Rubber Compound Mixing in Tire Production

A scalable method to disperse reduced graphene oxide (RGO) in rubber composites without using solvents. The method involves milling RGO with a liquid rubber to improve dispersion and prevent stacking compared to dry milling. The RGO and liquid rubber are ball milled together with milling media until the RGO particles reach the desired size. This milled RGO-liquid rubber mixture can then be added to rubber compounds during mixing. The liquid rubber acts as a co-agent to reduce RGO agglomeration and stacking during rubber processing.

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Mixing method to improve filler dispersion in rubber compounds by pre-dispersing fillers and processing aids before adding the rubber. In the mixing stage, fillers and processing aids are initially stirred in the mixer at lower speeds (40-60 rpm) for 30-200 seconds to fully mix and disperse the fillers. Then rubber is added to continue mixing. This pre-dispersion step shortens filler-processing aid distances and increases contact probability, leading to better filler dispersion and rubber compound properties like wear resistance and dynamic performance.

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Process for preparing diene rubber compositions with improved properties for tire treads. The process involves a specific order of mixing steps to optimize the rubber composition. It includes mixing the elastomer matrix alone first, then adding the modification agent, filler, silane, and vulcanization system in separate steps. This sequence allows the elastomer to fully incorporate and disperse before adding the other components. It reduces agglomeration and improves the distribution of filler and silane. The resulting rubber composition has lower hysteresis and higher rigidity compared to conventional mixing orders.

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A method for preparing a tire rubber composition that improves dispersion of fillers like silica and carbon black to enhance tire performance. The method involves a two-step mixing process. In step 1, raw rubber, fillers, and a low amount of vulcanizing agent are mixed. In step 2, additional vulcanizing agent and accelerator are added to the step 1 product. This two-step mixing sequence improves filler dispersion compared to adding all vulcanization components in step 1.

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Rubber compositions containing depolymerized carbon nanotubes as reinforcing fillers for tire components like treads. The carbon nanotubes are aggregated into a continuous network with defects and voids, rather than being dispersed individually. The network structure is achieved by compressing the nanotube powder and shearing it in a mixer. This prevents nanotube entanglement during mixing. The nanotubes have retained their original diameter and wall number. The network nanotubes provide improved physical properties like wear resistance compared to dispersed nanotubes.

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A method and device for producing rubber mixtures with improved dispersion and homogeneity of fillers like silica, without increasing production time. The method involves two mixers in tandem with specific blade design and volume ratios. The first mixer has higher blade speeds and lower volume. The second mixer has lower blade speeds and higher volume. This allows transferring and mixing the rubber between the mixers at lower speeds for better filler dispersion, while still maintaining efficient mixing overall. The device has a top mixer with higher aspect ratio rotor blades and a bottom mixer with lower aspect ratio rotor blades. The volume of the bottom mixer is higher than the top mixer.

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A mixing process for rubber compounds used in tire production that reduces heat generation during mixing of silica-filled rubber compounds compared to conventional mixing methods. The process uses a three-stage mixing sequence in internal mixers, all at temperatures below 150°C. This allows better dispersion of silica without agglomeration and reduces heat generation compared to longer, multi-stage mixing. The lower temperatures also prevent excessive rubber degradation. The three-stage process involves mixing raw materials, then adding silica and dispersing it, followed by final mixing. This controlled constant temperature mixing sequence improves dispersion of silica and reduces heat generation during mixing of silica-filled rubber compounds for tires.

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A method for producing a rubber composition for tires with improved vulcanization rate, low fuel consumption, and wet road braking performance. The method involves adding certain components like modified polymer, silica, silane coupling agent, zinc oxide, and amine antiaging agent into a closed mixer in a specific order. The kneading temperature is controlled to suppress reactions between the components until a later stage. This prevents agglomeration and improves dispersion of the fillers. Simultaneous kneading at higher temperature allows reactions to proceed while stabilizing the temperature. The optimized order and temperature control allows good dispersion, bonding, and vulcanization properties.

