One-Step Textile Adhesive Mixture Eliminates Toxic RFL Components
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Solution Overview
Problem
Existing methods for bonding textile reinforcements with rubber components using adhesive mixtures often involve carcinogenic formaldehyde and toxic resorcinol, and require multi-stage processes, which are not cost-effective or energy-efficient, especially for cellulosic materials like rayon or Lyocell.
Innovation Solution
A one-step process using an adhesive mixture containing latex, epoxy, isocyanate, and maleinized polybutadiene, where the textile reinforcement is wetted in a single immersion bath, allowing direct crosslinking with the rubber component through covulcanization, eliminating the need for resorcinol and formaldehyde.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-stage process is used with traditional RFL adhesive mixture, then good adhesion is achieved, but the process becomes complex and uses carcinogenic formaldehyde and toxic resorcinol
Solution Approach 1:
The patent combines multiple process stages into a single dip-coating operation. The adhesive mixture contains all necessary components (latex, epoxy, isocyanate, MAPBD) that are traditionally applied in separate stages, allowing simultaneous impregnation and crosslinking preparation in one step, thus reducing process complexity while maintaining adhesion strength
Solution Approach 2:
The patent uses a composite adhesive mixture containing multiple types of polymers and crosslinkers (latex, epoxy, isocyanate, MAPBD) that work together to provide both immediate adhesion and durable crosslinking, replacing the traditional resorcinol-formaldehyde system while eliminating toxic components
2Reliability
If traditional RFL adhesive mixture is used, then good adhesion is achieved, but carcinogenic formaldehyde and toxic resorcinol are present
Solution Approach 1:
The patent removes the toxic components (resorcinol and formaldehyde) from the adhesive system while retaining the essential adhesion and crosslinking functions through alternative substances (epoxy, isocyanate, MAPBD), thereby eliminating carcinogenic and toxic effects without sacrificing bond strength
Solution Approach 2:
The patent changes the chemical composition parameters of the adhesive mixture by substituting traditional RFL components with environmentally friendly alternatives that provide similar or superior adhesion properties while eliminating harmful substances
3Reliability
If multi-stage drying and curing process is used, then adequate crosslinking is achieved, but energy consumption increases
Solution Approach 1:
The patent merges the impregnation and crosslinking preparation stages into a single dip-coating operation, eliminating intermediate drying and handling steps. The adhesive mixture is applied once and then cured in a single continuous process, reducing the number of heating cycles and overall energy consumption while maintaining crosslinking quality
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 achieves strong adhesion between textile reinforcements and rubber components while being cost-effective and energy-efficient, with improved adhesion properties and environmental sustainability, as demonstrated by the adhesion tests and results.
Implementation Method 1
The crosslinker reacts directly with the rubber component of the adhesion promoter. A connection with the matrix of the rubber component occurs through covulcanization.
Implementation Method 2
adhesive mixture which, on the one hand, create a cross-linking with the rubber component and, on the other hand, also bind to the textile reinforcement
Data Source
Figure 1~2
Figure 3
AI summary
A method for bonding a textile reinforcement carrier to a rubber component by means of an adhesive mixture is provided, wherein the adhesive mixture contains at least one latex, at least one epoxy, at least one isocyanate and at least one maleinized polybutadiene, which is characterized in that the textile reinforcement carrier is wetted with the adhesive mixture in one step.