Foamed rubber composition for tires and pneumatic tire using the same

Abstract: A foamed rubber composition for tires comprises a particular amount of particles having specified hardness and average particle size and containing aluminum-bonded hydroxy group and/or silicon-bonded hydroxy group at its surface, and a particular amount of at least one specified silane coupling agent. Such a composition provides good performance on ice. Further, in a preferred aspect, pneumatic tires contain such a foamed rubber composition as a tread rubber thereof.

Description: This invention relates to foamed rubber compositions for tires and to pneumatic tires using the same, and also to a method of producing a foamed rubber composition. More particularly, the invention relates to a foamed rubber composition for tires having a high friction coefficient even on ice and/or snow road surfaces and a method of producing the same, as well as to pneumatic tires for passenger cars, trucks, buses and other vehicles using the same. Recently, the demand for so-called all season tires capable of being used without tire exchange even in the winter season and likewise in the summer season has been increasing. This type of all season tire develops dry gripping property, wet gripping property, steering stability, durability and low fuel consumption even in the winter season and likewise in the summer season, and further has sufficient traction and braking performances on snow and/or ice roads. As a tread rubber used in all season tires, there have hitherto been known a method of decreasing the hardness at a low temperature in a tread rubber for the summer season, and a method of using a polymer having a low glass transition temperature or using a softening agent capable of adequately maintaining the modulus of elasticity of the tread rubber at a low temperature. In the former method, however, the performances at snow and ice temperature range are almost developed owing to the hysteresis property of the polymer, but there are problems that the braking performance and steering stability on wet and dry roads are insufficient. On the other hand, the latter method is disclosed, for example, in JP-A-55-135149, JP-A-58-199203 and JP-A-60-137945, but has a serious problem that it badly affects the wear resistance and durability in the running on general-purpose roads even though the performances on snow and/or ice roads are improved. In any case, the tread rubbers produced by the above methods certainly exhibit good performances at a relatively low temperature range of not higher than -5°C or at so-called dry-on-ice state, but do not provide sufficient friction coefficient at a wet state of about 0°C or at so-called wet-on-ice state, so that it can not be said that the traction performance, braking performance and steering stability are sufficiently improved. Lately, there have been adopted some processes of applying means for the improvement of friction force to the tread rubber composition itself. As a first process, there is a process wherein the tread rubber is foamed by a proper means to form closed cells in the tread rubber composition (JP-A-63-89547). In general, a layer called a false liquid layer is existent on the surface of ice. When an object is forcedly moved on the ice surface, a part of the false liquid layer changes into a water film, which acts as a lubricant to develop a low friction constant. In the first process, the surface of the thus obtained tread rubber is covered with a great number of cells, so that the removal of water film created on a zone contacting with the ice surface and the edge action of scraping the false liquid layer accompanied with a microscopic movement of the cells are developed to provide high friction properties on ice. The tires manufactured by using this process are commercially available as studless tires. However, they have the effect of removing the false liquid layer from the ice surface, but can not directly scrape or break the ice itself, which is different from the conventionally used spike tire, so that the improvement of the performance on ice is not yet satisfied. As a second process, there is a process for attaining the high friction properties on ice by incorporating various high-hardness materials into the tread rubber to utilize the scratching effect of these materials on the ice surface (JP-B-46-31732, JP-A-51-147803, JP-B-56-52057 and JP-B-6-102737). This process is apparently a process for providing the high friction properties of the tread rubber on ice by a mechanism different from the above first process. In fact, as the amount of the high-hardness material incorporated becomes larger, the tread rubber tends to provide the high friction properties on ice. In the first process, the surface of the tread rubber