Graphene-Reinforced Rubber Curing Bladder for Tire Vulcanization
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Solution Overview
Problem
Existing rubber curing bladders for tire manufacturing have low thermal conductivity, leading to inefficient heat transfer and reduced vulcanization efficiency.
Innovation Solution
A process involving the pre-mixing of ultra-high thermally conductive graphene with rubber to create a graphene rubber compound, which is then extruded and molded into a curing bladder, significantly enhancing thermal conductivity and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional carbon black reinforced butyl rubber is used for curing bladder, then the bladder structure is simple and easy to manufacture, but the thermal conductivity is extremely low leading to poor heat transfer effect
Solution Approach 1:
The patent applies composite materials by combining graphene with butyl rubber to create a graphene-reinforced rubber compound. This composite structure leverages the exceptional thermal conductivity of graphene while maintaining the elastic properties of rubber, achieving high thermal conductivity (improving_feature) through material composition rather than complex structural design (managing worsening_feature).
Solution Approach 2:
The patent changes the material parameters by incorporating graphene at specific weight ratios (0.1-10 parts per 100 parts rubber) and controlling the compounding process parameters. This parameter change transforms the thermal conductivity of the bladder material from extremely low to ultra-high, resolving the thermal conductivity issue without requiring complex structural modifications.
2Productivity
If traditional curing bladder with low thermal conductivity is used, then the manufacturing process is simple, but the vulcanization efficiency is low
Solution Approach 1:
By using graphene-reinforced rubber composite material, the bladder achieves ultra-high thermal conductivity that enables rapid and uniform heat distribution during vulcanization. This composite material approach directly improves vulcanization efficiency (improving_feature) and reduces vulcanization time (addressing worsening_feature) without complicating the manufacturing process.
Solution Approach 2:
The graphene-reinforced bladder enables continuous and uniform heat transfer throughout the vulcanization process, eliminating hot spots and cold zones. This continuous heat distribution maintains optimal vulcanization conditions throughout, improving overall productivity and reducing the total time required for complete vulcanization.
3Duration of action of stationary object
If traditional curing bladder is used, then the service life is limited, but replacing the bladder frequently increases shutdown time
Solution Approach 1:
The graphene-reinforced rubber composite provides enhanced mechanical strength, thermal stability, and wear resistance compared to traditional rubber bladders. This composite material structure extends the service life (improving_feature) by making the bladder more durable and resistant to degradation during repeated use and high-temperature vulcanization cycles.
Solution Approach 2:
By incorporating graphene reinforcement in advance during bladder manufacturing, the bladder is pre-strengthened to withstand extended service conditions. This beforehand reinforcement prevents premature failure and reduces the frequency of replacements, thereby minimizing shutdown time associated with bladder replacement.
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 process increases thermal conductivity by 50% to 10,000%, reduces product defects, and extends the service life of the curing bladder by 30% to 3,000%, while shortening vulcanization time and improving efficiency by 20% to 100%.
Implementation Method 1
The present invention has greatly improved the thermal conductivity of a curing bladder and accelerated heat transfer
Data Source
AI summary
The present invention relates to a process for manufacturing an ultra-high thermally conductive graphene curing bladder, including the following steps: (1) pre-mixing an ultra-high thermally conductive graphene with rubber to obtain a pre-dispersed graphene master batch, performing a granulation process or a cutting process on the pre-dispersed graphene master batch to obtain a granular solid or a sheet solid, mixing the solid in a rubber mixing mill to obtain an ultra-high thermally conductive graphene rubber compound; (2) extruding, by an extruding machine, the ultra-high thermally conductive graphene rubber compound into a rubber strip of a desirable size; weighing and fixed-length processing the rubber strip of the ultra-high thermally conductive graphene rubber compound to obtain a rubber blank, placing the rubber blank into a pressing type curing bladder mold, closing the mold, pressurizing, heating and curing to obtain a finished product of the ultra-high thermally conductive graphene curing bladder. The present invention has the advantages of greatly improving the thermal conductivity of the curing bladder and accelerating the heat transfer, so that the vulcanization efficiency of products is improved.