Silica Tire Tread Compound Without Resorcinol for Heavy Vehicles
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Solution Overview
Problem
Existing rubber compounds for heavy vehicle tires, such as those used in trucks and buses, fail to provide the necessary load-bearing properties and fuel efficiency due to the presence of resorcinol and formaldehyde, which are toxic and volatile, and do not effectively utilize silica-based treads for improved rolling resistance.
Innovation Solution
A rubber compound formulation comprising natural rubber, silica, specialty silane coupling agents, hexamethoxymethylmelamine (HMMM), and phloroglucinol resins, which are free from resorcinol and formaldehyde, to create a highly fuel-efficient and durable tire tread.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resorcinol and formaldehyde are used in rubber compounds, then adhesion properties and dynamic properties are improved, but toxicity and volatility increase
Solution Approach 1:
The patent removes resorcinol and formaldehyde from the rubber compound formulation, extracting the harmful substances while maintaining the desired adhesion and dynamic properties through alternative compounds and formulations.
Solution Approach 2:
The patent converts the harmful resorcinol-formaldehyde system into a beneficial alternative using compounds that provide similar or improved adhesion and dynamic properties without the toxicity and volatility issues, effectively turning a harmful approach into a beneficial one.
2Reliability
If resorcinol and formaldehyde are used in rubber compounds, then dynamic properties are improved, but fuel efficiency deteriorates
Solution Approach 1:
The patent extracts resorcinol and formaldehyde from the formulation to improve fuel efficiency while maintaining dynamic properties through alternative compounds that do not negatively impact energy consumption.
Solution Approach 2:
The patent changes the chemical composition parameters by replacing resorcinol and formaldehyde with alternative compounds, which alters the physical and chemical properties of the rubber compound to achieve better fuel efficiency while preserving dynamic performance.
3Loss of energy
If silica-based treads are used, then rolling resistance is improved, but load-bearing properties deteriorate
Solution Approach 1:
The patent creates a composite rubber compound formulation that combines silica with alternative compounds and additives, achieving a synergistic effect that provides both low rolling resistance and sufficient load-bearing capacity for heavy vehicle applications.
Solution Approach 2:
The patent adjusts the formulation parameters by replacing resorcinol and formaldehyde with alternative compounds that enhance the load-bearing properties of silica-based treads without compromising the rolling resistance benefits.
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 compound achieves superior rolling resistance and durability without the drawbacks of resorcinol and formaldehyde, making it suitable for heavy-duty applications.
Implementation Method 1
at least one organosilane coupling agent; at least one reinforcing filler that is reactive with the at least one organosilane coupling agent
Implementation Method 2
at least one sulfur-donating compound; wherein the cured rubber composition comprises a crosslinked rubber polymer or crosslinked blend of polymers
Data Source
AI summary
A silane-based additive, rubber formulations including the additive and tires having tread portions made with the additive, together with methods of forming those products, are provided. Uncured rubber formulations in accordance with preferred embodiments of the invention comprise (1) a rubbery primary polymer or polymer blend, such as natural rubber and/or synthetic rubber; (2) reinforcing silica filler; (3) methylene donor compound; (4) a silane containing one or more moieties of the aforementioned network forming polymer. And (5) phloroglucinol resin. In particular networks which can be generated in-situ are preferred. The cured rubber formulation should comprise the silica, having the load-bearing-path reinforcing interpenetrating polymer network coupled thereto, within the rubber matrix, and not directly to the rubber chains via sulfidic linkages.