is rendered into a rugged surface by foaming or migrating of foreign matter, so that the ice surface is scratched by convex portions of the rugged surface and water existing on the ice surface is absorbed and discharged by concave portions of the rugged surface. However, the hardness of the rubber is relatively low as compared with the ice surface at a low temperature range (not higher than -3°C in the usual case), so that the scratching effect can not be expected at such a low temperature range. In the second process of incorporating the high-hardness material developing a high scratching effect into the matrix rubber of the tread, the effect of improving the performance on ice at about 0°C having a large water content is small at this temperature. Further, the high-hardness material is existent as a foreign matter having no affinity with rubber, so that the wear resistance and fatigue properties are considerably degraded. Under the above circumstances, the present inventor has examined the incorporation of composite particles consisting of syn-l,2-polybutadiene resin, sulfur, vulcanization accelerator, carbon black and scorch retarder into a foamed tread rubber in order to simultaneously establish the improvement of performances on snow and ice road surfaces at a wet state and the wear resistance and has confirmed that the use of such composite particles is not yet sufficient for commercial markets. That is, it is demanded to further improve the composite particles. Moreover, the actual ice surface temperature changes from day to night, so that it is strongly desired to develop a tire tread having more stable performances on ice over a wider temperature range and causing no degradation of wear resistance and fatigue properties. On the other hand, the conventional foamed rubber has a function of improving the friction coefficient on ice by the dewatering and water discharging effects of flowing out of water film generated between the ground contact region of the tire and the ice road surface. However, such effects are critical in order to remove a greater amount of water film at the wet-on-ice state, so that it is difficult to improve the friction coefficient on ice at the wet-on-ice state. Alternatively, the performance on ice is improved to a certain extent by incorporating particles having particular particle size and hardness as microspikes for developing the scratching effect into the tread rubber, but the synergistic action between the scratching effect and the water discharging effect is less, so that the level of the performance on ice is still insufficient. That is, the feature that the synergistic action is small is due to the fact that the hardness of the particles is in inverse proportion to the adhesion property of the particles to rubber. In the conventional technique, as the particles become harder, the adhesion property of the particles to rubber lowers though the scratching effect is improved. As a result, the particles are apt to migrate from the ground contact region of the tread at a friction face between the tire and the road surface and hence the number of effective microspikes undesirably reduces and the scratching effect is not maintained long and also there are problems that the wear resistance and crack resistance are degraded. When hard particles are added to a rubber composition containing a foaming agent, the foaming is caused at boundary surfaces of the particles to lower the adhesion force to rubber matrix. It is, therefore, an aim of the present invention to provide a foamed rubber composition for tires developing a scratching effect by compounding sufficiently hard particles and enhancing the continuity of this effect by strongly bonding these particles to rubber matrix through a silane coupling agent to thereby develop a true synergistic action between the scratching effect and the water discharging effect. It is another aim of the invention to provide a method of producing the above foamed rubber composition as well as pneumatic tires for passenger cars, trucks and buses and other vehicles using the same. According to a first aspect of the invention, there is provided a foamed rubber composition comprising 3-30 parts by weight, based on 100 parts by weight of rubber ingredient, of particles having a JIS C-type hardness of not less than 75 and an average particle size of 5-250 µm, measured by laser diffraction process using a particle size analyzer of NIKKISO microtrack MKII, and containing aluminium-bonded hydroxy groups and/or silicon-bonded hydroxy groups at their surface, and 3-50% by weight, based on the weight of the particles, of at least one silane coupling agent, and wherein said foamed rubber composition has an expansion ratio of 5-35%; wherein said silane coupling agent is represented by