Hose Rubber Composition Balancing Flame Retardancy and Wear
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Solution Overview
Problem
Hydraulic hoses used in construction and mining applications face issues with wear resistance and processability due to the exposure of reinforcing layers, leading to premature failure and potential leakage, despite the need for flame retardancy.
Innovation Solution
A rubber composition combining chloroprene rubber, butadiene rubber, sulfur, and aromatic oil, with specific ratios and the inclusion of a silane coupling agent, carbon black, and silica, to enhance flame retardancy, wear resistance, and compression set.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If chloroprene rubber and silica are blended to improve flame retardancy, then flame retardancy is improved, but scorch time becomes short and processability deteriorates
Solution Approach 1:
The patent optimizes the content of chloroprene rubber to 60-75 mass% and controls sulfur content at 0.2-2.5 parts by mass per 100 parts by mass of rubber component, along with adding aromatic oil (10 parts by mass or more per 100 parts by mass of rubber component) to adjust the curing characteristics and extend scorch time, thereby improving processability while maintaining flame retardancy
Solution Approach 2:
The patent creates a composite rubber composition containing chloroprene rubber, butadiene rubber (25-40 mass%), silica, carbon black, and aromatic oil, where the combination of these materials provides both flame retardancy and improved processability through synergistic effects
2Strength
If silane coupling agent is added to improve wear resistance, then wear resistance is improved, but compression set becomes poor and durability deteriorates
Solution Approach 1:
The patent precisely controls the sulfur content at 0.2-2.5 parts by mass per 100 parts by mass of rubber component and limits silane coupling agent to 0-2 mass% based on total rubber component mass, while adding aromatic oil to optimize the curing characteristics, achieving both wear resistance and good compression set
3Object-affected harmful factors
If rubber composition is optimized for flame retardancy, then flame retardancy is improved, but scorch time becomes short leading to poor processing stability
Solution Approach 1:
The patent adjusts the rubber composition by controlling chloroprene rubber at 60-75 mass%, adding butadiene rubber at 25-40 mass%, and incorporating aromatic oil at 10 parts by mass or more per 100 parts by mass of rubber component, which modifies the curing characteristics to extend scorch time and improve processing stability
Solution Approach 2:
The patent uses aromatic oil as an intermediary substance that mediates between the flame retardant properties of chloroprene rubber and the processing requirements, extending scorch time and improving processing stability without compromising flame retardancy
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 rubber composition improves processability, flame retardancy, wear resistance, and sealability, reducing the likelihood of premature hose failure and leakage while maintaining safety standards.
Implementation Method 1
it is effective to blend a silane coupling agent into a rubber composition in order to improve wear resistance
Implementation Method 2
it is effective to blend chloroprene rubber (CR) and silica into a rubber composition in order to improve flame retardancy
Implementation Method 3
a rubber composition for a hose including a rubber component, carbon black, and a plasticizer component
Implementation Method 4
the plasticizer component includes a flame-retardant plasticizer, and 2 parts by mass or more of the flame-retardant plasticizer is contained per 100 parts by mass of the rubber component
Data Source
AI summary
A rubber composition for a hose including a rubber component containing chloroprene rubber and butadiene rubber, sulfur, and an aromatic oil. With respect to the total mass of the rubber component: the chloroprene rubber being contained in an amount of 60 mass % or more and less than 75 mass %; and the butadiene rubber being contained in an amount of more than 25 mass % and 40 mass % or less. Relative to 100 parts by mass of the rubber component: the sulfur being contained in an amount of more than 0.2 parts by mass and less than 2.5 parts by mass; and the aromatic oil being contained in an amount of 10 parts by mass or more. An optional silane coupling agent may be contained in an amount of from 0 to 2 mass % with respect to the total mass of the rubber component.