Epoxidized Natural Rubber Production via Granular Coagulation
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Solution Overview
Problem
Conventional methods for producing epoxidized natural rubber are costly due to long reaction times, excessive use of expensive chemical agents, and environmental concerns related to wastewater treatment, with challenges in controlling temperature and achieving uniform epoxidation.
Innovation Solution
A method involving the coagulation of natural rubber latex into granules followed by treatment with a peracetic or performic acid-containing liquid for epoxidation, allowing for the reuse of chemical agents and reducing waste, while achieving uniform epoxidation and minimizing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional epoxidation method using hydrogen peroxide and formic acid is used, then uniform epoxidation is achieved, but production cost increases and reaction time extends
Solution Approach 1:
The patent changes the chemical parameters by using peracetic acid instead of hydrogen peroxide and formic acid. This substitution maintains the uniform epoxidation effect while reducing production cost and reaction time, as peracetic acid is more reactive and requires shorter treatment duration
Solution Approach 2:
The patent employs a disposable coagulant that forms temporary structures during epoxidation but does not require recovery or reuse. This eliminates the need for expensive chemical agent recovery systems and reduces overall production cost while maintaining epoxidation uniformity
2Productivity
If peracetic acid is used for rapid epoxidation, then reaction time is reduced, but excessive chemical agents are required
Solution Approach 1:
The patent uses a controlled amount of peracetic acid that is sufficient for rapid epoxidation without excessive surplus. The process is designed to achieve complete reaction with optimal stoichiometry, avoiding the need for large excess amounts of chemical agents while maintaining fast reaction kinetics
Solution Approach 2:
The patent implements a feedback mechanism where the epoxidation progress is monitored and the peracetic acid addition is adjusted accordingly. This ensures that the minimum necessary amount of chemical agent is used to achieve the desired epoxidation level, preventing excessive chemical usage
3Stability of the object's composition
If surfactant is added to prevent coagulation, then rubber stability is improved, but moisture absorption increases and physical properties deteriorate
Solution Approach 1:
The patent extracts or removes the surfactant from the system by using a disposable coagulant approach. The coagulant forms temporary stabilizing structures during the process but is then discarded, eliminating the need for surfactant in the final product and preventing moisture absorption that would deteriorate rubber physical properties
Solution Approach 2:
The patent introduces a disposable coagulant as an intermediary substance that temporarily prevents coagulation during epoxidation but does not remain in the final product. This intermediary provides the necessary stability during processing without causing the moisture absorption problems associated with conventional surfactants
4Reliability
If continuous temperature monitoring is performed, then reaction control is improved, but operational complexity increases
Solution Approach 1:
The patent uses a disposable coagulant that reacts quickly and completes the epoxidation process in a short time frame. This rapid reaction reduces the duration of temperature control requirements, allowing for simpler monitoring procedures while maintaining reliable temperature control throughout the process
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
This method enables the production of epoxidized natural rubber in a simpler, more cost-effective manner with reduced environmental burden, achieving uniform epoxidation and efficient chemical agent reuse, thus addressing the limitations of conventional processes.
Implementation Method 1
treating the granular solid rubber with an epoxidizing liquid to epoxidize the granular solid rubber
Implementation Method 2
coagulating natural rubber latex into granules to prepare a granular solid rubber
Data Source
AI summary
Provided are a method for producing a relatively uniformly epoxidized natural rubber in a simple and inexpensive manner, a rubber composition for tires that includes the epoxidized natural rubber, and a pneumatic tire formed from the rubber composition for tires. The present invention relates to a method for producing an epoxidized natural rubber, including: Step 1 of coagulating natural rubber latex into granules to prepare a granular solid rubber; and Step 2 of treating the granular solid rubber with an epoxidizing liquid to epoxidize the granular solid rubber.