Elastomer Laminate Bonding Without Surface Treatment
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Solution Overview
Problem
Current laminates of fluorine and acrylic elastomers face challenges in achieving strong bonding between layers, which complicates production and can lead to reduced sealing efficiency and limited design flexibility due to surface treatments and limited fluorine elastomer options.
Innovation Solution
A laminate comprising an epoxy group-containing acrylic elastomer layer and a fluorine elastomer layer, bonded using an onium salt as a crosslinking agent, allowing for strong vulcanization without the need for surface treatments, and enabling adjustable properties through varying monomer ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If surface treatments (metal sodium solution, discharge treatment, or plasma treatment) are applied to the fluorine elastomer surface to improve bonding strength, then the bonding strength between elastomer layers is improved, but the production process becomes more complicated and production cost increases
Solution Approach 1:
The patent extracts and eliminates the need for complex surface treatment processes (metal sodium solution treatment, discharge treatment, plasma treatment) by incorporating a coupling agent directly into the fluorine elastomer composition during compounding. This allows the bonding function to be achieved through chemical modification of the base material rather than through separate surface treatment steps, thereby simplifying the overall production process while maintaining strong bonding between layers.
Solution Approach 2:
The patent introduces a coupling agent as an intermediary substance that mediates the bonding between fluorine elastomer and acrylic elastomer layers. The coupling agent (silane-based or isocyanate-based) acts as a chemical bridge that forms strong covalent bonds with both elastomer types, enabling effective interlayer bonding without requiring complex surface treatments. This intermediary approach resolves the contradiction by providing a simple yet effective bonding mechanism.
2Strength
If surface treatments are applied to improve bonding strength, then the bonding strength between elastomer layers is improved, but the elastomer layer may degrade and sealing efficiency deteriorates
Solution Approach 1:
The patent employs a coupling agent that is incorporated into the elastomer composition during the compounding stage and performs its bonding function during vulcanization. The coupling agent is consumed in the bonding process, forming permanent chemical bonds between layers, which eliminates the need for repeated surface treatments and ensures long-term sealing reliability without degradation from multiple treatment cycles.
Solution Approach 2:
The patent changes the chemical composition parameters of the fluorine elastomer by incorporating specific coupling agents (silane-based or isocyanate-based) at controlled concentrations (0.1-5 parts by weight per 100 parts of fluorine elastomer). This compositional modification enables the elastomer to achieve strong bonding with acrylic elastomer while maintaining its inherent sealing properties, thereby improving bonding strength without compromising sealing efficiency.
3Strength
If only a particular fluorine elastomer is used to improve bonding strength, then the bonding strength between fluorine and non-fluorine elastomer layers is improved, but the flexibility to design laminate properties is limited
Solution Approach 1:
The patent introduces a universal coupling agent system that can be applied to various types of fluorine elastomers (Viton, Tecnoflon, Kalrez, etc.) to achieve bonding with acrylic elastomer. The coupling agent acts as a universal interface that accommodates different fluorine elastomer compositions and properties, allowing designers to select from a wide range of fluorine elastomers based on specific application requirements (temperature resistance, chemical resistance, flexibility) without being constrained by bonding compatibility issues.
Solution Approach 2:
The patent modifies the chemical composition parameters of the fluorine elastomer by adding coupling agents (silane-based or isocyanate-based) at varying concentrations (0.1-5 parts by weight per 100 parts of fluorine elastomer). This compositional adjustment enables strong bonding while preserving the ability to select different fluorine elastomer types and adjust other properties (crosslinking density, hardness, elasticity) according to specific application needs, thereby maintaining design flexibility.
4Reliability
If fluorine elastomers are used instead of acrylic elastomers to improve durability, then the heat-aging resistance and reliability are improved, but the low-temperature resistance decreases and cost increases
Solution Approach 1:
The patent segments the laminate into two distinct functional layers: a fluorine elastomer layer (providing heat-aging resistance and durability) and an acrylic elastomer layer (providing low-temperature flexibility and cost-effectiveness). The fluorine elastomer layer thickness is controlled at 0.1-5 mm to provide sufficient thermal and chemical resistance, while the acrylic elastomer layer provides the necessary low-temperature performance. This segmentation allows each material to perform its optimal function without the drawbacks of using fluorine elastomer throughout the entire laminate.
Solution Approach 2:
The patent creates a composite laminate structure combining fluorine elastomer and acrylic elastomer layers with strong interlayer bonding achieved through coupling agents. This composite structure leverages the superior heat-aging resistance of fluorine elastomer in the high-temperature exposure layer while utilizing the excellent low-temperature flexibility and cost-effectiveness of acrylic elastomer in the remaining structure, thereby achieving a balance between durability, low-temperature performance, and cost.
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 solution achieves high bonding strength between fluorine and acrylic elastomer layers, enhancing the reliability and durability of the laminate without increasing production complexity, and allows for flexible design of properties based on application requirements.
Implementation Method 1
an onium salt as the acrylic elastomer-crosslinking agent (functional group) in an amount of 2 to 10 parts with respect to 100 parts by weight of the epoxy group-containing acrylic elastomer
Implementation Method 2
a fluorine elastomer layer of a fluorine elastomer composition containing a polyol crosslinking agent
Data Source
Figure 1
AI summary
Provided is a laminate having elastomer layers tightly bonded to each other. The laminate according to the present invention 1 has an acrylic elastomer layer 11 and a fluorine elastomer layer 12 that are bonded to each other. The acrylic elastomer layer 11 is made of an acrylic elastomer composition having an epoxy group-containing acrylic elastomer and an onium salt added and the fluorine elastomer layer 12 is made of a fluorine elastomer composition having a fluorine elastomer and a polyol crosslinking agent added. In the laminate 1, the elastomer layers are bonded tightly to each other even without any surface treatment.