WO2021106559A1 - 表面改質繊維、補強繊維、及びそれを用いた成形体 - Google Patents
表面改質繊維、補強繊維、及びそれを用いた成形体 Download PDFInfo
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- WO2021106559A1 WO2021106559A1 PCT/JP2020/041979 JP2020041979W WO2021106559A1 WO 2021106559 A1 WO2021106559 A1 WO 2021106559A1 JP 2020041979 W JP2020041979 W JP 2020041979W WO 2021106559 A1 WO2021106559 A1 WO 2021106559A1
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- WIPO (PCT)
- Prior art keywords
- rubber
- group
- conjugated diene
- modified
- fiber
- Prior art date
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- D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
- D06M13/322—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing nitrogen
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/06—Reinforcing macromolecular compounds with loose or coherent fibrous material using pretreated fibrous materials
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
- C08J5/248—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using pre-treated fibres
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/16—Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
- D06M13/322—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing nitrogen
- D06M13/395—Isocyanates
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- D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
- D06M13/322—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing nitrogen
- D06M13/402—Amides imides, sulfamic acids
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- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/356—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of other unsaturated compounds containing nitrogen, sulfur, silicon or phosphorus atoms
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- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/356—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of other unsaturated compounds containing nitrogen, sulfur, silicon or phosphorus atoms
- D06M15/3562—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of other unsaturated compounds containing nitrogen, sulfur, silicon or phosphorus atoms containing nitrogen
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- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/55—Epoxy resins
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- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/61—Polyamines polyimines
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- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/693—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with natural or synthetic rubber, or derivatives thereof
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2307/00—Characterised by the use of natural rubber
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/16—Ethene-propene or ethene-propene-diene copolymers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2409/00—Characterised by the use of homopolymers or copolymers of conjugated diene hydrocarbons
- C08J2409/06—Copolymers with styrene
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/14—Polymer mixtures characterised by other features containing polymeric additives characterised by shape
- C08L2205/16—Fibres; Fibrils
Definitions
- the present invention relates to surface-modified fibers and reinforcing fibers having excellent adhesiveness to rubber, and a molded product using the same.
- Synthetic organic fibers such as polyethylene terephthalate (PET), nylon 66, vinylon and rayon are inexpensive, have high strength, have excellent heat resistance and durability, and are lightweight, so they are used for automobile tires and oil brake hoses. It is used as a reinforcing fiber. In these products, in order to fully exhibit the excellent physical properties (for example, high strength and high elastic modulus) of rubber, it is necessary to firmly bond the fiber and rubber.
- RFL resorcinol / formaldehyde resin and rubber latex as main components
- Patent Documents 1 and 2 formaldehyde contained in RFL is suspected to be carcinogenic, and resorcinol is suspected to be an endocrine disrupter. Therefore, it is desired to develop an alternative material that does not use these raw materials.
- Patent Document 3 proposes a technique using an adhesive containing an adhesive compound having an unsaturated carbon bond and an epoxy group that reacts with a vulcanizing agent used for vulcanizing rubber.
- Patent Document 4 proposes a technique in which an active functional group layer is provided by applying a blocked isocyanate compound and an epoxy compound in the first stage, and an adhesive component containing latex as a main component is used in the second stage. There is.
- Patent Document 4 The method using the adhesive described in Patent Document 3 has a problem that the adhesiveness is significantly inferior to that of the conventional method using RFL, and the practicality is poor. Further, the treatment described in Patent Document 4 requires a step of providing an intermediate layer called a rubberized layer, and also requires heat treatment at a high temperature in two steps, so that the treatment requires a large amount of energy. In addition, there is a concern that the fiber may be deteriorated due to heat, and the reinforcing performance may be deteriorated. Note that Patent Document 4 only describes a technique of using an adhesive component containing latex as a main component, and does not describe the use of an adhesive component containing a conjugated diene rubber as a main component.
- the present invention has been made in view of the above-mentioned conventional problems, and is a surface-modified fiber, a reinforcing fiber, and a molding using the same, which can improve the adhesiveness to rubber without using resorcinol and formaldehyde.
- the challenge is to provide the body.
- the present inventors have made the fiber and the adhesive component compatible with each other by adhering a specific compound to the fiber and adjusting the zeta potential on the fiber surface to a specific range. As a result, it was found that the adhesiveness between the fiber and the rubber was improved without using resorcinol and formaldehyde, and the present invention was completed.
- the present invention relates to the following [1] to [14].
- [1] Surface modification having a fiber and a surface modification layer covering at least a part of the surface of the fiber, and a solid surface zeta potential on the surface of the surface modification layer is -20.0 to 30.0 mV. Quality fiber.
- [2] The surface-modified fiber according to the above [1], wherein the fiber is one or more fibers selected from polyester fibers, polyamide fibers, polyvinyl alcohol fibers, and regenerated cellulose fibers.
- [3] The surface-modified fiber according to the above [1] or [2], wherein the surface-modified layer contains a compound having a nitrogen-containing functional group.