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A method for improving low heat generation, wet road braking performance, and wear resistance in tires by using a closed mixer with a weight that moves up and down during kneading. The mixer has a chamber, neck, and hole. Compressed gas is fed into the chamber through the hole while the weight is not pressed. This closed mixer with vertical movement of the weight allows kneading above the lower limit temperature for silane coupling reaction. Using this closed mixer with gas injection during kneading improves dispersion of silica in rubber compositions for tires.

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Stabilizing the foaming point of final rubber in tire manufacturing to reduce vulcanization time. The stabilization is achieved through a specific mixing and resting process. The final rubber compound is prepared in stages: primary mixing, secondary mixing, and final mixing. The final mixing is done with sulfur and accelerators. The key is to allow the mixed rubber to park for 8-48 hours before extrusion. The scorch retarder dosage is adjusted based on the mixing and resting time. This stabilizes the foaming point and vulcanization time.

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Rubber mixing method to improve efficiency, homogeneity, and prevent issues like whitening and deglazing in rubber compounding. The method involves mixing rubber compounds at lower temperatures (<110°C) using a closed internal mixer instead of open mixers. This allows adding vulcanization agents like accelerators and sulfur directly during mixing. The lower temperature prevents whitening and deglazing issues. By mixing in the closed internal mixer, it eliminates the need for re-mixing on open mixers to add vulcanization agents. This reduces energy consumption and improves efficiency compared to traditional mixing methods.

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Mixing method for tire rubber compounds to ensure uniformity in compound quality. The method involves preparing multiple master batches, each containing a silica compound, and then remilling and dispersing them together to form the final compound. This creates a uniform crosslinked structure with minimized variation compared to directly compounding the master batches. The remilling step allows consistent distribution of the silica and other components throughout the compound.

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A composition for preparing rubber compound, rubber compound, and a method to prepare it, along with a tire made from the compound. The composition includes natural rubber, butadiene rubber, styrene-butadiene rubber, carbon black, vulcanizing agent, syndiotactic 1,2 butadiene Dienes, peroxides, antioxidants, activators, accelerators, tackifiers, and coupling agents. The key innovation is adding syndiotactic 1,2 polybutadiene to the compound and using peroxides to reduce its crystallization and improve adhesion with other rubbers. This provides tires with improved wear resistance, flame retardancy, and lightweight properties.

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Device and method for efficiently producing rubber compounds, especially for tires, by staging the mixing steps. The device has three interconnected mixers arranged in sequence. The first mixer is loaded with initial ingredients, the second mixer receives the first mixer's output, and the third mixer receives the second mixer's output to complete the compound. This allows staged mixing and reworking of the rubber in multiple steps for improved efficiency compared to a single mixer.

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A rubber mixing process for tires that reduces loss of vulcanizing agents during mixing to improve tire quality. The process involves using a banbury mixer followed by multiple parallel open mills for supplementary mixing. The banbury mixer initially mixes the rubber, then evenly divides the batch between the parallel open mills for further mixing. This longer supplementary mixing compensates for the reduced rubber quantity in each mill compared to fewer parallel mills, preventing quality fluctuations and loss of volatile additives.

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A method for forming tire components like treads using a rotatable applicator head to coextrude rubber compounds with varying volume ratios. The rotatable head allows complex tire designs with specific performance and durability characteristics by coextruding multiple compounds from a single head. The head rotates around the tire build direction to prevent material curling and ensure uniform flow as the rubber changes direction. This allows efficient production of coextruded strips with varied compound ratios that can be used to manufacture complex tire components like treads with improved performance and durability.

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A one-step rubber mixing process for tires that improves efficiency, reduces costs, and provides better rubber quality compared to conventional one-shot mixing methods. The process involves refining the masterbatch in an internal mixer instead of adding sulfur directly in the mill. This reduces mixing time, eliminates issues like sticking, spilling, and inconsistent vulcanization. By returning a portion of the refined masterbatch to the mixer along with calculated amounts of sulfur, the desired rubber properties are achieved.

