Composite Articles With In-Situ Polymeric Coatings for Aramid-Fiber Adhesion
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Solution Overview
Problem
Existing composite articles with textile reinforced rubber face challenges in achieving strong adhesion between the textile layer and rubber layers, particularly with low surface energy substrates like aramid fibers, due to the limitations of current adhesion promoters such as silane and RFL, which are hazardous and environmentally costly.
Innovation Solution
The use of polymeric coatings formed by polymerizing specific polymeric precursors with electron withdrawing groups and hydrophobic properties, applied to both faces of the textile layer, to enhance adhesion between the textile and rubber layers, minimizing the need for solvents and VOCs, and effectively bonding to both low and high surface energy materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If silane or RFL adhesion promoters are used to enhance adhesion between textile and rubber layers, then adhesion strength is improved, but environmental harm and manufacturing complexity increase
Solution Approach 1:
The invention extracts and eliminates the harmful adhesion promoter chemicals (silane and RFL) from the composite article manufacturing process. Instead of using these hazardous substances, the patent employs a solvent-free polymerization approach where monomers directly polymerize on the textile surface to form adhesive polymeric layers, completely removing the need for harmful chemical intermediaries while maintaining strong adhesion between textile and rubber layers
Solution Approach 2:
The invention introduces a polymeric coating layer formed by in-situ polymerization as an intermediary between the textile reinforcement and rubber layers. This polymeric layer acts as a mediator that provides strong adhesion without requiring hazardous chemical promoters, effectively replacing the function of silane or RFL while avoiding their environmental harms
2Strength
If silane or RFL adhesion promoters are used to achieve strong adhesion, then bond strength is improved, but device complexity and cost increase due to filtering equipment
Solution Approach 1:
The invention removes the need for complex filtering equipment and RFL adhesion promoter handling systems by采用ing a solvent-free polymerization process. The monomers polymerize directly on the textile surface without requiring filtration infrastructure, thereby eliminating the costly and complex filtering equipment that would otherwise be necessary to manage RFL environmental effects
3Strength
If conventional adhesion promoters are used on aramid fibers, then adhesion is partially achieved, but adhesion strength remains insufficient for high-performance applications
Solution Approach 1:
The invention changes the fundamental parameters of the adhesion process by using solvent-free monomers with specific functional groups that polymerize directly on the aramid fiber surface. This parameter change - from using chemical adhesion promoters to using in-situ polymerization - creates a much stronger and more reliable bond that can withstand high temperatures and mechanical loads, enabling high-performance applications such as automotive hoses and power transmission belts
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
This approach achieves excellent adhesion between textile layers and polymeric layers, including aramid fibers, resulting in high-performance composite articles with improved strength and environmental sustainability.
Implementation Method 1
the polymeric coatings on the first and second faces of the textile layer are each formed by polymerising a polymeric precursor
Data Source
AI summary
According to the invention there is provided a composite article including: a textile layer having a first and a second face, each of the first and second faces having a polymeric coating thereon; a first polymeric layer adhered to the polymeric coating on the first face of the textile layer; and a second polymeric layer adhered to the polymeric coating on the second face of the textile layer; in which the polymeric coatings on the first and second faces of the textile layer are each formed by polymerizing a polymeric precursor which includes a group of sub-formula (I) where R2 and R3 are independently selected from (CR7R8)n, or a group CR9R10, CR7R8CR9R10 or CR9R10CR7R8 where n is 0, 1 or 2, R7 and R8 are independently selected from hydrogen, halo or hydrocarbyl, and either One of R9 or R10 is hydrogen and the other is an electron withdrawing group, or R9 and R10 together form an electron withdrawing group, and R4 and R5 are independently selected from CH or CR11 where R11 is an electron withdrawing group, the dotted lines indicate the presence or absence of a bond, X1 is a group CX2X3 where the dotted line bond to which it is attached is absent and a group CX2 where the dotted line bond to which it is attached is present, Y1 is a group CY2Y3 where the dotted line bond to which it is attached is absent and a group CY2 where the dotted line bond to which it is attached is present, and X2, X3, Y2 and Y3 are independently selected from hydrogen, fluorine or other substituents, R1 is selected from hydrogen, halo, nitro, hydrocarbyl, optionally substituted or interposed with functional groups, or formula (II), and R13 is C(0) or S(0)2.