DESC:TECHNICAL FIELD
The present invention relates to the field of Polymer Technology. The present invention in particular relates to recycled tyre textile fibres-based rubber composition and its method of preparation.

BACKGROUND
Carbon black is used as a filler, pigment and/or reinforcing material in polymer composites, for example, in rubbers and in plastic master batches. Manufacturers require consistent quality and consistency in the carbon black. Price is also a major factor when selecting a carbon black. Tire companies and compounders do selection of a carbon black based on its dispersive properties, hardness of the pellet, colloidal properties of the carbon black based on the end-product requirements and its functions. Quality is increasingly being recognized as an aspect of cost savings and thus as a basis for competition.
As the continuing accumulation of scrap tires has become a major global environmental hazard, there has been an increased focus on processes and methods for reclaiming the components of scrap rubber, including tire rubber. One of the materials reclaimed from tyres particularly from end of life tyre tyres through pyrolysis method has been recovered carbon black (rCB).
Similarly, waste tyre text fibres are also a byproduct of end of life tyres. Now a days recycled tire/waste tyre textile fibers have attracted significant attention to be used as a promising substitute to the commonly used natural/synthetic reinforcement fibers in geotechnical engineering applications, construction/civil structures, insulation materials, and polymer composites. Though the application of waste tyre textile fibres in tyres are not still fully explored.
IN Publication No. 202241033225 relates to a motorcycle tyre tread base rubber composition using recovered carbon black and its method thereof. A motorcycle tyre tread base rubber composition includes 100 parts by weight of a rubber; with the tri-blend NR, SBR and PBR or NR and PBR blend; produced using conventional reinforcing carbon black grade N220 or N330 replaced with 5 to 20 phr of recovered carbon black provides better processing properties, lower Payne effect, lower rolling resistance along with high rubber elasticity.
IN Publication No. 3409/DELNP/2007 relates to a truck pneumatic tyre, the bead core of which comprising: a) a plurality of coils of at least one metallic wire, said coils being radially superimposed and axially arranged side-by-side with respect to one another, and b) a retaining member enveloping said plurality of coils, said retaining member comprising a plurality of mutually substantially parallel elongated reinforcing elements that comprise at least one preformed threadlike metallic element.
Publication No. WO2020128257 relates to a tyre having a rubber composition based on at least one rubber crumb and a thermoplastic elastomer, wherein the rubber crumb is 50% by mass or more of the composition, and having a ratio of the chloroformic extract to the acetone extract of less than 2; the chloroformic and acetone extracts being expressed as percentages by weight.
Publication No. WO2020128256 relates to a tyre comprising a rubber composition based on at least one rubber crumb, a diene elastomer, a pro-oxidant, a reinforcing filler, and a cross-linking system, said rubber crumb representing 30% by mass or more of the composition, and having a ratio of chloroformic extract to acetone extract of less than 2; the chloroformic and acetone extracts being expressed as percentages by weight.
Publication No. EP0027538 relates to a tire cord dipping composition and a method of adhering textile materials to rubber, are disclosed, wherein an N-methylol group containing polymer is employed.
Patent No. US6959744 relates to a tire having a rubber tread comprised of cap/base construction where the tread cap layer is the running surface of the tread having a lug and groove configuration and the tread base layer underlies the tread cap layer wherein the base layer provides a transition zone between the tread cap layer and the remainder of the tire carcass and is not intended to be ground-contacting. For this invention, the tread cap layer is comprised of three distinct load-bearing zones which contain reinforcing fillers selected from precipitated silica and carbon black, namely a circumferential annular central zone of a rubber composition to promote traction for the running surface of the tread, wherein the central zone is positioned between two lateral and peripheral circumferential annular zones of a rubber composition to promote resistance to tread wear for the running surface of the tread. In one aspect, the zoned rubber tread cap layer and rubber tread base layer are co-extruded together to form an integral tread rubber composite.
Patent No. US8662123 relates to a tire having a rubber tread comprised of cap/base construction where the tread cap layer provides the running surface of the tread, and the tread base layer underlies the tread cap layer and thereby provides a transition between the tread cap layer and the tire carcass. For this invention, the tread cap layer is comprised of a plurality of individual circumferential load-bearing zones of rubber compositions, which exhibit graduated physical properties, and which extend from the outer running surface of the tread cap layer radially inward to said tread base layer. In one aspect, the zoned rubber tread cap layer and rubber tread base layer are co-extruded together to form a unit as an integral tread rubber composite.
