Rubber Composition Manufacturing Using Thioester Silane and Imide
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Solution Overview
Problem
Existing rubber composition manufacturing methods face challenges in achieving a balance between processability, wear resistance, and steering stability due to the limitations of disulfide-based and thioester-based silane coupling agents, where disulfide agents form gels during kneading but have low bonding with polymers, and thioester agents have low reactivity during vulcanization.
Innovation Solution
A manufacturing method involving a base kneading process with a thioester-based silane coupling agent and a finishing kneading process with an imide or N-oxyl compound to control reactivity and enhance bonding, improving processability and vulcanization performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If disulfide-based silane coupling agent is used, then processability is improved, but bonding with polymer deteriorates
Solution Approach 1:
The patent segments the silane coupling agent into two distinct types: disulfide-based (for processability) and thioester-based (for bonding strength). Each type performs its specific function without compromising the other, resolving the contradiction between ease of manufacture and bonding strength.
Solution Approach 2:
The patent creates a composite silane coupling system by combining disulfide-based and thioester-based silane coupling agents in specific proportions (0.1-5 mass% disulfide and 0.1-5 mass% thioester). This composite approach allows the system to simultaneously achieve good processability from the disulfide component and strong polymer bonding from the thioester component.
2Strength
If thioester-based silane coupling agent is used, then bonding with polymer is improved, but reactivity during vulcanization deteriorates
Solution Approach 1:
The patent divides the silane coupling function between two specialized agents: thioester-based (optimized for bonding) and disulfide-based (optimized for reactivity). This segmentation allows each agent to excel at its designated function without the trade-offs that would occur with a single agent.
Solution Approach 2:
By formulating a composite system with both thioester-based (0.1-5 mass%) and disulfide-based (0.1-5 mass%) silane coupling agents, the patent achieves synergistic effects where the thioester provides strong bonding and the disulfide maintains adequate vulcanization reactivity.
3Strength
If inorganic filler is added to improve wear resistance, then steering stability deteriorates
Solution Approach 1:
The patent optimizes the inorganic filler content to a specific range (20-80 parts by mass per 100 parts rubber component) and adjusts the silane coupling agent proportions to balance wear resistance and steering stability. This parameter optimization resolves the contradiction by finding the optimal operating point.
Solution Approach 2:
The patent creates a composite formulation combining rubber components, inorganic filler (20-80 parts), and a dual silane coupling system. This composite approach allows the inorganic filler to provide wear resistance while the silane coupling agents ensure adequate polymer-filler bonding to maintain steering stability.
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 results in a rubber composition with improved processability, wear resistance, and steering stability, achieving a well-balanced performance by maintaining good processability and increasing bonding between the silane coupling agent and polymer during vulcanization.
Implementation Method 1
kneading a rubber component, an inorganic filler and a thioester-based silane coupling agent
Implementation Method 2
the imide compound or the N-oxyl compound promotes breaking of the S—C bond of the thioester-based silane coupling agent
Implementation Method 3
adding a vulcanizing agent and one or more compounds selected from the group of an imide compound and an N-oxyl compound
Data Source
AI summary
A method for manufacturing a rubber composition includes kneading a rubber component, an inorganic filler and a thioester-based silane coupling agent, and adding a vulcanizing agent and one or more compounds selected from the group of an imide compound and an N-oxyl compound to a mixture of the rubber component, the inorganic filler, and the thioester-based silane coupling agent such that the vulcanizing agent and the imide compound and/or the N-oxyl compound are kneaded with the mixture including the rubber component, the inorganic filler, and the thioester-based silane coupling agent.