RFL-Free Cord Fabric Dipping Composition for Safer Rubber Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing water-based Resorcinol-Formaldehyde-Latex (RFL) adhesives used in bonding synthetic fibers with rubber in cord fabric production are hazardous to human and environmental health due to the toxic properties of resorcinol and formaldehyde, necessitating the development of more environmentally friendly and safer alternatives.
Innovation Solution
A dipping material composition comprising functional acrylic resin, epoxy, blocked polyisocyanate, and styrene-butadiene-vinyl pyridine latexes, which are more environmentally benign and provide high performance, is developed, allowing for shorter processing times and the production of cord fabrics in desired colors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If water-based RFL adhesives are used to bond synthetic fibers with rubber, then adhesion strength is improved, but human health and environmental safety deteriorate due to toxic resorcinol and formaldehyde
Solution Approach 1:
The patent removes the harmful components (resorcinol and formaldehyde) from the adhesive composition while retaining the essential bonding function. The new formulation uses alternative chemicals that provide adhesion without the toxic effects, directly extracting the harmful elements from the original RFL system.
Solution Approach 2:
The patent employs alternative adhesive chemicals that are safer and environmentally friendly, replacing the persistent toxic substances. These alternative components achieve the bonding function without long-term harmful effects, effectively using shorter-lived, safer chemical intermediates.
2Ease of manufacture
If conventional RFL adhesive formulation is used, then cost is reduced and adhesion performance is maintained, but processing time increases and color versatility is limited
Solution Approach 1:
The patent modifies the chemical composition parameters of the adhesive, using functional acrylic resin, epoxy, blocked polyisocyanate, and styrene-butadiene-vinyl pyridine latexes in specific proportions. These parameter changes enable faster curing times and improved color versatility while maintaining cost-effectiveness through optimized formulation.
Solution Approach 2:
The patent creates a composite adhesive system combining multiple functional components (acrylic resin, epoxy, polyisocyanate, and latexes) that work synergistically. This composite formulation achieves superior processing characteristics and color properties compared to conventional single-component RFL adhesives.
3Reliability
If RFL adhesive is applied to achieve strong cord-rubber bonding, then tire life and performance are improved, but environmental pollution and health risks increase
Solution Approach 1:
The patent converts the potentially harmful RFL adhesive system into a beneficial alternative by using safer chemicals that maintain or improve adhesion performance. The new formulation transforms the harmful chemical basis into an environmentally friendly system that still achieves reliable cord-rubber bonding for enhanced tire performance.
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 new composition achieves high peel adhesion strength comparable to RFL, while using safer chemicals, reducing environmental and health risks, and enabling the production of cord fabrics with improved properties and color versatility.
Implementation Method 1
the said two structures to each other
Implementation Method 2
The polar groups (amide, hydroxyl and carbonyl groups) present in the structure of the synthetic fibers
Data Source
AI summary
The present invention relates to a dipping material composition for cord fabric which is free of resorcinol and formaldehyde and production methods thereof comprising the steps of adding an acrylic resin containing a carboxylic acid group, adjusting pH value, adding an epoxy resin, adding a blocked polyisocyanate, adding a styrene butadiene latex and adding a styrene butadiene vinylpyridine latex into water, obtaining the dipping material, enabling the synthetic fiber and the rubber used in cord fabric reinforced rubber materials production to be attached to each other by providing an interface between the two said materials. Since the composition is formaldehyde-free, it is not as hazardous for human health as resorcinol-formaldehyde-latex (RFL) based systems and it is also environmentally friendly.