Functionalized Silica Masterbatch for Low-Shear Rubber Mixing

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Solution Overview

Problem

Existing rubber compositions for tires face challenges in incorporating silica fillers effectively, as they require high shear processing steps that can break down natural rubber, and current methods are inefficient in reducing processing temperatures and steps while improving performance-related properties.

Innovation Solution

The development of an uncured rubber composition that includes a rubber and functionalized silica, where the functionalized silica comprises silica particles, a coupling agent, and an alcohol ether with a specific formula, aiding in the dispersion of silica and allowing for mixing under milder conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If silica is incorporated into rubber compositions using conventional high shear processing steps, then silica dispersion is improved, but natural rubber breaks down

Engineering Contradiction:

Improvenatural rubber stabilityVSAvoidsilica incorporation difficulty

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent uses a silane coupling agent as an intermediary substance that chemically bonds to both silica particles and natural rubber polymer chains. This mediator enables effective silica incorporation without requiring harsh high-shear processing, thus preventing rubber degradation while achieving good dispersion

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the chemical parameters of silica by applying silane treatment, which modifies the silica surface properties. This parameter change allows silica to be incorporated into rubber at lower shear stresses, avoiding the breakdown of natural rubber while maintaining effective dispersion

Inventive Principle:

Principle #35Parameter changes

2Productivity

If rubber mixing is conducted in two stages with high temperature non-productive stage, then silica dispersion is improved, but processing time and energy input increase

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidprocessing temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The silane coupling agent is applied to silica particles in advance, before mixing with rubber. This preliminary action prepares the silica surface for effective bonding with rubber, allowing the mixing process to be completed at lower temperatures and in fewer stages, thus improving productivity while reducing temperature exposure

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces reliance on mechanical high-shear mixing and thermal energy input with a chemical bonding mechanism. The silane coupling agent enables effective silica-rubber integration through chemical reactions rather than purely mechanical forces, reducing both processing time and energy consumption

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution enables the effective incorporation of silica into rubber compositions without breaking down natural rubber, reduces processing temperatures and steps, and enhances performance-related properties such as wet traction and abrasion resistance.

Implementation Method 1

the coupling agent aids in the dispersal of the functionalized silica in the rubber

Methodology Applied

Scientific EffectChemical bonding: Chemical Bonding

Implementation Method 2

the functionalized silica comprises a plurality of silica particles, a coupling agent, and an alcohol ether

Methodology Applied

Scientific EffectSurface modification: Adsorption

Data Source

PatentUS20250188250A1Functionalized silica, masterbatch comprising the same, and rubber articles comprising the same

Publication Date: 2025.06.12 THE GOODYEAR TIRE & RUBBER CO

AI summary

In one aspect, the disclosure relates to an uncured rubber composition comprising a rubber and a functionalized silica, wherein the functionalized silica comprises a plurality of silica particles, a coupling agent, and an alcohol ether having the Formula I:CH3—(CH2)n—(O—(CH2)x)m—OH Formula Iwherein n is an integer from 1 to 18;wherein x is an integer from 1 to 8; andwherein m is an integer from 1 to 15.Also disclosed are methods of making the rubber compositions, articles such as tires made from the same, and the functionalized silica used to produce the same. The uncured rubber compositions can be or include a masterbatch. In an aspect, the coupling agent aids in the dispersal of the functionalized silica in the rubber, allowing for mixing under conditions that are not harsh, while retaining desirable properties in the final rubber products.