Vulcanized Laminate Adhesion via Dehydrofluorination
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Solution Overview
Problem
Current fuel hoses with fluororesin barrier layers face challenges in achieving low fuel permeability without increasing weight or complexity, as thicker layers reduce flexibility and require additional adhesion processes, and perhalogen fluororesins have poor adhesion with rubber layers.
Innovation Solution
A vulcanized laminate is developed with a rubber layer containing unvulcanized rubber, magnesium oxide, silica, and specific compounds that chemically adhere to a fluororesin layer during vulcanization, eliminating the need for adhesives and surface treatments, allowing for thinner, more flexible products with improved adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the barrier layer thickness is increased to achieve lower fuel permeability, then fuel permeability resistance is improved, but hose weight increases and flexibility is lowered
Solution Approach 1:
The invention changes the chemical composition parameters of the rubber layer by incorporating specific compounds (epoxidized rubber, polyfunctional compounds, or dehydrofluorinating compositions) that enable strong adhesion to fluororesin. This allows the use of thinner barrier layers while maintaining both fuel permeability resistance and flexibility, resolving the contradiction between reliability and weight.
2Reliability
If the barrier layer thickness is increased to achieve lower fuel permeability, then fuel permeability resistance is improved, but bendability is lowered
Solution Approach 1:
By changing the chemical composition of the rubber layer to include adhesion-enhancing compounds, the invention enables thinner barrier layers that maintain both fuel permeability resistance and bendability, resolving the contradiction between reliability and ease of operation.
3Reliability
If a perhalogen fluororesin is used in the barrier layer to achieve lowest permeability, then fuel permeability resistance is improved, but adhesion with rubber layers becomes difficult
Solution Approach 1:
The invention introduces intermediary compounds in the rubber layer (epoxidized rubber, polyfunctional compounds, or dehydrofluorinating compositions) that act as chemical mediators between the fluororesin barrier layer and the rubber layers. These intermediaries create strong chemical bonds with the fluororesin, enabling excellent adhesion while maintaining the use of perhalogen fluororesin for optimal fuel permeability resistance.
4Ease of manufacture
If surface treatment or additional adhesion steps are performed to improve adhesion between fluororesin and rubber, then adhesion is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention merges the adhesion enhancement function into the rubber layer composition itself by incorporating specific compounds during the rubber compound preparation stage. This eliminates the need for separate surface treatment steps or additional adhesion layers, simplifying the manufacturing process while ensuring strong adhesion between the fluororesin and 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
This solution enables strong, chemical adhesion between the rubber and fluororesin layers without additional procedures, enhancing flexibility and reducing production costs, while maintaining low fuel permeability.
Implementation Method 1
adhesiveness of a curable elastomeric compound to a fluoropolymer layer may be enhanced by using a fluoropolymer having at least one monomer unit containing a plurality of hydrogen atoms or a fluoropolymer essentially containing a vinilydene fluoride unit and blending a dehydrofluorinating composition therein
Implementation Method 2
a vulcanized laminate in which a rubber layer and a fluororesin layer are firmly adhered to each other without using an adhesive or performing a surface treatment on the rubber layer and the fluororesin layer
Data Source
AI summary
The present invention provides a vulcanized laminate in which a rubber layer and a fluororesin layer are firmly adhered to each other without using an adhesive or performing a surface treatment on the rubber layer and the fluororesin layer. The present invention relates to a laminate comprising a rubber layer (A) and a fluororesin layer (B) on the rubber layer (A), wherein the rubber layer (A) is a layer made of a rubber composition for vulcanization, the rubber composition for vulcanization contains an unvulcanized rubber (al); at least one compound (a2) selected from the group consisting of a 1,8-diazabicyclo(5.4.0)undec-7-ene salt, a 1,5-diazabicyclo(4.3.0)-non-5-ene salt, 1,8-diazabicyclo(5.4.0)undec-7-ene, and 1,5-diazabicyclo(4.3.0)-non-5-ene; magnesium oxide (a3); and silica (a4), the amount of the compound (a2) is larger than 1.0 part by mass and not larger than 5.0 parts by mass, for each 100 parts by mass of the unvulcanized rubber (a1), the fluororesin layer (B) is a layer made of a fluoropolymer composition, and the fluoropolymer composition contains a fluoropolymer (b1) having a copolymer unit derived from chlorotrifluoroethylene.