Styrene-Butadiene Copolymer Rubberization for Cord Capillary Filling
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Solution Overview
Problem
The existing manufacturing process for metal cord rubberized in situ for heavy industrial vehicle tires faces issues with radial overflowing of the rubber composition, leading to plant fouling and shutdowns due to imprecise control of the rubber amount, which is industrially restrictive and inefficient.
Innovation Solution
A metal cord is rubberized using a styrene-butadiene copolymer with a specific composition of 25-35% styrene units and 73-83% trans-1,4-bonds, reducing fluidity and preventing radial overflowing by ensuring precise filling of capillaries with the rubber composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the amount of rubber composition is increased to ensure complete filling of capillaries and gaps, then the filling completeness is improved, but radial overflowing occurs causing plant fouling and shutdowns
Solution Approach 1:
The patent changes the chemical composition parameters of the rubber composition by specifying a styrene-butadiene copolymer with 25-35% styrene units and controlling the microstructure (73-83% trans-1,4 bonds). These parameter changes modify the rheological properties of the rubber composition, reducing its fluidity and preventing radial overflowing while ensuring complete capillary filling.
2Object-generated harmful factors
If the amount of rubber composition is precisely controlled to prevent radial overflowing, then plant fouling is reduced, but the control process becomes more restrictive and complex
Solution Approach 1:
The patent simplifies the control process by changing the inherent parameters of the rubber composition (styrene content and microstructure) rather than relying on complex process control mechanisms. This material parameter change inherently prevents radial overflowing without requiring additional control devices or complex monitoring systems.
3Manufacturing precision
If the fluidity of rubber composition is increased to improve filling of capillaries, then the filling efficiency is improved, but radial overflowing is exacerbated
Solution Approach 1:
The patent optimizes the balance between fluidity and containment by precisely controlling the styrene-butadiene copolymer composition. The specific range of styrene units (25-35%) and trans-1,4 bonds (73-83%) creates a rubber composition with optimal rheological properties that fills capillaries efficiently while maintaining sufficient viscosity to prevent radial overflowing.
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 solution effectively reduces the risk of radial overflowing, maintaining the rubber composition within the cord and preventing plant fouling, allowing for continuous operation and improved industrial efficiency.
Implementation Method 1
The styrene-butadiene copolymer confers, on the rubber composition, a lower fluidity than that conferred by other diene elastomers, in particular natural rubber
Data Source
AI summary
A metal cord is rubberized in situ by a rubber composition that includes a styrene-butadiene copolymer. The styrene-butadiene copolymer includes styrene units at a proportion of between 25% and 35% by weight, limits included, of a total weight of the styrene-butadiene copolymer. The styrene-butadiene copolymer also includes trans-1,4-bonds at a proportion of between 73% and 83% by weight, limits included, of a total weight of a butadiene part of the styrene-butadiene copolymer.