Publication No. CN109627509 relates to a tread rubber material of a low-rolling resistance all-steel radial tire and a preparation method thereof. The tread rubber material is mainly prepared by mixing, by mass, 80-100 parts of natural rubber, 0-20 parts of butadiene rubber, 20-50 parts of carbon black, 10-30 parts of white carbon black, and 1-4 parts of a silane coupling agent, the preparation comprises the following steps of: adding the white carbon black and the silane coupling agent after the natural rubber and the butadiene rubber are pressed into a plug to be mixed to obtain master batch, standing for8-24 hours, and adding carbon black for continuous mixing. According to the tread rubber material of the all-steel radial tire, a low-lag matched rubber material system is adopted, and the components are matched with each other, so that the produced rubber material has excellent performances in all aspects, the resilience and the wear resistance are good, especially the rolling resistance performance is more remarkable, the tan delta value of the produced rubber is in the range of 0.04-0.06 at the temperature of 60 DEG C, and the rolling resistance coefficient of the produced tire reaches grade B.
Publication No. EP0633152 relates to a rubber composition suitable for use in inner liners of pneumatic tyres and having an improved gas impermeability which comprises a rubber and 5 to 60 parts by weight of an acrylonitrile thermoplastic resin per 100 parts by weight of the rubber. The composition provides inner liners having an excellent retainability of inner pressure of tyres, thus enabling to decrease the weight of tyres by decreasing its gauge or to increase the inner pressure of tyres to higher levels so as to achieve energy saving.
Publication No. CN101772543 relates to the rubber composition for the inner liner contains, to (A) 100 pts. wt. of specific rubber component, (B) 10-50 pts. wt. of specific mica, (C) 20-39 pts. wt. of carbon black and/or silica and (D) 0.2-10 pts. wt. of alkylphenol-sulfur chloride condensate expressed by a formula (D1), wherein R1-R3each represents a 5-12C alkyl group, x and y each represents an integer of 2-4, and n represents an integer of 0-10.
Patent No. US3946132 relates to an improved textile forming size for glass fibers utilized in the preparation of rubber coated glass fiber tire cord is described in which a starch based forming size has incorporated therein a non-ionic wetting agent, a silane coupling agent and a paraffinic or microcrystalline wax. The use of this forming size on glass fibers which are subsequently coated with elastomer for use as tire cord results in a tire cord having improved flex fatigue properties.
IN Publication No. 1171/DEL/2015 relates to rubber reclaim material exhibits excellent processability but compromises compound properties, whereas alternative options of recycled material are either cost prohibitive, degrade compound performance, or lead to unacceptable processing behavior. The renewed rubber of this invention can be processed much more easily than conventional recycled rubber compositions. It also consistently exhibits an array of better overall cured rubber properties with only minimal variations in characteristics, by using feed stocks made by various grinding methods. In the chemical functionalization of the renewed rubber compositions of this invention, the sulfur-sulfur bonds in micronized rubber powder are broken to partially devulcanize the rubber, with only a minimal number of carbon-carbon double bonds in the backbone of the polymer being broken. This allows for the renewed rubber of this invention to be used in rubber formulations that are used in manufacturing a wide array of rubber products, including tires, power transmission belts, conveyor belts, hoses, and a wide array of other products. The present invention more specifically discloses a method for manufacturing an environmentally friendly, chemically functionalized, renewed rubber composition having a highly desirable combination of physical properties and which exhibits excellent processability comprising the steps of (1) blending a micronized rubber powder with a processing aid and a chemical functionalizing agent to produce a blended mixture; (2) processing the blended mixture under conditions of high shear and low temperature to produce a reacted mixture; (3) adding a stabilizer to the reacted mixture to produce the chemically functionalized renewed rubber composition.