- the surface modification layer contains a compound having a functional group derived from one or more selected from an oxazoline group, an oxazolidinone group, a carbodiimide group, a carbamide group, an amino group, and an aziridine group.
- the surface-modified fiber according to any one of [3].
- the conjugated diene rubber is a modified conjugated diene rubber having a hydrogen-binding functional group as a part of the conjugated diene rubber, and the hydrogen-binding functional group is a hydroxy group, an epoxy group, an aldehyde group, and the like.
- the hydrogen-binding functional group is a hydroxy group, an epoxy group, an aldehyde group, and the like.
- the reinforcing fiber according to any one of the above [6] to [8], which is one or more of the above.
- the present invention can provide a surface-modified fiber, a reinforcing fiber, and a molded product using the same, which can improve the adhesiveness to rubber without using resorcinol and formaldehyde.
- the surface-modified fiber of the present invention has a fiber and a surface-modified layer that covers at least a part of the surface of the fiber, and the solid surface zeta potential on the surface of the surface-modified layer is -20.0 to 30. It is characterized by having a voltage of 0.0 mV. According to the present invention, since the zeta potential on the solid surface is adjusted to the above range, a strong affinity is exhibited between the modified conjugated diene rubber contained in the adhesive component and the fiber. Then, the fiber, the adhesive component, and the rubber are firmly adhered to each other, and as a result, the adhesiveness between the fiber and the rubber is improved.
- the "surface modifying layer covering at least a part of the surface of the fiber” means that the surface modifying layer is present on at least a part of the surface of the fiber, for example, as a film or a layer.
- the raw material of the fiber may contain a component corresponding to the surface-modified layer, and the component of the surface-modified layer may be present on a part of the surface of the fiber itself.
- the solid surface zeta potential on the surface of the surface modification layer is -20.0 to 20.0 mV. It is preferably -15.0 to 15.0 mV, further preferably -10.0 to 12.0 mV, and even more preferably -5.0 to 10.0 mV. , -5.0 to 9.0 mV is even more preferable, -5.0 to 6.0 mV is even more preferable, and -5.0 to 0 mV is even more preferable.
- the surface modification layer in the present invention is not particularly limited as long as it is composed of a compound capable of adjusting the solid surface zeta potential within the above range, but is, for example, a layer containing a compound having a nitrogen-containing functional group. It is preferable that the layer contains a compound having a functional group derived from one or more selected from an oxazoline group, an oxazolidinone group, a carbodiimide group, a carbamide group, an amino group, and an aziridine group. ..
- Examples of the compound having a functional group include an oxazolidinone group-containing compound obtained by reacting a blocked isocyanate compound with an epoxy compound, and oxazoline in which an oxazoline group is introduced into the polymer main chain of an acrylic or styrene / acrylic copolymer.
- Group-containing compounds carbodiimide group-containing compounds with carbodiimide groups introduced into the molecule (polyvalent carbodiimide), carbamide group-containing compounds such as urea derivatives, amino group-containing high molecular weight bodies with amino groups introduced into the molecule, at the end of the molecule
- Examples thereof include an aziridine group-containing compound having an aziridine group introduced (2,2-bis (hydroxymethyl) butanol tris [3- (1-aziridinyl) propionate]), and among these, adhesion between the surface-modified fiber and rubber.
- An oxazolidinone group-containing compound obtained by reacting a blocked isocyanate compound with an epoxy compound is preferable from the viewpoint of improving the properties, and an oxazoline group-containing compound is preferable from the viewpoint of reducing the environmental load.
- the surface modification layer preferably covers the entire surface of the fiber from the viewpoint of improving the adhesiveness with rubber, but it may substantially cover at least a part of the surface of the fiber.
- the specific amount of the surface modification layer covering the surface of the fiber is preferably 0.01 to 5.0 parts by mass, and 0.05 to 1.0 parts by mass with respect to 100 parts by mass of the fiber used as a raw material. It is more preferably parts, and even more preferably 0.1 to 0.3 parts by mass.
- the fiber used for the surface-modified fiber of the present invention is not particularly limited, but it can be suitably used for a hydrophobic fiber made of a hydrophobic resin which cannot be firmly adhered to rubber by the conventional technique. Since the hydrophobic fiber generally does not have a polar functional group on the fiber surface, it has poor affinity with the adhesive component described later and cannot be firmly adhered to the rubber. However, by providing the surface modification layer on the fiber surface as in the present invention, even hydrophobic fibers can be firmly adhered to rubber.
- the term "fiber” includes not only single fibers and long fibers but also forms such as non-woven fabrics, woven fabrics, knitted fabrics, felts and sponges.
- hydrophobic fibers examples include polyolefin fibers such as polyethylene and polypropylene, polyester fibers such as polyethylene terephthalate, and total aromatic polyester fibers, among which the production cost is high. Polyester fibers are preferable because they are excellent in strength, heat resistance, durability and the like.
- Hydrophilic fibers may be used in the present invention.
