Masterbatch Manufacturing via Latex Slurry Mixing
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Solution Overview
Problem
The compound (2Z)-4-[(4-aminophenyl)amino]-4-oxo-2-butene acid sodium tends to flocculate and form clumps during dry kneading, making it difficult to achieve high dispersion within rubber and homogeneous reaction at the surface of carbon black, which limits the improvement of wear resistance in vulcanized rubber.
Innovation Solution
A method involving the mixing of rubber latex and a carbon black slurry containing the compound, using a high-shear mixer or other dispersers, to suppress flocculation and enable homogeneous reaction, resulting in improved wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dry kneading is employed to disperse the compound in rubber, then the processing is simple, but the compound flocculates and forms clumps, resulting in poor dispersion and non-homogeneous reaction at the carbon black surface
Solution Approach 1:
The patent introduces water as an intermediary medium to dissolve the compound (2Z)-4-[(4-aminophenyl)amino]-4-oxo-2-butene acid sodium before mixing with rubber. This intermediary step prevents direct contact between the compound and rubber particles, eliminating flocculation and enabling homogeneous dispersion. The compound is first dissolved in water to form a uniform solution, which is then mixed with rubber, ensuring even distribution and reaction at the carbon black surface.
Solution Approach 2:
The patent changes the physical state and concentration parameters by using aqueous solutions with controlled compound concentrations (0.1-5% by mass). This parameter change from dry mixing to wet mixing with controlled concentration enables the compound to dissolve properly and disperse uniformly in the rubber matrix, preventing clump formation while maintaining processing feasibility.
2Reliability
If the compound is added directly to rubber without dissolution, then the manufacturing process is simpler, but the compound cannot react homogeneously at the carbon black surface, limiting wear resistance improvement
Solution Approach 1:
The patent applies preliminary action by dissolving the compound in water before the mixing step. This preliminary dissolution ensures the compound is in a uniform, reactive state prior to contact with rubber and carbon black. By performing this preparation step in advance, the compound can react homogeneously at the carbon black surface during vulcanization, improving wear resistance without significantly complicating the overall manufacturing process.
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 method enhances the wear resistance of vulcanized rubber by ensuring the compound dissolves in the carbon black slurry and reacts homogeneously, leading to superior performance in abrasion resistance.
Implementation Method 1
it is possible for the compound according to Formula (I) to dissolve in the carbon black slurry
Implementation Method 2
flocculation of the compound according to Formula (I) is suppressed at the carbon black slurry
Implementation Method 3
using a high-shear mixer or other dispersers, to suppress flocculation and enable homogeneous reaction
Data Source
AI summary
A masterbatch manufacturing method comprises an operation in which rubber latex and a carbon black slurry containing a compound according to Formula (I), below, are mixed.At Formula (I), R1 and R2 each indicates a hydrogen atom, an alkyl group having 1 to 20 carbons, an alkenyl group having 1 to 20 carbons, or an alkynyl group having 1 to 20 carbons. R1 and R2 may be the same or different. M+ indicates sodium ion, potassium ion, or lithium ion.