Microfibrillated Plant Fiber Rubber Composition Dispersion
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Solution Overview
Problem
Microfibrillated plant fibers have strong self-aggregation properties and poor compatibility with rubber, leading to incomplete incorporation and agglomerate formation in tire rubber compositions, resulting in premature wear, cracks, chipping, air leakage, and reduced handling stability and durability.
Innovation Solution
A rubber composition is developed by mixing rubber latex with microfibrillated plant fibers and a cationic polymer, where 0.01 to 5 parts of the cationic polymer are added per 100 parts of rubber latex, ensuring uniform dispersion and improved compatibility, with a masterbatch containing 5 to 30 parts of microfibrillated plant fibers per 100 parts of rubber latex.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If microfibrillated plant fibers are added to rubber latex to reinforce the rubber composition, then the modulus is improved, but the fibers aggregate and form agglomerates that reduce handling stability and cause premature wear
Solution Approach 1:
A masterbatch is introduced as an intermediary carrier that pre-disperses microfibrillated plant fibers in a controlled environment before incorporation into the final rubber composition. This masterbatch acts as a mediator that prevents direct aggregation of fibers during final mixing, thereby maintaining both reinforcement properties and handling stability.
Solution Approach 2:
The fibers are pre-dispersed and processed in the masterbatch stage before being added to the main rubber composition. This preliminary dispersion action ensures uniform distribution of fibers at a smaller scale where aggregation is easier to control, preventing the formation of large agglomerates that would compromise handling stability.
2Strength
If microfibrillated plant fibers are incorporated into rubber composition, then the modulus is enhanced, but the fibers remain partially unincorporated and form agglomerates causing cracks and chipping
Solution Approach 1:
The incorporation process is segmented into two stages: first, fibers are dispersed in the masterbatch at a controlled concentration (5-30 parts per 100 parts rubber latex); second, the masterbatch is incorporated into the final rubber composition. This segmentation allows optimal dispersion conditions to be achieved in each stage, preventing aggregation and ensuring uniform distribution.
Solution Approach 2:
The invention creates a composite masterbatch material consisting of rubber latex and microfibrillated plant fibers in specific proportions. This composite structure ensures that fibers are already bound within a rubber matrix in the masterbatch, preventing their aggregation when added to the final composition and ensuring uniform dispersion throughout the tire product.
3Strength
If a high amount of microfibrillated plant fibers is added to improve reinforcement, then the modulus increases, but the compatibility with rubber component deteriorates leading to phase separation
Solution Approach 1:
The invention optimizes the fiber concentration parameter in the masterbatch to a specific range (5-30 parts per 100 parts rubber latex). This parameter change ensures that the fiber-rubber interface maintains adequate compatibility while achieving sufficient reinforcement. The controlled concentration prevents excessive fiber-fiber interactions that would lead to aggregation and phase separation.
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 achieves balanced improvement in tire performance properties such as handling stability, riding comfort, abrasion resistance, and fuel economy by ensuring uniform dispersion of microfibrillated plant fibers, reducing agglomerates, and maintaining good elongation at break.
Implementation Method 1
mixing rubber latex, microfibrillated plant fibers and a cationic polymer
Implementation Method 2
mixing rubber latex, microfibrillated plant fibers and a cationic polymer
Data Source
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AI summary
The present invention provides a rubber composition that allows uniform dispersion of microfibrillated plant fibers so as to improve the required performance for a tire in a balanced manner, and a pneumatic tire formed from the rubber composition. The present invention relates to a rubber composition prepared from a masterbatch obtained by mixing rubber latex, microfibrillated plant fibers and a cationic polymer, wherein 0.01 to 5 parts by mass of the cationic polymer is added per 100 parts by mass of a rubber component of the rubber latex.