Rubber Mixture Two-Stage Mixing Silane Coupling
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Solution Overview
Problem
Existing rubber mixtures for tires face a trade-off between improving wet grip and reducing rolling resistance, which often results in compromised abrasion and heat build-up, affecting tire handling.
Innovation Solution
A method involving a two-stage mixing process where one or more rubbers are mixed with mercaptosilane, anti-aging agents, anti-ozone waxes, plasticizers, inorganic activators, sulfenamide accelerators, and additional silanes in the first stage, followed by the addition of the vulcanization system in the second stage, optimizing the distribution and binding of silica and carbon black for improved processing and abrasion properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If silica is added to improve rolling resistance, then rolling resistance is reduced, but abrasion and heat build-up worsen
Solution Approach 1:
The patent uses a silane coupling agent as an intermediary substance that chemically bonds to both the silica particles and the rubber polymer matrix. This mediator improves the interfacial adhesion between silica and rubber, allowing silica to reduce rolling resistance while the coupling agent prevents silica aggregation and reduces heat build-up, thereby maintaining abrasion resistance
Solution Approach 2:
The patent creates a composite material system consisting of silica particles, silane coupling agent, and rubber polymer. This composite structure allows the combination of silica's low rolling resistance properties with the coupling agent's heat dissipation and adhesion-enhancing properties, achieving both reduced rolling resistance and maintained abrasion resistance
2Manufacturing precision
If mixing energy is increased to improve silica distribution, then distribution improves, but heat build-up increases
Solution Approach 1:
The patent applies the silane coupling agent to the silica particles before mixing them into the rubber compound. This preliminary treatment creates a hydrophobic surface layer on the silica particles that improves their dispersibility in the rubber matrix, reducing the mixing energy required and consequently limiting heat build-up during the mixing process
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 method enhances processing behavior and abrasion resistance while maintaining wet braking and rolling resistance performance, as demonstrated by smoother rubber skin and improved abrasion characteristics in test specimens.
Implementation Method 1
coupling agents, especially in the form of silanes, must generally be added to the base mixture, which at the same time provide hydrophobization the silica surface also enables a chemical bond to the surrounding rubber molecules during the subsequent vulcanization
Implementation Method 2
The addition of the vulcanization system in the form of sulfur and/or sulfur-donating substances and one or more further vulcanization accelerators takes place in a second mixing stage in a mixer and then the finished rubber mixture obtained is vulcanized
Data Source
AI summary
Manufacturing a rubber composition comprises: mixing (a) a rubber, a mercaptosilane, a filler, an aging inhibitor, an ozone protecting wax, a softener, an inorganic activator, and a processing agent, (b) a sulfenamide accelerator and/or thiazole accelerator, (c) a further silane, (d) sulfur and/or a sulfur source, and (e) a vulcanization accelerator to obtain a rubber blend; and vulcanizing the rubber blend.