Ethylene-Rich Rubber Composition for Faster Tire Vulcanization
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Solution Overview
Problem
Traditional dienic rubber compositions for tires, reinforced with strongly saturated dienic elastomers, require long vulcanization times, reducing productivity and resulting in higher rigidity, making them unsuitable for certain applications, and extracting them prematurely leads to insufficient vulcanization and increased hysteresis.
Innovation Solution
A rubber composition comprising an ethylene copolymer with more than 50% ethylene units, a first 1,3-diene (such as 1,3-butadiene or isoprene), and a second 1,3-diene with an unsaturated hydrocarbon chain, offering a balanced compromise between rigidity and hysteresis, and incorporating a reinforcing load like silica or carbon black, along with a vulcanization system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If copolymers of ethylene and 1,3-butadiene with more than 50 mol% ethylene units are used in rubber compositions, then the saturation level increases, but the vulcanization time increases and productivity decreases
Solution Approach 1:
The patent modifies the chemical composition parameters of the elastomer by incorporating a specific third component (1,3-diene with formula CH2=CR-CH=CH2 where R is an unsaturated aliphatic hydrocarbon chain with 3 to 20 carbon atoms) in controlled amounts (5 to 50 mol%). This compositional parameter change enables the rubber to achieve adequate vulcanization within 5 to 20 minutes at 150°C, resolving the productivity issue while maintaining high saturation level
Solution Approach 2:
The patent creates a composite elastomer system combining three components: ethylene (50-95 mol%), first 1,3-diene (1,3-butadiene or isoprene) (5-40 mol%), and second 1,3-diene with unsaturated chain (5-50 mol%). This composite material structure synergistically combines the benefits of high saturation from ethylene-rich composition with improved vulcanization kinetics from the unsaturated third component
2Stability of the object's composition
If copolymers of ethylene and 1,3-butadiene with more than 50 mol% ethylene units are used in rubber compositions, then the saturation level increases, but the rigidity increases and may become unsuitable for certain applications
Solution Approach 1:
The patent adjusts the compositional parameters to include 5-50 mol% of the unsaturated 1,3-diene component, which introduces flexibility and reduces rigidity. This parameter optimization allows achieving adequate vulcanization speed while maintaining appropriate rigidity levels for various tire applications
Solution Approach 2:
The composite elastomer combines rigid ethylene units (50-95 mol%) with flexible unsaturated 1,3-diene units (5-50 mol%), creating a balanced material with both structural stability from saturation and appropriate flexibility from the unsaturated component, making it suitable for different tire applications
3Productivity
If the rubber composition is extracted from the curing press before the end of the vulcanization reaction, then the productivity increases, but the hysteresis increases due to insufficient curing
Solution Approach 1:
The elastomer is pre-formulated with optimal composition (5-50 mol% unsaturated 1,3-diene component) before vulcanization to ensure that the vulcanization reaction reaches completion within a short, controlled time frame (5 to 20 minutes at 150°C). This preliminary optimization of composition enables full curing in reduced time, allowing extraction at the optimal moment without excessive hysteresis
Solution Approach 2:
The patent optimizes the chemical composition parameters to achieve complete vulcanization within 5 to 20 minutes at 150°C, as indicated by torque increase of at least 90% of the difference between minimum and maximum torque. This parameter optimization ensures that productivity is maximized while hysteresis remains acceptable by completing the curing process at the right time
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 composition achieves improved vulcanization efficiency, reduced hysteresis, and appropriate rigidity, enhancing tire manufacturing productivity and suitability for various applications by optimizing the vulcanization process and properties.
Implementation Method 1
these rubber compositions require relatively long residence times in a curing press to be vulcanized
Data Source
AI summary
The invention relates to a rubber composition which comprises a reinforcing filler, a vulcanisation system and more than 50 to 100 phr of an elastomer which contains more than 50 mol% of ethylene units and which is a copolymer of ethylene, of a first 1,3-diene which is 1,3-butadiene, isoprene or a mixture thereof and of a second 1,3-diene of formula CH2=CR-CH=CH2, where the symbol R represents an unsaturated aliphatic hydrocarbon chain having 3 to 20 carbon atoms.