Poly Alkylacrylate Rubber Composition for High-Temperature Stiffness
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Solution Overview
Problem
Existing rubber compositions for tires face challenges in achieving high stiffness while maintaining properties beyond 120°C, and they often suffer from increased weight and processing difficulties due to the use of high amounts of fillers like silica or carbon black.
Innovation Solution
A rubber composition comprising at least one elastomer, one filler, and a thermoplastic polymer, specifically a poly alkylacrylate with a polycyclic substituent, which enhances stiffness, processability, and heat resistance without the drawbacks of high filler content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high amounts of filler materials (silica or carbon black) are used to improve stiffness, then stiffness is improved, but weight increases and processing becomes more difficult
Solution Approach 1:
The patent changes the chemical structure parameters of the acrylic polymer by introducing polycyclic substituents (bicyclic or tricyclic groups) at the oxygen atom position. This structural modification increases the glass transition temperature and enhances stiffness without requiring high filler content, thereby avoiding the weight penalty associated with traditional filler-based stiffening approaches.
Solution Approach 2:
The patent creates a composite rubber composition combining elastomer, filler, and a specifically designed thermoplastic polymer (poly alkylacrylate with polycyclic substituent). This multi-component composite achieves synergistic effects where the thermoplastic polymer provides reinforcement and stiffness enhancement while maintaining lower weight compared to filler-only approaches.
2Strength
If high amounts of filler materials (silica or carbon black) are used to improve stiffness, then stiffness is improved, but mixing and processing become more difficult
Solution Approach 1:
The patent modifies the thermoplastic polymer parameters by incorporating polycyclic substituents, which change the material's processability characteristics. The bulky polycyclic groups create steric hindrance that prevents excessive chain entanglement and improves dispersion during mixing, making processing easier while still achieving high stiffness in the final product.
3Strength
If polyethylene is used to improve stiffness, then stiffness is improved, but processing becomes difficult and dispersion is poor
Solution Approach 1:
The patent changes the chemical parameters of the thermoplastic component by selecting poly alkylacrylate with polycyclic substituent instead of polyethylene. The acrylic polymer structure with its polar carbonyl group and bulky polycyclic substituent provides better compatibility with rubber matrices and improved dispersion characteristics during processing, while still delivering the desired stiffness enhancement.
4Strength
If polyethylene is used to improve stiffness, then stiffness is improved, but melting point is relatively low (around 135°C)
Solution Approach 1:
The patent changes the thermal parameters of the thermoplastic component by selecting poly alkylacrylate with polycyclic substituent. The polycyclic groups introduce rigid structural elements that significantly elevate the glass transition temperature and thermal stability of the polymer, ensuring the composition maintains stiffness at temperatures well above 135°C where polyethylene would soften.
5Strength
If high filler content is used to achieve reinforcement, then reinforcement is improved, but hysteresis and weight increase
Solution Approach 1:
The patent employs a composite approach combining elastomer, filler, and thermoplastic polymer (poly alkylacrylate with polycyclic substituent). The thermoplastic polymer acts as a reinforcing agent with low hysteresis characteristics, providing reinforcement benefits while minimizing energy loss during deformation cycles, unlike high filler content formulations that typically exhibit higher hysteresis.
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 rubber composition achieves significant reinforcement with limited hysteresis and weight, maintaining high stiffness substantially beyond 120°C, and improves processability and heat resistance, outperforming compositions with high filler content.
Implementation Method 1
its substituents limit significantly the chain mobility within the material
Implementation Method 2
Provision of such a poly alkylacrylate reinforces the rubber compound
Implementation Method 3
there may also be less forces resulting in phase separation during mixing which may help to achieve better dispersion
Implementation Method 4
has also a relatively high heat resistance
Data Source
Figure 1
AI summary
In a first aspect of the present invention, a rubber composition is provided, comprising at least one rubber, at least one filler, at least one thermoplastic polymer, wherein the thermoplastic polymer is a poly alkylacrylate, and wherein the alkylacrylate comprises a polycyclic substituent at its single bonded oxygen atom. In another aspect of the invention, an article of manufacture such as a tire, a power transmission belt, a hose, a track, an air sleeve, and a conveyor belt is provided which comprises the rubber composition in accordance with the first aspect.