the following general formula: Y 3 -Si-C n H 2n A wherein A is a -S m C n H 2n Si-Y 3 group, Y is an alkyl or alkoxy group having a carbon number of 1-4 or a chlorine atom, provided that the three Y groups may be same or different, and m and n are each an integer of 1-6, or wherein said silane coupling agent is selected from 3-trimethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 3-triethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 2-triethoxysilylethyl-N,N-dimethylthiocarbamoyl tetrasulfide, 3-trimethoxysilylpropylbenzothiazole tetrasulfide, 3-triethoxysilylpropylbenzothiazole tetrasulfide, 3-triethoxysilylpropyl methacrylate monosulfide, 3-trimethoxysilylpropyl methacrylate monosulfide, dimethoxymethylsilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, and dimethoxymethylsilylpropylbenzothiazole tetrasulfide. In a preferable embodiment of the first aspect of the invention, the particles consist of at least 20% by weight of at least one selected from Al(OH) 3 and SiO 2 and the remainder being an organic binder. According to a second aspect of the invention, there is provided a method of producing a foamed rubber composition by kneading at least one rubber ingredient, a silane coupling agent and particles having an average particle size of 5-250 µm, measured by laser diffraction process using a particle size analyzer of NIKKISO microtrack MKII, adding with a foaming agent and then curing, characterized in that (1) said silane coupling agent is represented by the following general formula: Y 3 -Si-C n H 2n A wherein A is a -S m C n H 2n Si-Y 3 group, Y is an alkyl or alkoxy group having a carbon number of 1-4 or a chlorine atom, provided that the three Y groups may be same or different, and m and n are each an integer of 1-6, or (2) said silane coupling agent is selected from 3-trimethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 3-triethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 2-triethoxysilylethyl-N,N-dimethylthiocarbamoyl tetrasulfide, 3-trimethoxysilylpropylbenzothiazole tetrasulfide, 3-triethoxysilylpropylbenzothiazole tetrasulfide, 3-triethoxysilylpropyl methacrylate monosulfide, 3-trimethoxysilylpropyl methacrylate monosulfide, dimethoxymethylsilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, and dimethoxymethylsilylpropylbenzothiazole tetrasulfide, and the particles have a JIS C-type hardness of not less than 75 and contain aluminium-bonded hydroxy groups and/or silicon-bonded hydroxy groups at their surface, and the kneading is carried out at a temperature of at least 150°C, and the curing is carried out at an expansion ratio of 5-35%, and in that the particles are added in an amount of 3-30 parts by weight based on 100 parts by weight of the rubber ingredient, and the silane coupling agent is used in an amount of 3-50% by weight based on the weight of the particles. In a preferable embodiment of the second aspect of the invention, the particles consist of at least 20% by weight of at least one selected from Al(OH) 3 and SiO 2 and the remainder being an organic binder. According to a third aspect of the invention, there is provided a pneumatic tire having a tread, said tread being made from a foamed rubber composition according to the first aspect of the invention. In a preferable embodiment of the third aspect of the invention, the particles consist of at least 20% by weight of at least one selected from Al(OH) 3 and SiO 2 and the remainder being an organic binder. According to the invention, a rubber ingredient is added with particular particles and coupling agent and sufficiently kneaded at a kneading temperature of not lower than 150°C and then cured to sufficiently adhere the particular particles to the rubber matrix, whereby it is possible to include closed cells into the rubber matrix while preventing separation of the particles and foaming at the boundary surfaces of the particles. As the rubber ingredient used in the invention, there may be suitably used at least one rubber selected from natural rubber, diene series rubbers such as isoprene rubber, butadiene rubber, and styrene-butadiene rubber, and non-diene series rubbers such as butyl rubber. The particles used in the invention have a JIS C-type hardness of not less than 75 and an average particle size of 5-250 µm and contain aluminium-bonded. hydroxy groups and/or silicon-bonded hydroxy groups at their surface. When the JIS C-type hardness is less than 75, a sufficient scratching effect of the particles is not obtained. The JIS C-type hardness of the particles is preferably not less than 90, more particularly not less than 95. In particular, when particles having such a high hardness are incorporated into a foaming rubber matrix, if the resulting foamed rubber is used as a tread rubber of a pneumatic tire, the scratching