Epoxide-Free Dipping Bath Composition for Reinforcing Insert Adhesion
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Solution Overview
Problem
Existing dipping bath compositions for producing reinforced rubber products face challenges with adhesion properties, particularly peel adhesion and surface covering, due to the use of epoxides, which cause foaming, reduce storability, and lead to incomplete dissolving issues, and also include health-damaging resorcinol-formaldehyde latex systems.
Innovation Solution
An aqueous solids-containing dipping bath composition is developed, comprising a blocked methylene diphenyl isocyanate mixture, latex, and polyacrylates or lignin derivatives, which is essentially free of epoxides and resorcinol-formaldehyde, using a blocked MDI mixture with MDI oligomers and monomers, and optionally additives, to achieve improved adhesion without the drawbacks of epoxides and health-damaging components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxides are added to dipping bath compositions to achieve good adhesion properties, then peel adhesion and surface covering are improved, but foaming occurs requiring defoamers, storability is reduced, and high shearing forces are required for dissolution
Solution Approach 1:
The patent removes epoxides from the dipping bath composition entirely, replacing them with alternative adhesion-promoting components such as polyisocyanates and specific rubber-like polymers. This extraction eliminates the harmful foaming effect while maintaining adhesion properties through different chemical mechanisms.
Solution Approach 2:
The patent combines multiple adhesion-promoting components (polyisocyanates, rubber-like carboxylated diene copolymers, and other polymers) into a synergistic formulation that achieves good adhesion properties without relying on epoxides. This merging of alternative components compensates for the removal of epoxides while avoiding their harmful side effects.
2Strength
If epoxides are added to dipping bath compositions to achieve good adhesion properties, then peel adhesion and surface covering are improved, but storability is reduced
Solution Approach 1:
The patent removes epoxides from the composition, which are responsible for reduced storability due to their reactivity and tendency to polymerize over time. The alternative formulation uses more stable components that maintain adhesion effectiveness while preserving long-term storability.
Solution Approach 2:
The patent employs adhesion promoters that are stable and durable over time, replacing the short-lived, reactive epoxides. These alternative components maintain their effectiveness throughout the storability period without degrading or polymerizing prematurely.
3Strength
If epoxides are added to dipping bath compositions to achieve good adhesion properties, then peel adhesion and surface covering are improved, but high shearing forces and time are required for complete dissolving
Solution Approach 1:
The patent removes epoxides, which require high shearing forces and extended time to dissolve completely. The alternative adhesion promoters used in the patent are designed to dissolve more readily under normal mixing conditions, reducing both the energy input required and the time needed for complete dissolution.
Solution Approach 2:
The patent changes the physical and chemical parameters of the adhesion promoters to improve solubility and dissolution rate. The selected polymers and polyisocyanates are formulated to dissolve efficiently in the dipping bath medium without requiring excessive shearing forces or prolonged mixing times.
4Strength
If resorcinol-formaldehyde latex systems are used to connect synthetic fibres to rubber products, then adhesion is improved, but health-damaging materials are introduced
Solution Approach 1:
The patent removes resorcinol and formaldehyde from the dipping bath composition, eliminating these health-damaging materials. Alternative adhesion promoters such as polyisocyanates and environmentally friendly polymers are used instead, maintaining adhesion effectiveness while improving safety and environmental compatibility.
Solution Approach 2:
The patent replaces harmful resorcinol-formaldehyde systems with benign alternatives that provide equivalent or superior adhesion performance. The alternative components offer the same functional benefits (strong bonding between fibre and rubber) without the toxicological drawbacks, effectively converting a harmful system into a beneficial one.
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 provides reinforced rubber products with excellent adhesion properties, including high peel adhesion and surface covering, while avoiding the issues associated with epoxides and health-damaging materials, ensuring stable and effective coating processes.
Implementation Method 1
an aqueous, solids-containing dipping bath composition for treating reinforcing inserts, which comprises a blocked methylene diphenyl isocyanate mixture
Implementation Method 2
the synthetic fibre, which is environmentally friendly and is used in the production of cord fabric, and the rubber are fixed together
Data Source
AI summary
The present invention relates to an aqueous, solids-containing dipping bath composition for treating reinforcing inserts for rubber products comprising the following components or consisting of these components, (A) at least one blocked MDI mixture, the MDI mixture comprising MDI oligomers of formula (I), n being a whole number from 1 to 8, and MDI monomers; (B) at least one latex; (C) at least one compound selected from the group consisting of polyacrylates, lignin derivatives and mixtures hereof; and (D) possibly at least one additive; the dipping bath composition being essentially free of epoxides, and the dipping bath composition being essentially free of resorcinol, formaldehyde and the reaction products thereof.