Rubber Laminate Composition for Direct Bonding Without Adhesive Layers
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Solution Overview
Problem
It is challenging to bond non-polar rubbers, such as ethylene/propylene/diene rubber (EPDM), with different materials due to their low polarity, often requiring the use of adhesive layers which can compromise performance.
Innovation Solution
A layered product incorporating an ethylene/propylene/non-conjugated polyene copolymer with specific structural units and a metallocene catalyst system, allowing direct contact or adhesion with other layers without the need for adhesive layers, enhancing mechanical properties and thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If non-polar rubber layers are bonded directly without adhesive layers, then the number of layers and complexity is reduced, but bonding strength and reliability are insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the rubber layers by incorporating specific polar components (carboxylic acid groups, hydroxyl groups, or amine groups) into the non-polar rubber matrix. This parameter change enables direct bonding between layers without adhesive layers, resolving the contradiction by maintaining simplicity while achieving reliable bonding through modified material properties
Solution Approach 2:
The patent creates composite rubber materials by combining non-polar rubber base polymers with polar functional components. This composite approach allows the material to exhibit both the elasticity and processability of non-polar rubbers and the bonding capability of polar materials, eliminating the need for separate adhesive layers while ensuring strong interlayer bonding
2Reliability
If expensive fluorine and acrylic rubbers are stacked to achieve high heat aging resistance and fatigue resistance, then performance is improved, but material cost increases
Solution Approach 1:
The patent applies local quality by concentrating polar functional components specifically at the bonding interfaces between layers rather than throughout the entire material structure. This localized approach provides the necessary bonding and heat resistance properties at critical locations while using more economical rubber materials in the bulk, reducing overall material cost while maintaining performance
Solution Approach 2:
The patent modifies the chemical structure parameters of conventional rubbers by introducing polar functional groups, enabling the use of less expensive rubber base materials that can achieve heat aging resistance and bonding performance comparable to expensive fluorine and acrylic rubbers, thereby reducing material cost while maintaining reliability
3Ease of manufacture
If non-polar rubber such as EPDM is bonded via adhesive layer, then bonding is achieved, but the adhesive layer compromises overall performance and adds complexity
Solution Approach 1:
The patent merges the bonding function with the rubber layer itself by incorporating polar functional components directly into the non-polar rubber matrix. This integration eliminates the need for separate adhesive layers, maintaining ease of manufacture while improving overall performance by removing the interface between rubber and adhesive that could become a failure point
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 solution enables robust bonding and improved mechanical and thermal performance of non-polar rubbers, specifically enhancing fatigue resistance and thermal stability in applications like turbocharger hoses.
Implementation Method 1
a metallocene catalyst system, allowing direct contact or adhesion with other layers
Implementation Method 2
an organic peroxide crosslinking agent
Data Source
AI summary
An object of this invention is to provide a layered product of a non-polar rubber or a rubber having a small polarity which makes it difficult to bond the rubber with a different material and a different kind of rubber, which are stacked directly or via an adhesive layer, the layered product of this invention including at least one type of layer selected from the layers (1) and (2), and at least one type of layer selected from the layers (3) and (4), in which at least one layer of the at least one type of layer selected from the layers (1) and (2) is directly in contact with or adjacent via an adhesive layer to at least one layer of the at least one type of layer selected from the layers (3) and (4): layer (1): a layer prepared using an ethylene/α-olefin/non-conjugated polyene copolymer; layer (2): a layer prepared using an ethylene/carboxylic acid copolymer; layer (3) : a layer prepared using an acrylic-type rubber; and layer (4): a layer prepared using a halogen-containing polymer.