Metal-Reinforced Rubber Composition With Peroxide Adhesion System
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Solution Overview
Problem
Existing rubber-based products, such as pneumatic tires and conveyor belts, face challenges in achieving strong adhesion between reinforcing elements and the rubber composition while minimizing sulfur content and avoiding premature crosslinking, and require high levels of sulfur, zinc oxide, and cobalt salts, which complicate production.
Innovation Solution
A reinforced product using a rubber composition based on diene elastomer, silica as a reinforcing filler, a peroxide-based crosslinking system, and a polyphenolic compound with vicinal hydroxyl groups, along with a guanidine compound, eliminates sulfur and cobalt salts, enhancing adhesion without the need for zinc oxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high levels of sulfur and zinc oxide are used to achieve strong adhesion between reinforcements and rubber composition, then adhesion is improved, but premature crosslinking occurs during production
Solution Approach 1:
The invention changes the chemical parameters of the crosslinking system by replacing sulfur-based vulcanization with peroxide-based crosslinking. This parameter change allows achieving strong adhesion (improving feature) while avoiding premature crosslinking during production (worsening feature), as peroxides have different reactivity characteristics and can be controlled to crosslink only under specific conditions (heat, presence of activators) after the product is manufactured.
2Strength
If sulfur-based vulcanization systems are used to achieve good adhesion, then adhesion is improved, but the formulation becomes complex with multiple additives
Solution Approach 1:
The invention extracts and removes sulfur and zinc oxide from the formulation, replacing them with a peroxide-based crosslinking system. This extraction simplifies the formulation by eliminating the need for multiple sulfur-related additives (accelerators, activators, retarders) while maintaining or improving adhesion performance through the polyphenolic compound and peroxide system.
3Strength
If cobalt salt and gallic acid are used to achieve good adhesion to metal, then adhesion is improved, but the composition requires sulfur which complicates production
Solution Approach 1:
The invention changes the crosslinking mechanism from sulfur-based to peroxide-based, and replaces gallic acid with polyphenolic compounds. This parameter change maintains the adhesion-promoting function (cobalt salt and gallic acid provide good adhesion) while eliminating sulfur and simplifying production, as peroxides do not require the same complex sulfur chemistry management.
4Strength
If epoxy-functionalized elastomers are used to achieve low sulfur and zinc oxide content, then adhesion is maintained, but specific elastomers are required limiting material selection
Solution Approach 1:
The invention creates a universal adhesion system based on polyphenolic compounds and peroxides that works with various elastomer types (diene elastomers, styrene-butadiene rubber, nitrile rubber, etc.). The polyphenolic compound serves as a universal adhesion promoter and crosslinking activator that is not limited to specific elastomer chemistries, unlike epoxy-functionalized elastomers which require specific material selection.
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 solution provides excellent adhesion to metallic reinforcing elements, improves durability, and simplifies production by reducing or eliminating sulfur, zinc oxide, and cobalt salt usage, while maintaining good resistance to cracking and external aggressions.
Implementation Method 1
a crosslinking system based on at least one peroxide compound
Implementation Method 2
at least one non-elastomeric polyphenolic compound, the non-elastomeric polyphenolic compound comprising at least three benzene rings, each bearing at least two vicinal hydroxyl groups
Data Source
AI summary
The invention relates to a reinforced product based on at least one metal reinforcement embedded in a rubber composition, the rubber composition being based on at least one diene elastomer, a reinforcing filler mainly comprising silica, a crosslinking system based on at least one peroxide compound and at least one non-elastomeric polyphenolic compound, the non-elastomeric polyphenolic compound comprising at least three benzene rings, each one bearing at least two vicinal hydroxyl groups, and at least one compound from the guanidine family. The invention further relates to a rubber item comprising such a reinforced product.