Phenolic Fatty Acid Coupling for Synthetic Fabric-Phenolic Bonding
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Solution Overview
Problem
Current methods for fabric-reinforced polymer materials fail to establish strong chemical bonding between synthetic fabrics and phenolic adhesives, leading to inadequate adhesion in composite materials like rubber tires, hoses, and belts.
Innovation Solution
A process involving the creation of phenolic fatty acid compounds with reduced phenolic ester content, which are used to chemically bond phenolic resins with non-phenolic polymers and synthetic fabrics, introducing a hydroxy phenyl functional group to enhance adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional adhesive systems (RFL or hexamethylenetetramine-resorcinol) are used to promote adhesion between fabric and polymer matrix, then adhesion is improved to some extent, but strong chemical bonding between fabric phase and phenolic adhesive is not sufficiently established
Solution Approach 1:
The invention changes the chemical parameters of the adhesive system by using phenolic fatty acid compounds with specific molecular structures containing both phenolic hydroxyl groups and fatty acid chains. This parameter change enables the adhesive to simultaneously interact with both the fabric fibers and the polymer matrix through different chemical mechanisms, establishing reliable chemical bonding that conventional adhesives cannot achieve
Solution Approach 2:
The phenolic fatty acid compound itself acts as a composite molecular structure combining phenolic resin characteristics with fatty acid properties. This composite molecular design allows the single compound to provide multiple functions: adhesion to fabric through phenolic groups and compatibility with polymer matrix through fatty acid chains, thereby achieving both improved adhesion strength and reliable chemical bonding
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 method significantly improves the adhesion between synthetic fabrics and phenolic resins, resulting in enhanced mechanical properties and integrity of composite materials such as synthetic fabric-reinforced rubber compositions and articles.
Implementation Method 1
reacting a phenolic compound with the fatty acid composition in the presence of an acidic catalyst at a temperature ranging from about 90° C. to about 120° C. to form the phenolic fatty acid compound
Implementation Method 2
react the carboxylic acid-reactive functional group of the non-phenolic polymer with the carboxylic acid group of the phenolic fatty acid compound, thereby attaching a hydroxy phenyl functional group to the non-phenolic polymer
Implementation Method 3
reacting the hydroxy phenyl functional group of the non-phenolic polymer with a phenolic resin or a phenolic crosslinker composition capable of forming a phenolic resin, to chemically bond the phenolic resin with the non-phenolic polymer
Data Source
AI summary
This invention relates to a process for making phenolic fatty acid compounds having a reduced phenolic ester content. The invention also relates to method for chemically bonding a phenolic resin with a non-phenolic polymer (e.g., a synthetic fabric). The method comprises contacting a phenolic fatty acid compound with a non-phenolic polymer to introduce a hydroxy phenyl functional group into the non-phenolic polymer; and reacting the hydroxy phenyl functional group contained in the non-phenolic polymer with a phenolic resin or a phenolic crosslinker composition capable of forming a phenolic resin, to chemically bond the phenolic resin with the non-phenolic polymer. The invention is particularly useful for making a synthetic fabric-reinforced article, such as synthetic fabric-reinforced rubber article, circuit board substrate, or fiberglass.