Rubber Composition Molten Mixture Dispersibility
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Solution Overview
Problem
The existing rubber compositions face challenges with poor dispersibility of benzoic acid zinc and t-butyl benzoic acid zinc, leading to nonuniform cross-linking, low fuel consumption, and deteriorated elongation at break and crack growth resistance due to their high melting points.
Innovation Solution
Incorporating benzoic acid zinc and/or t-butyl benzoic acid zinc as a molten mixture with fatty acid zinc, specifically zinc oleate, in combination with wet synthetic silica and/or aluminum hydroxide, to improve dispersibility and achieve uniform cross-linking, thereby enhancing low fuel consumption and crack growth resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If benzoic acid zinc and/or t-butyl benzoic acid zinc are used as vulcanization activators, then reversion suppression is improved, but dispersibility deteriorates due to high melting points (193°C and 215°C respectively)
Solution Approach 1:
The patent introduces a mediator substance (fatty acid zinc such as zinc stearate or zinc oleate with low melting point) that facilitates the dispersal of high-melting-point benzoic acid zinc and t-butyl benzoic acid zinc during rubber compounding. The mediator acts as a carrier that allows the vulcanization activators to be uniformly distributed at lower processing temperatures, after which the activators exert their reversion-suppressing function.
Solution Approach 2:
The patent changes the temperature parameter by which the high-melting-point benzoic acid zinc and t-butyl benzoic acid zinc are incorporated into the rubber composition. Instead of requiring temperatures above 193°C or 215°C for melting and dispersal, the invention enables effective incorporation at lower temperatures (below 150°C) through the mediator, thereby improving dispersibility while maintaining reversion suppression functionality.
2Reliability
If benzoic acid zinc and/or t-butyl benzoic acid zinc are used without improvement in dispersibility, then reversion suppression is achieved, but cross-linking uniformity deteriorates
Solution Approach 1:
The mediator (fatty acid zinc) serves as an intermediary carrier that enables uniform distribution of benzoic acid zinc and t-butyl benzoic acid zinc throughout the rubber matrix during the compounding process. This uniform distribution ensures consistent cross-linking density and properties throughout the vulcanized rubber product, eliminating the nonuniformity that would result from poor dispersibility.
3Reliability
If high melting point vulcanization activators are used, then reversion suppression is improved, but fuel consumption increases due to poor dispersibility
Solution Approach 1:
The patent changes the temperature parameter for incorporating the vulcanization activators by using a mediator that enables effective dispersal at lower temperatures. This temperature reduction during compounding directly translates to lower energy consumption and improved fuel efficiency in rubber processing, while the high-melting-point benzoic acid zinc and t-butyl benzoic acid zinc still fulfill their reversion suppression function.
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 exhibits improved dispersibility and uniform cross-linking, resulting in enhanced low fuel consumption and crack growth resistance, with the molten mixture's reduced melting point facilitating easier dispersion during the kneading process.
Implementation Method 1
the molten mixture has a melting point of 150 °C or less
Data Source
AI summary
[Problem to be solved] To provide a rubber composition excellent in low heat generation, elongation at break and crack growth resistance. [Solution] A rubber composition of the present invention, which contains a rubber component, 0.05 - 6.0 parts by mass of benzoic acid zinc and/or t-butyl benzoic acid zinc and 0.5 - 140 parts by mass of wet synthetic silica and/or aluminum hydroxide with respect to 100 parts by mass of the rubber component, is a rubber composition excellent in low heat generation, elongation at break and crack growth resistance.