Publication No. CN108102181 relates to a method for preparing reclaimed rubber from waste rubber powder. Waste tires are cleaned up, dried, smashed and sieved, and a product is taken as black rubber powder for standby application; leftover materials of shoe soles are cleaned up, dried, smashed and sieved, and a product is taken as yellow rubber powder for standby application; 50 parts of carbon black, 50 parts of the black rubber powder and 50 parts of the yellow rubber powder are subjected to high-temperature plastication on a plasticator, reclaimed rubber master batch is prepared, the rubber master batch is mixed with zinc oxide, stearic acid, a reclaiming agent and an accelerant, a product is left to stand for 10-20 h, and a rubber compound is prepared; the rubber compound is put in an open mill for vulcanization, the accelerant and sulfur are added, thin-passing triangular bag beating processing is performed 4-7 times, and a finished product is obtained. According to the method, the reclaimed rubber is prepared with a high-temperature reclaiming vulcanization method, the preparation is environmentally friendly, and operation is simple. With the adoption of the preparation method, the utilization rate of waste rubber is increased, industrial rubber garbage is reduced, the reclaimed rubber can meet national or industrial standard, and the method has the advantages of waste utilization, environmental protection, and the like.
Hence there still needed a rubber composition which can provide tyres with better performance.
In order to overcome above listed prior art, the present invention aims to provide a tread rubber composition for tyre using recycled tyre/waste tyre textile fibres and its method of preparation thereof.
OBJECT OF THE PRESENT INVENTION
The principal object of the present invention is to provide a rubber composition for tyre using recycled tyre textile fibres and its method of preparation thereof.
Yet another object of the present invention is to provide a rubber composition for tyre tread.
Yet another objection of the present invention is to replace silica or carbon reinforcing fillers using recycled tyre textile fabric or to use recycled tyre textile fabric along with reinforcing fillers carbon black or silica.
Another object of the present invention is to provide a rubber composition for tyre using recycled tyre textile fibres which improves dynamic mechanical properties of the rubber vulcanizate.
Another object of the present invention is to provide cost effectiveness.

SUMMARY
In one aspect of the present disclosure, a tyre tread rubber composition is provided.
The tyre tread rubber composition includes oil-extended solution styrene butadiene (SSBR) rubber ranging from 60-75 phr. The tyre tread rubber composition further includes polybutadiene rubber (PBR) ranging from 10-20 phr. The tyre tread rubber composition further includes natural rubber ranging from 30-40 phr. The tyre tread rubber composition further includes precipitated silica ranging from 0-30phr. The tyre tread rubber composition further includes recycled tyre textile fibre ranging from 1-15 phr. The tyre tread rubber composition further includes carbon black ranging from 20-60phr. The tyre tread rubber composition further includes coupling agent ranging from 0.5-3.0 phr. The tyre tread rubber composition further includes vulcanization activators ranging from 1.0-8.0 phr. The tyre tread rubber composition further includes processing aid ranging from 1-30 phr. The tyre tread rubber composition further includes antidegradants ranging from 0.5-6.5phr. The tyre tread rubber composition further includes vulcanization agent ranging from 1.0-3.0 phr. The tyre tread rubber composition further includes cure accelerators ranging from 1.0-5.0 phr.
In some aspects of the present disclosure, the carbon black selected from grades in the N100, N200, or N300 series, or a blend thereof.
In some aspects of the present disclosure, the coupling agent comprises sulfur-containing organosilane.
In some aspects of the present disclosure, the vulcanization activators comprise zinc oxide and stearic acid.
In some aspects of the present disclosure, the antidegradants includes 6PPD (N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine), TQ (1,2 dihydro-2,2,4-trimethylquinoline), microcrystalline wax, or mixtures thereof.
In some aspects of the present disclosure, the processing aid is selected from MES oil (Mild Extract Solvate Oil), TDAE (Treated Distillate Aromatic Extracted) oil, naphthenic oil, hydrocarbon resin, C5/C9 resin, or combinations thereof.
In some aspects of the present disclosure, the cure accelerators comprise N-cyclohexyl-2-benzothiazolesulfenamide (CBS), Diphenyl guanidine (DPG), or mixtures of accelerators such as guanidines, thiazoles, sulfenamides, or thiuram sulfides.
In some aspects of the present disclosure, the vulcanization agent comprises sulfur or different grades of insoluble sulfur.
In second aspect of the present disclosure, a method of preparing a tyre tread rubber composition is provided.
