NdBR Wet Masterbatch Filler Distribution
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Solution Overview
Problem
Current methods for producing carbon black masterbatches are energy-intensive and time-consuming, and conventional techniques struggle to economically produce high-quality masterbatches with optimal filler distribution, especially for tires, which affects rolling resistance and fuel efficiency.
Innovation Solution
A neodymium-catalyzed polybutadiene (NdBR) wet masterbatch is developed, comprising a high proportion of cis-1,4 units and low 1,2-vinyl content, combined with specific carbon blacks, processed in a two-stage method involving suspension and solution polymerization, to enhance vulcanized rubber properties and reduce production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional dry mixing techniques are used to produce carbon black masterbatches, then filler distribution can be achieved, but production time increases and energy consumption rises
Solution Approach 1:
The patent changes the physical state parameter of the mixing system from dry to wet, using a liquid medium (oil or solvent) to facilitate carbon black dispersion. This parameter change enables faster mixing while achieving satisfactory filler distribution, resolving the contradiction between manufacturing precision and productivity
Solution Approach 2:
The patent introduces a liquid intermediary substance (oil or solvent) that acts as a mediator between carbon black particles and the rubber matrix. This intermediary facilitates uniform dispersion and binding of carbon black, achieving good filler distribution without requiring prolonged mixing times
2Loss of energy
If vigorous mixing is used to achieve good filler binding, then energy dissipation reduces, but production costs increase
Solution Approach 1:
The patent changes the mixing regime from vigorous mechanical mixing to gentle stirring in a liquid medium. The liquid medium enables effective filler binding through solvation and reduced particle aggregation, achieving low energy dissipation in the final product without requiring high mixing energy input
3Ease of manufacture
If conventional mixing apparatus are used for carbon blacks with specific surface and structural properties, then production is possible, but economic viability is compromised
Solution Approach 1:
The patent changes the processing parameters by using wet mixing with liquid media, which enables the use of standard, economically viable mixing apparatus even for carbon blacks with challenging surface and structural properties. The liquid medium reduces aggregation and facilitates dispersion without requiring specialized high-cost equipment
4Loss of energy
If masterbatches are produced with satisfactory filler binding, then rolling resistance decreases, but production complexity increases
Solution Approach 1:
The patent extracts the binding function from complex mechanical mixing processes and replaces it with a simpler liquid-phase dissolution and evaporation sequence. The liquid medium naturally facilitates filler binding through solvation, eliminating the need for complex multi-stage mixing apparatus and procedures while achieving low rolling resistance
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 NdBR wet masterbatch improves rolling resistance and reduces production costs by achieving better filler distribution and processing characteristics, resulting in more efficient and cost-effective production of vulcanized rubbers for tires and other applications.
Implementation Method 1
a neodymium-catalysed polybutadiene (NdBR) wet masterbatch is developed, comprising a high proportion of cis-1,4 units and low 1,2-vinyl content, processed in a two-stage method involving suspension and solution polymerization
Implementation Method 2
suspending a carbon black in a liquid, preferably in water, hexane or a water/hexane mixture, thereby forming a carbon black-liquid suspension
Implementation Method 3
The solvent and the suspension liquid are removed by means of a stripping process or by means of evaporative concentration
Data Source
AI summary
The invention relates to an NdBR wet masterbatch comprising -neodymium-catalysed polybutadienes having a high proportion of cis-1,4 units of > 95% and a low proportion of 1,2-vinyl content of < 1%, with narrow polydispersity of less than 3, with a Mooney viscosity (ML1+4100°C) between 30 and 90 MU, with a high linearity index (ratio of solution viscosity to Mooney viscosity) of 3 to 10 m Pas/MU and with a Mooney relaxation after 30 seconds of 2 to 12%, the latter being prepared by means of solution polymerization, -at least one carbon black, the carbon black having an iodine absorption number (ION) between 85 and 210 mg/g, measured to ASTM D1510-1304, and an oil absorption number (OAN) between 75 and 150 ml/100g, measured to ASTM D2414, and -an oil.