- the hydrophilic synthetic fiber is composed of a hydrophilic functional group such as a hydroxy group, a carboxy group, a sulfonic acid group, and an amino group, and / or a thermoplastic resin having a hydrophilic bond such as an amide bond.
- Synthetic fibers can be mentioned.
- thermoplastic resins include polyvinyl alcohol-based resins and polyamide-based resins [polyamide 6, polyamide 66, polyamide 11, polyamide 12, polyamide 610, polyamide 612, and polyamide 9C (polyamide composed of nonanediamine and cyclohexanedicarboxylic acid).
- hydrophilic synthetic fiber one type may be used alone, or two or more types may be used in combination. Further, these hydrophilic synthetic fibers may be further subjected to a hydrophilization treatment described later in order to further increase the hydrophilicity.
- hydrophilic natural fibers include natural cellulose fibers such as wood pulp such as kraft pulp and non-wood pulp such as cotton pulp and straw pulp.
- hydrophilic regenerated fiber include regenerated cellulose fibers such as rayon, lyocell, cupra, and polynosic.
- One type of each of these natural fibers and regenerated fibers may be used alone, or two or more types may be used in combination. Further, these hydrophilic natural fibers and regenerated fibers may be further subjected to a hydrophilization treatment described later in order to further increase the hydrophilicity.
- the hydrophilic fiber may have at least a hydrophilic surface.
- hydrophilic resins that make up the sheath the description of hydrophilic synthetic fibers is cited.
- the hydrophobic fiber made of a hydrophobic resin include the above-mentioned hydrophobic fiber.
- the hydrophilization treatment is not particularly limited as long as it is a treatment for chemically or physically imparting a hydrophilic functional group to the fiber surface, and for example, the hydrophobic fiber made of the hydrophobic resin is subjected to an isocyanate group, an epoxy group, or a hydroxy. It is carried out by a method of modifying with a compound containing a hydrophilic functional group such as a group, an amino group, an ether group, an aldehyde group, a carbonyl group, a carboxy group and a urethane group or a derivative thereof, or a method of modifying the surface by irradiation with an electron beam. be able to.
- hydrophilic fiber used in the present invention synthetic fiber and regenerated fiber are preferable from the viewpoint of being used as a reinforcing fiber, and among them, polyester fiber, polyamide fiber, polyvinyl alcohol fiber, and regenerated cellulose fiber are selected 1. More than seed fibers are preferred. In the present invention, one type of fiber may be used alone, or two or more types may be used in combination.
- the method for producing the surface-modified fiber of the present invention is not particularly limited, but a solution of the compound constituting the surface-modified layer described above with water or an organic solvent is prepared, and this solution is attached to the fiber and then heat-treated. It can be produced by a method of drying with or the like.
- the method of adhering the solution of the surface modifier to the fiber is not particularly limited, and is performed by, for example, one or more selected from immersion, roll coater, oiling roller, oiling guide, nozzle (spray) coating, brush coating and the like. Is preferable.
- the heat treatment for drying the solution is preferably performed at a treatment temperature of 100 to 250 ° C. and a treatment time of 0.1 seconds to 2 minutes.
- the heat treatment may be performed only once at a specific temperature, or may be performed twice or more by changing the treatment temperature and the treatment time.
- the surface modification layer may contain other components other than the above.
- other components include cross-linking agents, acids, bases, inorganic salts, organic salts, pigments, dyes, antioxidants, polymerization initiators, plasticizers and the like.
- the content of the other components in the surface-modified layer is preferably 20% by mass or less, more preferably 10 from the viewpoint of improving the adhesive force with the rubber. It is mass% or less, more preferably 5 mass% or less.
- the reinforcing fiber of the present invention has the surface-modified fiber of the present invention and an adhesive layer containing a conjugated diene-based rubber covering at least a part of the surface of the surface-modified fiber.
- the surface-modified fiber and the adhesive layer have a high affinity, the fiber and the adhesive layer, and the adhesive layer and the rubber can be firmly adhered to each other.
- the entire surface of the surface-modified fiber may be covered with an adhesive layer, but at least a part thereof may be covered with an adhesive layer. It may be an existing aspect.
- the adhesive layer in the present invention can obtain reinforcing fibers having excellent adhesiveness to rubber even if it does not contain formaldehyde, which is harmful to the human body, or a resin made from formaldehyde as a raw material.
- the adhesive layer contains a resin made from formaldehyde as a raw material
- examples of the resin include resanol / formaldehyde resin, phenol / formaldehyde resin, melamine / formaldehyde resin and derivatives thereof.
- the content thereof is preferably 10 parts by mass or less, more preferably 5 parts by mass or less, and 3 parts by mass with respect to 100 parts by mass of the conjugated diene rubber. It is more preferably parts or less, particularly preferably 1 part by mass or less, and particularly preferably not substantially contained.
- the formaldehyde content can be measured by extracting the adhesive layer from the reinforcing fiber with a solvent such as toluene and then using HPLC or the like.
- the adhesive layer in the reinforcing fiber of the present invention is not particularly limited as long as it contains a conjugated diene rubber.
