Masterbatch Manufacturing Method Reducing Mooney Viscosity
Solution Overview
Problem
Conventional wet masterbatch manufacturing methods result in vulcanized rubber with high Mooney viscosity and increased heat generation, limiting their effectiveness in tire production.
Innovation Solution
A masterbatch manufacturing method involving pre-coagulation of rubber latex with a filler, followed by dewatering and plasticization using an extruder, where a peptizing agent is added during the drying process to reduce Mooney viscosity and control heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If wet masterbatch is manufactured using conventional procedure (mixing carbon black slurry and natural rubber latex, coagulation, dewatering, and plasticization during drying), then heat generation of vulcanized rubber is reduced, but Mooney viscosity becomes high
Solution Approach 1:
The invention applies preliminary action by adding the peptizing agent during the coagulation step rather than during the plasticization step. This timing allows the agent to be incorporated into the coagulum structure before dewatering, enabling it to effectively reduce Mooney viscosity during subsequent plasticization while maintaining the heat generation benefits of wet masterbatch processing
Solution Approach 2:
The invention changes the parameter of chemical composition by introducing a peptizing agent (such as zinc stearate, zinc oxide, or mercaptan compounds) to the coagulation mixture. This chemical parameter change modifies the rubber-coagulum interaction during plasticization, reducing Mooney viscosity without compromising the heat generation properties achieved through wet processing
2Ease of manufacture
If dry masterbatch is used (carbon black dry-kneaded into rubber), then Mooney viscosity is lower, but heat generation increases
Solution Approach 1:
The invention creates a composite approach by combining elements of both wet and dry masterbatch methods. It uses wet coagulation to form the base structure (like wet method) but incorporates dry-kneadable peptizing agents that enable effective plasticization (like dry method), achieving low Mooney viscosity while maintaining reduced heat generation through the wet processing foundation
3Ease of manufacture
If peptizing agent is added during dewatering, then Mooney viscosity is reduced, but the agent is eluted into aqueous phase reducing effectiveness
Solution Approach 1:
The invention applies preliminary action by adding the peptizing agent during coagulation rather than during dewatering. This ensures the agent is incorporated into the forming coagulum matrix before water removal begins, preventing elution into the aqueous phase and ensuring the agent remains available to reduce Mooney viscosity during subsequent plasticization
Solution Approach 2:
The coagulum structure acts as an intermediary that traps and retains the peptizing agent during dewatering. By incorporating the agent during coagulation, the coagulum matrix serves as a protective medium that prevents the agent from being washed away into the aqueous phase, ensuring its effectiveness is maintained through the dewatering and plasticization processes
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 effectively reduces Mooney viscosity and minimizes heat generation in vulcanized rubber, enhancing the workability and thermal properties of the rubber compounds used in tire manufacturing.
Implementation Method 1
pre-coagulation rubber latex comprising filler is coagulated to obtain a coagulum
Implementation Method 2
the coagulum is dewatered
Implementation Method 3
the dewatered coagulum is plasticized as it is dried by means of an extruder
Implementation Method 4
the dewatered coagulum is plasticized as it is dried by means of an extruder
Implementation Method 5
the heating and shearing that take place during this operation reduce the molecular weight of the rubber and lower the Mooney viscosity
Implementation Method 6
the coagulum comprises a peptizing agent... the heating and shearing that take place during this operation reduce the molecular weight of the rubber and lower the Mooney viscosity
Data Source
AI summary
A masterbatch manufacturing method in accordance with the present disclosure comprises an operation in which pre-coagulation rubber latex comprising filler is coagulated to obtain a coagulum; an operation in which the coagulum is dewatered; and an operation in which the dewatered coagulum is plasticized as it is dried by means of an extruder; wherein, during the operation in which the dewatered coagulum is plasticized as it is dried, the coagulum comprises a peptizing agent.