Ferulic Ester Rubber Composition for Heat-Stable Tire Wear Resistance

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Solution Overview

Problem

Existing rubber compositions using sulfur and sulfur-containing compounds for vulcanization often result in polymer breakage, leading to decreased abrasion resistance and tensile performance, particularly at high temperatures.

Innovation Solution

Incorporating a ferulic acid ester compound, such as γ-oryzanol, into the rubber composition, which inhibits polymer breakage by absorbing radicals and maintaining molecular weight, thereby improving abrasion resistance and tensile performance in a balanced manner.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If sulfur and/or sulfur-containing compound is blended for vulcanization, then processability and compatibility between filler and polymer are improved, but abrasion resistance and tensile performance are decreased due to polymer breakage

Engineering Contradiction:

ImproveprocessabilityVSAvoidtensile performance

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The ferulic acid ester compound acts as an intermediary substance between sulfur and the polymer. It preferentially reacts with sulfur to form a complex, preventing direct contact between sulfur and polymer chains. This mediator role allows the vulcanization process to proceed while protecting the polymer from breakage, thus maintaining both processability and tensile performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention converts the harmful effect of sulfur-induced polymer breakage into a beneficial outcome. By using the ferulic acid ester compound to control the reaction, the sulfur that would normally damage the polymer is instead channeled into forming a protective complex. The harmful radical generation is transformed into a controlled vulcanization process that improves processability without sacrificing strength.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Ease of manufacture

If sulfur and/or sulfur-containing compound is blended for vulcanization, then processability is improved, but abrasion resistance is decreased due to polymer breakage

Engineering Contradiction:

ImproveprocessabilityVSAvoidabrasion resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The ferulic acid ester compound serves as a protective intermediary during the vulcanization process. It forms a complex with sulfur that prevents direct attack on polymer chains, thereby maintaining polymer integrity and abrasion resistance while still enabling the processability benefits of sulfur vulcanization.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The ferulic acid ester compound provides beforehand cushioning by pre-reacting with sulfur to form a stable complex. This preliminary action cushions the polymer from the harmful effects of sulfur radicals during subsequent processing and vulcanization, ensuring that abrasion resistance is preserved while processability is enhanced.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If p-phenylenediamine-based antioxidant is used, then oxidation resistance is improved, but polymer breakage cannot be fully inhibited

Engineering Contradiction:

Improveoxidation resistanceVSAvoidpolymer integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The invention changes the chemical parameter of the antioxidant system by introducing a ferulic acid ester compound with different reactivity characteristics. This compound has higher affinity for sulfur radicals than conventional p-phenylenediamine antioxidants, changing the protection mechanism from general oxidation resistance to specific radical scavenging that prevents polymer breakage while maintaining oxidation resistance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite antioxidant system combining p-phenylenediamine-based antioxidant and ferulic acid ester compound. This composite approach allows the p-phenylenediamine to provide oxidation resistance while the ferulic acid ester compound specifically prevents polymer breakage by reacting with sulfur radicals, achieving both functions simultaneously.

Inventive Principle:

Principle #40Composite materials

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 ferulic acid ester compound enhances abrasion resistance and tensile performance, particularly at elevated temperatures, while maintaining processability, by inhibiting polymer breakage and promoting uniform dispersion of sulfur.

Implementation Method 1

sulfur atoms generate radicals in kneading a rubber composition, so that a polymer is broken... breakage of a polymer can be inhibited by a ferulic acid ester compound

Methodology Applied

Scientific EffectRadical absorption: Absorption (physical)

Data Source

PatentEP3476892B1Rubber composition and pneumatic tire

Publication Date: 2025.12.03 SUMITOMO RUBBER INDUSTRIES LTD

AI summary

A rubber composition capable of improving abrasion resistance and tensile performance in a balanced manner and a pneumatic tire using the rubber composition are provided. The rubber composition contains a rubber component, carbon black and/or silica, sulfur and/or a sulfur-containing compound, and a ferulic acid ester compound, and an amount of the ferulic acid ester compound per 100 parts by mass of the rubber component is 0.01 to 10 parts by mass.