with specific carbon black and controlled sulfur-vulcanization accelerator systems. This composite approach achieves uniform crosslinked structures that reduce energy loss at low temperatures without significantly increasing formulation complexity
2Use of energy by moving object
If rubber composition is optimized for low temperature performance, then power consumption reduces, but manufacturing precision requirements increase
Solution Approach 1:
The patent establishes clear parameter ranges that balance performance and manufacturability: glass transition temperature ≤ -65°C, nitrogen adsorption specific surface area ≤ 90 m²/g, and sulfur-to-vulcanization accelerator mass ratio ≤ 1.5. These defined parameters provide manufacturing guidance while achieving the required low-temperature energy efficiency
Solution Approach 2:
The patent applies local quality by focusing precision requirements on specific critical parameters (glass transition temperature, surface area, mass ratio) rather than all composition elements. This selective precision approach ensures low-temperature performance while simplifying overall manufacturing control
3Strength
If sulfur content is increased to improve crosslinking, then structural strength increases, but heat build-up increases causing higher power consumption
Solution Approach 1:
The patent resolves this contradiction by optimizing the sulfur-to-vulcanization accelerator mass ratio to 1.5 or less. This parameter control enables sufficient crosslinking for structural strength while preventing excessive heat build-up, thereby reducing power consumption at low temperatures
Solution Approach 2:
The patent converts the potential harm of sulfur-induced heat build-up into a benefit by carefully controlling the sulfur-to-vulcanization accelerator ratio. This transforms what could be a harmful thermal effect into a controlled crosslinking process that achieves uniform structure without excessive heat generation
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 composition results in excellent reductions in power consumption at low temperatures by suppressing heat build-up and ensuring a uniform crosslinked structure, enhancing energy efficiency and conveyor belt performance in cold environments.
Implementation Method 1
a glass transition temperature of the butadiene rubber and the styrene butadiene rubber being −65° C. or lower
Implementation Method 2
a nitrogen adsorption specific surface area of the carbon black being 90 m2/g or less
Implementation Method 3
a mass ratio (sulfur/vulcanization accelerator) of a content of the sulfur to a content of the vulcanization accelerator being 1.5 or less
Data Source
AI summary
The present technology provides a rubber composition for a conveyor belt. The rubber composition comprises: a rubber component containing butadiene rubber and/or styrene butadiene rubber, carbon black, sulfur, and a vulcanization accelerator; the glass transition temperature of the butadiene rubber and the styrene butadiene rubber being −65° C. or lower; the nitrogen adsorption specific surface area of the carbon black being 90 m2/g or less; the total content of the butadiene rubber and the styrene butadiene rubber being 50% by mass or greater relative to the content of the rubber component; the content of the carbon black being from 30 to 50 parts by mass per 100 parts by mass of the rubber component; and the mass ratio (sulfur/vulcanization accelerator) of the content of the sulfur to the content of the vulcanization accelerator being 1.5 or less.