Magnetic Nitrile Rubber Composition for Processability and Adhesion
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Solution Overview
Problem
Existing nitrile rubber-based compositions face challenges in maintaining processability and adhesion when high amounts of magnetic powder are added, leading to increased viscosity and reduced flexibility and adhesion to metal plates.
Innovation Solution
A nitrile rubber-based composition incorporating 1,000 to 2,500 parts by weight of magnetic powder with a compressed density of 3.4 to 3.7 g/cm3, 0.5 to 20 parts by weight of alkoxyalkylsilane, and 8 to 40 parts by weight of plasticizer, ensuring improved processability and maintaining flexibility and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the compounding amount of magnetic powder is increased to enhance magnetic force, then the magnetic force is improved, but the viscosity of the rubber compound increases and processability deteriorates
Solution Approach 1:
The patent applies parameter changes by carefully controlling the compressed density of magnetic powder within the specific range of 3.4 to 3.7 g/cm3 and optimizing the compounding amount to 1000-1200 parts per 100 parts of rubber. This parameter optimization resolves the contradiction by achieving high magnetic force while maintaining acceptable processability through precise control of magnetic powder characteristics
Solution Approach 2:
The patent uses composite materials by combining nitrile rubber with highly fillable magnetic powder having specific compressed density characteristics. The composite formulation allows for high magnetic powder content (1000-1200 parts) while maintaining rubber flexibility and processability, resolving the contradiction between magnetic force enhancement and manufacturing ease
2Force
If the compounding amount of magnetic powder exceeds 1,200 parts by weight based on 100 parts by weight of rubber, then the magnetic force is further improved, but the hardness of the molded product increases and flexibility is lost
Solution Approach 1:
The patent establishes the optimal compounding amount range of 1000-1200 parts of magnetic powder per 100 parts of rubber, and controls the compressed density within 3.4-3.7 g/cm3. These parameter changes prevent excessive hardness while maintaining high magnetic force, resolving the contradiction between magnetic force improvement and hardness control
3Force
If the compounding amount of magnetic powder is increased to enhance magnetic force, then the magnetic force is improved, but the adhesion between adhesive and rubber is reduced
Solution Approach 1:
The patent optimizes the compounding amount of magnetic powder to 1000-1200 parts per 100 parts of rubber and controls compressed density within 3.4-3.7 g/cm3. This parameter optimization maintains sufficient adhesion between adhesive and rubber while achieving high magnetic force, resolving the contradiction between magnetic force enhancement and adhesion preservation
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 composition maintains low viscosity, flexibility, and high magnetic force while ensuring excellent adhesion to metal plates, even with high magnetic powder content, facilitating continuous winding and vulcanization moldability.
Implementation Method 1
0.5 to 20 parts by weight of alkoxyalkylsilane
Implementation Method 2
8 to 40 parts by weight of a plasticizer
Data Source
AI summary
A nitrile rubber-based composition comprising 1,000 to 2,500 parts by weight of a magnetic powder or silylated magnetic powder having a compressed density of 3.4 to 3.7 g/cm3, 0.5 to 20 parts by weight of alkoxyalkylsilane, and 8 to 40 parts by weight of a plasticizer, based on 100 parts by weight of nitrile rubber, hydrogenated nitrile rubber, or blend rubber thereof. The nitrile rubber-based composition that does not cause deterioration in roll processability and in adhesion between an adhesive applied to a metal plate and the rubber, even when a magnetic powder is added at a ratio as high as 1,000 parts by weight or more based on 100 parts by weight of nitrile rubber, hydrogenated nitrile rubber, or blend rubber thereof.