- an adhesive component composed of a solution of the conjugated diene rubber in oil or water of the conjugated diene rubber is used. It can be formed by adhering an adhesive component composed of an emulsion dispersed in a surface-modified fiber to a surface-modified fiber.
- aspects of the adhesive layer will be specifically described.
- the conjugated diene-based rubber used in the present invention contains at least a monomer unit derived from the conjugated diene (hereinafter, also referred to as “conjugated diene unit”) in the molecule, and for example, all units in the conjugated diene-based rubber. It is preferable that the weight unit contains 50 mol% or more of a monomer unit derived from a conjugated diene.
- the conjugated diene monomer include butadiene, 2-methyl-1,3-butadiene (hereinafter, also referred to as "isoprene”), 2,3-dimethylbutadiene, 2-phenylbutadiene, 1,3-pentadiene, and the like.
- conjugated diene 2-Methyl-1,3-pentadiene, 1,3-hexadiene, 1,3-octadien, 1,3-cyclohexadiene, 2-methyl-1,3-octadien, 1,3,7-octatriene, ⁇ -farnesene (Hereinafter, also referred to as "farnesen”), milsen, chloroprene and the like can be mentioned.
- conjugated diene may be used alone, or two or more thereof may be used in combination.
- the conjugated diene rubber preferably has a monomer unit derived from one or more selected from butadiene, isoprene, and farnesene.
- the conjugated diene rubber used in the present invention may contain a unit derived from a monomer other than the conjugated diene monomer as long as it does not inhibit adhesion.
- monomers include copolymerizable ethylenically unsaturated monomers and aromatic vinyl compounds.
- the ethylenically unsaturated monomer include olefins such as ethylene, 1-butene, and isobutylene.
- aromatic vinyl compound examples include styrene, ⁇ -methylstyrene, 2-methylstyrene, 3-methylstyrene, 4-methylstyrene, 4-propylstyrene, 4-t-butylstyrene, 4-cyclohexylstyrene, and 4 -Dodecylstyrene, 2,4-dimethylstyrene, 2,4-diisopropylstyrene, 2,4,6-trimethylstyrene, 2-ethyl-4-benzylstyrene, 4- (phenylbutyl) styrene, 1-vinylnaphthalene, 2 -Vinylnaphthalene, vinylanthracene, N, N-diethyl-4-aminoethylstyrene, vinylpyridine, 4-methoxystyrene, monochlorostyrene, dichlorostyrene, divinyl
- the conjugated diene rubber contains a monomer unit derived from a monomer other than the conjugated diene monomer, the content thereof is preferably 30 mol% or less, preferably 10 mol% or less. Is more preferable, and 5 mol% or less is further preferable.
- the conjugated diene-based rubber used in the present invention is preferably a modified conjugated diene-based rubber having a hydrogen-bonding functional group as a part of the conjugated diene-based rubber, and at least a part of the polymer chains contains a conjugated diene unit. Moreover, a modified conjugated diene-based rubber having a hydrogen-bonding functional group at the side chain or the end of the polymer chain is more preferable.
- the modified conjugated diene rubber can be bonded to each other by interacting with each of the rubber as an adherend and the surface-modified fiber.
- the modified conjugated diene rubber and the adherend rubber are vulcanized to form a covalent bond, a strong cohesive force is generated, so that the adhesiveness is further improved. Further, it is considered that the hydrogen-bonding functional group contained in the modified conjugated diene-based rubber forms a hydrogen bond with the surface-modified layer of the surface-modified fiber to improve the adhesiveness.
- the "hydrogen bond” refers to a hydrogen atom (donor) that is bonded to an atom having a large electronegativity (O, N, S, etc.) and is electrically positively polarized, and a lone electron pair. It means a binding interaction formed with an electrically negative atom (acceptor).
- the "hydrogen-bonding functional group” is a functional group capable of functioning as a donor and an acceptor in the hydrogen bond. Specifically, hydroxy group, epoxy group, ether group, mercapto group, carboxy group, carbonyl group, aldehyde group, amino group, imino group, imidazole group, urethane group, amide group, urea group, isocyanate group, nitrile group, Examples thereof include a silanol group and derivatives thereof. Examples of the derivative of the aldehyde group include its acetalized form. Derivatives of the carboxy group include its salt, its esterified product, its amidated product, and its acid anhydride.
- Examples of the silanol group derivative include its esterified product.
- Examples of the carboxy group include a monocarboxylic acid-derived group and a dicarboxylic acid-derived group. Among these, hydroxy group, epoxy group, aldehyde group, acetalized form of aldehyde group, carboxy group, salt of carboxy group, esterified form of carboxy group, acid anhydride of carboxy group, esterification of silanol group and silanol group.
- One or more selected from the body, amino group, imidazole group, and mercapto group is preferable.
- hydroxy group, carboxy group, carbonyl group, carboxy group salt, carboxy group esterified product, and carboxy group acid anhydride from the viewpoint of improving adhesiveness and easiness of producing conjugated diene rubber, hydroxy group, carboxy group, carbonyl group, carboxy group salt, carboxy group esterified product, and carboxy group acid anhydride.
