Silica-Reinforced Tire Compound With Dual-Silane Vulcanization
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Solution Overview
Problem
The use of high amounts of sulfur in vulcanization processes leads to reversion phenomena, while high carbon black content increases rolling resistance, and silica replacement reduces mechanical properties, necessitating improved coupling agents to balance hysteresis and mechanical properties in tire production.
Innovation Solution
A mixture of sulfur-silane and amino-silane is used in an elastomeric composition with functionalized and non-functionalized polymers to modulate the vulcanization curve, enhancing mechanical properties and reducing hysteresis, allowing stable and efficient vulcanization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high amounts of sulfur are used in vulcanization, then cross-linking and mechanical properties are improved, but reversion phenomena occur causing performance degradation
Solution Approach 1:
The patent changes the chemical composition parameters of the vulcanization system by introducing organosilane coupling agents (specifically silanes with alkoxy groups) alongside traditional sulfur vulcanization. This creates a dual cross-linking mechanism where silane forms additional cross-links between silica and polymer chains, allowing reduced sulfur content while maintaining mechanical properties and preventing reversion
Solution Approach 2:
The patent creates a composite vulcanization system combining organic polymer matrix, inorganic silica filler, and organosilane coupling agents. The silane acts as an interface material that chemically bonds silica to the polymer, forming a hybrid network structure that improves both mechanical properties and thermal stability while reducing reliance on high sulfur content
2Strength
If high amounts of carbon black are used to improve mechanical properties, then strength is enhanced, but hysteresis increases leading to higher rolling resistance and fuel consumption
Solution Approach 1:
The patent changes the filler composition parameter by replacing carbon black with white reinforcing fillers (silica) and modifying the chemical environment through organosilane coupling agents. This creates a low-hysteresis compound that achieves adequate mechanical properties through improved silica-polymer interaction rather than high filler content, reducing energy loss during dynamic deformation
Solution Approach 2:
The patent substitutes traditional carbon black reinforcement with a silica-based system that, while requiring coupling agents, provides longer service life through reduced heat generation and lower rolling resistance, effectively replacing a short-lived high-performance material with a more sustainable low-loss alternative
3Loss of energy
If silica is used to replace carbon black to reduce hysteresis, then rolling resistance decreases, but mechanical properties are reduced due to low affinity between silica and elastomeric polymers
Solution Approach 1:
The patent introduces organosilane coupling agents as intermediary substances that chemically bridge silica particles and elastomeric polymer chains. The silane's alkoxy groups hydrolyze and condense to form siloxane bonds with silica surface hydroxyl groups, while the organic side chains interact with the polymer matrix, creating strong interfacial adhesion and transferring stress effectively from polymer to filler
Solution Approach 2:
The patent modifies the chemical parameters of the silica surface through silane treatment, transforming hydrophilic silica into hydrophobic silane-modified silica that is compatible with non-polar elastomeric polymers. This chemical modification changes the surface energy and affinity parameters, enabling strong bonding without requiring excessive silica content or prolonged mixing
4Strength
If coupling agents are used to improve silica-polymer affinity, then mechanical properties are enhanced, but the maximum mixing temperature is limited to avoid thermal degradation of the coupling agents
Solution Approach 1:
The patent selects silane coupling agents with specific chemical structures (alkoxy groups that are stable at high temperatures) and optimizes their concentration in the compound. The silane's thermal stability parameter is enhanced through molecular structure selection, allowing processing temperatures up to 150-180°C during vulcanization without degradation, while maintaining effective coupling function
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 silane mixture improves static and dynamic mechanical properties, reduces hysteresis and rolling resistance, and stabilizes the vulcanization process, enabling faster kinetics and shorter production cycles with acceptable viscosity and workability.
Implementation Method 1
vulcanisation of a vulcanisable elastomeric composition comprising at least one functionalised polymer and at least one non-functionalised polymer, and silica as a reinforcing filler
Implementation Method 2
to increase the affinity of silica with elastomeric polymers, it is necessary to use suitable coupling agents, such as, for example, organosilane products containing sulfur ('silanisation' process)
Implementation Method 3
such a process influences the static and dynamic modules as well as the hysteresis of the elastomeric compositions at different temperatures
Data Source
AI summary
The present invention relates to a tyre comprising at least one structural element including a cross-linked elastomeric material obtained by cross-linking a cross-linkable elastomeric composition comprising per 100 phr of vulcanisable polymer: (a) from 90 to 10 phr of at least one non-functionalised elastomeric polymer; (b) from 10 to 90 phr of at least one functionalised elastomeric polymer; (c) from about 10 phr to about 120 phr, preferably about 20 phr to about 90 phr of at least one white reinforcing filler; (d) from about 5% to about 15% by weight with respect to the amount of white reinforcing filler of a mixture of silanes, said mixture comprising at least one sulfur-silane and at least one amino-silane.