The method includes preparation of the master batch that includes mixing an elastomeric matrix comprising oil-extended solution styrene-butadiene rubber (OESBR), natural rubber (NR), and polybutadiene rubber (PBR) with reinforcing fillers including carbon black and silica, recycled tyre textile fibres derived from end-of-life tyres, coupling agents, process oil, activators, and antidegradants. The preparation of master batch further includes conducting the mixing in a Banbury mixer at a temperature of 65°C to 90°C with an unloaded rotor speed of 45 to 70 rpm for 0 to 60 seconds. The preparation of master batch further includes performing silanization by reducing the rotor speed to 20 to 30 rpm for 100 to 280 seconds to improve filler-rubber interaction. The preparation of master batch further includes adding rubber chemicals, process oil, stearic acid, microcrystalline wax, and recycled tyre textile fibres to the Banbury mixer and continuing mixing for an additional 100 to 280 seconds. The preparation of master batch further includes sweeping the compound in the mixing chamber or orifice for 100 to 320 seconds to ensure uniform dispersion of ingredients. The preparation of master batch further includes dumping the master batch compound at a temperature of 145°C to 165°C and sheeting it out on a laboratory two-roll mill. The method further includes preparation of the intermediate batch that includes adding zinc oxide and N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine (6PPD) to the master batch in the Banbury mixer. The preparation of intermediate batch includes mixing the compound at a temperature of 120°C to 155°C with a rotor speed of 45 to 70 rpm for 80 to 200 seconds. The preparation of intermediate batch includes dumping the intermediate batch compound at a temperature of 120°C to 155°C and sheeting it out on a laboratory two-roll mill. The method further includes preparation of the final batch that includes charging the Banbury mixer with the intermediate batch compound and adding curatives, including sulfur and cure accelerators such as N-cyclohexyl-2-benzothiazolesulfenamide (CBS) and Diphenylguanidine (DPG). The preparation of the final batch further includes mixing the final batch compound in the Banbury mixer at a temperature of 105°C to 120°C with a rotor speed of 45 to 70 rpm for 40 to 110 seconds. The preparation of the final batch further includes dumping the final batch compound at a temperature of 90°C to 110°C and sheeting it out on a laboratory two-roll mill.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure. Thus, the following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in certain instances, known details are not described in order to avoid obscuring the description.
References to one or an embodiment in the present disclosure can be references to the same embodiment or any embodiment; and, such references mean at least one of the embodiments.
Reference to "one embodiment", "an embodiment", “one aspect”, “some aspects”, “an aspect” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others.
The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Alternative language and synonyms may be used for any one or more of the terms discussed herein, and no special significance should be placed upon whether or not a term is elaborated or discussed herein. In some cases, synonyms for certain terms are provided.
A recital of one or more synonyms does not exclude the use of other synonyms.
The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and is not intended to further limit the scope and meaning of the disclosure or of any example term. Likewise, the disclosure is not limited to various embodiments given in this specification. Without intent to limit the scope of the disclosure, examples of instruments, apparatus, methods and their related results according to the embodiments of the present disclosure are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. Unless otherwise defined, technical and scientific terms used herein have the meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions will control.
Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims, or can be learned by the practice of the principles set forth herein.
As mentioned before, there is a need for technology that overcomes these drawbacks associated with the prior arts. The present disclosure, therefore, also provides a recycled tyre textile fibres-based rubber composition. The present disclosure provides the use of recycled tyre textile fibres as a filler in tyre rubber composition. The present disclosure provides the use of recycled tyre textile fibres as a filler in tyre rubber composition.
In some aspects of the present disclosure, a rubber composition for motorcycle tyre treads, includes Oil-extended solution styrene butadiene (SSBR) rubber, polybutadiene rubber (PBR), natural rubber, precipitated silica, recycled tyre textile fibre, carbon black, coupling agent, vulcanization activators, processing aid, antidegradants, vulcanization agent, and cure accelerators.
In some aspects of the present disclosure, the Oil-extended solution styrene butadiene (SSBR) rubber ranges from 60-75 phr. In some aspects of the present disclosure, the polybutadiene rubber (PBR) ranges from 10-20 phr. In some aspects of the present disclosure, natural rubber ranging from 30-40 phr. In some aspects of the present disclosure, precipitated silica ranging from 0-30 phr. In some aspects of the present disclosure, recycled tyre textile fibre ranges from 1-15 phr. In some aspects of the present disclosure, carbon black ranges from 20-60 phr. In some aspects of the present disclosure, coupling agent ranges from 0.5-3.0 phr. In some aspects of the present disclosure, vulcanization activators ranges from 1.0-8.0 phr. In some aspects of the present disclosure, processing aid ranges from 1-30 phr. In some aspects of the present disclosure, antidegradants ranges from 0.5-6.5phr. In some aspects of the present disclosure, vulcanization agent ranges from 1.0-3.0 phr. In some aspects of the present disclosure, cure accelerators ranges from 1.0-5.0 phr.