- carboxy group, esterified carboxy group, and acid anhydride of carboxy group are more preferable, and esterified product of maleic anhydride and functional group derived from maleic anhydride. Is more preferable.
- the number of hydrogen-bonding functional groups in the modified conjugated diene-based rubber is preferably 1 or more, more preferably 3 or more, still more preferably 4 on average per molecule from the viewpoint of obtaining reinforcing fibers having excellent rubber adhesiveness. More than one.
- the number of hydrogen-bonding functional groups is preferably 80 or less, more preferably 40 or less, on average per molecule from the viewpoint of controlling the viscosity of the modified conjugated diene rubber in an appropriate range and improving handleability.
- the number is less than, more preferably 30 or less, still more preferably 20 or less, still more preferably 15 or less.
- the average number of hydrogen-bonding functional groups per molecule of modified conjugated diene-based rubber is calculated from the equivalent of hydrogen-bonding functional groups (g / eq) of the modified conjugated diene-based rubber and the number average molecular weight Mn in terms of styrene based on the following formula. Will be done.
- the equivalent of the hydrogen-bonding functional group of the modified conjugated diene-based rubber means the mass of the conjugated diene bonded to each hydrogen-bonding functional group and other monomers other than the conjugated diene contained as necessary. To do.
- Average number of hydrogen-bonding functional groups per molecule [(number average molecular weight (Mn)) / (molecular weight of styrene unit) ⁇ (average of conjugated diene and other monomer units other than conjugated diene contained as needed) Molecular weight)] / (equivalent to hydrogen-bonding functional group)
- the method for calculating the equivalent of the hydrogen-bonding functional group can be appropriately selected depending on the type of the hydrogen-bonding functional group.
- Examples of the method for obtaining the modified conjugated diene rubber include a method obtained by adding a modified compound to a polymer of a conjugated diene monomer (hereinafter, also referred to as “production method (1)”), and a conjugated diene polymer. (Hereinafter, also referred to as “production method (2)”), a method obtained by copolymerizing a conjugated diene monomer and a radically polymerizable compound having a hydrogen-binding functional group (hereinafter, also referred to as “manufacturing method (2)").
- production method (3) a modified compound capable of reacting with the polymerization active terminal is added to the polymer of the unmodified conjugated diene monomer having a polymerization active terminal before the polymerization terminator is added.
- production method (4) a modified compound capable of reacting with the polymerization active terminal is added to the polymer of the unmodified conjugated diene monomer having a polymerization active terminal before the polymerization terminator is added.
- the production method (1) is a method of adding a modified compound to a polymerized conjugated diene monomer, that is, an unmodified conjugated diene rubber (hereinafter, also referred to as “unmodified conjugated diene rubber”).
- the unmodified conjugated diene-based rubber can be obtained by polymerizing a conjugated diene and, if necessary, a monomer other than the conjugated diene by, for example, an emulsion polymerization method or a solution polymerization method.
- a known or known method can be applied.
- a polar compound optionally in the presence of a polar compound.
- the solvent examples include aliphatic hydrocarbons such as n-butane, n-pentane, isopentane, n-hexane, n-heptane and isooctane; alicyclic hydrocarbons such as cyclopentane, cyclohexane and methylcyclopentane; benzene, Examples include aromatic hydrocarbons such as toluene and xylene.
- anion-polymerizable active metals examples include alkali metals such as lithium, sodium and potassium; alkaline earth metals such as beryllium, magnesium, calcium, strontium and barium; and lanthanoid rare earth metals such as lanthanum and neodymium. .. Among these anionically polymerizable active metals, alkali metals and alkaline earth metals are preferable, and alkali metals are more preferable. As the anionic polymerizable active metal compound, an organic alkali metal compound is preferable.
- organic alkali metal compound examples include organic monolithium compounds such as methyllithium, ethyllithium, n-butyllithium, sec-butyllithium, t-butyllithium, hexyllithium, phenyllithium and stillbenlithium; , 1,4-Dilithiobutane, 1,4-dilithio-2-ethylcyclohexane, 1,3,5-trilithiobenzene and other polyfunctional organic lithium compounds; sodium naphthalene, potassium naphthalene and the like.
- organic alkali metal compounds an organic lithium compound is preferable, and an organic monolithium compound is more preferable.
- the amount of the organic alkali metal compound used can be appropriately set according to the melt viscosity, molecular weight, etc. of the target unmodified conjugated diene rubber and modified conjugated diene rubber, but 100 parts by mass of all the monomers containing the conjugated diene. However, it is usually used in an amount of 0.01 to 3 parts by mass.
- the organic alkali metal compound can also be used as an organic alkali metal amide by reacting with a secondary amine such as dibutylamine, dihexylamine, or dibenzylamine.
- Polar compounds are usually used in anionic polymerization to adjust the microstructure of the conjugated diene site without inactivating the reaction.
