Thermoplastic Elastomer Composition for Tire Innerliners
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Solution Overview
Problem
Existing thermoplastic elastomer compositions for tire and industrial rubber applications face challenges in achieving a balance between flexibility, durability, and heat resistance, with previous solutions either lacking flexibility or exhibiting insufficient low-temperature durability.
Innovation Solution
A thermoplastic elastomer composition comprising halogenated isobutylene-containing elastomers as dispersed particles in a continuous nylon resin matrix, formed through dynamic vulcanization, with a high volume percentage of elastomer particles and controlled cure state to enhance durability and impermeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermoplastic resin/thermoplastic resin blends are used to achieve low gas permeability, then gas barrier performance is improved, but flexibility deteriorates and the material becomes liable to break
Solution Approach 1:
The invention uses a composite material system consisting of a thermoplastic resin matrix (nylon 6, nylon 66, or their copolymers) and dispersed vulcanized rubber particles (halogenated isobutylene-containing elastomers). This composite structure combines the gas barrier properties of the thermoplastic resin with the flexibility and durability of the rubber phase, resolving the contradiction between gas permeability and flexibility.
Solution Approach 2:
The invention changes the physical and chemical parameters of the rubber component by applying dynamic vulcanization treatment, transforming the rubber from a soft, deformable state to a vulcanized, cross-linked state with enhanced durability. The vulcanization degree is controlled to maintain flexibility while improving low-temperature durability, achieving a balance between softness and durability.
2Strength
If rubber ratio is increased to achieve sufficient flexibility and durability, then flexibility and durability are improved, but the rubber becomes the matrix and the composition loses thermoplasticity
Solution Approach 1:
The invention controls the viscosity ratio parameter between the rubber and resin phases, maintaining it close to 1:1. This parameter control ensures that the thermoplastic resin remains the continuous matrix phase even at high rubber concentrations (60-80 volume%), preserving thermoplasticity while achieving sufficient flexibility and durability through the high rubber content.
Solution Approach 2:
The invention creates a composite material where vulcanized rubber particles are dispersed in a thermoplastic resin matrix. The vulcanization of the rubber phase provides durability and flexibility, while the thermoplastic resin matrix maintains processability and thermoplasticity, allowing the composition to exhibit both rubber-like performance and thermoplastic characteristics.
3Strength
If thermoplastic resin with melting point less than tire vulcanization temperature is used as matrix, then flexibility is improved, but heat resistance deteriorates and the resin sticks to or rubs with the vulcanization bladder
Solution Approach 1:
The invention selects thermoplastic resins with specific melting points (nylon 6: 210-230°C, nylon 66: 250-270°C, or their copolymers) that balance flexibility and heat resistance. These melting points are carefully chosen to be below the tire vulcanization temperature to maintain flexibility and prevent sticking to the vulcanization bladder, while still providing sufficient heat resistance for tire applications.
4Reliability
If rubber particle size is reduced to improve durability, then durability is improved, but the viscosity ratio control becomes more difficult and manufacturing complexity increases
Solution Approach 1:
The invention controls the viscosity ratio parameter between rubber and resin to be close to 1:1 during mixing. This parameter control facilitates easy dispersion and reduces rubber particle size without requiring complex manufacturing processes, improving durability while maintaining manufacturing simplicity.
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 composition achieves excellent durability, impermeability, and extensibility, suitable for tire innerliners and hoses, with improved resistance to both gases and liquids, while maintaining flexibility and heat resistance.
Implementation Method 1
formed through dynamic vulcanization
Data Source
AI summary
A thermoplastic elastomer composition having excellent durability and flexibility while possessing superior air impermeability. In particular, a process for producing a thermoplastic elastomer composition having high rubber content by multistage addition of at least one vulcanizable rubber component, in which the time required to substantially cure the at least one rubber component preferably is less the mixer residence time. Such compositions are particularly useful in applications such as tire innerliners and barrier films or layers.