Multi-Layer Barrier Structure for Rubber Bonding Without Bubbles
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Solution Overview
Problem
Existing multi-layered structures used in applications like gas-filled bladders and tires face challenges in achieving low gas transmission rates and preventing bubble formation due to off-gassing during the vulcanization process.
Innovation Solution
A multi-layered structure comprising a core layer with a low gas transmission rate and a cap layer made of polydiene polyol-based polyurethane, which includes an uncured rubber compound with less than 5 weight percent of volatile compounds, enhancing bonding with rubber and reducing bubble formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a multi-layered structure with cap layer is used to improve bonding with rubber, then bonding strength is improved, but bubble formation due to off-gassing during vulcanization worsens
Solution Approach 1:
The patent changes the chemical composition parameters of the cap layer by incorporating polydiene polyol-based polyurethane with specific functional groups that can react with rubber. This parameter change enables strong chemical bonding while the controlled formulation minimizes volatile content to prevent bubble formation during vulcanization.
Solution Approach 2:
The cap layer is formulated as a composite material combining polydiene polyol-based polyurethane with specific additives and uncured rubber compounds. This composite structure provides both strong bonding capability through chemical reactivity and reduced off-gassing through controlled material composition, resolving the contradiction between bonding strength and bubble formation.
2Adaptability or versatility
If thermoplastic polymers are used for flexibility and reusability, then flexibility and environmental sustainability are improved, but gas transmission rate increases
Solution Approach 1:
The patent uses composite multi-layered structures where thermoplastic polyurethane layers provide flexibility and reusability, while barrier layers with low gas permeability reduce gas transmission. The cap layers with uncured rubber compounds further enhance bonding and seal integrity, creating a composite system that balances flexibility with gas barrier performance.
Solution Approach 2:
The structure is segmented into multiple functional layers: thermoplastic layers for flexibility, barrier layers for gas transmission control, and cap layers for bonding. This segmentation allows each layer to optimize its specific function, maintaining overall flexibility while achieving low gas transmission rates through the combined structure.
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 proposed multi-layered structure effectively reduces bubble formation at the interface with rubber, maintaining low gas transmission rates and improving bonding, thus enhancing the performance and durability of applications such as tires and athletic shoes.
Implementation Method 1
The first cap layer can include one or more polydiene polyol-based polyurethane having one or more different characteristics or qualities to enhance the performance of the multi-layered structure by improved bonding with the core and/or a rubber disposed on the cap layer
Implementation Method 2
The core layer can include a multi-layer polymeric material and can include alternating layers of a first thermoplastic material and a second thermoplastic material, where a layer of the second thermoplastic material has a lower gas permeability than a layer of the first thermoplastic material
Implementation Method 3
The uncured rubber compound can include less than 5 weight percent of volatile compounds, where the volatile compounds are volatile compounds released from the uncured rubber compound when the uncured rubber compound is heated to a temperature of about 200 degrees Celsius
Data Source
AI summary
Multi-layered structures and methods for producing them are disclosed.