effect of the particles is developed even at such a low temperature that the hardness of ice is very high, whereby high friction properties can be attained to improve e.g. the braking performance. The average particle size of these high-hardness particles is restricted to a range of 5-250 µm. When the average particle size is less than 5 µm, sufficient scratching effect is not obtained, while when it exceeds 250 µm, there are caused problems in respect of e.g. the wear resistance, crack resistance and durability. Moreover, the average particle size is measured by laser diffraction process (light scattering process) using a particle size analyzer of NIKKISO microtrack MKII (made by Nikkiso Kabushiki Kaisha) according to usual manner. The amount of these particles added is 3-30 parts by weight based on 100 parts by weight of the rubber ingredient. When the amount of the particles is less than 3 parts by weight, sufficient scratching effect is not obtained, while when it exceeds 30 parts by weight, there are caused problems in respect of e.g. the durability. As the particles containing aluminium-bonded hydroxy groups and/or silicon-bonded hydroxy groups at their surface, there may be suitably used Al(OH) 3 , SiO 2 , 1,4-bis(hydroxydimethylsilyl) benzene, diphenylsilane diol, triethyl silanol, and triphenyl silanol. Among them, it is preferable that the particles consist of at least 20% by weight of at least one selected from Al(OH) 3 and SiO 2 and the remainder being an organic binder. In this case, when the amount is less than 20% by weight, the reactive sites of the particles to the coupling agent is less and the adhesion property can not be ensured, and also foaming is caused at the boundary surfaces of the particles to bring about the degradation of adhesion force and resistance to breakage. As the organic binder, there may be suitably used polymethyl methacrylate (PMMA), polyvinyl alcohol (PVA), polyvinyl acetate, polyacrylic acid, styrene-butadiene copolymer resin, polyester resin, epoxy resin, acrylic resin, phenolic resin, melamine resin, polypropylene resin (PP), and syn-1,2-polybutadiene resin. As the silane coupling agent represented by the general formula of Y 3 -Si-C n H 2n A according to the invention, there may be suitably used bis(3-triethoxysilylpropyl) tetrasulfide, bis(2-triethoxysilylethyl) tetrasulfide, bis(3-trimethoxysilylpropyl) tetrasulfide, bis(2-trimethoxysilylethyl) tetrasulfide, 3-trimethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 3-triethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 2-triethoxysilylethyl-N,N-dimethylthiocarbamoyl tetrasulfide, 3-trimethoxysilylpropylbenzothiazole tetrasulfide, 3-triethoxysilylpropylbenzothiazole tetrasulfide, 3-triethoxysilylpropyl methacrylate monosulfide, and 3-trimethoxysilylpropyl methacrylate monosulfide. Among them, bis(3-triethoxysilylpropyl) tetrasulfide and 3-trimethoxysilylpropylbenzothiazole tetrasulfide are particularly preferred. When three Y groups in the general formula are different, there may be suitably used bis(3-diethoxymethylsilylpropyl) tetrasulfide, dimethoxymethylsilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, and dimethoxymethylsilylpropylbenzothiazole tetrasulfide. The amount of the silane coupling agent added is 3-50% by weight based on the weight of the particles. When the amount of the silane coupling agent is less than 3% by weight, sufficient adhesion force is not obtained, while when it exceeds 50% by weight, a great amount of sulfur atoms is discharged from the group A of excessive coupling agent to increase the modulus of elasticity of rubber, and also the cost is undesirably and largely increased. As the foaming agent used in the invention, there may be suitably used azodicarbonamide, dinitrosopentamethylene tetramine, azobisisobutyronitrile, and aromatic sulfonylhydrazides such as benzene sulfonylhydrazide, toluene sulfonylhydrazide, and oxybisbenzene sulfonylhydrazide. According to the invention, the foaming rubber composition is cured at an expansion ratio of 5-35% by using the foaming agent, whereby closed cells are formed in the foamed rubber. The presence of such closed cells is indispensable to obtain a sufficiently large microscopically water discharging effect at a state where there exists a great amount of water on ice surface at about 0°C to develop excellent performances on snow and ice surfaces. When the expansion ratio is less than 5%, the foaming effect is not sufficient, while when it exceeds 35%, the rigidity of rubber is insufficient, and if such a foamed rubber is used in a tire tread, the wear resistance is degraded and the cracking at groove bottoms occurs. The term "expansion ratio" used herein is represented by the following equation (1): V s = {(ρ 0 -ρ g )/(ρ 1 -ρ g )-1} x 100 (%) wherein