Distiller's Corn Oil Process Oil for Aging-Resistant Rubber Compounds
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Solution Overview
Problem
The rubber industry faces challenges with high energy consumption during production and susceptibility to tearing, abrasion, and crack growth in rubber compounds, while existing process oils, such as naphthenic and paraffinic oils, are costly and may degrade upon aging when vegetable oils are used.
Innovation Solution
The use of distiller's corn oil with increased free fatty acid content and reduced fatty acid alkyl ester content as a process oil in rubber compositions, which improves the performance of rubber compounds by enhancing tensile strength, elongation, and tear resistance, and reduces energy consumption during the vulcanization process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If vegetable oils are used as process oils in rubber compounds, then cost is reduced and accessibility is improved, but tensile strength and elongation worsen upon aging
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the process oil. Specifically, it uses vegetable oils with controlled levels of unsaturation (iodine value between 50-150) and specific fatty acid profiles to achieve a balance between cost-effectiveness and aging resistance. This resolves the contradiction by finding optimal parameter ranges that satisfy both economic and performance requirements.
2Strength
If high unsaturation vegetable oils like corn oil are used, then crosslink density increases, but double bonds become subject to degradation
Solution Approach 1:
The patent resolves this contradiction by precisely controlling the unsaturation parameter (iodine value) and fatty acid composition of the vegetable oil. By selecting oils with moderate unsaturation levels and specific fatty acid profiles, the patent achieves sufficient crosslink density while minimizing degradation of double bonds during aging.
3Reliability
If typical process oils (naphthenic and paraffinic) are used, then rubber specification criteria are met, but cost increases to around $0.70/lb
Solution Approach 1:
The patent applies this principle by replacing expensive petroleum-derived process oils with cheaper vegetable oil alternatives. Although vegetable oils have different chemical properties, the patent demonstrates that with proper selection and formulation, they can meet rubber specification criteria at lower cost, effectively substituting a cheaper material for a more expensive one.
4Strength
If vegetable oils with high unsaturation are used, then immediate rubber compound properties improve, but aged compound properties deteriorate
Solution Approach 1:
The patent resolves this time-dependent contradiction by optimizing the unsaturation parameter (iodine value) and fatty acid composition of the vegetable oil. By controlling these parameters within specific ranges, the patent achieves good immediate mechanical properties while maintaining acceptable aging resistance, effectively balancing short-term and long-term performance requirements.
Data Source
AI summary
Process oils comprising distiller's corn oil are incorporated into rubber compositions useful for manufacturing tires or various tire components including tire sub-treads.