Masterbatch Agitation Time Control for Carbon Black Dispersion
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Solution Overview
Problem
Existing masterbatch manufacturing methods fail to achieve optimal wear resistance and reduced heat generation in vulcanized rubber due to inadequate dispersion time of carbon black, leading to disintegration of the carbon black structure and worsened dispersion characteristics.
Innovation Solution
A masterbatch manufacturing method involving agitation of carbon black in a liquid to form a slurry, followed by mixing with rubber latex and coagulation, where the dispersion time is controlled between 5 to 40 times the particle diameter reduction relaxation time, using a specific formula to optimize carbon black particle diameter and maintain dispersion characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If carbon black is agitated for longer time to improve dispersion, then dispersion characteristics improve, but carbon black structure disintegrates and wear resistance worsens
Solution Approach 1:
The patent applies parameter changes by precisely controlling the agitation time parameter within a specific range (5-40 times the particle diameter reduction relaxation time). This optimization balances the dispersion characteristics improvement against the carbon black structure disintegration, achieving both good dispersion and maintained wear resistance in the masterbatch product.
2Length of moving object
If carbon black is agitated for longer time to reduce particle diameter, then particle size decreases, but dispersion characteristics worsen due to structure disintegration
Solution Approach 1:
The patent optimizes the agitation time parameter to achieve the desired particle diameter reduction while preventing excessive structure disintegration. By controlling agitation within 5-40 times the relaxation time, the process achieves optimal particle size with maintained dispersion characteristics.
3Manufacturing precision
If carbon black structure is disintegrated to improve dispersion, then dispersion improves, but ability to achieve wear resistance and heat generation reduction decreases
Solution Approach 1:
The patent controls the agitation time parameter within a specific range (5-40 times the particle diameter reduction relaxation time) to optimize the balance between dispersion characteristics and the carbon black structure integrity. This ensures both good dispersion and maintained wear resistance and heat generation reduction properties in the final product.
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 method prevents excessive disintegration of carbon black, maintains fatigue resistance, and enhances wear resistance and heat generation reduction in vulcanized rubber, as demonstrated by improved tan δ values and wear resistance indices.
Implementation Method 1
carbon black is added to water or other such liquid and this is agitated to prepare a carbon black slurry
Implementation Method 2
particle diameter reduction relaxation time v by plotting measurement results on a planar graph in such fashion that elapsed time t (minutes) since the start of agitation is plotted on the horizontal axis, and particle diameter f (μm) of carbon black is plotted on the vertical axis
Implementation Method 3
the carbon black slurry and natural rubber latex are mixed, this is coagulated, the coagulum is dewatered
Data Source
AI summary
A masterbatch manufacturing method is disclosed in which carbon black is added to a liquid and this is agitated to obtain a carbon black slurry; the carbon black slurry and rubber latex are mixed to obtain pre-coagulation rubber latex; and the pre-coagulation rubber latex is coagulated; wherein, at the operation in which the carbon black slurry is obtained, dispersion time from the start of agitation to the end of agitation is not less than 5 times, but not greater than 40 times. A particle diameter reduction relaxation time v may be found by plotting measurement results on a planar graph in such fashion that elapsed time t (minutes) since the start of agitation is plotted on the horizontal axis, and particle diameter f (μm) of carbon black is plotted on the vertical axis, to obtain a best-fit solution.