Formaldehyde-Free Cord Fabric Dipping Solution for Safer Adhesion
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Solution Overview
Problem
Existing dipping solutions for cord fabrics rely on resorcinol and formaldehyde, which are hazardous to human and environmental health, and require longer processing times, while also limiting the production of colorful cord fabrics.
Innovation Solution
A dipping solution comprising an acrylic polymer resin, epoxy, polyisocyanate, and latex, with specific stoichiometric ratios and pH adjustment using ammonium hydroxide, which forms a stable adhesive without resorcinol and formaldehyde, allowing for faster processing and the production of white or colored cord fabrics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resorcinol-formaldehyde-latex (RFL) adhesive solution is used to attach synthetic fiber and rubber, then adhesion strength is improved, but environmental harm and health hazards increase
Solution Approach 1:
The patent removes resorcinol and formaldehyde from the adhesive composition, extracting the harmful components while retaining the essential adhesion function through alternative chemicals (carboxylic acid-containing polymer and epoxy resin). This directly resolves the contradiction by eliminating the harmful factors while maintaining bonding strength.
Solution Approach 2:
The patent employs readily available, environmentally benign chemicals (carboxylic acid-containing polymers and epoxy resins) that can be easily applied and cured without requiring the hazardous RFL system. These alternatives provide sufficient adhesion strength without the long-term environmental and health costs of resorcinol-formaldehyde systems.
2Strength
If traditional RFL dipping process is used, then adhesion performance is achieved, but processing time increases
Solution Approach 1:
The patent changes the chemical parameters of the dipping solution by using carboxylic acid-containing polymers combined with epoxy resins, which exhibit different curing characteristics compared to RFL systems. This parameter change enables faster processing while maintaining adhesion performance.
Solution Approach 2:
The adhesive composition is pre-formulated with all necessary components (carboxylic acid-containing polymer, epoxy resin, and catalyst) in optimal ratios, allowing the dipping process to proceed directly without additional steps. This preliminary preparation reduces processing time while ensuring consistent adhesion performance.
3Strength
If RFL adhesive is used for cord fabric production, then cord-rubber adhesion is improved, but production of colorful cord fabrics is limited
Solution Approach 1:
The patent removes the color-limiting RFL adhesive system and replaces it with a clear or neutral-colored alternative composition. This extraction of the harmful RFL system simultaneously eliminates the constraint on color production, allowing cord fabrics to be manufactured in various colors without adhesion compromise.
Solution Approach 2:
The patent changes the optical parameters of the adhesive by using transparent or neutral-colored carboxylic acid-containing polymers and epoxy resins instead of the yellowish RFL system. This parameter change enables better color fidelity and versatility in cord fabric production while maintaining the essential adhesion function.
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 initial and aged adhesion performance without using hazardous chemicals, enabling the production of environmentally friendly, cost-effective, and aesthetically appealing cord fabrics with improved processing efficiency.
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
A dipping solution comprising an acrylic polymer resin, epoxy, polyisocyanate, and latex, with specific stoichiometric ratios and pH adjustment using ammonium hydroxide
Implementation Method 3
The solution achieves high initial and aged adhesion performance without using hazardous chemicals, enabling the production of environmentally friendly, cost-effective, and aesthetically appealing cord fabrics with improved processing efficiency.
Data Source
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.