Elastomeric Masterbatch Silica Dispersion Coagulation
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Solution Overview
Problem
Existing rubber compositions face challenges in achieving optimal dispersion of inorganic fillers like silica in the elastomeric matrix, leading to reduced reinforcing properties and increased consistency, which complicates the production of tires with low rolling resistance and high wear resistance.
Innovation Solution
A rubber composition is developed using a masterbatch of diene elastomer and carbon black with excellent dispersion, where silica is incorporated into the masterbatch in solid form, allowing for improved hysteresis properties and maintaining good filler dispersion, achieved through a process involving coagulation and drying in a coagulation reactor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If inorganic filler (silica) is used to reduce rolling resistance and improve grip, then hysteresis is lowered and wet/snowy surface grip is improved, but the filler tends to agglomerate due to mutual affinities, limiting dispersion and reinforcing properties
Solution Approach 1:
The patent applies preliminary action by pre-dispersing the inorganic filler (silica) in a liquid phase medium before incorporating it into the elastomeric matrix. The filler is first homogeneously distributed in the liquid phase, ensuring that when the composition is later processed, the filler particles are already separated and ready to be evenly incorporated, preventing agglomeration that would occur with direct solid-phase mixing.
Solution Approach 2:
The patent utilizes the liquid phase (hydraulic principle) as a dispersing medium to overcome the tendency of inorganic filler particles to agglomerate. By suspending the filler in a liquid phase during the masterbatch preparation, the composition benefits from the fluid's ability to separate and distribute particles uniformly, which is then transferred to the elastomeric matrix during processing.
2Strength
If inorganic filler is incorporated into the elastomeric matrix, then reinforcing properties and grip are improved, but consistency increases making processability more difficult
Solution Approach 1:
The patent applies preliminary action by pre-dispersing the inorganic filler (silica) in a liquid phase medium before incorporating it into the elastomeric matrix. The filler is first homogeneously distributed in the liquid phase, ensuring that when the composition is later processed, the filler particles are already separated and ready to be evenly incorporated, preventing agglomeration that would occur with direct solid-phase mixing.
Solution Approach 2:
The patent changes the physical state parameter of the filler incorporation process by using a liquid phase medium instead of direct solid-phase mixing. This parameter change from solid to liquid state during masterbatch preparation reduces the consistency increase that would normally occur with inorganic filler addition, thereby improving processability while maintaining reinforcing properties.
3Ease of manufacture
If solid phase mixing of elastomer and reinforcing filler is used, then the process is simple, but the dispersion of filler in the elastomeric matrix is insufficient
Solution Approach 1:
The patent utilizes the liquid phase (hydraulic principle) as a dispersing medium to overcome the tendency of inorganic filler particles to agglomerate. By suspending the filler in a liquid phase during the masterbatch preparation, the composition benefits from the fluid's ability to separate and distribute particles uniformly, which is then transferred to the elastomeric matrix during processing.
Solution Approach 2:
The patent changes the physical state parameter of the filler incorporation process by using a liquid phase medium instead of direct solid-phase mixing. This parameter change from solid to liquid state during masterbatch preparation reduces the consistency increase that would normally occur with inorganic filler addition, thereby improving processability while maintaining reinforcing properties.
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 approach results in rubber compositions with enhanced hysteresis properties and maintained dispersion of fillers, improving tire performance by reducing rolling resistance and increasing tearability while maintaining excellent dispersion and processability.
Implementation Method 1
the mixing of these two fluids being sufficiently energetic to allow the elastomer latex to coagulate almost completely with the filler before the outlet of the coagulation reactor
Implementation Method 2
drying the coagulum obtained to recover a masterbatch with improved filler dispersion
Data Source
AI summary
The invention relates to a rubber composition based on at least one diene elastomer, a filler comprising at least carbon black and an inorganic filler with an amount of inorganic filler of less than or equal to 50 parts by weight per hundred parts of elastomer, phr, and also to a crosslinking system, characterized in that the dispersion of the filler in the elastomeric matrix has a Z score greater than or equal to 80; and also to the process for preparing such a composition.