Tire Rubber Masterbatch with Nanofiber-Silica Dispersion Control
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Solution Overview
Problem
Existing tire materials struggle to achieve reduced fuel consumption and improved cutting resistance, primarily due to limitations in heat generation and tearing strength.
Innovation Solution
A masterbatch manufacturing method involving the mixing of cellulose nanofiber dispersion, colloidal silica, and diene-based rubber latex, followed by coagulation, to enhance the dispersibility and intercalation of silica particles, thereby improving the thermal properties and tearing strength of vulcanized rubber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cellulose nanofibers are dried and then mixed with diene-based rubber latex, then the mixing process is simpler, but the dispersion degree of cellulose nanofibers is insufficient
Solution Approach 1:
The patent changes the physical state parameter of cellulose nanofibers from dried solid to dispersed liquid form (nanofiber dispersion), enabling better integration with rubber latex while maintaining manufacturing feasibility through liquid-phase mixing processes
Solution Approach 2:
The patent creates a composite system by combining cellulose nanofiber dispersion with diene-based rubber latex and colloidal silica, forming a multi-component masterbatch that achieves superior dispersion and performance characteristics
2Quantity of substance
If wet silica is used as a filler in pneumatic tires, then cost is reduced, but the dispersibility of silica particles is poor leading to agglomeration
Solution Approach 1:
The patent transforms silica from conventional wet silica aggregates to colloidal silica with controlled particle size (2-40 nm) and uses the liquid dispersion medium as a carrier, fundamentally changing the physical state and dispersibility parameters while maintaining cost effectiveness
Solution Approach 2:
The patent introduces a liquid dispersion medium as an intermediary carrier that enables individual silica particles to be uniformly distributed throughout the rubber matrix, preventing agglomeration while maintaining the cost benefits of using silica-based fillers
3Ease of manufacture
If conventional rubber compositions are used, then manufacturing is simpler, but the ability to achieve reduced fuel consumption and improved cutting resistance is insufficient
Solution Approach 1:
The patent develops a composite masterbatch system integrating cellulose nanofibers, colloidal silica, and diene-based rubber latex, creating a multi-functional material that simultaneously improves fuel efficiency through reduced heat generation and enhances cutting resistance through improved tearing strength
Solution Approach 2:
The patent applies different functional components at specific levels: cellulose nanofibers provide structural reinforcement for tearing strength, while colloidal silica provides dispersion and heat management, with each component optimized for its specific function within the composite system
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 method effectively reduces heat generation and enhances tearing strength, leading to improved fuel efficiency and cutting resistance in tires.
Implementation Method 1
an operation in which a cellulose nanofiber dispersion and diene-based rubber latex are mixed and the liquid mixture is coagulated
Implementation Method 2
Colloidal silica is a dispersion of silica particles. The silica particles in colloidal silica are dispersed individually, that is, without agglomeration.
Implementation Method 3
it is possible to intercalate not only rubber particles but also cellulose nanofibers between the silica particles
Data Source
AI summary
A masterbatch manufacturing method includes an operation in which at least a cellulose nanofiber dispersion, colloidal silica, and diene-based rubber latex are mixed to prepare a liquid mixture; and an operation in which the liquid mixture is coagulated.