Cord Fabric Dipping Composition for Rubber-Fiber Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The incompatibility between synthetic fibers and rubber in cord fabrics, due to their differing chemical and physical structures, requires an adhesive solution that is environmentally friendly and free from hazardous chemicals like resorcinol and formaldehyde, while also being time-efficient and capable of producing colorful cords.
Innovation Solution
A dipping solution comprising a mixture of functional acrylic polymer resin, epoxy, polyisocyanate, and latex, with specific stoichiometric ratios and pH adjustment using ammonium hydroxide, is used to create a bonding agent that adheres synthetic fibers to rubber, eliminating the need for resorcinol-formaldehyde-based adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If water-based Resorcinol-Formaldehyde-Latex (RFL) adhesive solutions are used to attach synthetic fibers to rubber, then strong adhesion is achieved, but health and environmental hazards increase due to the presence of resorcinol and formaldehyde
Solution Approach 1:
The invention extracts and removes the hazardous components (resorcinol and formaldehyde) from the adhesive system while retaining the essential bonding functionality through alternative chemistries that do not rely on these toxic substances
Solution Approach 2:
The invention employs alternative adhesive chemistries that may have shorter shelf lives or require fresh preparation but eliminate the need for handling and storing hazardous resorcinol and formaldehyde, thereby reducing health and environmental risks
2Strength
If traditional multi-step dipping processes are used to apply adhesive compositions to cord fabrics, then adequate adhesion is achieved, but production time increases
Solution Approach 1:
The invention combines multiple adhesive functions into a single integrated dipping solution that provides both initial adhesion and durable bonding in one application step, eliminating the need for separate treatment steps
Solution Approach 2:
The adhesive composition is pre-formulated with all necessary components including latex, resorcinol, formaldehyde, and ancillary chemicals in optimal concentrations, allowing direct application without further preparation or multiple processing steps
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 solution provides strong and durable adhesion that retains performance over time, is environmentally friendly, reduces production time, and allows for the creation of colorful cord fabrics, while avoiding the health and environmental risks associated with resorcinol and formaldehyde.
Implementation Method 1
The synthetic fibers have high strength and low elongation whereas the rubbers contrarily are polymeric materials which have high elongation and low strength. 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. This incompatibility is eliminated with water-based Resorcinol-Formaldehyde-Latex (RFL) adhesive solutions which form a phase between the cord and the rubber and enable the rubber and the fiber to be attached to each other.
Implementation Method 2
RF functional group within RFL is attached to the polar groups of fiber, Latex (L) group is attached to the fiber with vulcanization so that a rubber-fiber composite structure is formed. The strength of the bonds formed between the rubber and the cord is examined by means of adhesion tests.
Implementation Method 3
A dipping solution comprising a mixture of functional acrylic polymer resin, epoxy, polyisocyanate, and latex, with specific stoichiometric ratios and pH adjustment using ammonium hydroxide
Implementation Method 4
Latex (L) group is attached to the fiber with vulcanization so that a rubber-fiber composite structure is formed
Data Source
Figure 1
AI summary
The present invention relates to a formaldehyde and resorcinol free dipping solution for cord fabrics and a production method thereof comprising the steps of adding acrylic polymer resin into water (11), adjusting pH value (12), adding epoxy to the composition (13), adding polyisocyanate to the composition (14), adding latex to the composition (15), obtaining the dipping material (16); enabling the synthetic fiber and the rubber used in cord fabric reinforced rubber materials production to be attached to each other by providing an interface between two said materials; not as hazardous as RFL for human health and also being environmentally friendly.