Multiphase Tire Tread Rubber Composition for Heat and Tear Resistance
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Solution Overview
Problem
Existing rubber compositions for tires do not adequately address improvements in heat build-up, tear performance, and abrasion and wear resistance, particularly when utilizing preformed elastomeric composite blends.
Innovation Solution
A method of forming a vulcanizable rubber composition by mixing elastomers in multiple stages, incorporating a composite blend with different elastomers and carbon black, followed by the addition of a curing agent, resulting in a multiphase mixture with varying carbon black distribution across the elastomers, enhancing tear resistance and abrasion properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a homogeneous polymer matrix is formed by combining elastomers in a first non-productive stage, then uniform dispersion of ingredients is achieved, but improved heat build-up and tear performance cannot be obtained
Solution Approach 1:
The rubber composition is segmented into multiple phases with different elastomers (first elastomer phase, second elastomer phase, third elastomer phase) rather than forming a single homogeneous matrix. Each phase contains carbon black dispersed within it, creating a multiphase structure that provides both uniform dispersion benefits and improved performance characteristics through phase-specific properties.
Solution Approach 2:
Different regions of the rubber composition are given different qualities through the multiphase structure. Each elastomer phase can have tailored properties (such as different glass transition temperatures, crystallinity, or carbon black affinity) that locally optimize for specific functions like heat dissipation, tear resistance, or abrasion resistance, while collectively providing uniform overall performance.
2Productivity
If preformed elastomeric composite blends are used, then manufacturing efficiency is improved, but adequate tear performance and abrasion resistance are not achieved
Solution Approach 1:
The composite blend is prepared in advance with carbon black pre-dispersed in the second elastomer, creating a preformed intermediate product that simplifies the final compounding process. This preliminary action maintains manufacturing efficiency while the subsequent multiphase formulation ensures adequate tear and abrasion performance through the controlled distribution of carbon black across different elastomer phases.
Solution Approach 2:
The invention uses a composite structure at the micro level by combining multiple elastomer phases, each containing carbon black. This composite material approach allows the final rubber composition to achieve superior mechanical properties (tear and abrasion resistance) that cannot be obtained with single-phase systems, while still utilizing the manufacturing advantages of preformed composite blends.
3Ease of operation
If carbon black is uniformly dispersed throughout all elastomers, then processing ease is improved, but enhanced durability through selective filler distribution is lost
Solution Approach 1:
Carbon black is distributed non-uniformly across different elastomer phases, with each phase containing carbon black at concentrations optimized for its specific elastomer's properties. This local quality approach creates regions with different reinforcement characteristics, improving overall durability through synergistic effects while maintaining adequate processability.
Solution Approach 2:
Instead of uniformly distributing carbon black throughout all elastomers as in conventional approaches, the invention inverts the strategy by creating distinct phases where carbon black is selectively concentrated in specific elastomer matrices. This inversion allows for optimized interaction between carbon black and different elastomer types, enhancing durability through selective filler-elastomer affinity in each phase.
Data Source
Figure 1
AI summary
A method of forming a vulcanizable rubber composition for use in a tire tread is disclosed. The method includes a sequence of non-productive mixing steps. In a first of the non-productive mixing steps, a composite blend is mixed with a first elastomer to generate a first mixture. The composite blend includes a second elastomer, which may be the same as, or different from, the first elastomer, and carbon black. In a second of the non-productive mixing steps, a third elastomer, different from the first elastomer, is mixed with the first mixture, or with a mixture generated from the first mixture, to generate a second mixture. In a productive mixing step, a curing agent is mixed with the second mixture, or with a mixture generated from the second mixture, to generate the vulcanizable rubber composition, which includes the first, second, and third elastomers, carbon black from the composite blend, and an additional amount of a reinforcing filler.