Plasma-Polymer Coating for Reinforcement Cord Rubber Adhesion

Solution Overview

Problem

Existing methods for reinforcing rubber with cords, such as steel and polymeric cords, face inefficiencies in interfacial adhesion and require excessive use of expensive cobalt salts, which can cause aging issues and are not fully utilized in bonding reactions.

Innovation Solution

A method involving the atomization of a mixture of polymerizable monomers, halogenated saturated hydrocarbons, and a carrier gas to generate atmospheric pressure plasma, which is then applied to the reinforcement cords to form a polymer that enhances adhesion to rubber, potentially reducing the need for cobalt salts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If excessive amounts of cobalt salt are added to the wire coat to achieve maximum bonding strength, then adhesion of reinforcement cords to rubber is improved, but cost increases and aging problems occur

Engineering Contradiction:

Improveadhesion strengthVSAvoidaging problems

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes cobalt salt from the wire coat compound formulation. Instead of using cobalt salt as a bonding promoter, the invention uses plasma treatment to create adhesion, thereby eliminating the harmful aging effects associated with excessive cobalt salt while maintaining bonding strength.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical mechanism (cobalt salt bonding promotion) with a physical mechanism (plasma treatment). The plasma process modifies the surface of the reinforcement cords to enhance adhesion without requiring cobalt salt, thus substituting a harmful chemical approach with a cleaner physical approach.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If excessive amounts of cobalt salt are added to the wire coat to achieve maximum bonding strength, then adhesion of reinforcement cords to rubber is improved, but cost increases

Engineering Contradiction:

Improveadhesion strengthVSAvoidcost

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent extracts and removes cobalt salt from the wire coat compound formulation. Instead of using cobalt salt as a bonding promoter, the invention uses plasma treatment to create adhesion, thereby eliminating the harmful aging effects associated with excessive cobalt salt while maintaining bonding strength.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical mechanism (cobalt salt bonding promotion) with a physical mechanism (plasma treatment). The plasma process modifies the surface of the reinforcement cords to enhance adhesion without requiring cobalt salt, thus substituting a harmful chemical approach with a cleaner physical approach.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If specialized coatings such as resorcinol/formaldehyde latex adhesives or brass plating are applied to fiber and wire reinforcements, then interfacial adhesion is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveinterfacial adhesionVSAvoidcoating process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces complex chemical coating processes (resorcinol/formaldehyde latex adhesives or brass plating) with a plasma treatment process. The plasma modifies the surface properties of the reinforcement cords to enhance adhesion without requiring separate coating applications, thereby simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent combines the surface modification and adhesion enhancement functions into a single plasma treatment step. Instead of applying separate specialized coatings and then using the reinforcement in the rubber compound, the plasma treatment integrates these functions into one process step.

Inventive Principle:

Principle #5Merging (Combining)

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 improves the adhesion of reinforcement cords to rubber, reducing the reliance on cobalt salts and enhancing the properties of the coat compounds, while also lowering costs and minimizing aging issues.

Implementation Method 1

generating an atmospheric pressure plasma from the atomized mixture

Methodology Applied

Scientific EffectPlasma: Plasma

Implementation Method 2

exposing the reinforcement cord to the atmospheric pressure plasma under conditions suitable to form a polymer strongly bonded to the tire cord

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS9133360B2Atmospheric plasma treatment of reinforcement cords and use in rubber articles

Publication Date: 2015.09.15 THE GOODYEAR TIRE & RUBBER CO

AI summary

The present invention is directed to a method of treating a reinforcement cord, comprising the steps ofA) atomizing a mixture of at least one polymerizable monomer, a halogenated saturated hydrocarbon, and a carrier gas to form an atomized mixture;B) generating an atmospheric pressure plasma from the atomized mixture; andC) exposing the reinforcement cord to the atmospheric pressure plasma under conditions suitable to form a polymer strongly bonded to the reinforcement cord and capable of bonding to rubber.