ρ 1 is density of foamed rubber (g/cm 3 ), ρ 0 is density of solid phase portion in the foamed rubber (g/cm 3 ), and ρ g is density of gas portion in the foamed rubber (g/cm 3 ). The foamed rubber is composed of the solid phase portion and the gas portion formed in the solid phase portion as cavities (closed cells). Therefore, the density ρg of the gas portion is very small and is approximately zero, so that the equation (1) is approximated to the following equation (2): V s = {(ρ 0 /ρ 1 )-1} x 100 (%) Moreover, the foamed rubber composition according to the invention may be compounded with additives usually used in the manufacture of pneumatic tires such as carbon black, silica, vulcanizing agent, vulcanization accelerator, and antioxidant. In the production of the foamed rubber composition, the rubber ingredient, silane coupling agent, and particles are kneaded in a kneader at a final kneading temperature of not lower than 150°C before the addition of the foaming agent, whereby S-S bonds in the group A of the general formula of the silane coupling agent reacted with the surfaces of the particles are cleaved and reacted with matrix rubber, while the functional groups of the silane coupling agent (polar groups in the groups A and Y) are reacted with the particles to form particle gel having such a shape that the particles are restrained with the matrix rubber. Thus, the surroundings of the particles are enveloped with the matrix rubber by the primary reaction therewith, so that sufficient adhesion force can be ensured. Furthermore, there is no active site of the foaming gas at the surfaces of the particles accompanied with the above reaction, so that foaming at the boundary surfaces of the particles is not caused in the curing reaction and consequently closed cells can existed in the matrix rubber independently of the particles. As a result, stronger adhesion force can be obtained. On the other hand, when the final kneading temperature is lower than 150°C, the reactions between the polar groups of the coupling agent and the particles are not sufficiently conducted and hence the formation of the particle gel is insufficient and the adhesion of the particles to the rubber matrix becomes insufficient. As a result, a portion of the particles not enveloped with the rubber matrix is existent on the particle surface and forms a reactive site of the foaming gas, so that foaming is created at the boundary surfaces of the particles during the curing to considerably degrade the adhesion of the particles to the rubber matrix. If the resulting foamed rubber is used in a tire tread, the desired performances on ice are not obtained, and also the wear resistance and crack resistance are considerably degraded. The foamed rubber composition according to the invention is applied to a tread in pneumatic tires, particularly pneumatic radial tires for passenger cars, trucks, buses and heavy duty vehicles used on snow and/or ice road surfaces, whereby excellent running performances on snow and/or ice roads are stably obtained over a wider temperature range. Further, the foamed rubber composition may be applied to other rubber articles such as shoe soles and caterpillar tracks. The invention will be further described with reference to the following illustrative Examples. Various foamed rubber compositions are prepared by kneading various components according to compounding recipes as shown in Table 1 at a kneading temperature as shown in Table 1 and then curing under usual conditions. Furthermore, various pneumatic tires having a tire size of 185/70R13 are manufactured by using these foamed rubber compositions as a tread of the tire. The properties of the foamed rubber and the performances of the pneumatic tire are measured according to the following methods to obtain results as shown in Table 1. (1) Resistance to breakage The tensile strength of the foamed rubber is measured according to a method of JIS K6301 and represented by an index on the basis that Comparative Example 1 is 100. The larger the index value, the better the resistance to breakage. (2) E' (-20°C) The modulus of elasticity (E') at -20°C is measured with respect to the foamed rubbers in order to confirm that the property at low temperature is satisfactorily maintained in the foamed rubbers according to the invention because the lowering of the modulus of elasticity at low temperature is carried out as a method of improving the performances on ice. (3) Percentage of particles retained in tread rubber after running After the tire to be tested is run on a test course over a distance of 200 km, the number of retained particles (A) per 1 mm 2 of a surface area of a tread center is measured, and then a percentage of particles retained in the tread rubber after the running is calculated by