Wet Rubber Masterbatch Fatigue Resistance
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Solution Overview
Problem
Vulcanized rubbers produced using dry rubber masterbatches lack sufficient fatigue resistance due to increased viscosity and aggregated lumps during the mixing process, which affects the dispersibility and performance of carbon black in the rubber composition.
Innovation Solution
A method involving the use of carbon black, a dispersing solvent, and a rubber latex solution to create a wet rubber masterbatch, where a specific compound is dispersed into the rubber solidified product containing water, improving its dispersibility, and then silica and a silane coupling agent are added and dry-mixed to enhance the rubber's fatigue resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If carbon black, rubber, specific compound, silica, and silane coupling agent are simultaneously dry-mixed in a mixer, then the mixing process is simplified, but the mixture viscosity increases unfavorably causing aggregated lumps and poor dispersibility
Solution Approach 1:
The mixing process is divided into multiple stages: first wet-mixing carbon black with rubber latex solution and dispersing solvent to form a wet masterbatch, then dry-mixing this wet masterbatch with silica and silane coupling agent. This segmentation prevents simultaneous mixing of all components which would cause viscosity increase and aggregation.
Solution Approach 2:
A wet masterbatch is introduced as an intermediary material that combines carbon black, rubber, and specific compound in a dispersed state before final mixing. This intermediary form maintains low viscosity during preparation and enables better dispersibility when subsequently mixed with other components.
2Productivity
If a dry rubber masterbatch is used to simplify production, then manufacturing efficiency increases, but fatigue resistance of the vulcanized rubber decreases due to aggregated lumps
Solution Approach 1:
The invention changes the physical state parameter of the masterbatch from dry to wet form. The wet masterbatch contains dispersing solvent that maintains low viscosity and prevents aggregation, thereby improving fatigue resistance while still enabling efficient production through masterbatch preparation.
Solution Approach 2:
The invention creates a composite wet masterbatch system combining carbon black, rubber, specific compound, and dispersing solvent. This composite structure ensures uniform distribution of carbon black and compound particles, preventing aggregation and improving the fatigue resistance of the final vulcanized rubber product.
3Loss of time
If all components are mixed simultaneously in solid phase, then the process time is reduced, but the rubber composition contains aggregated lumps with insufficient fatigue resistance
Solution Approach 1:
The carbon black, rubber, and specific compound are preliminarily mixed in liquid phase with dispersing solvent to create a wet masterbatch before final mixing with silica and silane coupling agent. This preliminary dispersion action prevents aggregation and ensures uniform distribution, improving fatigue resistance without excessive process time.
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 significantly improves the dispersibility of the compound in the rubber, leading to better carbon black distribution and increased fatigue resistance in the vulcanized rubber, addressing the limitations of dry rubber masterbatches by maintaining improved properties even after dehydration.
Implementation Method 1
mixing the carbon black, the dispersing solvent and the rubber latex solution with each other to produce a rubber latex solution including the carbon black
Implementation Method 2
solidifying the resultant rubber latex solution including the carbon black to produce a rubber solidified product including the carbon black
Implementation Method 3
adding, to the resultant rubber solidified product including the carbon black, a compound represented by the following formula (I), and dispersing the compound represented by the formula (I) into the rubber solidified product including the carbon black, this product containing water
Implementation Method 4
dehydrating the rubber solidified product including the carbon black to produce a wet rubber masterbatch
Implementation Method 5
adding, to the resultant wet rubber masterbatch, silica and a silane coupling agent, and dry-mixing these substances with each other
Data Source
AI summary
Provided is a method for producing a tire member that can give a vulcanized rubber high in fatigue resistance. The method includes: (i) mixing carbon black, a dispersing solvent and a rubber latex solution with each other to produce a rubber latex solution including the carbon black; (ii) solidifying the resultant rubber latex solution including the carbon black to produce a rubber solidified product including the carbon black; (iii) adding, to the resultant rubber solidified product including the carbon black, a compound represented by the following formula (I):and dispersing the compound represented by the formula (I) into the rubber solidified product including the carbon black, this product containing water, while dehydrating the rubber solidified product including the carbon black to produce a wet rubber masterbatch; and (iv) adding, to the resultant wet rubber masterbatch, silica and a silane coupling agent, and dry-mixing these substances with each other.