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Automated rubber mixing system and method to improve efficiency, quality and consistency of rubber compounding. The system involves a two-stage mixing process with separate banbury mixers. Raw materials except vulcanizing agent and accelerator are mixed in the first banbury. The product is then transferred to the second banbury where vulcanizing agent and accelerator are added for final mixing. The first mixing stage temperature is higher than the second stage to enable better homogenization. This two-step process allows better control and consistency of mixing compared to conventional single-stage mixing. The system also uses automated feeders to precisely measure and add materials instead of manual weighing. The automated feeders are connected to the mixers and the system monitors and controls the mixing parameters.

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Device and method for producing rubber mixtures used in tire manufacturing that improves efficiency and processability. The device has two mixing chambers connected by a transfer device. One chamber mixes rubber and filler, the other chamber mixes additives like zinc oxide and diamines. Solid additives are fed directly into the second chamber. This allows separate optimization of base rubber and additive mixing. The transfer device moves the base rubber into the second chamber for final mixing. The method involves separately mixing the rubber/filler and additives in each chamber, then transferring the rubber to the additive chamber for final mixing. This enables better control over the rubber properties and additive distribution compared to mixing everything together.

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Mixing rubber components using a single stage process that reduces the dump temperature of the final rubber mixture to a temperature below 120°C. The mixing includes mixing at least one polymer, a peptizer, a soft carbon black and at least one first additive sequentially in an internal mixer to obtain a first mixture; b) contacting the first mixture with a cold oil to obtain a second mixture; and c) kneading the second mixture with at least one second additive to obtain a final rubber mixture.

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A functionalized rubber with improved filler compatibility for tire compounds. The rubber is made by end-group functionalizing a living anionic polymer like styrene-butadiene rubber (SBR) with a specific terminator. The terminator has a structure containing alkane diyl, alkyl, and alkyl groups. This functionalization improves the rubber's affinity for fillers like silica and carbon black, enhancing filler dispersion, interface formation, and filler network building. The functionalized rubber can be used in tire compounds for better tire properties like stress-strain, abrasion resistance, and tear propagation resistance.

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Method for making tire rubber compositions with improved fracture properties and tires using those compositions. The method involves starting kneading the rubber, sulfur donor, and sulfur-containing vulcanization accelerator before adding filler. Then, after adding filler, kneading at high temperature (120°C or more) to form a suspension-type structure where the accelerator is bonded to the rubber. This improves dispersion and crosslinking uniformity compared to adding filler first.

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Rubber compound for pneumatic tires with improved dispersion of lignin, a natural dispersant derived from wood pulping processes, by functionalizing it. The functionalized lignin has groups like -OCH3, -OH, and -COOCH3 that increase its compatibility with the rubber matrix. Using this functionalized lignin as a dispersing agent instead of unmodified lignin provides better dispersion of fillers like silica in the rubber compound. This leads to improved rubber compound properties like reduced viscosity, lower rolling resistance, and better abrasion resistance in tire parts made from the compound.

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A process to prepare rubber compositions using recycled rubber powder for applications like tires. The process involves two-stage mixing. In the first stage, the diene elastomer and reinforcing filler are mixed. Once the temperature exceeds 100°C, the rubber powder is added. This two-stage mixing sequence improves the properties of the resulting rubber compositions made with recycled rubber powder compared to one-stage mixing. The compositions have better fatigue and abrasion resistance when prepared using this process.

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A method for manufacturing tire rubber compositions with reduced rolling resistance. The method involves a three-step mixing process to produce the tire rubber composition. In step 1, raw rubber, carbon black, and carbon black coupling agent are mixed. In step 2, vulcanization accelerator and anti-aging agent are added. In step 3, vulcanization accelerator and vulcanizing agent are mixed. This step-wise mixing improves dispersion and bonding of the carbon black filler, which reduces rolling resistance.

