Intensive Mixing Tool for Elastomer Masterbatch
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Solution Overview
Problem
Existing methods for producing elastomer-filler masterbatches, particularly those using silica as the reinforcing agent, face challenges in achieving uniform dispersion due to silica agglomeration, limiting the attainment of optimal reinforcing properties in rubber compositions like tire treads.
Innovation Solution
An intensive mixing tool with a tangential jet mixer design is employed, where an elastomer emulsion and a slurry solution are simultaneously injected into a mixing chamber to form a vortex, ensuring efficient and uniform distribution of the filler, even with silica, by utilizing a central body with injector inlets and a supply piece that stabilizes the flow and maintains pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If silica particles are used as the reinforcing agent in elastomer masterbatch, then the wear resistance and durability of rubber products are improved, but the filler tends to agglomerate in the elastomer matrix, limiting the uniform dispersion
Solution Approach 1:
The patent applies preliminary action by pre-dispersing silica particles in an aqueous slurry medium before mixing with the elastomer emulsion. This preliminary dispersion in liquid phase prevents agglomeration during the mixing process, allowing uniform distribution of silica throughout the elastomer matrix while maintaining the wear resistance benefits of silica reinforcement.
2Ease of manufacture
If conventional mixing methods are used to produce elastomer-filler masterbatch, then the process is simple, but the filler cannot be uniformly dispersed due to agglomeration
Solution Approach 1:
The patent uses an aqueous slurry as an intermediary medium to facilitate uniform dispersion of silica particles. The slurry acts as a carrier that distributes silica particles evenly before they are incorporated into the elastomer matrix. This intermediary approach maintains process simplicity while achieving manufacturing precision in terms of dispersion uniformity.
3Productivity
If high pressure injection is used to coagulate elastomer with filler particles, then the mixing efficiency is improved, but the equipment complexity and energy consumption increase
Solution Approach 1:
The patent employs hydraulic principles by injecting the aqueous silica slurry under pressure into the elastomer emulsion stream. This pressure-driven injection method achieves efficient mixing and coagulation without requiring complex high-energy equipment. The hydraulic injection system provides sufficient mixing efficiency while maintaining reasonable energy consumption levels.
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 approach achieves a highly homogeneous masterbatch with improved reinforcing properties, enhancing wear resistance and durability of rubber products by ensuring the filler is finely divided and uniformly distributed within the elastomer matrix.
Implementation Method 1
The majority of intensive mixing tools rely on turbulent mixing as an efficient mechanism for dispersing the solutions into sufficiently small volume elements (or 'turbulent eddies'). The small size of these eddies enables fast diffusion of the reactants over very short distances.
Implementation Method 2
each injector inlet including a supply conduit defined therein that establishes fluid communication between an injector ingress via which one of an elastomer emulsion and a slurry solution enter the mixing unit and a corresponding injection conduit in registry therewith
Implementation Method 3
simultaneous injection of the elastomer emulsion and the slurry solution into the mixing chamber forms a vortex therein
Implementation Method 4
the passage of a liquid mixture (e.g., a mixture of an emulsion of elastomer and a slurry of charge or filler) to a viscoelastic solid is effected by coagulation
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A system is provided for producing an elastomer-filler masterbatch. The system includes an elastomer emulsion stored in a liquid phase in an emulsion reservoir; a slurry solution stored in a liquid phase in a slurry reservoir; and an intensive mixing tool (10) in fluid communication with each of the emulsion reservoir and the slurry reservoir. The intensive mixing tool includes a mixing unit (12) having a central body (14) and an injector inlet (22) that extends normally from each of a pair of opposed side surfaces (14c) of the central body such that at least a pair of injection inlets are located symmetrically and in opposing manner relative to a central axis of the central body. Each injector inlet establishes fluid communication between one of an elastomer emulsion reservoir and a slurry solution reservoir such that simultaneous injection of the elastomer emulsion and the slurry solution into the mixing chamber, each as a continuous flow under pressure, forms a vortex therein.