In-situ Cord Rubberization Using Organic Polysulphide
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Solution Overview
Problem
The existing rubber composition application in tire manufacturing often results in radial overflow due to imprecise control, leading to continuous fouling of equipment and disruptive cleaning stops in industrial processes.
Innovation Solution
Incorporating organic polysulphides, such as alkyl phenol disulphides, into the rubber composition to partially vulcanize the rubber at low temperatures, reducing fluidity and viscosity, thereby preventing radial overflow during the sheathing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the quantity of rubber composition is increased to ensure complete filling of capillaries and interstices, then the filling completeness is improved, but radial overflow occurs and equipment fouling increases
Solution Approach 1:
The patent changes the chemical composition parameters of the rubber composition by adding organic polysulfide (0.1-5 phr) and sulfur (0.5-5 phr), which fundamentally alters the rheological properties of the composition. This enables the composition to achieve complete filling without overflow by controlling its curing behavior rather than just adjusting physical parameters like viscosity or quantity.
Solution Approach 2:
The patent applies preliminary vulcanization action by incorporating sulfur and organic polysulfide into the rubber composition before extrusion. This preliminary chemical action initiates crosslinking during extrusion, causing the rubber to set quickly and prevent radial overflow while still filling all capillaries and interstices completely.
2Manufacturing precision
If the rubber composition is made more fluid to facilitate filling of capillaries and interstices, then the filling capability is improved, but radial overflow and equipment fouling worsen
Solution Approach 1:
The patent changes the chemical composition by adding organic polysulfide and sulfur, which fundamentally alters the rheological behavior of the rubber composition. This chemical modification enables the composition to maintain appropriate fluidity for filling while preventing overflow through in-situ crosslinking, rather than relying solely on physical viscosity adjustments.
Solution Approach 2:
The patent replaces mechanical control of fluidity (viscosity adjustment) with chemical control (vulcanization system). Instead of mechanically controlling the composition's flow properties through viscosity modifiers, the patent uses chemical crosslinking to control the filling process, substituting a chemical mechanism for a mechanical one.
3Object-generated harmful factors
If the quantity of rubber composition is precisely controlled to prevent overflow, then equipment fouling is reduced, but complete filling of all capillaries and interstices becomes difficult
Solution Approach 1:
The patent changes the chemical parameters by incorporating a vulcanization system (sulfur and organic polysulfide), which fundamentally alters how the rubber composition behaves during extrusion. This enables complete filling with controlled quantity by initiating crosslinking that prevents overflow while ensuring all capillaries and interstices are filled, eliminating the need for imprecise quantity control.
Solution Approach 2:
The patent applies preliminary chemical action through the vulcanization system, which begins crosslinking during extrusion. This preliminary chemical setting action allows the rubber to fill all capillaries and interstices completely while preventing overflow, achieving both complete filling and minimal fouling without requiring imprecise quantity control.
4Reliability
If regular cleaning stops are implemented to remove rubber fouling, then equipment performance is maintained, but production continuity and efficiency are reduced
Solution Approach 1:
The patent converts the harmful effect of rubber composition into a beneficial one by adding a vulcanization system that causes rapid in-situ crosslinking. This transforms the potentially fouling rubber composition into a material that sets quickly and cleanly, eliminating overflow and fouling problems, thereby converting a harmful substance into a beneficial self-cleaning solution that maintains equipment performance without production stops.
Solution Approach 2:
The patent enables the rubber composition to serve itself by incorporating organic polysulfide and sulfur, which automatically initiate crosslinking during extrusion. This self-curing mechanism prevents overflow and fouling without requiring external intervention or cleaning operations, allowing the system to maintain its own performance and eliminate the need for production-stopping cleaning cycles.
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 use of organic polysulphides effectively reduces the risk of radial overflow, ensuring continuous operation by maintaining the rubber composition within the cable, thus avoiding equipment fouling and enhancing manufacturing efficiency.
Implementation Method 1
The organic polysulphide allows partial vulcanization of the rubber at low temperature, for example prior to assembly and during assembly of the rubberized cable in situ. Thus, this organic polysulphide makes it possible to reduce the fluidity of the composition and therefore to increase its viscosity.
Data Source
Figure 1~3
Figure 4~6
AI summary
The metal cord (30) is rubberized in situ with a rubber composition (32). The rubber composition (32) contains an organic polysulphide.