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Rubber composition with improved dispersion and reinforcement properties for tires. The composition contains partially pre-hydrophobated silica dispersed in the rubber matrix. The silica is pre-treated with an alkylsilane to make it more dispersible in the rubber. This avoids using high silica loadings which can negatively impact dispersion. The pre-treatment leaves some unreacted hydroxyl groups on the silica. In situ curing then couples the silica to the rubber using a separate silane coupling agent. This fixes the dispersed silica and provides reinforcement without hindering dispersion.

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Rubber compositions containing reduced graphene oxide (rGO) with specific surface area, oxygen content, and non-aromaticity/aromaticity ratio for improved mixing and dispersion in rubber compounds. The rGO has a surface area of at least 700 m2/g, oxygen content less than 8%, and non-aromaticity/aromaticity ratio of at least 0.7. This rGO provides rigidity and reinforcement when added to rubber compositions mixed in internal mixers, unlike other rGOs. The optimal rGO characteristics enable good dispersion and distribution in the rubber matrix.

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Modified liquid diene rubber for improving filler dispersion in rubber compositions like tires. The rubber has two types of polymer blocks with different reactivities, one containing butadiene units and the other a dissimilar polymer. The blocks are modified with a silane compound. The modified rubber contains functional groups derived from the silane. This modification enhances filler dispersion in the rubber composition and crosslinked product, leading to improved properties like wet grip and abrasion resistance. The modified rubber has 0.1-50 parts by mass per 100 parts of base rubber, and filler content is 20-200 parts by mass.

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In situ isomerization of polybutadiene during rubber composition mixing to improve low-temperature properties of rubber compositions containing high cis-1,4 polybutadiene. The isomerization reduces the cis-1,4 content by converting some cis bonds to trans. This is done by adding disulfide isomerization agents like 2,2-dithiobis(benzothiazole) during mixing in an internal mixer. The mixing generates heat to isomerize the polybutadiene. This allows using higher cis-1,4 polybutadiene in tires without crystallization and stiffening at low temperatures. The isomerization reduces the cis-1,4 content enough to prevent crystallization without needing to use lower cis-1,4 polybutadiene.

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Method to prepare highly dispersed rubber compositions with improved mixing efficiency, reduced energy consumption, and better dispersion of additives. The method involves a two-stage mixing process using internal mixers and open mills. The rubber is initially mixed with one additive at lower temperature and shorter time. Then additional additives are mixed at higher temperature and longer time. This staged mixing sequence prevents aggregate formation and allows better dispersion of all additives. The lower temperature step also reduces energy consumption.

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A process to make rubber compounds with improved properties by using a metallated aminosilane compound as an initiator for anionic polymerization. The metallated aminosilane compound is prepared by reacting a metallating agent with a compound containing an aminosilane functional group. This metallated aminosilane initiator is then used to polymerize rubber monomers in place of traditional initiators. The aminosilane functionality in the initiator improves rubber properties like mixing, dispersion, and hysteresis loss.

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A four-season semi-steel tire tread rubber composition that provides good grip, wet traction, low rolling resistance, braking distance, and wear resistance in all seasons. The rubber has specific weight percentages of styrene butadiene rubber, butadiene rubber, carbon black, aromatic oil, zinc oxide, stearic acid, antioxidants, sulfur, accelerators, and scorch inhibitor. The mixing process involves lower rotor speed and higher discharge temperature to improve uniformity and efficiency.

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Rubber composition for tire treads that balances stiffness, abrasion resistance, and hysteresis. The composition contains dual polybutadiene elastomers, specialized and designated, along with reinforcing filler and silica couplers. The specialized polybutadiene is blended with carbon black and a higher average polysulfide silica coupler. The designated polybutadiene is blended with precipitated silica and a lower average polysulfide silica coupler. This balanced filler network improves stiffness, abrasion resistance, and reduces hysteresis compared to using just one polybutadiene type. The compositions can be prepared by separately mixing the specialized and designated polybutadiene rubber masterbatches before blending.