In some aspects of the present disclosure, the carbon black selected from grades in the N100, N200, or N300 series, or a blend thereof.
In some aspects of the present disclosure, the coupling agent includes sulfur-containing organosilane.
In some aspects of the present disclosure, the vulcanization activators includes zinc oxide and stearic acid.
In some aspects of the present disclosure, the antidegradants includes 6PPD (N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine), TQ (1,2 dihydro-2,2,4-trimethylquinoline), microcrystalline wax, or mixtures thereof.
In some aspects of the present disclosure, the processing aid is selected from MES oil (Mild Extract Solvate Oil), TDAE (Treated Distillate Aromatic Extracted) oil, naphthenic oil, hydrocarbon resin, C5/C9 resin, or combinations thereof.
In some aspects of the present disclosure, the cure accelerators includes N-cyclohexyl-2-benzothiazolesulfenamide (CBS), Diphenyl guanidine (DPG), or mixtures of accelerators such as guanidines, thiazoles, sulfenamides, or thiuram sulfides.
In some aspects of the present disclosure, the vulcanization agent includes sulfur or different grades of insoluble sulfur.
Table 1: Tread Rubber compositions in Phr
Ingredients Comparative Example C1, in phr Example F1, in phr Example F2, in phr
SSBR 1 68.75 68.75 68.75
PBR 2 15.00 15.00 15.00
NR 3 35.00 35.00 35.00
Recycled tyre textile fibres 4 5.0 15.0
Precipitated Silica 5 15.00 15.00 15.00
Carbon black 6 45.00 40.00 30.0
Coupling agent 7 1.50 1.50 1.50
Zinc oxide 8 3.50 3.50 3.50
Stearic acid 9 2.00 2.00 2.00
Process Oil 10 3.00 3.00 3.00
MC Wax 11 1.75 1.75 1.75
6PPD 12 2.00 2.00 2.00
DPG 13 0.50 0.50 0.50
CBS 14 1.00 1.00 1.00
Sulphur 15 1.75 1.75 1.75

1- SSBR Tufdene E680- It is an oil extended solution polymerized styrene butadiene rubber with a vinyl content of 58 % and bound styrene content of 34 % and a polymer Tg of -24 Deg C and it is from Asahi Kasei, Singapore.
2- PBR – Poly butadiene Rubber PBR 1220 with the Mooney Viscosity, ML (1+4) at 100°C ranging from 40 MU to 50 MU from Reliance Industries Limited, India
3- NR - Indian Standard Natural Rubber ISNR 20 with the Mooney Viscosity, ML (1+4) at 100°C is 65 to 80 MU and it is obtained from Mamparambil Rubber India Pvt Ltd, India.
4- Recycled tyre textile fabrics - It is a sustainable development goal material, as a byproduct of end-of-life tyres (scrap tyres) used as a filler. It is from Rathi Industrial Enterprises, A-9/S-2 Sipcot, Gummidipoondi, Tamilnadu, India.
5- Precipitated Silica – It is from Madhu Silica Private Ltd, India. It is the reinforcing filler having nitrogen surface area value 170 to 190 m2/gm and it is used for the present invention is to provide a high performance motor cycle tyre treads.
6- Carbon Black –ASTM Grade N110 is the reinforcing filler SAF, Superior Abrasion Furnace having the Iodine adsorption No. 140 to 150 mg/gm, tinting strength value between 118 to 128 % ITRB, nitrogen surface area value between 122 to 132 m2/gm and COAN value ranges between 92 to 102 cc/100 gm.
7- Coupling Agent - Si75 is a bifunctional, sulfur- containing organosilane from Nanjing Shuguang Silane Chemical Co Ltd, China. It is used to provide a satisfactory bonding of, chemical/or physical nature between the inorganic filler and diene elastomer(s).
8- Zinc Oxide- It is used as an activator for the sulphur vulcanization of rubbers enhances the vulcanization efficiency and reduces the vulcanization time from Ambica Dhatu Private Limited, India.
9- Stearic acid- It is from 3F Industries Ltd., India. It is used as a Process aid. Also, Zinc oxide and Stearic acid are added to form zinc soap, improves the solubility of zinc oxide in the compound, and with the accelerator to form a complex, this complex reacts with sulphur to produce a strong cure activating system.
