Wet Rubber Masterbatch Compression for Strength and Molding Time
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Solution Overview
Problem
The existing methods for manufacturing wet rubber masterbatch often result in reduced tensile strength and tear strength of vulcanized rubber and require excessive time for molding when press conditions are not optimal.
Innovation Solution
A method involving the compression of granular coagula under specific pressure and diameter conditions, defined by the formula 3≤P×Da≤500, where P is pressure in kgf/cm² and Da is granule diameter in mm, to produce a wet rubber masterbatch with improved tensile and tear strength, allowing for faster molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If press conditions are not optimal, then molding time increases, but tensile strength and tear strength of vulcanized rubber are reduced
Solution Approach 1:
The invention changes the physical parameters of the coagula (granule diameter Da) and establishes a quantitative relationship between pressure P and granule diameter Da through Formula I (3≤P×Da≤500). By adjusting these parameters within the specified range, the invention achieves optimal balance between molding time and vulcanized rubber strength, resolving the contradiction between productivity and strength.
2Productivity
If pressure P×Da is less than 3, then molding time increases significantly, but if P×Da is greater than 500, then tensile strength and tear strength are reduced
Solution Approach 1:
The invention establishes a feedback mechanism through Formula I (3≤P×Da≤500) that provides quantitative guidance for controlling press conditions. By monitoring and adjusting pressure P and granule diameter Da to maintain their product within the specified range, the invention ensures optimal molding efficiency and rubber strength, preventing both excessive molding time and strength reduction.
3Productivity
If granule diameter is below 1 mm, then molding time increases, but if granule diameter is above 39 mm, then tensile strength and tear strength are reduced
Solution Approach 1:
The invention specifically controls the granule diameter parameter Da within the range of 1 mm to 39 mm as a key physical parameter. This parameter control, combined with the pressure relationship in Formula I, optimizes the balance between molding time and vulcanized rubber strength, preventing both excessive molding time and strength degradation.
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 enables the production of vulcanized rubber with enhanced tensile and tear strength while reducing the time required for molding, by optimizing the pressure and granule diameter conditions during the compression process.
Implementation Method 1
the collection of granules is compressed under conditions satisfying Formula I: 3≤P×Da≤500 (where P indicates pressure applied to the collection of granules)
Implementation Method 2
causing filler and dispersion solvent to be mixed together in advance in a given ratio, causing rubber latex solution and a filler-containing slurry solution in which filler has been dispersed by means of mechanical force within dispersion solvent to be mixed together while in liquid phase
Implementation Method 3
thereafter adding acid or other such coagulant, and collecting and drying the coagulum
Data Source
AI summary
A method for manufacturing a wet rubber masterbatch that will serve as raw material for vulcanized rubber having excellent tensile strength and tear strength and that will permit wet rubber masterbatch to be molded in a short time. A method comprising an operation in which a collection of granules comprising a plurality of granular coagula are obtained from a liquid mixture comprising filler and rubber latex solution, and an operation in which the collection of granules is compressed under conditions satisfying Formula I; 3≤P×Da≤500 (P indicates pressure (kgf/cm2) applied to the collection of granules. Da indicates granule diameter (mm) of the granular coagula), making it possible to cause a wet rubber masterbatch capable of serving as raw material for vulcanized rubber having excellent tensile strength and tear strength to be molded in a short time.