A RFL-free dipping composition providing high performance for cord fabrics
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Solution Overview
Problem
The existing water-based Resorcinol-Formaldehyde-Latex (RFL) adhesives used for bonding synthetic fibers and rubber in cord fabric production are hazardous to human health and the environment, necessitating the development of more environmentally friendly and high-performance alternatives.
Innovation Solution
A dipping material composition comprising functional acrylic resin, epoxy resin, blocked polyisocyanate, styrene-butadiene latex, and styrene-butadiene-vinyl pyridine latex, which forms a durable bond between synthetic fibers and rubber without using resorcinol or formaldehyde, allowing for a shorter processing time and enabling the production of cord fabrics in various colors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If water-based RFL adhesives are used for bonding synthetic fibers and rubber, then adhesion strength is improved, but human health and environmental safety deteriorate
Solution Approach 1:
The patent removes the harmful components (resorcinol and formaldehyde) from the adhesive composition while retaining the bonding function through alternative safe chemicals. The new composition uses acrylic resin, epoxy resin, and latex without resorcinol or formaldehyde, thereby extracting the toxic elements while preserving adhesion performance.
Solution Approach 2:
The patent replaces expensive and hazardous chemicals (resorcinol and formaldehyde) with more affordable and safe alternatives (acrylic resin, epoxy resin, latex). This substitution not only improves safety but also reduces cost, making the adhesive more economically viable while eliminating long-term health risks.
2Strength
If traditional RFL adhesive composition is used, then bonding performance is achieved, but processing time is extended
Solution Approach 1:
The patent modifies the chemical composition parameters of the adhesive by replacing RFL components with acrylic resin, epoxy resin, and latex in specific proportions. This parameter change enables faster curing and processing times while maintaining or improving bonding performance, thereby reducing the loss of time in production.
3Strength
If resorcinol and formaldehyde are used in adhesive formulation, then adhesion strength is improved, but production costs increase due to safety regulations
Solution Approach 1:
The patent substitutes expensive and regulated chemicals (resorcinol and formaldehyde) with cheaper and safer alternatives (acrylic resin, epoxy resin, latex). This replacement reduces compliance costs associated with safety regulations while maintaining adhesion strength, thereby improving ease of manufacture.
4Strength
If RFL adhesive is used for cord fabric production, then cord-rubber adhesion is achieved, but color versatility is limited
Solution Approach 1:
The patent uses a composite adhesive system comprising acrylic resin, epoxy resin, and latex that can be easily combined with colorants. This composite formulation maintains strong cord-rubber adhesion while providing excellent color versatility, allowing production of cord fabrics in various colors without compromising bonding performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new composition provides high peel adhesion strength, is safer for human health and the environment, and allows for the production of cord fabrics with improved performance and color versatility, while reducing processing time and costs.
Implementation Method 1
The polar groups (amide, hydroxyl and carbonyl groups) present in the structure of the synthetic fibers are incompatible with the non-polar structures of the rubber
Implementation Method 2
Latex (L) group is attached to the fiber by vulcanization
Implementation Method 3
blocked polyisocyanate, which reacts with hydroxyl and carboxyl groups on fiber surfaces
Implementation Method 4
styrene-butadiene latex, and styrene-butadiene-vinyl pyridine latex, which forms a durable bond between synthetic fibers and rubber
Data Source
AI summary
The present invention relates to a dipping material composition that is environmentally friendly and used in production of cord fabric and the rubber to be attached to each other by providing a phase between the said two structures. The objective of the present invention is to provide a dipping solution comprising more environmentally friendly chemicals (an acrylic resin containing a carboxylic acid group, an epoxy resin, a blocked polyisocyanate, a styrene butadiene latex and a styrene butadiene vinylpyridine latex) relative to the chemicals used in the state of the art, providing the desired effect by treating cord fabrics for shorter period of time, and enabling the cords to be produced in desired colors owing to their pale yellowish color.