10- MES oil– Mild Extracted Solvate or Low PCA oil is used to improve the processability of rubber compounds from IOCL Limited, India.
11- MC Wax- (Microcrystalline wax) from GPL, India. It is used to protect against degradation by ozone.
12- 6PPD- It is (N-(1,3-dimethylbutyl)-N’-phenyl-p-phenylenediamine) from Finorchem Limited, India. It is added to the rubber composition to provide resistance to thermo-oxidative ageing of elastomers.
13- DPG- Diphenylguanidine It is secondary accelerator, used to activate the primary accelerator) from PMC Rubber Chemicals India Pvt ltd, India.
14- CBS- (N-cyclohexyl-2-benzothiazolesulfenamide) It is a delayed action accelerator suitable for diene rubbers from Nocil Limited, India.
15- Sulphur- Sulphur is the vulcanizing agent from The Standard Chemical Co. Pvt Ltd, India.
Example 1: Characterization of Cured Rubber Vulcanizate and Uncured Rubber Compound:
The study was conducted to evaluate performance and characteristics of two novel tyre tread rubber compositions, F1 and F2, which incorporated recycled tyre textile fabrics as partial replacements for carbon black, compared to a control composition, C1. The compositions, F1 and F2, consisted of a blend of synthetic and natural rubbers (SSBR, PBR, NR) with 5 phr and 15 phr of recycled tyre textile fabrics, respectively, while the control (C1) used the same rubber blend reinforced with 45 phr of carbon black and 15 phr of silica. The results showed that the inclusion of recycled tyre textile fabrics in F1 and F2 reduced Mooney viscosity by 7%, indicating enhanced processability and reduced energy consumption during manufacturing. Both compositions exhibited Shore A hardness values of 60 to 61, maintaining structural integrity and suitability for tyre tread applications.
F1 and F2 outperformed C1 in key performance areas, demonstrating up to 7% improvement in ice traction, making them ideal for cold or icy environments, and achieving a 4-6% reduction in rolling resistance, which translated to better fuel efficiency and lower carbon emissions. The wet grip performance of F1 and F2 remained optimal, ensuring safety in wet conditions. Additionally, F1 and F2 showed a 1-10% improvement in rubber elasticity, enhancing their shock absorption and resilience, critical for high-performance tyres. The partial replacement of carbon black with recycled tyre textile fabrics as filler also contributed to sustainability by reducing dependency on non-renewable fillers and promoting a circular economy through waste repurposing.
The compound properties are listed in Table 2 below-
Table 2: Characterization of Uncured Rubber Compound and Cured Rubber Vulcanizate
Properties C1 F1 F2 F1, Index F2, Index
M1. Processability Characteristics of Rubber Compound
Mooney Viscosity @ 125 Deg C, MU (Lower the Index value is better) 51.0 51.20 47.60 100 93
M2. Hardness of a Rubber Vulcanizate
Hardness, Shore A 58 61 60 - -
M3. Dynamic Mechanical Properties of the Rubber Vulcanizate
Ice Traction, tan delta at -10 Deg C (Higher the index value is better) 0.656 0.659 0.702 100 107
Wet traction, tan delta at 0°C
(Higher the index value is better) 0.528 0.522 0.523 99 99
Rolling resistance, tan delta 60 Deg C
(Lower the index value is better) 0.158 0.149 0.151 94 96
M4. High Rubber Elasticity of Rubber Vulcanizate
Rebound Resilience at 23+/- 2 Deg C
(Higher the index value is better) 39.37 39.79 43.19 101 110
Example 2: Mooney Scorch Characteristics
Mooney Scorch was measured using a Mooney Viscometer (MV 2000) as per ASTM D1646. The minimum viscosity (MV) value indicates the ease of processing before vulcanization.
Lower Mooney viscosity values suggest improved processability and better handling during manufacturing. This means the material flows more efficiently, reducing energy costs and processing time. The inclusion of recycled tyre textile fabrics likely contributed to this improved processability compared to conventional compositions.
Example 3: Hardness test
Shore A Hardness was tested in accordance with ASTM D2240. Shore A hardness values (60–61) indicate that the vulcanized rubber maintains adequate stiffness and structural integrity. These values are suitable for tyre tread applications, ensuring resistance to deformation under load and durability in use.
Example 3: Dynamic Properties of the Rubber Vulcanizate
Dynamic properties were assessed using a dynamic mechanical analyzer (DMA) over a temperature range of -40°C to +80°C, at a frequency of 10 Hz, in tension mode (ASTM D5992). Key performance predictors included Tan Delta values at different temperatures.
