Tire Insulation Rubber Composition for Low Rolling Resistance
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Solution Overview
Problem
Current tire insulation rubber compositions fail to balance rolling resistance, durability, and cost effectiveness, often requiring high-cost materials and overperforming in properties like cord adhesion and crack growth resistance for insulation applications.
Innovation Solution
A tire insulation rubber composition comprising 0.2 to 4 parts by mass of alkylphenol-sulfur chloride condensate and 20 to 59 parts by mass of carbon black with a BET specific surface area of 25 to 50 m^2/g, based on 100 parts by mass of a rubber component including natural rubber, styrene butadiene rubber, and high cis 1,4-polybutadiene rubber, with optional fillers like pulverized bituminous coal powder, to achieve improved rolling resistance and durability while reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a rubber composition for case topping is used as a rubber composition for insulation, then rolling resistance is reduced, but cost is increased
Solution Approach 1:
The patent replaces expensive case topping rubber composition with a cheaper, simplified insulation rubber composition that contains only the essential components (vulcanization accelerator, carbon black, and rubber component) needed to achieve the required performance for insulation applications, eliminating unnecessary additives and fillers
Solution Approach 2:
The patent extracts and removes unnecessary components from the case topping rubber composition formulation, keeping only the critical elements (vulcanization accelerator, carbon black, rubber component) that provide the essential functions for insulation, thereby reducing material cost while maintaining performance
2Loss of energy
If a rubber composition for sidewall, clinch and/or insulation is used, then rolling resistance and steering stability are improved, but cost is high and sheet processability is not enough
Solution Approach 1:
The patent optimizes the parameters of the rubber composition by specifying precise ranges for carbon black content (20-59 parts by mass per 100 parts rubber component) and vulcanization accelerator content (0.2-4 parts by mass per 100 parts rubber component), along with carbon black surface area (25-50 m²/g), to achieve the desired balance between rolling resistance, sheet processability, and durability
Solution Approach 2:
The patent tailors the rubber composition properties specifically for insulation application requirements, using carbon black with controlled surface area (25-50 m²/g) to provide appropriate balance between reinforcement, processability, and rolling resistance characteristics that are locally optimized for insulation rather than general-purpose tire components
3Strength
If a rubber composition for case topping is used, then proper rubber strength and reversion property are achieved, but crack growth property, tear strength and cord adhesion are over performed
Solution Approach 1:
The patent uses a simplified rubber composition formulation that contains only the essential components needed for insulation performance (vulcanization accelerator, carbon black, rubber component), eliminating expensive additives and fillers that provide crack growth resistance, tear strength, and cord adhesion properties that are not required for insulation applications
Solution Approach 2:
The patent applies partial action by providing only the necessary level of performance for insulation requirements rather than excessive performance in all areas, using a minimal formulation that achieves adequate rubber strength and reversion property without over-engineering crack growth resistance, tear strength, and cord adhesion
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 provides a tire insulation with superior rolling resistance and durability at a reduced cost compared to traditional case topping compositions, ensuring low fuel consumption and effective processability.
Implementation Method 1
20 to 59 parts by mass of (C) carbon black having a BET specific surface area of 25 to 50 m 2/g
Implementation Method 2
0.2 to 4 parts by mass of (B) an alkylphenol-sulfur chloride condensate
Data Source
Figure 1
AI summary
For the purpose of improving rolling resistance and durability, the present invention provides a rubber composition for insulation of a tire comprising 0.2 to 4 parts by mass of (B) an alkylphenol-sulfur chloride condensate, and 20 to 59 parts by mass of (C) carbon black having a BET specific surface area of 25 to 50 m2/g based on 100 parts by mass of (A) a rubber component comprising 30 to 85% by mass of (a1) a natural rubber and/or an isoprene rubber, 0 to 70% by mass of (a2) at least one styrene butadiene rubber selected from the group consisting of an emulsion-polymerized styrene butadiene rubber, a solution-polymerized styrene butadiene rubber and a modified styrene butadiene rubber, and 0 to 60% by mass of (a3) a butadiene rubber, and a tire having insulation prepared from the rubber composition.