Epichlorohydrin Rubber Laminate Bonding via Maleimide Mediator
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Solution Overview
Problem
Existing rubber-thermoplastic resin laminates face challenges in achieving sufficient adhesive strength between dissimilar polymer materials, particularly between epichlorohydrin-based rubber and thermoplastic resin, which are essential for fuel-resistant applications but often require high amounts of adhesive activators, leading to processing difficulties and reduced practical use.
Innovation Solution
A vulcanized rubber laminate is created by bonding an unvulcanized epichlorohydrin-based rubber composition layer containing a maleimide compound, a vulcanizing agent, and an acid acceptor with a thermoplastic resin layer, using specific compounds and processes to enhance adhesiveness without compromising the rubber's elastic modulus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermoplastic resin layer having excellent fuel barrier properties and an epichlorohydrin-based rubber layer are bonded together, then fuel permeation resistance is improved, but adhesiveness between the dissimilar materials is insufficient
Solution Approach 1:
A maleimide compound is introduced as an intermediary substance between the thermoplastic resin layer and the epichlorohydrin-based rubber layer. This maleimide compound acts as a chemical mediator that enhances interfacial bonding by reacting with both the thermoplastic resin and the rubber, creating strong chemical bonds at the interface and significantly improving adhesiveness while maintaining fuel barrier properties.
Solution Approach 2:
The chemical composition parameters of the rubber layer are modified by incorporating specific compounds: a maleimide compound (0.1-10 parts by weight per 100 parts rubber), an acid acceptor (0.1-10 parts by weight), and a vulcanizing agent (0.1-5 parts by weight). These parameter changes enable chemical bonding with the thermoplastic resin while preserving the rubber's elastic properties and the laminate's fuel resistance.
2Strength
If a large amount of adhesive activator is mixed to firmly bond the thermoplastic resin and epichlorohydrin-based rubber, then adhesiveness is improved, but processing becomes difficult
Solution Approach 1:
The dosage of the maleimide compound is precisely controlled within a specific range (0.1-10 parts by weight per 100 parts rubber). This optimized parameter range achieves sufficient adhesiveness through efficient chemical bonding while preventing excessive viscosity increase and maintaining good processability during mixing and molding operations.
Solution Approach 2:
The rubber composition is formulated as a composite system containing multiple components in specific proportions: epichlorohydrin-based rubber, maleimide compound, acid acceptor, and vulcanizing agent. This composite formulation creates synergistic effects where each component contributes to both bonding strength and processability, avoiding the need for excessive adhesive activators.
3Strength
If the epichlorohydrin-based rubber composition contains a maleimide compound, a vulcanizing agent and an acid acceptor, then adhesiveness to thermoplastic resin is significantly improved, but composition complexity increases
Solution Approach 1:
The maleimide compound serves multiple functions simultaneously: it acts as an adhesive promoter by reacting with the thermoplastic resin, serves as a crosslinking agent for the rubber matrix, and functions as a bonding bridge between the resin and rubber layers. This multi-functionality reduces the need for separate additives and simplifies the overall composition despite the enhanced bonding performance.
Solution Approach 2:
The adhesive promoter, crosslinking agent, and bonding bridge functions are merged into a single maleimide compound system. By combining these multiple roles into one compound, the composition complexity is minimized while achieving superior interlayer bonding between the thermoplastic resin and epichlorohydrin-based rubber layers.
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 resulting laminate exhibits excellent adhesiveness and firm bonding between the rubber and resin layers, making it suitable for applications requiring gasoline permeation resistance, aging resistance, and weatherability, such as fuel hoses and filler hoses.
Implementation Method 1
an unvulcanized epichlorohydrin-based rubber composition layer containing a maleimide compound, a vulcanizing agent and an acid acceptor, and a thermoplastic resin layer are heated and bonded
Implementation Method 2
a vulcanized rubber laminate in which an unvulcanized epichlorohydrin-based rubber composition layer containing a maleimide compound, a vulcanizing agent and an acid acceptor, and a thermoplastic resin layer are heated and bonded
Data Source
AI summary
Disclosed is a vulcanized rubber laminate, wherein a thermoplastic resin layer and an unvulcanized epichlorohydrin rubber composition layer containing a specific maleimide compound, vulcanizing agent, and acid acceptor are heated and bonded. Specifically disclosed is a laminate configured by heating and bonding an unvulcanized epichlorohydrin rubber composition layer (A) and a thermoplastic resin (B), wherein the unvulcanized epichlorohydrin rubber composition contains: an epichlorohydrin rubber (a), a compound containing one or more maleimide group within the molecule (b), a vulcanizing agent (c), and an acid acceptor (d).