Micronized Rubber Powder Surface Activation for Tire Performance
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Solution Overview
Problem
The reuse of micronized rubber powders (MRP) in tires is limited due to size reduction constraints and low surface energy, which affects mechanical and dynamic performance, leading to compromised tear strength, abrasion resistance, and increased rolling resistance.
Innovation Solution
A method involving the chemical activation/functionalization of MRP using agents like synthetic amorphous precipitated silica and silane-treated silica, combined with a two-step grinding process and surface activation techniques, to enhance the vulcanization potential and performance of MRP in tire compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If micronized rubber powder is used as a filler to reduce cost, then material cost is reduced, but mechanical performance and surface energy are insufficient
Solution Approach 1:
The patent applies chemical treatment to change the surface parameters of MRP particles, specifically increasing surface energy through functionalization. This transforms the material properties to enable both cost reduction (by using MRP as filler) and maintaining mechanical performance (through improved surface characteristics that enhance bonding).
Solution Approach 2:
The patent creates a composite system by combining MRP with chemically treated surface layers. The functionalized surface forms a composite structure that integrates the low-cost filler core with a high-performance surface layer, achieving both cost efficiency and mechanical strength.
2Manufacturing precision
If MRP particle size is reduced to improve dispersion and surface appearance, then surface finish is improved, but particle aggregation and processing difficulty increase
Solution Approach 1:
The patent introduces chemical surfactants or coupling agents as intermediary substances that mediate between the MRP particles and the polymer matrix. These intermediaries prevent aggregation of fine particles while maintaining good surface appearance, solving the processing difficulty associated with reduced particle size.
Solution Approach 2:
The patent modifies surface parameters of MRP through chemical treatment to reduce inter-particle attraction forces. This parameter change prevents aggregation and improves processability while maintaining the fine particle size needed for good surface finish.
3Reliability
If chemical treatment is applied to functionalize MRP surface, then compatibility and performance are improved, but processing complexity and cost increase
Solution Approach 1:
The patent performs chemical functionalization of MRP surfaces in advance, before the rubber compounding process. This preliminary action ensures that the surface treatment is already complete when the filler is incorporated into the rubber compound, simplifying the overall processing while achieving improved compatibility and performance.
4Quantity of substance
If MRP is used to replace natural rubber and synthetic polymers, then material cost is reduced, but vulcanization potential and mechanical properties deteriorate
Solution Approach 1:
The patent changes the chemical parameters of MRP surface through functionalization, introducing reactive groups that enable vulcanization bonding. This parameter transformation allows MRP to participate in the vulcanization process, maintaining crosslinking potential and mechanical properties while using cost-effective filler material.
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 chemical activation of MRP significantly improves mechanical and dynamic performance, enabling large-scale reuse in tires with enhanced tear strength, abrasion resistance, and reduced rolling resistance, thus addressing environmental concerns and maximizing the value of end-of-life tire materials.
Implementation Method 1
the MRP is given a chemical treatment to activate, or 'make functional' the surface of the powder particles
Implementation Method 2
a method for manufacturing micronized rubber powders comprising grinding of a rubber granulated feedstock
Data Source
AI summary
A method for manufacturing micronized rubber powders including grinding of a rubber granulated feedstock, size classification and storage of the micronized rubber powders thus obtained. A rubber formulation including at least one natural or synthetic rubber, a micronized rubber composition and optionally one or more of processing aids, antidegradants, fillers, accelerators and curatives. A method for manufacturing a rubber product, as well as to a solid rubber product.