- the polar compound include ether compounds such as dibutyl ether, tetrahydrofuran and ethylene glycol diethyl ether, and 2,2-di (2-tetrahydrofuryl) propane; tertiary amines such as tetramethylethylenediamine and trimethylamine; alkali metal alkoxides and phosphines. Examples include compounds.
- the polar compound is usually used in an amount of 0.01-1000 mol with respect to the organic alkali metal compound.
- the temperature of solution polymerization is usually in the range of ⁇ 80 to 150 ° C., preferably in the range of 0 to 100 ° C., and more preferably in the range of 10 to 90 ° C.
- the polymerization mode may be either a batch type or a continuous type.
- the polymerization reaction can be stopped by adding a polymerization inhibitor.
- the polymerization terminator include alcohols such as methanol and isopropanol.
- the unmodified conjugated diene rubber can be isolated by pouring the obtained polymerization reaction solution into a poor solvent such as methanol to precipitate a polymer, or by washing the polymerization reaction solution with water, separating and drying.
- the solution polymerization method is preferable as the method for producing the unmodified conjugated diene rubber.
- emulsification polymerization method a known or known method can be applied.
- a monomer containing a predetermined amount of conjugated diene is emulsified and dispersed in the presence of an emulsifier, and emulsion polymerization is carried out with a radical polymerization initiator.
- the emulsifier include long-chain fatty acid salts having 10 or more carbon atoms and rosin salts.
- the long-chain fatty acid salt include potassium salts or sodium salts of fatty acids such as capric acid, lauric acid, myristic acid, palmitic acid, oleic acid, and stearic acid.
- Water is usually used as the dispersion solvent, and a water-soluble organic solvent such as methanol or ethanol may be contained as long as the stability during polymerization is not impaired.
- a water-soluble organic solvent such as methanol or ethanol
- examples of the radical polymerization initiator include persulfates such as ammonium persulfate and potassium persulfate, organic peroxides, hydrogen peroxide and the like.
- a chain transfer agent may be used to adjust the molecular weight of the resulting unmodified conjugated diene rubber.
- chain transfer agent examples include mercaptans such as t-dodecyl mercaptan and n-dodecyl mercaptan; carbon tetrachloride, thioglycolic acid, diterpenes, turpinolene, ⁇ -terpinene, ⁇ -methylstyrene dimer and the like.
- the temperature of emulsion polymerization can be appropriately set depending on the type of radical polymerization initiator used, etc., but is usually in the range of 0 to 100 ° C, preferably in the range of 0 to 60 ° C.
- the polymerization mode may be either continuous polymerization or batch polymerization.
- the polymerization reaction can be stopped by adding a polymerization inhibitor.
- the polymerization terminator include amine compounds such as isopropylhydroxylamine, diethylhydroxylamine and hydroxylamine, quinone compounds such as hydroquinone and benzoquinone, and sodium nitrite.
- an anti-aging agent may be added if necessary.
- unreacted monomers are removed from the obtained latex as needed, and then salts such as sodium chloride, calcium chloride and potassium chloride are used as coagulants, and nitric acid, sulfuric acid and the like are used as necessary.
- the polymer is recovered by coagulating the polymer while adjusting the pH of the coagulation system to a predetermined value by adding an acid, and then separating the dispersion solvent. Then, after washing with water, dehydrating, and drying, an unmodified conjugated diene-based rubber can be obtained.
- latex and a stretched oil prepared as an emulsified dispersion may be mixed and recovered as an oil-expanded unmodified conjugated diene-based rubber.
- the modified compound used in the production method (1) is not particularly limited, but one having a hydrogen-bonding functional group is preferable from the viewpoint of improving the adhesiveness of the reinforcing fibers.
- the hydrogen-bonding functional group include the same as described above. Among them, an amino group, an imidazole group, a urea group, a hydroxy group, an epoxy group, a mercapto group, a silanol group, an aldehyde group, a carboxy group and a derivative thereof are preferable from the viewpoint of the strength of hydrogen bonding force.
- the derivative of the carboxy group is preferably a salt thereof, an esterified product thereof, an amidated product thereof, or an acid anhydride thereof.
- One of these modified compounds having a hydrogen-bonding functional group may be used alone, or two or more thereof may be used in combination.
- modified compound examples include unsaturated carboxylic acids such as maleic acid, fumaric acid, citraconic acid, and itaconic acid; unsaturated carboxylic acids such as maleic anhydride, citraconic anhydride, 2,3-dimethylmaleic anhydride, and itaconic anhydride.
- Saturated carboxylic acid imides such as maleate imide, fumaric acid imide, citraconic acid imide, and itaconic acid imide; vinyl trimethoxysilane, ⁇ -methacryloxypropyltrimethoxysilane, mercaptomethylmethyldiethoxysilane, mercaptomethyltriethoxysilane , 2-Mercaptoethyltrimethoxysilane, 2-Mercaptoethyltriethoxysilane, 2-Mercaptoethylmethoxydimethylsilane, 2-Mercaptoethylethoxydimethylsilane, 3-Mercaptopropyltrimethoxysilane, 3-Mercaptopropyltriethoxysilane, 3 -Mercaptopropyldimethoxymethylsilane, 3-mercaptopropyldiethoxymethylsilane, 3-mercaptopropyldimethoxyethylsilane, 3-mercaptopropyldiethoxyeth
- the amount of the modified compound used is preferably 0.1 to 100 parts by mass, more preferably 0.5 to 50 parts by mass, and further preferably 1 to 30 parts by mass with respect to 100 parts by mass of the unmodified conjugated diene rubber.