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A method to prepare modified styrene-butadiene rubber with improved properties for tires. The method involves polymerizing styrene and butadiene with a metal catalyst to create an "active polymer" with reactive sites. This active polymer is then mixed with a modifier in a specific way to modify the polymer chain ends. The mixing is done at low flow rates and controlled Reynolds numbers to ensure homogeneous mixing. The modified polymer has enhanced properties like rolling resistance, tensile strength, and wet grip compared to unmodified SBR.

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A system for preparing tire curing bladder rubber with improved mixing efficiency to enhance properties like airtightness, strength, and aging resistance. The system uses segmented feeding in the initial mixing stage to overcome issues like compounding agent agglomeration and carbon black agglomeration that cause uneven rubber. The segmented feeding involves adding half the rubber in the first stage, then the remaining half in the next stage. This allows better compatibility and integration of the added materials. The system also uses an internal mixer, open mixer, weighing materials, auxiliary feeding machine, filter, and tablet press to prepare the tire curing bladder rubber compound.

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Method for producing a rubber composition for tires that balances fuel efficiency and wet grip performance. The method involves adding a high percentage of inorganic filler to the rubber during initial kneading, then adding a thermoplastic elastomer with reactivity to the filler surface during a second kneading step. This improves wet grip without sacrificing fuel efficiency. The thermoplastic elastomer interacts with the filler surface and disperses better due to reduced filler content.

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Rubber raw material mixing equipment for better mixing of rubber compounds. The equipment has a two-stage mixing process with a pre-mixing box on top of the main mixing box. A mixing screw in the pre-mixing box mixes the materials before they enter the main mixing box with two rollers. This staged mixing improves homogeneity of the rubber compound compared to just using a single mixer. The pre-mixing box also has a separate discharge port and control valve. Heating chambers are provided in both the pre-mixing and main mixing boxes.

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A method for producing a masterbatch for rubber compounds that improves the 300% elongation tensile strength and wear resistance of vulcanized rubber. The method involves combining a filler slurry and rubber latex to make a mixed solution, stirring while irradiating with ultrasonic waves, and coagulating the solution. This breaks up filler agglomerates and suppresses reaggregation. The masterbatch is then used in rubber compositions for tires.

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Reducing viscosity and improving processing of rubber composites, especially for silica-filled rubber composites used in high performance tires, by optimizing the order of adding accelerators and filler during compounding. The method involves separately mixing the rubber, accelerator, and filler, then adding the filler-accelerator mixture to the rubber. This prevents excessive viscosity increases during compounding. The separate mixing step allows filler surface interaction with accelerator before adding to the rubber. This reduces viscosity and improves processing of the intermediate composite.

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A method to produce filler-contained rubber mixtures with improved filler dispersion and reduced polymer chain degradation compared to conventional mixing methods. The method involves separately compounding a highly filled rubber component with most of the filler, followed by compounding a lower filled rubber component with the remaining filler. The two compounded components are then combined. This decouples the conflicting objectives of good filler dispersion and reduced polymer chain degradation by separately optimizing filler distribution in each component.

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A method for preparing tire curing bladders using continuous mixing to improve rubber compound uniformity and quality stability compared to traditional staged mixing. The method involves continuously mixing butyl rubber and EPDM rubber along with other components like carbon black, silane, brominated phenolic resin, sulfur, zinc oxide, stearic acid, antioxidant, and accelerator. This allows tight control and avoids scorching issues that occur during long mixing times. The continuous mixing system has separate feed ports for butyl and EPDM, cooling water circulation, and sections for mixing, auxiliary feeding, and discharge.

