Heat-Sensitive Coagulation for Thick Rubber Layer Laminate Production
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Solution Overview
Problem
Existing methods for producing protective gloves with thick surface rubber layers face issues of increased manufacturing steps, interface formation leading to peeling, and non-uniform coagulation resulting in cracks, which compromise durability.
Innovation Solution
A method involving a heat-sensitive coagulating process where a substrate is contacted with a polymer latex of 2,000 to 100,000 mPa·s viscosity at 25°C to form a rubber layer with a thickness of 200 µm or more, reducing peeling and cracks, and enhancing solvent protection, comfort, and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If multiple dip molding processes are used to form a thick surface rubber layer, then the thickness of the rubber layer is increased, but the number of manufacturing steps increases and interfaces are formed causing peeling
Solution Approach 1:
The substrate is pre-heated before contact with the polymer latex. This preliminary heating action enables the substrate to immediately coagulate the latex upon contact, forming a thick rubber layer in a single step without requiring multiple dip molding cycles, thereby reducing manufacturing complexity while achieving the desired layer thickness
2Length of stationary object
If multiple dip molding processes are used to form a thick surface rubber layer, then the thickness of the rubber layer is increased, but interfaces are formed leading to peeling and poor durability
Solution Approach 1:
The substrate is pre-heated before contact with the polymer latex. This preliminary heating ensures uniform temperature distribution across the substrate surface, enabling uniform coagulation of the latex and formation of a homogeneous rubber layer without internal interfaces that would cause peeling, thereby improving durability
Solution Approach 2:
The substrate temperature is changed to a heated state (elevated temperature) before contact with the polymer latex. This parameter change enables the substrate to act as a coagulant, causing immediate and uniform gelation of the latex upon contact, forming a thick, uniform rubber layer without interface formation, thus improving reliability
3Length of stationary object
If a polymer latex with high viscosity is used for dip molding to thicken the surface rubber layer, then the rubber layer thickness is increased, but coagulation does not progress uniformly causing cracks
Solution Approach 1:
Instead of using a coagulant solution to coagulate the latex (conventional method), the invention inverts the approach by using the heated substrate itself as the coagulant. The substrate's thermal energy causes the polymer latex to gel immediately upon contact, enabling uniform coagulation even with high viscosity latex, thereby achieving thick uniform rubber layers without cracks
4Length of stationary object
If a polymer latex with high viscosity is used for dip molding to thicken the surface rubber layer, then the rubber layer thickness is increased, but cracks are formed reducing durability
Solution Approach 1:
The conventional approach of using chemical coagulants is inverted by using the heated substrate's thermal energy as the coagulating agent. This enables immediate and uniform gelation of high viscosity polymer latex upon substrate contact, forming a thick, uniform, crack-free rubber layer with improved durability
Solution Approach 2:
The substrate temperature is changed to an elevated state, transforming it into an active coagulant. This parameter change enables the substrate to induce uniform gelation of the polymer latex throughout its thickness, preventing crack formation and improving the reliability of the resulting rubber layer
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 method produces a laminate with a rubber layer that significantly reduces peeling and cracks, providing excellent protection performance, comfort, and wear resistance.
Implementation Method 1
contacting the substrate in a heated state with a polymer latex having a viscosity of 2,000 to 100,000 mPa·s at 25°C to thereby coagulate the polymer latex in contact therewith
Implementation Method 2
the substrate in a heated state is contacted with the polymer latex, and the polymer latex in contact with the substrate is coagulated by heat
Data Source
Figure 1(A)~1(B)
AI summary
The present invention provides a method for producing a laminate comprising a substrate and a rubber layer, the rubber layer having a thickness of 200 µm or more from the surface of the substrate, the method comprising contacting the substrate in a heated state with a polymer latex having a viscosity of 2,000 to 100,000 mPa·s at 25°C to thereby coagulate the polymer in contact therewith to form the rubber layer.