Functionalized Rubber Compound for High MRP Loading
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Solution Overview
Problem
There is a pressing global issue of managing end-of-life tyres in an environmentally friendly manner and maximizing their value and volume for circular economy principles, as current technologies lack significant reuse of waste tyres in new tyres.
Innovation Solution
A method for chemically activating micronized rubber powders (MRP) by functionalizing their surface with a combination of silica, silane, and functionalization components, enhancing their mechanical and dynamic performance, allowing high concentrations of activated/functionalized micronized rubber powder (FMRP) to be incorporated into natural rubber compounds and converted into solid strips or slabs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If micronized rubber powder (MRP) is used as a filler to replace natural rubber and synthetic polymers, then cost is reduced and sustainability is improved, but mechanical performance and dynamic performance deteriorate
Solution Approach 1:
The patent applies parameter changes by chemically modifying the surface properties of micronized rubber powder particles through functionalization. This involves changing the chemical parameters of the MRP surface to enable better interaction with the rubber matrix, thereby improving mechanical performance while maintaining high MRP concentration. The functionalization process transforms the surface chemistry of MRP particles to achieve optimal performance characteristics.
Solution Approach 2:
The patent creates a composite material system where functionalized micronized rubber powder is combined with natural rubber and various additives (silica, zinc oxide, stearic acid, sulfur, accelerators). This composite approach allows the MRP to function not just as a filler but as an active component that contributes to the overall performance of the vulcanized rubber compound, resolving the performance deterioration issue.
2Quantity of substance
If high concentrations of micronized rubber powder are incorporated into rubber compounds, then natural rubber and synthetic polymer usage is reduced, but processing difficulty increases
Solution Approach 1:
The patent applies preliminary action by pre-functionalizing the micronized rubber powder before compounding. This pre-treatment of the MRP surface with functionalizing agents (such as silanes, sulfonamides, or other coupling agents) prepares the particles for optimal dispersion and interaction in the rubber matrix, significantly easing the subsequent processing and compounding steps.
Solution Approach 2:
The patent uses functionalizing agents as intermediaries between the micronized rubber powder and the rubber matrix. These intermediary substances (such as silane coupling agents, sulfonamides, or other surface modifiers) facilitate better bonding and dispersion, acting as a bridge that improves processing ease while enabling high MRP concentrations.
3Ease of manufacture
If micronized rubber powder is used without functionalization, then production cost is reduced, but compatibility with host materials and performance deteriorate
Solution Approach 1:
The patent applies parameter changes by selectively modifying the chemical parameters of the MRP surface through functionalization. Rather than leaving MRP as a simple filler, the surface chemistry is altered to provide specific functional groups that enhance compatibility with the rubber matrix and improve overall performance, while maintaining cost-effectiveness.
Solution Approach 2:
The patent introduces functionalizing agents as intermediaries that improve the interface between micronized rubber powder and the host rubber materials. These intermediary substances enhance adhesion, dispersion, and overall compatibility, thereby improving reliability and performance without excessive cost increase.
4Productivity
If end-of-life tyres are not reused in new tyres, then environmental pollution increases, but circular economy principles cannot be maximized
Solution Approach 1:
The patent applies the discarding and recovering principle by taking end-of-life tyre material, grinding it into micronized rubber powder, and recovering it as a valuable feedstock for new rubber compound formulations. The functionalization process restores and enhances the properties of the recovered MRP, enabling its effective reuse in new tyres and rubber products, thereby closing the loop in the circular economy and reducing environmental pollution.
Solution Approach 2:
The patent applies parameter changes to transform the properties of recovered end-of-life tyre material through functionalization. By modifying the surface chemistry and physical parameters of the MRP, the patent enables the recovered material to meet the performance requirements for reuse in new tyres, thus maximizing circular economy productivity while minimizing environmental harm.
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 method significantly improves the mechanical and dynamic performance of MRP in rubber compounds, enabling large-scale reuse in tyres and other rubber products, increasing bulk density and facilitating efficient transportation.
Implementation Method 1
wherein the surface of the micronized rubber powders is functionalized with a silica component, a silane component and one or more functionalization components
Data Source
AI summary
A rubber compound mixture including a matrix of a non-vulcanized rubber including micronized rubber powders and one or more auxiliaries. Also relates a method for preparing such a rubber compound mixture, as well as to a rubber article, and to develop a method for chemically activating/functionalizing micronized rubber powders.