Tire Rubber Composition Kneading Process
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Solution Overview
Problem
Existing methods for manufacturing rubber compositions for tires face challenges in achieving a balance between processability, fuel efficiency, rubber strength, and abrasion resistance, particularly due to issues with vulcanization accelerator dispersion and crosslinking reactions during kneading.
Innovation Solution
A method involving the initial kneading of a rubber component, sulfur donor, and sulfur atom-containing vulcanization accelerator before adding a filler, followed by kneading at 120° C or higher, to enhance dispersion and form a pendant-type structure, thereby improving fracture properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polysulfide-based silane coupling agent or mercapto-based silane coupling agent is used for silica compounding, then the coupling reaction progresses during kneading, but this deteriorates the processability of the rubber composition
Solution Approach 1:
The kneading process is divided into two distinct stages: a first kneading step where rubber components, filler, and silane coupling agent are mixed at lower temperature without vulcanization chemicals, and a second kneading step where vulcanization chemicals are added at higher temperature. This segmentation prevents premature coupling reactions that would harm processability while ensuring proper coupling occurs during vulcanization.
Solution Approach 2:
The silane coupling agent is pre-mixed with the rubber components and filler before the vulcanization step. This preliminary action allows the coupling agent to be properly distributed without triggering harmful premature reactions, and the actual coupling reaction is then activated during the controlled vulcanization process.
2Device complexity
If vulcanization accelerator is kneaded at the same time or after charging of the filler, then the kneading process is simplified, but dispersion of the vulcanization accelerator is suppressed
Solution Approach 1:
The addition of vulcanization accelerator is segmented into a separate second kneading step, distinct from the first kneading step where filler is charged. This ensures that the accelerator is added to a pre-mixed base that already contains properly dispersed filler and silane coupling agent, preventing aggregation and ensuring uniform dispersion.
Solution Approach 2:
The filler and silane coupling agent are preliminarily mixed and dispersed in the rubber components during the first kneading step before the vulcanization accelerator is introduced. This preliminary dispersion of other components creates a suitable matrix that prevents accelerator aggregation when it is subsequently added.
3Use of energy by moving object
If rolling resistance is reduced to enhance fuel efficiency, then fuel consumption decreases, but mechanical strength and various performance deteriorate
Solution Approach 1:
The invention optimizes the timing and temperature parameters of the kneading process to control the coupling reaction. By conducting the first kneading at lower temperature (without vulcanization chemicals) and the second kneading at higher temperature (with vulcanization chemicals), the process achieves proper silica-rubber coupling that enhances mechanical strength while maintaining low rolling resistance through appropriate filler distribution.
Solution Approach 2:
The invention creates a composite rubber composition with silica filler and uses a two-stage kneading process to achieve optimal interfacial bonding between the silica and rubber matrix. This composite structure, with proper coupling achieved through the segmented process, simultaneously provides low rolling resistance and high mechanical strength.
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
This approach results in a rubber composition with improved fracture properties, uniform crosslinking density, and enhanced mechanical strength, addressing the limitations of previous methods.
Implementation Method 1
kneading a rubber component, a sulfur donor, and a sulfur atom-containing vulcanization accelerator together before kneading the rubber component with a filler
Implementation Method 2
form a pendant-type structure, thereby improving fracture properties
Implementation Method 3
adding a filler to an obtained kneaded product and then performing kneading at a kneading temperature of 120° C. or higher
Data Source
AI summary
Provided are a method for manufacturing a rubber composition for a tire and a method for manufacturing a tire including this manufacturing method for the rubber composition in the present invention, which are characterized by including the steps of: starting to knead a rubber component, a sulfur donor, and a sulfur atom-containing vulcanization accelerator together before kneading the rubber component with a filler; and then adding a filler to an obtained kneaded product and performing kneading at a kneading temperature of 120° C. or higher. According to the manufacturing methods of the present invention, a rubber composition for a tire and a tire which have good fracture property can be manufactured.