Multilayer Ionic Butyl Tire Sealants for Temperature-Stable Puncture Sealing
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Solution Overview
Problem
Current tire manufacturing processes face challenges in applying and bonding sealant layers within tires, leading to poor adhesion, separation, and inadequate puncture sealing, especially due to the need for low viscosity sealants that are cumbersome to apply and maintain effective viscosity across varying temperatures.
Innovation Solution
The development of a tire with in-situ generated two or more intrinsic puncture sealant layers based on ionic butyl, formed during tire cure through chain scission of butyl ionomer compositions catalyzed by peroxide, which provides self-sealing properties with interfacial cross-linking between layers, ensuring effective adhesion and viscosity adaptation across temperature ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sealant is applied to cured tire, then physical bonding is achieved, but adhesion is poor leading to separation
Solution Approach 1:
The sealant precursor is applied to the innerliner before the tire is cured, allowing the sealant to be formed in-situ during the curing process. This preliminary action ensures proper adhesion through interfacial cross-linking before the tire structure is finalized, preventing separation issues that occur with post-cure application.
Solution Approach 2:
The invention changes the chemical state of the sealant material by using a precursor that transforms into active sealant during curing. The precursor contains peroxide and ionic butyl components that undergo chemical transformation under curing conditions, creating strong interfacial bonds with the innerliner that physical bonding alone cannot achieve.
2Reliability
If single layer of low viscosity sealant is used, then puncture sealing is effective at low temperature, but sealant flows out at high temperature
Solution Approach 1:
The sealant system is segmented into multiple layers with different viscosity characteristics. The first sealant layer has lower viscosity for effective puncture sealing at low temperatures, while the second sealant layer has higher viscosity to prevent sealant displacement at high temperatures. This segmentation allows each layer to perform its specific function optimally.
Solution Approach 2:
The invention uses composite sealant structure combining materials with different rheological properties. The composite multi-layer sealant system integrates low-viscosity and high-viscosity materials to achieve temperature-dependent performance, where the combination provides both low-temperature sealing effectiveness and high-temperature stability.
3Stability of the object's composition
If single layer of high viscosity sealant is used, then sealant stability is good at high temperature, but puncture sealing is ineffective at low temperature
Solution Approach 1:
The sealant system is segmented into multiple layers with different viscosity characteristics. The first sealant layer has lower viscosity for effective puncture sealing at low temperature, while the second sealant layer has higher viscosity to prevent sealant displacement at high temperature. This segmentation allows each layer to perform its specific function optimally.
Solution Approach 2:
The invention changes the viscosity parameter across different layers to optimize performance. By creating a viscosity gradient from the first layer to the second layer, the system achieves both low-temperature flowability for sealing and high-temperature stability, resolving the contradiction between viscosity stability and sealing effectiveness.
4Reliability
If sealant precursor is applied before tire cure, then interfacial cross-linking is achieved, but manufacturing complexity increases
Solution Approach 1:
The invention merges the sealant application step with the tire curing process. By applying the sealant precursor during tire building and then curing the entire tire structure together, the sealant formation and tire curing operations are combined into a single integrated process, eliminating the need for separate sealant application equipment and steps.
Solution Approach 2:
The sealant precursor contains all necessary components (peroxide, ionic butyl, fillers) to self-transform into active sealant during the curing process. The curing heat and pressure automatically activate the chemical reactions needed to form the sealant and create interfacial cross-linking, eliminating the need for additional activation equipment or complex application procedures.
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 a more efficient and durable tire manufacturing process with improved sealant adhesion and puncture sealing capabilities, maintaining effective viscosity across temperatures and reducing tire building complexities, while minimizing material usage and heat generation.
Implementation Method 1
formed during tire cure through chain scission of butyl ionomer compositions catalyzed by peroxide
Implementation Method 2
inner layer of sealant is in direct contact with and interfacially cross-linked to outer layer of sealant
Data Source
AI summary
A tire with in-situ generated two or more intrinsic puncture sealant layers based on ionic butyl with two or more different viscosities comprising a supporting tire carcass having one or more layers of ply, an outer circumferential tread, and a radially inner layer, a pair of beads, sidewalls extending radially inward from the axial outer edges of a tread portion to join the respective beads, a sealant comprising an outer layer of sealant and an inner layer of sealant, disposed radially inwardly from the radially inner layer of the tire carcass, wherein the outer layer of sealant and the inner layer of sealant have different viscosities, wherein the sealant provides self-sealing properties to the tire, and wherein the inner layer of sealant is cross-linked to the outer layer of sealant with no barrier separating the inner and outer layers of sealant.