Rubber Wet Masterbatch Production via Carbon Black Parameter Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rubber compositions used in tire production do not adequately address the need for vulcanized rubbers with low exothermicity and abrasion resistance.
Innovation Solution
A method for producing a rubber wet masterbatch using carbon black with specific dibutyl phthalate oil absorption and statistical thickness specific surface area values, combined with a rubber latex solution and dispersing solvent, to achieve improved exothermicity and abrasion resistance in vulcanized rubbers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon black with high DBP oil absorption is used to improve abrasion resistance, then abrasion resistance is improved, but exothermicity increases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the DBP oil absorption (105-230 mL/100g) and STSA (90-205 m2/g) of carbon black, along with the difference between these parameters (≥15). This optimization of physical parameters enables the carbon black to provide adequate abrasion resistance while limiting exothermicity, resolving the contradiction between these two properties.
2Object-generated harmful factors
If carbon black with large STSA is used to decrease exothermicity, then exothermicity is decreased, but abrasion resistance deteriorates
Solution Approach 1:
The patent resolves this contradiction by optimizing multiple parameters simultaneously: STSA (90-205 m2/g) to control exothermicity, DBP oil absorption (105-230 mL/100g) to maintain abrasion resistance, and the difference between DBP and STSA (≥15) to balance both properties. This multi-parameter optimization ensures that exothermicity is controlled while abrasion resistance is maintained.
3Ease of manufacture
If rubber dry masterbatch is used to simplify production, then production process is simplified, but dispersibility of carbon black deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-dispersing carbon black in a dispersing solvent to form a slurry solution before mixing with rubber latex. This preliminary dispersion step ensures uniform distribution of carbon black particles, and when combined with the optimized carbon black parameters, achieves excellent dispersibility in the final rubber composition.
4Stability of the object's composition
If rubber wet masterbatch is used to improve dispersibility, then dispersibility of carbon black is improved, but production complexity increases
Solution Approach 1:
The patent reduces production complexity by optimizing the physical parameters of carbon black (DBP oil absorption, STSA, and their difference). These parameter optimizations improve the inherent dispersibility of carbon black, reducing the need for complex dispersion equipment and processes while still achieving excellent dispersibility in the rubber composition.
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 provides a balance between low exothermicity and abrasion resistance in vulcanized rubbers, enhancing their performance in tire applications.
Implementation Method 1
dispersing the carbon black in the dispersing solvent by a mechanical force
Implementation Method 2
adding a coagulant such as an acid to the mixture to coagulate the mixture
Data Source
AI summary
A method for producing a rubber wet master batch is disclosed including: producing a carbon black-containing rubber latex solution by mixing carbon black, a dispersion solvent and a rubber latex solution; producing a carbon black-containing rubber coagulum by coagulating the thus-obtained carbon black-containing rubber latex solution; and producing a rubber wet master batch by dehydrating and drying the thus-obtained carbon black-containing rubber coagulum. With respect to this method for producing a rubber wet master batch, the carbon black satisfies conditions such that: the DBP oil absorption is 105-230 mL/100 g; STSA is 90-205 m2/g; and the value obtained by subtracting the value of STSA from the value of DBP oil absorption is 15 or more. This method for producing a rubber wet master batch enables the achievement of a vulcanized rubber that has wear resistance and low heat generation properties.