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Method and apparatus for producing elastomeric compounds used in tire manufacturing that improves functionality without sacrificing productivity. The method involves using a specialized mixer with a pressure piston that moves up and down during mixing cycles. In each cycle, the piston holds at the bottom for multiple stages separated by brief piston lifts. This allows powders to settle before mixing resumes. The alternating piston motion prevents compacting powders into the mixer walls, improving dispersion and compound properties.

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Using functionalized lignin as a dispersant in rubber compounds for tire treads to improve lignin dispersion and rubber compound properties. The functionalized lignin has multiple functional groups like esters and ethers. This modified lignin provides better dispersion of the natural rubber filler in the compound compared to unmodified lignin. The functionalized lignin also improves the compound's viscosity, dynamic properties, and abrasion resistance.

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A method for producing a rubber composition with improved filler dispersion in tires. The method involves a two-step base kneading process. In the first base kneading step, part of the other rubbers and all the fillers are kneaded. In the second base kneading step, the remaining butadiene rubber is added and kneaded separately. This allows optimizing filler dispersion in the other rubbers without affecting butadiene rubber. By sequentially kneading the components instead of all together, better filler dispersion is achieved in the final rubber composition.

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Rubber mixing process to improve hardness, modulus, and tear resistance of vulcanized rubber compounds. The process involves adding fillers like carbon black and white carbon black in the final mixing stage instead of the initial masterbatch mixing. This leads to increased hardness, modulus, and tear resistance due to more containment rubber generated as the fillers coat some of the rubber during mixing, and also improves tear resistance by increasing anisotropy of the vulcanized rubber.

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Polymer with pendant associative groups along its chain to improve filler dispersion in composites like rubber. The polymer has specific monomer units and grafted pendant groups. The main chain units are butadiene-based with controlled structures. The grafted pendant groups contain associative groups like imidazolidinyl, triazolyl, triazinyl, ureido-pyrimidyl. They have reactive groups that attach to the polymer chain during grafting. The associative groups allow filler interaction to improve dispersion. The polymer can be made by grafting a modifying agent containing the pendant groups to a diene polymer.

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Method to produce masterbatches with improved filler dispersion in rubber for tires. The method involves mixing a rubber latex with a filler dispersion having specific zeta potential ranges, then adjusting the zeta potential of the resulting latex compound to a narrow range. This enhances filler dispersion in rubber compared to direct mixing of latex and filler. The zeta potential ranges are -100 to -20 mV for the latex and -90 to -10 mV for the filler dispersion. Adjusting the latex compound zeta potential to -30 to 0 mV further improves filler dispersion.

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A method to improve dispersibility of microfibrillated cellulose in rubber compositions for tires by oxidizing the cellulose fibers with an N-oxyl compound and then mixing with rubber latex and coagulating at pH 2-6. This step before vulcanization enables better dispersion of the cellulose fibers in the rubber matrix, resulting in improved tire properties like fuel economy, tensile strength, adhesion, resistance to tension set, and building processability compared to unoxidized cellulose.

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Rubber composition for tires with improved processability and reduced rubber degradation during mixing. The composition contains a diene rubber, a silane coupling agent with a mercapto group, and a polysulfide compound. The key step is to initially knead the rubber and polysulfide compound before adding the mercapto silane coupling agent. This prevents gelation during mixing by capturing the reactive mercapto groups on the polysulfide compound instead of the rubber. This allows using the mercapto silane coupling agent without issues in mixing.

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A method for producing a masterbatch with improved filler dispersion in rubber compositions. The method involves mixing a rubber latex with a filler dispersion having specific zeta potentials, resulting in a latex compound with optimized zeta potential. The latex compound has a zeta potential range of -20 to 0 mV. This enhances filler dispersion in rubber when using the masterbatch in applications like tire rubber compositions. The method involves mixing a latex with a filler dispersion having zeta potentials of -100 to -20 mV and 10 to 90 mV respectively, preparing the latex compound with zeta potential of -20 to 0 mV. This finely disperses fillers like microfibrillated fibers and crystalline polymers in the rubber matrix.

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