dividing the number A by the number of total surface area of particles (B) in 1 mm 2 of surface area of the tread center before the running according to the following equation: Percentage of particles retained (%) = A/B x 100 The larger the numerical value, the larger the number of particles retained in the tread rubber after the running. (4) Braking performance on ice The tire to be tested is run on an ice road of a given ice surface temperature at a speed of 60 km/h over a distance of 200 km and then braked from a speed of 20 km/h to measure a running distance after the braking. The braking performance on ice is represented by an index on the basis that the running distance of a control tire is 100. The larger the index value, the better the braking performance on ice. (5) Wear resistance The tire to be tested is actually run on a concrete road surface of a test course at a speed of 60 km/h over a distance of 10,000 km and then the remaining groove depth is measured. The wear resistance is represented by an index on the basis that the measured groove depth in a control tire is 100. The larger the index value, the better the wear resistance. (6) Cracking appearance The tire to be tested is actually run on a general-purpose road over a distance of 7000 km and thereafter the surface of the tread rubber is observed at the circumference of the tire. The cracking appearance is evaluated as o ○: no crack, ○: crack length of not more than 0.5 mm, Δ: crack length of not more than 1 mm, and X: crack length of more than 1 mm. The coupling agents A and B used in Table 1 are as follows: A: bis(3-triethoxysilylpropyl) tetrasulfide B: trimethoxysilylpropyl benzothiazole tetrasulfide The kinds A-Y of the particles used in Table 1 are shown in Table 2. Kind of particle Composition (weight ratio) JIS C-type hardness Average particle size (µm) A Al(OH) 3 /PMMA=4/6 93 70 B Al(OH) 3 /PMMA=6/4 99 70 C SiO 2 /PMMA=4/6 93 70 D SiO 2 /PMMA=6/4 99 70 E Al(OH) 3 /PMMA=6/4 99 15 F Al(OH) 3 /PMMA=6/4 99 8 G Al(OH) 3 /PMMA=6/4 99 240 H Al(OH) 3 /PMMA=6/4 99 300 I Al(OH) 3 /PMMA=6/4 99 40 J Al(OH) 3 /PMMA=6/4 99 120 K Al(OH) 3 /PMMA=6/4 99 2 L Al(OH) 3 /PMMA=2/8 92 70 M Al(OH) 3 /PMMA=2.5/7.5 92 70 N Al(OH) 3 /PMMA=3/7 93 70 O PMMA100% 91 70 P Al(OH) 3 /PVA=6/4 76 70 Q Al(OH) 3 /PVA=4/6 72 70 R Al(OH) 3 /SiO 2 /PMMA=3/3/4 99 70 S Al 2 O 3 99 S 1 :70 S 2 :40 S 3 :15 T Al(OH) 3 99 70 U Al(OH) 3 99 55 V Al(OH) 3 99 25 W Al(OH) 3 99 18 X SiO 2 99 52.5 Y Al(OH) 3 /PMMA=8/2 99 40 Particles A, B, E-K, Y: crushed product of synthetic marble Particles C, D, L-N, P-R: trial product Particle O: powder of polymethyl methacrylate resin (made by Mitsubishi Rayon Co., Ltd. trade name: Acrypet IR-VH) Particle S: trade name: Alumina A-12C, made by Showa Denko K.K., The particles are sieved into S 1 : average particle size of 70 µm, S 2 : average particle size of 40 µm and S 3 : average particle size of 15 µm. Particle T: trade name: Hidilite H-10C, made by Showa Denko K.K. Particle U: trade name: Hidilite H-10A, made by Showa Denko K.K. Particle V: trade name: Hidilite H-21, made by Showa Denko K.K. Particle W: trade name: Hidilite H-31, made by Showa Denko K.K. Particle X: trade name: Silica Gel 60, Product No. 9385-2M, made by Merck & Co., Inc. (Hidilite is a Registered Trade Mark) In Table 1, the control for Examples 1-14, 17-18 and 25-29 is Comparative Example 1, and the control for Example 15 is Comparative Example 6, and the control for Example 16 is Comparative Example 7, and the control for Examples 19-24 is Comparative Example 15, and the control for Examples 30-37 and 43-44 is Comparative Example 24, and the control for Example 38 is Comparative Example 28, and the control for Examples 39-42 is Comparative Example 29. As seen from Table 1, according to the invention, excellent performances on ice are developed not only on an ice road surface of -2°C having a large water content but also on an ice road surface of -8°C having a very high ice hardness. Furthermore, the durability is sufficiently improved without degrading the wear resistance and without creating cracks. Moreover, the requirements for the particles used in the invention are satisfied by synthetic marble, so that waste building materials can effectively be utilized. As mentioned above, the invention can provide a foamed rubber composition stably developing excellent performances on ice over a wide ice temperature range by incorporating particles containing Al-OH and/or Si-OH groups in their surface and a particular silane coupling agent into a foaming rubber to ensure the bonding of these particles to rubber while avoiding he separation of these particles from rubber, and pneumatic tires having excellent running performances on ice without degrading of the wear resistance and fatigue properties can be obtained.

