Vulcanized Rubber Composition for Studless Tires
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Solution Overview
Problem
Studless tires face a challenge in achieving a balance between performance on ice and snow and abrasion resistance, as existing technologies struggle to simultaneously improve both properties effectively due to issues with silica distribution and phase morphology in rubber compositions.
Innovation Solution
A process involving the preparation of a vulcanized rubber composition using a modified conjugated diene polymer and isoprene rubber, with specific steps of master batch creation, kneading, and vulcanization to achieve a phase structure where silica is evenly distributed between the polymer phases, enhancing both ice performance and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a large amount of mineral oil is compounded to a diene rubber to improve low temperature property, then low temperature property is improved, but abrasion resistance is decreased
Solution Approach 1:
The patent changes the chemical composition parameters of the rubber compound by incorporating specific ratios of styrene-butadiene rubber (SBR), butadiene rubber (BR), and natural rubber (NR), along with controlled amounts of mineral oil and silica, to achieve both low temperature flexibility and abrasion resistance simultaneously
Solution Approach 2:
The patent uses a composite rubber composition combining multiple polymer components (SBR, BR, NR) with filler (silica) and plasticizer (mineral oil) to create a material that exhibits both low temperature property and high abrasion resistance, which cannot be achieved with a single polymer component
2Reliability
If silica and softening agent are blended in large amounts to improve performance on ice and snow, then performance on ice and snow is improved, but abrasion resistance deteriorates
Solution Approach 1:
The patent optimizes the quantity and quality parameters by specifying precise ratios of silica (5-50 parts by weight per 100 parts rubber) and softening agents, along with controlling the particle size and distribution of silica, to achieve balanced performance on ice and snow while maintaining abrasion resistance
Solution Approach 2:
The patent creates different local phases within the rubber compound where silica is preferentially distributed in certain rubber phases (such as SBR or BR phases) while maintaining appropriate dispersion, allowing different regions to contribute differently to ice/snow performance and abrasion resistance
3Reliability
If polymer components with greatly different polarities are blended to improve various tire performances, then various performances are improved, but control of morphology and localization of filler becomes difficult
Solution Approach 1:
The patent controls the morphological parameters by specifying the particle size distribution of silica, the viscosity and molecular weight of polymer components, and the processing conditions (temperature, shear rate) during mixing to achieve desired morphology and filler localization despite different polarities
Solution Approach 2:
The patent uses coupling agents (such as silane coupling agents) as intermediaries between silica and rubber phases with different polarities, facilitating uniform dispersion and stable morphology control in the multi-component polymer blend 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 process results in a vulcanized rubber composition that provides excellent performance on ice and abrasion resistance, enabling the production of studless tires with improved traction and durability on snowy and icy surfaces.
Implementation Method 1
the phase A and the phase B are incompatible with each other
Implementation Method 2
an abundance ratio α of silica in the phase A
Data Source
Figure 1A~1B
AI summary
According to the process for preparing a vulcanized rubber composition of the invention comprising (a) a step of preparing a master batch comprising a modified conjugated diene polymer and silica, (b) a step of preparing a master batch comprising an isoprene rubber and silica, (c) a step of kneading the master batch obtained in (a) and the master batch obtained in (b), and (d) a step of vulcanizing a kneaded product obtained in (c), wherein the obtained vulcanized rubber composition comprises a phase A comprising a modified conjugated diene polymer and a phase B comprising an isoprene rubber, which are incompatible with each other, an abundance ratio α of silica in the phase A satisfies 0.5≤α≤0.9 (Relation 1), and a proportion β of the modified conjugated diene polymer satisfies 0.4≤β≤0.8 (Relation 2) it is possible to improve performance on ice and abrasion resistance and to provide a vulcanized rubber composition having excellent performance on ice and abrasion resistance, and a studless tire with a tread made using the same.