Wire Coat Rubber Composition for Lower Rolling Resistance
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Solution Overview
Problem
Current tire rubber compositions do not adequately reduce rolling resistance and internal heat generation, which limits fuel efficiency and tire performance, particularly in heavy-duty applications.
Innovation Solution
A rubber composition incorporating interconnected crystalline carbon nanofilaments as a first filler and silica as a second filler, along with other additives, to enhance hysteresis, strength, and wire coat adhesion, thereby reducing rolling resistance and internal heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional rubber compositions with carbon black and silica are used, then tire strength and durability are maintained, but rolling resistance and internal heat generation are not sufficiently reduced
Solution Approach 1:
The patent uses a composite filler system combining carbon-based inorganic compound (interconnected crystalline carbon nanofilaments) with silica. This composite approach allows the carbon nanofilaments to provide structural strength and reinforcement while the silica component contributes to reduced rolling resistance and hysteresis, achieving both strength maintenance and energy loss reduction simultaneously
Solution Approach 2:
The patent changes the physical and chemical parameters of the carbon filler by using interconnected crystalline carbon nanofilaments with specific surface area (50-200 m²/g) and aspect ratio (10:1 to 100:1) instead of conventional carbon black. This parameter change enables reduced hysteresis and rolling resistance while maintaining adequate strength through the unique nanofilament structure
2Loss of energy
If conventional carbon black fillers are used, then tire strength is maintained, but hysteresis and internal heat generation are not sufficiently reduced
Solution Approach 1:
The patent transforms the carbon filler from conventional carbon black particles to interconnected crystalline carbon nanofilaments with controlled surface area (50-200 m²/g) and aspect ratio (10:1 to 100:1). This parameter transformation reduces hysteresis and internal heat generation while the interconnected nanofilament structure maintains tire strength through enhanced load distribution
Solution Approach 2:
The interconnected crystalline carbon nanofilaments create a porous-like network structure that allows for reduced hysteresis by facilitating energy dissipation through the three-dimensional network, while maintaining strength through the interconnected architecture that distributes mechanical stresses effectively
3Loss of energy
If silica content is increased to reduce rolling resistance, then fuel economy improves, but wire coat adhesion and strength may be compromised
Solution Approach 1:
The patent creates a composite filler system where carbon-based inorganic compound (interconnected crystalline carbon nanofilaments) serves as the primary reinforcement providing wire coat adhesion and strength, while silica acts as a secondary filler contributing to rolling resistance reduction. This composite approach allows optimization of both adhesion and energy loss properties
Solution Approach 2:
The patent assigns different functional roles to different filler components: the carbon nanofilaments provide localized reinforcement and adhesion at the wire-rubber interface, while the silica particles contribute to bulk hysteresis reduction. This local quality differentiation allows simultaneous optimization of adhesion and rolling resistance
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 rubber composition achieves improved hysteresis, strength, and wire coat adhesion, leading to reduced rolling resistance and energy expenditure, enhancing fuel economy and tire performance.
Implementation Method 1
Reduced rubber hysteresis property for a ply rubber composition is often desired to promote reduced internal heat generation within the ply during tire service
Implementation Method 2
a first filler in an amount in the range of from 15 to 70 parts by weight per 100 parts by weight of the rubber (phr), the first filler comprising a carbon-based inorganic compound, wherein the carbon-based inorganic compound comprises interconnected crystalline carbon nanofilaments
Data Source
Figure 1~2
AI summary
A rubber composition (20) is disclosed comprising rubber, a first filler in an amount in the range of from 15 to 70 parts by weight per 100 parts by weight of the rubber, the first filler comprising a carbon-based inorganic compound, wherein the carbon-based inorganic compound comprises interconnected crystalline carbon nanofilaments, and a second filler in an amount in the range of from 5 to 30 phr, the second filler comprising silica. Also, pneumatic tire (1) comprising such a rubber composition (20) is disclosed, preferably as a wire coat rubber composition.