At Tan Delta at -10°C (Ice Traction), the F1 and F2 compositions demonstrated higher values than the control, confirming their better performance in icy conditions.
At Tan Delta at 0°C (Wet Traction), the F1 and F2 composition maintain grip on wet surfaces, ensuring safety and reliability.
At Tan Delta at 60°C (Rolling Resistance), the F1 and F2 achieved reduced values compared to the control, highlighting their superior energy-saving potential.
Example 4: Rubber Elasticity of the Rubber Vulcanizate:
The elasticity was measured using a Rebound Resilience Tester per ASTM D7121. The F1 and F2 compositions showed increased rubber elasticity, indicating their ability to endure dynamic stresses and enhance ride comfort.
In second aspect of the present disclosure, a method of preparing the rubber composition is provided.
The method of preparing the rubber composition may include mixing the elastomeric matrix, recycled tyre textile fibres, carbon black, silica, coupling agent, activators, anti-degradants, and process oil in a Banbury mixer at a temperature of 65 to 90°C and a rotor speed of 45 to 70 rpm.
The method of preparing the rubber composition may further include dumping the compound and sheeting it out on a laboratory two-roll mill.
The method of preparing the rubber composition may further include adding zinc oxide and 6PPD to the compound and mixing in a Banbury mixer at a temperature of 120 to 155°C and a rotor speed of 45 to 70 rpm.
The method of preparing the rubber composition may further include dumping the compound and sheeting it out on a laboratory two-roll mill.
The method of preparing the rubber composition may further include adding curatives to the compound and mixing in a Banbury mixer at a temperature of 105 to 120°C and a rotor speed of 45 to 70 rpm.
In some aspects of the present disclosure, the curatives comprise a primary accelerator and sulphur.
Example 1: preparation of master batch
Mixing was done with the head temperature of the Banbury mixer maintained between 65 and 90°C and the unloaded rotor speed maintained between 45 and 70 rpm. The mixing chamber was charged with rubbers and mixed for 0 to 60 seconds. Silanization was carried out with a reduced rotor speed of 20 to 30 rpm. Rubber chemicals, process oil, stearic acid, MC Wax (except zinc oxide and 6PPD), and recycled textile fibers were added and mixed for 100 to 280 seconds. Sweeping was done in the orifice for 100 to 320 seconds.
The compound was then dumped at a temperature in the range of 14 to 165°C and sheeted out on a laboratory two-roll mill.
Step 2
Zinc oxide and 6PPD were added to the step I master batch in the laboratory Banbury Mixer and mixed for 80 to 200 seconds. The compound was then dumped at a temperature in the range of 120 to 155°C and sheeted out on a laboratory two-roll mill.
Step 3
Mixing chamber of the banbury was charged with the Step II master batch, mixed for 120 to 140 seconds, and dumped at the temperature range of 125°C to 140°C. The compound was sheeted out in the laboratory two-roll mill.
Preparation of the final Batch
The Mixing chamber was charged with the Step III master batch and the curatives Sulphur, CBS (N-cyclohexyl-2-benzothiazolesulfenamide), and DPG (Diphenylguanidine) were added, mixed for 40 to 110 seconds, and dumped at the temperature range of 90°C to 110°C. Final sheeting out was done in the laboratory mill.
The dynamic properties of the rubber vulcanizate are measured in a dynamic mechanical analyzer (DMA Metravib +1000) with a dynamic strain 0.3%, static strain: 0.6% and temperature sweep ranges from -40 to +80°C, frequency: 10Hz in tension mode as per ASTM D5992.

Advantages:
The present disclosure provides a composition that reduce the rubber compound cost.
The present disclosure provides a composition that improve the circular economy by using sustainable development goal materials.
The present disclosure provides a rubber composition to reduce carbon footprint.
The present disclosure provides a rubber composition to provide improved ice traction and lower rolling resistance (LRR) property along with optimum wet grip.
The present disclosure provides a rubber composition to provide better processing properties.
The present disclosure provides a rubber composition provide sustainable goal material use in potential application like tyres.
The present disclosure provides a way to use the end-of-life tyres (ELT) derived products in an effective method.
The present disclosure provides a rubber composition suitable for high performance motorcycle tyre tread.