- the reaction temperature is usually preferably in the range of 0 to 200 ° C, more preferably in the range of 50 to 200 ° C.
- a compound having a hydroxyl group such as 2-hydroxyethyl methacrylate or methanol after grafting maleic anhydride on an unmodified conjugated diene rubber obtained by living anionic polymerization, or a compound such as water.
- a method of reacting There is a method of reacting.
- the addition amount of the modified compound in the modified conjugated diene rubber is preferably 0.5 to 40 parts by mass and more preferably 1 to 30 parts by mass with respect to 100 parts by mass of the unmodified conjugated diene rubber. , 1.5 to 20 parts by mass is more preferable.
- the amount of the modified compound added to the modified conjugated diene rubber can be calculated based on the acid value of the modified compound, and various analytical instruments such as infrared spectroscopy and nuclear magnetic resonance spectroscopy are used. You can also ask for it.
- the method for adding the modified compound to the unmodified conjugated diene-based rubber is not particularly limited, and is selected from, for example, a liquid unsaturated conjugated diene-based rubber, an unsaturated carboxylic acid, an unsaturated carboxylic acid derivative, a silane compound, and the like.
- examples thereof include a method in which one or more modified compounds and, if necessary, a radical generator are added and heated in the presence or absence of an organic solvent.
- the radical generator to be used is not particularly limited, and commercially available organic peroxides, azo compounds, hydrogen peroxide and the like can be used.
- the organic solvent used in the above method generally include hydrocarbon solvents and halogenated hydrocarbon solvents.
- hydrocarbon solvents such as n-butane, n-hexane, n-heptane, cyclohexane, benzene, toluene, and xylene are preferable.
- an antiaging agent may be added from the viewpoint of suppressing side reactions.
- the anti-aging agent commercially available ones can be used, for example, butylated hydroxytoluene (BHT), N-phenyl-N'-(1,3-dimethylbutyl) -p-phenylenediamine (Nocrack 6C) and the like. Can be mentioned.
- BHT butylated hydroxytoluene
- Nocrack 6C N-phenyl-N'-(1,3-dimethylbutyl) -p-phenylenediamine
- the amount of the antiaging agent added is preferably 0.01 to 10 parts by mass, more preferably 0.05 to 5 parts by mass with respect to 100 parts by mass of the unmodified conjugated diene rubber. When the amount of the antiaging agent added is within the above range, side reactions can be suppressed and a modified conjugated diene rubber can be obtained in good yield.
- the weight average molecular weight (Mw) of the conjugated diene rubber is not particularly limited, but is preferably more than 2,000, more preferably 5,000 or more, and more preferably 10,000 or more from the viewpoint of improving the adhesiveness. It is more preferably 15,000 or more, further preferably 20,000 or more, particularly preferably 25,000 or more, and 120 from the viewpoint of handleability. It is preferably 000 or less, more preferably 100,000 or less, further preferably 75,000 or less, and even more preferably 55,000 or less.
- the number average molecular weight (Mn) of the conjugated diene rubber is not particularly limited, but is preferably 2,000 or more, more preferably 5,000 or more, and 10,000 or more from the viewpoint of improving adhesiveness. It is more preferably 15,000 or more, further preferably 20,000 or more, particularly preferably 25,000 or more, and from the viewpoint of handleability. , 120,000 or less, more preferably 75,000 or less, further preferably 50,000 or less, and even more preferably 47,000 or less.
- Mw and Mn of the conjugated diene rubber are polystyrene-equivalent weight average molecular weight and number average molecular weight obtained from the measurement of gel permeation chromatography (GPC), and specifically, they shall be measured by the method described in Examples. Can be done.
- the molecular weight distribution (Mw / Mn) of the conjugated diene rubber is preferably 1.00 to 5.00, more preferably 1.00 to 3.00, and 1.00 to 2.00. It is even more preferably 1.00 to 1.50, and even more preferably 1.00 to 1.30. When Mw / Mn is within the above range, the variation in viscosity of the conjugated diene rubber is small and handling is easy.
- the molecular weight distribution (Mw / Mn) means the ratio of the weight average molecular weight (Mw) / number average molecular weight (Mn) in terms of standard polystyrene obtained by GPC measurement.
- the conjugated diene rubber is preferably liquid.
- liquid means that the melt viscosity of the conjugated diene rubber measured at 38 ° C. is 4,000 Pa ⁇ s or less.
