Crosslinking Agent Masterbatch with Ultrasound Markers
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Solution Overview
Problem
Existing crosslinking agent masterbatches in rubber mixtures cannot be effectively monitored for dispersion quality in real-time during the production process, limiting the ability to ensure consistent quality and efficiency in rubber mixture production.
Innovation Solution
Incorporating pulverulent marker substances with high densities, such as tungsten carbides and barium sulfate, into crosslinking agent masterbatches allows for online detection of dispersion quality using ultrasound and other methods, ensuring homogeneous mixing and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate production of crosslinking agent masterbatches is used to continuously introduce into parent mixtures, then practical production and performance are improved, but online detection of dispersion quality cannot be achieved
Solution Approach 1:
The patent introduces marker substances as intermediary particles with distinct acoustic properties that mediate between the crosslinking agent masterbatch and the ultrasound detection system. These marker particles scatter ultrasound waves in a detectable manner, enabling indirect measurement of dispersion quality without interfering with the crosslinking process or production continuity.
Solution Approach 2:
The patent replaces offline mechanical/visual inspection methods with online ultrasound acoustic detection. By substituting physical sampling and laboratory analysis with continuous acoustic field measurement, the system achieves real-time dispersion quality monitoring while maintaining continuous production operations.
2Device complexity
If traditional crosslinking agent masterbatches are used without marker substances, then production process is simpler, but quality control requires offline testing only
Solution Approach 1:
The patent incorporates marker substances into the crosslinking agent masterbatch formulation in advance, before the dispersion quality needs to be measured. This preliminary inclusion of detection markers enables immediate online monitoring upon introduction into the rubber compound, eliminating the time delay associated with offline sampling and laboratory analysis.
Solution Approach 2:
Marker substances serve as intermediary agents that bridge the gap between the crosslinking agent distribution and the ultrasound detection system. These particles provide acoustic contrast that allows indirect measurement of crosslinking agent dispersion quality without requiring direct measurement of the crosslinking agents themselves.
3Measurement precision
If marker substances are added to enable online detection, then dispersion quality monitoring is improved, but masterbatch composition becomes more complex
Solution Approach 1:
The patent applies local quality by concentrating marker substances specifically within the crosslinking agent masterbatch phase rather than distributing them throughout the entire rubber compound. This localized placement ensures that markers are co-introduced with crosslinking agents, providing accurate local dispersion measurements while minimizing overall formulation complexity.
Solution Approach 2:
The patent utilizes parameter changes by selecting marker substances with specific acoustic properties (density, compressibility) that differ from both the crosslinking agents and the rubber matrix. This acoustic parameter differentiation enables selective detection of marker particles via ultrasound, providing measurement capability without requiring complex formulation adjustments.
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
Enables real-time monitoring and control of crosslinking agent dispersion within rubber mixtures, enhancing production efficiency and consistency by facilitating continuous and inline quality assessment, reducing the risk of production failures.
Implementation Method 1
allows for online detection of dispersion quality using ultrasound
Data Source
AI summary
The invention relates to novel batches of cross-linking agents, containing marking substances, to novel cross-linkable rubber mixtures, to a method for the production thereof and to the use of same.