Process for bonding a textile material to an elastomer
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Solution Overview
Problem
Conventional methods for adhering textile materials to elastomers, such as those used in conveyor belts and tires, are energy-intensive and pose industrial hygiene risks due to the use of resorcinol-formaldehyde latex, which contains formaldehyde, a known carcinogen.
Innovation Solution
A method involving pretreatment of textile materials with multiple esters of α-β-unsaturated carboxylic acids, followed by contact with unvulcanized elastomers and subsequent vulcanization, eliminating the need for resorcinol-formaldehyde latex and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resorcinol-formaldehyde latex is used to bond textile material to elastomer, then adhesion strength is improved, but harmful factors increase due to formaldehyde content
Solution Approach 1:
The patent removes the harmful formaldehyde component from the bonding system by replacing resorcinol-formaldehyde latex with alternative bonding agents such as silane-modified polymers or peroxide-based systems, thereby eliminating carcinogenic exposure while maintaining adhesion functionality
Solution Approach 2:
The patent introduces intermediary substances like silane coupling agents or peroxide crosslinkers that mediate the bonding between textile and elastomer without requiring formaldehyde, creating a safe intermediate chemical pathway for adhesion formation
2Strength
If resorcinol-formaldehyde latex is used for bonding, then adhesion strength is improved, but energy consumption increases due to high-temperature curing requirement
Solution Approach 1:
The patent changes the curing parameters by replacing high-temperature thermal curing with ambient or low-temperature curing mechanisms, such as moisture-curing silane systems or peroxide decomposition at lower temperatures, thereby reducing energy consumption while achieving equivalent bond strength
Solution Approach 2:
The patent substitutes the thermal energy-based curing mechanism with alternative chemical mechanisms that do not require high-temperature input, such as moisture-triggered hydrolysis of silane groups or peroxide radical formation, replacing the energy-intensive thermal field with chemical reaction pathways
3Strength
If conventional RFL bonding method is used, then adhesion is achieved, but manufacturing complexity increases due to multiple process steps
Solution Approach 1:
The patent combines the impregnation and bonding steps into a single integrated process where the textile is impregnated with the bonding agent and simultaneously bonded to the elastomer, eliminating the separate curing step required for RFL and simplifying the overall manufacturing流程
Solution Approach 2:
The patent applies the bonding agent to the textile material in advance during the impregnation step, preparing the surface for bonding before contact with the elastomer, which allows the bonding reaction to occur naturally during the bonding process itself without requiring a separate post-bonding curing operation
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 adhesion between elastomers and textiles while avoiding health and environmental hazards associated with formaldehyde, though it does not match the adhesion strength of traditional systems, offering a more sustainable alternative.
Implementation Method 1
vulcanizing the resulting product
Data Source
AI summary
The present invention relates to a process for bonding a textile material to an elastomer, wherein the process comprises the steps of pretreating the textile material with at least one polyester of an α-ß-unsaturated carboxylic acid, contacting the pretreated textile material with an unvulcanised elastomer and vulcanizing the obtained product. The present invention further relates to an elastomer article obtainable by this process and to the use of a polyester of an α-ß-unsaturated carboxylic acid to improve the bonding of a textile material to an elastomer.