Hydrophilic Fumed Silica Masterbatch for Tire Wear and Dispersion
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Solution Overview
Problem
Heavy duty tires require improved wear resistance and mechanical properties, but existing rubber compositions using silica from the wet-process or carbon black fail to meet these demands, leading to decreased performance.
Innovation Solution
A rubber composition is developed using hydrophilic fumed silica as a filler, combined with a silane coupling agent and a specific kneading process to ensure adequate dispersion, resulting in a masterbatch and rubber composition suitable for producing tires with enhanced wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If silica produced by wet-process is blended as a filler into a rubber composition for a tire, then the rolling resistance is reduced, but the wear resistance performance remarkably decreases
Solution Approach 1:
The patent changes the physical and chemical parameters of the silica filler by using fumed silica with specific BET specific surface area (50-500 m²/g) and hydrophilic surface properties, rather than wet-process silica. This parameter change enables simultaneous achievement of low rolling resistance and high wear resistance
Solution Approach 2:
The patent creates a composite rubber composition by combining fumed silica with specific rubber compounds and additives in defined proportions (5-90 parts by mass of fumed silica per 100 parts by mass of diene-based rubber). This composite approach optimizes both fuel efficiency and wear resistance
2Loss of energy
If carbon black is blended as a filler into a rubber composition for a tire, then the rolling resistance is reduced, but the mechanical properties such as tensile strength, tensile elongation, and rubber hardness decrease
Solution Approach 1:
The patent replaces carbon black with fumed silica that has different physical parameters (BET specific surface area of 50-500 m²/g, hydrophilic surface). This parameter change maintains the rolling resistance reduction effect while preserving mechanical properties
Solution Approach 2:
The patent uses fumed silica as a more sustainable and performance-superior alternative to carbon black, achieving both fuel efficiency and mechanical property requirements for heavy duty tires
3Strength
If hydrophilic fumed silica is used as a filler, then the wear resistance is improved, but the silica tends to scatter during kneading and dispersibility becomes difficult to achieve
Solution Approach 1:
The patent controls the BET specific surface area of fumed silica within 50-500 m²/g and uses hydrophilic surface-modified fumed silica, which changes the physical parameters to improve both wear resistance and dispersibility during kneading
Solution Approach 2:
The patent employs silane coupling agents as intermediary substances that facilitate the dispersion of hydrophilic fumed silica in the rubber matrix during kneading, resolving the scattering issue while maintaining wear resistance benefits
4Productivity
If a Banbury mixer is used for kneading the rubber composition, then the productivity is maintained, but the hydrophilic fumed silica scatters and sufficient dispersion cannot be obtained
Solution Approach 1:
The patent uses silane coupling agents as intermediary substances that enable effective kneading of hydrophilic fumed silica in Banbury mixers, maintaining high productivity while achieving sufficient dispersion
Solution Approach 2:
The patent optimizes the physical parameters of fumed silica (BET specific surface area, hydrophilic surface properties) to enable compatibility with high-shear Banbury mixing while maintaining dispersibility
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 use of hydrophilic fumed silica and a silane coupling agent in the rubber composition significantly improves wear resistance and mechanical properties of heavy duty tires, while maintaining fuel efficiency and heat resistance.
Implementation Method 1
a silane coupling agent, with respect to 100 parts by mass of a diene-based rubber
Implementation Method 2
hydrophilic fumed silica instead of carbon black or silica produced by wet-process as a filler of a rubber composition for a tire
Data Source
AI summary
A masterbatch contains 13 parts by mass or more and 130 parts by mass or less of hydrophilic fumed silica, and 1 part by mass or more and 40 parts by mass or less of a silane coupling agent, with respect to 100 parts by mass of a diene-based rubber. A rubber composition for a tire contains 5 parts by mass or more and 90 parts by mass or less of hydrophilic fumed silica, and 1.5 parts by mass or more and 30 parts by mass or less of a silane coupling agent, with respect to 100 parts by mass of a diene-based rubber. A method for producing a masterbatch includes kneading a diene-based rubber, hydrophilic fumed silica, and a silane coupling agent.