Tyre Tread Compound Resin Dispersion via Continuous Mixing
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Solution Overview
Problem
The production of high and ultra-high performance tyres and racing tyres faces challenges in achieving efficient dispersion of resins within elastomeric compounds, leading to issues with stickiness, productivity, and reproducibility, particularly due to the high amounts of resin required, which complicates the compounding process and affects the friction and road holding capabilities of the tyres.
Innovation Solution
A process involving the use of a continuous mixer to incorporate a substantial amount of resin after the completion step, allowing for better dispersion and increased productivity, while maintaining the quality and stability of the elastomeric compound, forming a single-phase system that ensures a uniform release of resins for enhanced grip and road holding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a continuous mixer is used to incorporate resin after the completion step, then dispersion quality and productivity are improved, but the process complexity increases
Solution Approach 1:
The compounding process is divided into two distinct stages: first, the completion step in traditional mixers where crosslinking agents and accelerators are added; second, the resin incorporation step in a continuous mixer. This segmentation allows each mixer type to perform its optimal function while maintaining overall process simplicity.
Solution Approach 2:
The resin is incorporated after the completion step, meaning the elastomeric compound is first prepared with all necessary crosslinking agents and accelerators before adding the resin. This preliminary preparation ensures that the resin can be dispersed effectively without interfering with the crosslinking chemistry.
2Reliability
If high amounts of resin are incorporated in the elastomeric compound, then friction and road holding are improved, but stickiness and handling difficulty increase
Solution Approach 1:
The continuous mixer operates continuously to incorporate the resin into the elastomeric compound, ensuring uniform dispersion throughout the material. This continuous action prevents localized concentration of resin that would cause excessive stickiness, while still achieving the high resin content needed for improved road holding.
Solution Approach 2:
The process parameters of the continuous mixer (speed, temperature, residence time) are optimized to achieve effective resin dispersion without excessive heating or mechanical degradation. This allows handling of high-resin compounds with reduced stickiness by controlling the mixing conditions.
3Productivity
If resin is incorporated before the completion step, then mixing efficiency is improved, but thermal-mechanical degradation of the polymer occurs
Solution Approach 1:
The completion step (adding crosslinking agents and accelerators) is performed first as a preliminary action, establishing the chemical framework before resin incorporation. This sequence protects the polymer from thermal-mechanical degradation by completing the sensitive chemical reactions before the resin mixing stage.
Solution Approach 2:
The process segments the mixing operations into distinct stages: completion step in traditional mixers, then resin incorporation in continuous mixer. This segmentation isolates the polymer from prolonged exposure to intense mixing conditions, preventing degradation while maintaining efficiency.
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 process improves the balance of performance and stability in high and ultra-high performance tyres by increasing friction and road holding during extreme manoeuvres, achieving better grip and maintaining performance levels consistently.
Implementation Method 1
mixing and dispersing said at least one part of said at least one resin in said first elastomeric compound by means of said at least one continuous mixer
Implementation Method 2
forming a single-phase system that ensures a uniform release of resins
Data Source
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AI summary
The invention relates to a process for producing a tyre (100) for vehicle wheels, wherein the tread band (109) of the green tyre comprises at least one tread compound (209), including at least one resin in a total amount higher than 20 phr, said tread compound (209) being produced by: feeding to at least one mixing apparatus (201a) comprising at least one discontinuous mixer (201) and/or at least one continuous mixer (305) at least the following components of a first elastomeric compound (204): at least one elastomeric polymer, at least one reinforcing filler (202) and at least one vulcanizing agent; mixing and dispersing said components so as to obtain said first elastomeric compound (204); discharging said first elastomeric compound (204) from said mixing apparatus (201 a) and feeding said first elastomeric compound (204) and at least one part (207) of said amount of at least one resin into at least one continuous mixer (205).