Claims: A foamed rubber composition comprising 3-30 parts by weight, based on 100 parts by weight of rubber ingredient, of particles having a JIS C-type hardness of not less than 75 and an average particle size of 5-250 µm, measured by laser diffraction process using a particle size analyzer of NIKKISO microtrack MKII, and containing aluminium-bonded hydroxy groups and/or silicon-bonded hydroxy groups at their surface, and 3-50% by weight, based on the weight of the particles, of at least one silane coupling agent, and wherein said foamed rubber composition has an expansion ratio of 5-35%; wherein said silane coupling agent is represented by the following general formula: Y 3 -Si-C n H 2n A wherein A is a -S m C n H 2n Si-Y 3 group, Y is an alkyl or alkoxy group having a carbon number of 1-4 or a chlorine atom, provided that the three Y groups may be same or different, and m and n are each an integer of 1-6, or wherein said silane coupling agent is selected from 3-trimethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 3-triethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 2-triethoxysilylethyl-N,N-dimethylthiocarbamoyl tetrasulfide, 3-trimethoxysilylpropylbenzothiazole tetrasulfide, 3-triethoxysilylpropylbenzothiazole tetrasulfide, 3-triethoxysilylpropyl methacrylate monosulfide, 3-trimethoxysilylpropyl methacrylate monosulfide, dimethoxymethylsilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, and dimethoxymethylsilylpropylbenzothiazole tetrasulfide. A foamed rubber composition as claimed in claim 1, characterized in that said particles consist of at least 20% by weight of at least one selected from Al(OH) 3 and SiO 2 and the remainder being an organic binder. A method of producing a foamed rubber composition by kneading at least one rubber ingredient, a silane coupling agent and particles having an average particle size of 5-250 µm, measured by laser diffraction process using a particle size analyzer of NIKKISO microtrack MKII, adding with a foaming agent and then curing, characterized in that (1) said silane coupling agent is represented by the following general formula: Y 3 -Si-C n H 2n A wherein A is a -S m C n H 2n Si-Y 3 group, Y is an alkyl or alkoxy group having a carbon number of 1-4 or a chlorine atom, provided that the three Y groups may be same or different, and m and n are each an integer of 1-6, or (2) said silane coupling agent is selected from 3-trimethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 3-triethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 2-triethoxysilylethyl-N,N-dimethylthiocarbamoyl tetrasulfide, 3-trimethoxysilylpropylbenzothiazole tetrasulfide, 3-triethoxysilylpropylbenzothiazole tetrasulfide, 3-triethoxysilylpropyl methacrylate monosulfide, 3-trimethoxysilylpropyl methacrylate monosulfide, dimethoxymethylsilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, and dimethoxymethylsilylpropylbenzothiazole tetrasulfide, and the particles have a JIS C-type hardness of not less than 75 and contain aluminium-bonded hydroxy groups and/or silicon-bonded hydroxy groups at their surface, and the kneading is carried out at a temperature of at least 150°C, and the curing is carried out at an expansion ratio of 5-35%, and in that the particles are added in an amount of 3-30 parts by weight based on 100 parts by weight of the rubber ingredient, and the silane coupling agent is used in an amount of 3-50% by weight based on the weight of the particles. A method as claimed in claim 3, characterized in that said particles consist of at least 20% by weight of at least one selected from Al (OH) 3 and SiO 2 and the remainder being an organic binder. A pneumatic tire having a tread, said tread being made from a foamed rubber composition as claimed in claim 1 or 2.

Inventors: TERATANI HIROYUKI, TERATANI, HIROYUKI
Applicants: BRIDGESTONE CORP, BRIDGESTONE CORPORATION
Application year: 1995
Main classification: B60C1
IPC codes: C08K3, B60C1, C08J9, C08K5