A Blend of AI and Sustainability in Rubber Compound Development

Highlights

• Introduction
• Digital tools for the development of rubber compound
• The advent of eco-friendly rubber compound

The rubber compound is a final material created by processing raw rubber along with fillers and various chemicals. These additives improve the raw rubber's properties to meet specific performance needs. Ingredients such as fillers, polymers, curing agents, antioxidants, accelerators, and oil are used in varying concentrations to enhance the physical properties, processability, and longevity of rubber, while also impacting its vulcanization. The compound is available in silicone rubber, fluoro rubber, and butyronitrile rubber, and widely utilized in the tire and automotive industries.

The automotive industry is the largest rubber consumer, using it in components like car seats, tires, flooring, piping, hoses, gaskets, door and window profiles, and other automotive parts. The product's characteristics such as hardness, abrasion resistance, temperature resilience, and tensile strength, make it suitable for automotive applications. Additionally, its outstanding anti-slip properties make it ideal for use in interior flooring mats and vehicle pedals. Due to this high demand, the rubber compound industry is gaining prominence. 

The impact of digital tools on rubber compound formulation and production

The integration of digital technologies like AI, machine learning, high-throughput experimentation, and predictive modeling is revolutionizing the development of rubber compounds. These advancements facilitate quicker discovery of new materials, faster optimization of compound formulations, and more efficient manufacturing processes, leading to innovative and high-performance rubber compound formation.

The idea of digital twins creating virtual replicas of physical rubber products and processes is becoming increasingly popular. By simulating the performance of rubber compounds under different conditions, engineers design and optimize compounds for specific applications, minimizing the need for physical testing and prototyping.

Moreover, advanced computational techniques, including finite element analysis and molecular dynamics simulations, allow for the prediction of rubber compound behavior under various conditions. These digital tools enable the optimization of compound formulations and processing parameters, helping to reduce the need for expensive physical prototyping and testing. The incorporation of sensors and data analytics into rubber manufacturing processes offers real-time insights into compound properties and production efficiency. By tracking key parameters, manufacturers maintain consistent quality, optimize processing conditions, and detect potential issues before they arise.

Yokohama Rubber developed a rubber compound design system based on AI

The Yokohama Rubber Company announced the implementation of a proprietary rubber compound design system that leverages AI-based compound generation technology. This new system, developed in collaboration with Hamagomu Aicom, a Yokohama Rubber subsidiary focused on information systems, is anticipated to accelerate product development and enhance product performance.

The new system represents the latest advancement in Yokohama Rubber's HAICoLab AI utilization concept. According to Yokohama, HAICoLab’s AI has been trained on structuring of thousands of rubber compounds and generate candidate compounds using over 100 types of compounding agents. The system then compares the predicted physical properties of these candidates with the desired property values, suggesting those that meet the specified targets.

Advancements in biodegradable and renewable rubber compounds

Another focus in rubber technology research is the creation of sustainable and eco-friendly rubber compounds. Traditional rubber production and disposal negatively impact the environment through greenhouse gas emissions, toxic chemicals, and waste generation. As a result, there is an increasing demand for rubber materials that are environmentally friendly and minimize these issues.

One of the common methods for manufacturing sustainable rubber compounds involves using renewable and biodegradable raw materials. Natural rubber, obtained from the rubber tree (Hevea brasiliensis), is a renewable resource harvested and processed sustainably. Nonetheless, natural rubber has some drawbacks, including limited availability and vulnerability to environmental conditions. To address these challenges, researchers have explored alternative sources of renewable rubber, namely guayule and dandelion root. These plants are cultivated on less productive land and processed to produce rubber with performance characteristics similar to natural rubber. 

Eco-friendly synthetic rubber by Kumho

Kumho Petrochemical Co., Ltd. announced the launch of its sustainable synthetic rubber composite by utilizing biosilica. Recently, the company has intensified its research into environmentally friendly synthetic rubber composites using biosilica. This effort was supported by MOUs and collaborative projects with local and international manufacturers and partners.

When silica is added to synthetic rubber for high-performance tires, it enhances fuel efficiency, braking power, and the tire's abrasion resistance. This addition makes silica a compelling alternative to traditional carbon black as a raw material. The new silica that Kumho Petrochemical uses is sourced from rice bran (rice husk) extract. This silica is then transformed into sodium silicate. The sodium silicate is then processed into biosilica for use in petrochemical products.

To sum up, the rubber compound industry is evolving rapidly with digital technological advancements and sustainable materials. However, innovations like AI-driven design systems and eco-friendly alternatives are driving improvements in performance and environmental impact. This evolution makes rubber compounds more efficient and sustainable and highlights the industry's integral role in modern manufacturing.

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