Crosslinked Rubber Composition Abrasion Resistance via Density Control
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Solution Overview
Problem
Existing crosslinked rubber compositions for tire treads often face challenges in achieving excellent abrasion resistance despite high hardness, with the mechanism of abrasion resistance not being fully understood, and existing analysis methods do not effectively assess the material's properties under external energy or elongation.
Innovation Solution
A crosslinked rubber composition with a high volume of low density region at 1.5 MPa elongation and a low volume of void region at 3.0 MPa elongation, combined with a hardness of 65 or more, is developed, utilizing X-ray computerized tomography for evaluation, which enhances abrasion resistance by inhibiting cracking growth and improving stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the hardness of crosslinked rubber composition is increased to improve steering stability, then steering stability is improved, but abrasion resistance does not necessarily improve and may even deteriorate
Solution Approach 1:
The patent applies local quality by creating regions with different density characteristics within the rubber composition. Specifically, it controls the distribution of low density regions (0.1-0.8 times the density of crosslinked rubber before elongation) and void portions (0-0.1 times the density) to achieve uniform stress distribution while maintaining high hardness, thereby improving both steering stability and abrasion resistance simultaneously
Solution Approach 2:
The patent changes physical parameters by specifying precise density ratios and volume proportions of low density regions and void portions. By controlling these parameters - the density relative to crosslinked rubber before elongation and the volume percentages - the invention optimizes the balance between hardness and abrasion resistance, resolving the contradiction where higher hardness does not guarantee better abrasion resistance
2Strength
If the rigidity of tire tread portion is increased to improve curve turning capability, then curve turning capability is improved, but the mechanism of abrasion resistance remains unclear and cannot be reliably enhanced
Solution Approach 1:
The patent employs feedback by using X-ray computerized tomography to measure and evaluate the density distribution, low density region volume, and void portion volume of the rubber composition. This measurement feedback allows precise control and optimization of the internal structure to ensure both high rigidity for curve turning and excellent abrasion resistance through controlled stress distribution
Solution Approach 2:
The patent replaces traditional mechanical testing methods with X-ray computerized tomography technology to analyze the internal structure and density distribution of the rubber composition. This substitution enables non-destructive measurement of low density regions and void portions, providing reliable data to optimize both rigidity and abrasion resistance without relying on unclear mechanical mechanisms
3Measurement precision
If existing analysis methods are used to evaluate material properties, then visual analysis of material composition is possible, but analysis under external energy or elongation conditions cannot be performed
Solution Approach 1:
The patent applies universality by implementing a multi-functional evaluation system using X-ray computerized tomography that can simultaneously analyze material composition, density distribution, low density region volume, and void portion volume under various conditions including external energy and elongation. This universal measurement approach enables comprehensive evaluation of rubber composition properties across different operational states
Solution Approach 2:
The patent applies dynamics by enabling the measurement system to evaluate the rubber composition under dynamic conditions such as elongation and external energy application. The X-ray computerized tomography technology captures real-time density distribution changes during deformation, allowing analysis of low density region and void portion behavior under stress, thereby providing versatile evaluation capabilities beyond static visual inspection
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 composition achieves superior abrasion resistance by maintaining high hardness and minimizing void formation, leading to improved durability and resistance against external stress, as demonstrated by increased abrasion resistance indices in tire tests.
Implementation Method 1
an X-ray computerized tomography is known as a technology for analyzing a material constituting a solid sample and a low density region contained in an inside thereof
Implementation Method 2
a method of evaluating a density distribution of a crosslinked rubber composition when extended, and volumes of a low density region and a void portion, by means of an X-ray computerized tomography
Data Source
AI summary
A pneumatic tire includes bead cores, a carcass ply, an inner liner, and a tread having a volume of the low density region of 35% or more at elongation by an applied stress of 1.5 MPa, a volume of the void portion of 7.5% or less at elongation by an applied stress of 3.0 MPa and a hardness of 65 or more and the crosslinked rubber composition of the present invention having a volume of the low density region of 35% or more at elongation by an applied stress of 1.5 MPa, a volume of the void portion of 7.5 or less at elongation by an applied stress of 3.0 MPa and a hardness of 65 or more are excellent in abrasion resistance.