Diatomite Reinforced Elastomer Viscosity Reduction
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Solution Overview
Problem
The rubber industry faces challenges in improving the processability of crosslinkable elastomeric compositions used in tire manufacturing, particularly with reinforcing fillers like carbon black and silica, which lead to increased rolling resistance, fuel consumption, and defects due to high temperatures and viscosity issues.
Innovation Solution
Incorporating diatomite particles with high BET surface area and average maximum dimension into crosslinkable elastomeric compositions to enhance processability and maintain or improve mechanical properties, reducing viscosity and thermoplastic behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large amount of sulfur or carbon black is used to increase crosslinking density and improve mechanical properties, then static and dynamic moduli are increased, but reversion phenomena occur and rolling resistance increases
Solution Approach 1:
The patent changes the chemical composition parameters by introducing diatomite particles with specific surface area (10-50 m²/g) and particle size (0.5-5 μm) characteristics, replacing traditional sulfur/carbon black reinforcement mechanisms with a new reinforcement pathway that avoids reversion and excessive hysteresis
Solution Approach 2:
The patent creates a composite elastomeric composition incorporating diatomite particles as a novel reinforcing filler combined with elastomeric polymer, achieving mechanical property enhancement through composite structure rather than traditional sulfur crosslinking or carbon black reinforcement
2Strength
If a large amount of carbon black is used to increase crosslinking density, then static and dynamic moduli are increased, but viscosity of the elastomeric composition increases and processability deteriorates
Solution Approach 1:
The patent changes the particle size parameter of the reinforcing filler to sub-micron range (0.5-5 μm) with controlled surface area (10-50 m²/g), which provides sufficient reinforcement while maintaining lower viscosity and better processability compared to traditional carbon black formulations
3Ease of operation
If high temperatures are used to improve processability of crosslinkable elastomeric compositions, then flowability is improved, but productivity decreases and scorching defects increase
Solution Approach 1:
The patent changes the thermal parameters by utilizing diatomite particles that enable effective processing at lower temperatures (below 100°C during blending), avoiding scorching defects while maintaining good flowability and productivity through the unique thermal properties of the diatomite reinforcement
4Strength
If reinforcing fillers like silica are used to replace carbon black, then tear resistance is improved, but affinity with elastomeric polymers is poor and prolonged thermo mechanical blending is required
Solution Approach 1:
The patent changes the surface area parameter of the silica-based filler to a moderate range (10-50 m²/g), which provides adequate reinforcement and tear resistance while reducing the tendency to aggregate, thereby enabling effective blending in shorter times compared to high-surface-area silica formulations
Data Source
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AI summary
A tire comprising at least one structural element including a crosslinked elastomeric material obtained by crosslinking a crosslinkable elastomeric composition comprising: (a) 100 phr of at least one elastomeric polymer; (b) from about 1 phr to about 150 phr, preferably from about 5 phr to about 100 phr, of diatomite particles having a BET surface area, measured according to Standard ISO 5794-1 :2005, higher than or equal to about 10 m2/g, preferably higher than or equal to about 25 m2/g, more preferably higher than or equal to about 35 m2/g and an average maximum dimension higher than or equal to about 0.3 μm, preferably lower than or equal to about 35 μm, more preferably lower than or equal to about 15 μm; (c) from about 5 phr to about 120 phr, preferably from about 20 phr to about 90 phr of at least one reinforcing filler. Preferably, said structural element is selected from: tread band, sidewalls, bead filler, tread underlayer, sidewall inserts, anti-abrasive layer, liner or under-liner.