Rubber Composition Kneading Silane Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rubber compositions with inorganic fillers, such as silica, face challenges in achieving low-heat-generation properties and abrasion resistance due to aggregation issues and suboptimal kneading conditions, which affect the coupling function activity of silane coupling agents.
Innovation Solution
A process involving multiple stages of kneading with specific energy input between 0.05 to 1.50 kWh/kg and blade rotation speeds of 25 to 100 rpm, incorporating a silane coupling agent and vulcanization accelerators like guanidines, sulfenamides, and thiazoles, to enhance the coupling function activity and dispersibility of inorganic fillers in rubber compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a silane coupling agent is incorporated to prevent silica aggregation, then the coupling function activity is improved, but the low-heat-generation property and abrasion resistance are not sufficiently achieved due to suboptimal kneading conditions
Solution Approach 1:
The patent applies parameter changes by optimizing specific kneading conditions including blade rotation speed (20-100 rpm), kneading time (1-30 minutes), and temperature (50-150°C) to maximize the coupling function activity of the silane coupling agent. This systematic parameter optimization resolves the contradiction by transforming the manufacturing process parameters to achieve both improved coupling activity and desired product performance.
Solution Approach 2:
The patent employs dynamics by implementing multi-stage kneading processes where the silane coupling agent is added at specific stages and kneading conditions are dynamically adjusted between stages. This dynamic approach allows the coupling function to develop optimally while preventing aggregation, thereby achieving both improved reliability and manufacturability.
2Reliability
If the activity of the silane coupling agent is increased through various trials, then the coupling function is improved, but the low-heat-generation property and abrasion resistance remain insufficient without proper kneading condition optimization
Solution Approach 1:
The patent simultaneously optimizes multiple parameters including blade rotation speed (20-100 rpm), kneading time (1-30 minutes), and temperature (50-150°C) to achieve both low-heat-generation property and abrasion resistance. This multi-parameter optimization resolves the contradiction by finding the optimal parameter combination that satisfies both performance requirements.
Solution Approach 2:
The patent applies preliminary action by adding the silane coupling agent during the kneading process before final vulcanization, allowing the coupling function to activate and prevent aggregation in advance. This preliminary treatment ensures that the silica particles are properly dispersed and bonded before the tire is put into service, achieving both low-heat-generation and high abrasion resistance.
3Loss of energy
If inorganic filler such as silica is incorporated to reduce rolling resistance, then the low-heat-generation property is improved, but aggregation occurs due to hydroxyl groups on silica surface
Solution Approach 1:
The patent uses a silane coupling agent as an intermediary substance that chemically bonds to the hydroxyl groups on the silica surface and also bonds to the rubber matrix. This intermediary action prevents silica aggregation while maintaining the low-heat-generation property, resolving the contradiction between energy loss reduction and compositional stability.
Solution Approach 2:
The patent optimizes kneading parameters including blade rotation speed (20-100 rpm), kneading time (1-30 minutes), and temperature (50-150°C) to ensure proper dispersion of silica particles and activation of the silane coupling agent. These parameter changes prevent aggregation while maintaining the desired low-heat-generation property.
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
This process effectively improves the low-heat-generation property and abrasion resistance of rubber compositions by optimizing the kneading conditions and activator usage, leading to improved tire performance and reduced rolling resistance.
Implementation Method 1
a silane coupling agent is used
Implementation Method 2
the rubber component (A), all or a portion of the inorganic filler (B), all or a portion of the silane coupling agent (C) and the vulcanization accelerator (D) are added and kneaded
Implementation Method 3
a vulcanization accelerator (D) selected from guanidines, sulfenamides, thiazoles, thiurams, dithiocarbamates, thioureas and xanthates
Data Source
AI summary
The invention is a process for producing a rubber composition containing at least one rubber component (A) selected from natural rubbers and synthetic diene rubbers, a filler containing an inorganic filler (B), a silane coupling agent (C) and a vulcanization accelerator (D), wherein the rubber composition is kneaded in multiple stages, the rubber component (A), all or a portion of the inorganic filler (B), all or a portion of the silane coupling agent (C) and the vulcanization accelerator (D) are added and kneaded in the first stage of kneading, and the specific energy for kneading in the first stage is from 0.05 to 1.50 kWh/kg. The specific energy is obtained by dividing the power consumption by the motor in the kneading device in the first stage of kneading by the total mass of the rubber composition therein. In the process, the coupling function activity can be further increased and a rubber composition favorably having a low-heat-generation property and having good abrasion resistance can be obtained.