The implementation set forth in the foregoing description does not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detain above, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementation described can be directed to various combinations and sub combinations of the disclosed features and/or combinations and sub combinations of the several further features disclosed above. In addition, the logic flows depicted in the accompany figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other implementations may be within the scope of the following claims.
,CLAIMS:1. A tyre tread rubber composition comprising:
Oil-extended solution styrene butadiene (SSBR) rubber ranging from 60-75phr;
polybutadiene rubber (PBR) ranging from 10-20phr;
natural rubber ranging from 30-40phr;
reinforcing filler silica ranging from 0-30phr;
recycled tyre textile fibre as filler ranging from 1-15 phr;
reinforcing filler carbon black ranging from 20-60phr;
coupling agent ranging from 0.5-3.0 phr;
vulcanization activators ranging from 1.0-8.0 phr;
processing aid ranging from 1-30 phr;
antidegradants ranging from 0.5-6.5phr;
vulcanization agent ranging from 1.0-3.0 phr; and
cure accelerators ranging from 1.0-5.0 phr.

2. The tyre tread rubber composition as claimed in claim 1, wherein the carbon black selected from grades in the N100, N200, or N300 series, or a blend thereof.

3. The tyre tread rubber composition as claimed in claim 1, wherein the coupling agent comprises sulfur-containing organosilane.
4. The tyre tread rubber composition as claimed in claim 1, wherein the vulcanization activators comprise zinc oxide and stearic acid.

5. The tyre tread rubber composition as claimed in claim 1, wherein the antidegradants comprise 6PPD (N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine), TQ (1,2 dihydro-2,2,4-trimethylquinoline), microcrystalline wax, or mixtures thereof.

6. The tyre tread rubber composition as claimed in claim 1, wherein the processing aid is selected from MES oil (Mild Extract Solvate Oil), TDAE (Treated Distillate Aromatic Extracted) oil, naphthenic oil, hydrocarbon resin, C5/C9 resin, or combinations thereof.

7. The tyre tread rubber composition as claimed in Claim 1, wherein the cure accelerators comprise N-cyclohexyl-2-benzothiazolesulfenamide (CBS), Diphenyl guanidine (DPG), or mixtures of accelerators such as guanidines, thiazoles, sulfenamides, or thiuram sulfides.

8. The tyre tread rubber composition as claimed in claim 1, wherein the vulcanization agent comprises sulfur or different grades of insoluble sulfur.

9. A method of preparing a tyre tread rubber composition, comprising:
a. preparation of the master batch:
mixing an elastomeric matrix comprising oil-extended solution styrene-butadiene rubber (OESBR), natural rubber (NR), and polybutadiene rubber (PBR) with reinforcing fillers including carbon black and silica, recycled tyre textile fibres derived from end-of-life tyres, coupling agents, process oil, activators, and antidegradants;
conducting the mixing in a Banbury mixer at a temperature of 65°C to 90°C with an unloaded rotor speed of 45 to 70 rpm for 0 to 60 seconds;
performing silanization by reducing the rotor speed to 20 to 30 rpm for 100 to 280 seconds to improve filler-rubber interaction;
adding rubber chemicals, process oil, stearic acid, microcrystalline wax, and recycled tyre textile fibres to the Banbury mixer and continuing mixing for an additional 100 to 280 seconds;
sweeping the compound in the mixing chamber or orifice for 100 to 320 seconds to ensure uniform dispersion of ingredients;
dumping the master batch compound at a temperature of 145°C to 165°C and sheeting it out on a laboratory two-roll mill;
b. preparation of the intermediate batch:
adding zinc oxide and N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine (6PPD) to the master batch in the Banbury mixer;
mixing the compound at a temperature of 120°C to 155°C with a rotor speed of 45 to 70 rpm for 80 to 200 seconds;
dumping the intermediate batch compound at a temperature of 120°C to 155°C and sheeting it out on a laboratory two-roll mill;
c. preparation of the final batch:
charging the Banbury mixer with the intermediate batch compound and adding curatives, including sulfur and cure accelerators such as N-cyclohexyl-2-benzothiazolesulfenamide (CBS) and Diphenylguanidine (DPG);
mixing the final batch compound in the Banbury mixer at a temperature of 105°C to 120°C with a rotor speed of 45 to 70 rpm for 40 to 110 seconds; and
dumping the final batch compound at a temperature of 90°C to 110°C and sheeting it out on a laboratory two-roll mill.