Rubber Wet Masterbatch Dispersion Stability
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Solution Overview
Problem
Existing rubber wet masterbatch production methods result in poor carbon black dispersion and re-flocculation, leading to low thermogenic performance and fatigue resistance in vulcanized rubber, while also increasing electric resistance, which is undesirable for tire applications.
Innovation Solution
A rubber wet masterbatch is produced using carbon black with an iodine adsorption number of 41 mg/g or less, dispersed in a solvent with a rubber latex solution, and then mixed and dried to ensure even carbon black distribution, reducing re-flocculation and enhancing thermogenic and fatigue resistance while lowering electric resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If carbon black is dispersed in water to form a slurry solution and then mixed with natural rubber latex, then carbon black dispersibility is improved, but re-flocculation occurs over time leading to poor dispersion stability
Solution Approach 1:
The patent applies preliminary action by adding a protective colloid to the carbon black slurry solution before mixing with natural rubber latex. This protective colloid forms a stabilizing layer around carbon black particles in advance, preventing re-flocculation during storage and subsequent processing. The protective colloid is incorporated into the dispersing system prior to the main mixing operation, ensuring dispersion stability is established before the composition undergoes further transformations.
2Strength
If conventional carbon black is used in rubber composition, then rubber reinforcement is achieved, but electric resistance increases which is undesirable for tire applications
Solution Approach 1:
The patent applies parameter changes by carefully controlling the particle size distribution of carbon black, specifically setting the D90 value to 30 μm or less. This parameter modification allows the carbon black to provide adequate reinforcement while reducing the formation of continuous conductive networks that would increase electric resistance. The controlled particle size distribution optimizes the balance between mechanical reinforcement and electrical properties.
Solution Approach 2:
The patent applies composite materials by combining carbon black with a protective colloid system to create a hybrid dispersion structure. The protective colloid acts as a matrix or interfacial material that modifies how carbon black particles interact with each other and with the rubber matrix. This composite approach allows the carbon black to provide reinforcement while the protective colloid prevents excessive particle aggregation that would create conductive pathways.
3Productivity
If carbon black is dispersed with high concentration in slurry solution, then productivity is improved, but re-flocculation advances easily leading to poor dispersion
Solution Approach 1:
The patent applies the intermediary principle by introducing a protective colloid as a mediating substance between carbon black particles and the aqueous dispersing medium. This protective colloid acts as a spacer or barrier that prevents direct contact and aggregation of carbon black particles, even at high concentrations. The intermediary substance enables high solids content in the slurry solution without sacrificing dispersion stability, thereby maintaining both productivity and dispersion quality.
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 resulting vulcanized rubber exhibits improved low thermogenic performance, fatigue resistance, and reduced electric resistance, with excellent carbon black dispersion stability over time, suitable for use in tire components.
Implementation Method 1
mixing the carbon black beforehand with a dispersing solvent at a predetermined ratio; using mechanical force to mix the resultant carbon-black-containing slurry solution, in which the carbon black is dispersed in the dispersing solvent
Implementation Method 2
at least one portion of the rubber latex solution is added to the carbon-black-dispersed solvent to produce a slurry solution containing the carbon black to which rubber latex particles adhere
Data Source
AI summary
A rubber wet masterbatch obtained, using at least a carbon black, a dispersing solvent, and a latex solution of a rubber as raw materials, the carbon black being a carbon black having an iodine adsorption number of 41 mg/g or less, and the rubber wet masterbatch being obtained through the following process: a process in which at the time of dispersing the carbon black into the dispersing solvent, at least one portion of the rubber latex solution is added to the carbon-black-dispersed solvent to produce a slurry solution comprising the carbon black to which rubber latex particles adhere, subsequently the slurry solution is mixed with the rest of the rubber latex solution, and next the mixture is solidified and dried.