Magnetic Nitrile Rubber Composition With High Filler Processability

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Solution Overview

Problem

Existing nitrile rubber-based compositions face issues with deteriorating 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 comprising 1,000 to 2,500 parts by weight of magnetic powder with a high compressed density, 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

VSEngineering 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 causing deterioration in processability

Engineering Contradiction:

Improvemagnetic forceVSAvoidprocessability

Core Design Contradiction:

ForceVSEase of manufacture

Solution Approach 1:

The patent changes the particle size parameter of magnetic powder to 1.00 to 1.50 μm (optimal range) and controls the compounding amount to 600-1,200 parts by weight based on 100 parts by weight of rubber. This parameter optimization allows achieving high magnetic force while maintaining low viscosity and good processability of the rubber compound

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite rubber system comprising nitrile rubber and hydrogenated nitrile rubber in specific ratios (nitrile rubber 30-70 parts, hydrogenated nitrile rubber 70-30 parts based on 100 parts total rubber). This composite material approach balances magnetic force, processability, and adhesion properties

Inventive Principle:

Principle #40Composite materials

2Force

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

Engineering Contradiction:

Improvemagnetic forceVSAvoidadhesion

Core Design Contradiction:

ForceVSStrength

Solution Approach 1:

The patent employs a composite rubber system of nitrile rubber and hydrogenated nitrile rubber in specific proportions. Hydrogenated nitrile rubber provides better adhesion properties while nitrile rubber contributes to magnetic force, achieving a balance where adhesion is maintained even with high magnetic powder content (600-1,200 parts)

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent controls the magnetic powder compounding amount within 600-1,200 parts by weight based on 100 parts by weight of rubber, preventing excessive filler content that would compromise adhesion while still achieving high magnetic force

Inventive Principle:

Principle #35Parameter changes

3Force

If the compounding amount of magnetic powder is increased to enhance magnetic force, then the magnetic force is improved, but the flexibility of the molded product is lost

Engineering Contradiction:

Improvemagnetic forceVSAvoidflexibility

Core Design Contradiction:

ForceVSEase of operation

Solution Approach 1:

The patent uses a composite of nitrile rubber and hydrogenated nitrile rubber where hydrogenated nitrile rubber (70-30 parts) provides flexibility and softness, while nitrile rubber (30-70 parts) provides magnetic force. This composite maintains flexibility even with high magnetic powder content

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent optimizes the magnetic powder particle size to 1.00 to 1.50 μm and controls the compounding amount to 600-1,200 parts by weight based on 100 parts by weight of rubber. This parameter control ensures high magnetic force while maintaining flexibility and preventing excessive hardness

Inventive Principle:

Principle #35Parameter changes

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 and flexibility while retaining high magnetic force, ensuring good adhesion to metal plates even with high magnetic powder content.

Implementation Method 1

adding a magnetic powder or silylated magnetic powder having a high compressed density, and a plasticizer to nitrile rubber and/or hydrogenated nitrile rubber

Methodology Applied

Scientific EffectSilane modification: Chemical Bonding

Implementation Method 2

Since the magnetic force is almost proportional to the amount of magnetic powder compounded with a rubber compound

Methodology Applied

Scientific EffectFerromagnetism: Ferromagnetism

Implementation Method 3

adding a magnetic powder or silylated magnetic powder having a high compressed density, and a plasticizer to nitrile rubber and/or hydrogenated nitrile rubber

Methodology Applied

Scientific EffectPlasticization:

Data Source

PatentEP4245803B1Nitrile rubber-based composition

Publication Date: 2025.07.09 NOK CORP

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.