- the melt viscosity is preferably 0.1 Pa ⁇ s or more, more preferably 1 Pa ⁇ s or more, further preferably 10 Pa ⁇ s or more, and 30 Pa ⁇ s or more. It is even more preferably 50 Pa ⁇ s or more, and from the viewpoint of handleability, it is preferably 2,500 Pa ⁇ s or less, and more preferably 2,100 Pa ⁇ s or less. ..
- the melt viscosity of the conjugated diene rubber means the viscosity measured at 38 ° C. using a Brookfield type viscometer (B type viscometer).
- the glass transition temperature (Tg) of a conjugated diene rubber may vary depending on the vinyl content of the conjugated diene unit, the type of the conjugated diene, the content of a unit derived from a monomer other than the conjugated diene, etc., but is -100.
- the temperature is preferably -10 ° C, more preferably -100 to 0 ° C, and even more preferably -100 to -10 ° C.
- the vinyl content of the conjugated diene rubber is preferably 80 mol% or less, more preferably 50 mol% or less, and further preferably 30 mol% or less. When the vinyl content is within the above range, the adhesiveness is improved.
- the term "vinyl content” refers to a conjugated diene unit contained in a modified liquid diene rubber, which is bonded by a 1,2-bond or a 3,4-bond in a total of 100 mol% of the conjugated diene unit. It means the total mol% of (conjugated diene unit having a bond other than 1,4-bond).
- the vinyl content is derived from the signal derived from the conjugated diene unit bonded by 1,2-bond or 3,4-bond and the conjugated diene unit bonded by 1,4-bond using 1 H-NMR. It can be calculated from the integrated value ratio of the signals of.
- the adhesive layer in the present invention can be formed, for example, by applying an adhesive component consisting of a solution of a conjugated diene rubber in oil to a surface-modified fiber.
- an adhesive component consisting of a solution of a conjugated diene rubber in oil
- the oil does not volatilize for a long period of time even after the adhesive component is applied to the surface of the fiber, so that the coating spots of the adhesive component are less likely to occur and the adhesiveness is improved.
- the vapor pressure of the oil at 20 ° C.
- the vapor pressure of oil at 20 ° C. refers to a value calculated by an optimum curve obtained by applying the Antoine equation to the measured value measured by the gas flow method.
- the oil having a vapor pressure of 10 Pa or less at 20 ° C. that can be used in the present invention is not particularly limited as long as it is compatible with the conjugated diene rubber, and examples thereof include natural oil and synthetic oil.
- natural oils include mineral oils and vegetable oils.
- the mineral oil includes paraffin-based mineral oil, aromatic mineral oil, naphthen-based mineral oil obtained by ordinary refining methods such as solvent refining and hydrogenation refining, and wax (gas) produced by Fishertropus process or the like. Liquid wax), mineral oil produced by isomerizing the wax, and the like.
- Examples of commercially available paraffin-based mineral oils include the "Diana Process Oil” series manufactured by Idemitsu Kosan Co., Ltd.
- Vegetable oils include, for example, flaxseed oil, camellia oil, macadamia nut oil, corn oil, mink oil, olive oil, avocado oil, southern ka oil, sunflower oil, red flower oil, jojoba oil, sunflower oil, almond oil, rapeseed oil, sesame oil, soybean oil. , Peanut oil, cottonseed oil, coconut oil, palm kernel oil, rice bran oil and the like.
- the synthetic oil include hydrocarbon-based synthetic oils, ester-based synthetic oils, ether-based synthetic oils, and the like.
- hydrocarbon-based synthetic oil examples include ⁇ -olefin oligomers such as polybutene, polyisobutylene, 1-octene oligomer, 1-decene oligomer, and ethylene-propylene copolymer, or hydrides thereof, alkylbenzene, and alkylnaphthalene. ..
- ester-based synthetic oil examples include triglycerin fatty ester, diglycerin fatty acid ester, monoglycerin fatty acid ester, monoalcohol fatty acid ester, and polyhydric alcohol fatty acid ester.
- the ether-based synthetic oil examples include polyoxyalkylene glycol and polyphenyl ether. Examples of commercially available synthetic oils include "Linearlen” series manufactured by Idemitsu Kosan Co., Ltd., ANDEROL, "FGC32", “FGC46", “FGC68” and the like.
- the oil may be one selected from the above-mentioned natural oils and synthetic oils, but two or more kinds of natural oils, two or more kinds of synthetic oils, or a mixture of one or more kinds of natural oils and synthetic oils. But it may be.
- mineral oil is preferable, and at least one selected from paraffin-based mineral oil and naphthen-based mineral oil is more preferable from the viewpoint of setting the viscosity of the adhesive component in an appropriate range and improving workability.
- the flash point of the oil used in the present invention is preferably 70 ° C. or higher from the viewpoint of safety. From this point of view, the flash point of the oil is more preferably 100 ° C. or higher, further preferably 130 ° C. or higher, and even more preferably 140 ° C. or higher.
- the upper limit of the flash point of the oil is not particularly limited, but is preferably 320 ° C. or lower.
- the content of the conjugated diene rubber in the adhesive component is preferably 1% by mass or more, more preferably 5% by mass or more, still more preferably 10% by mass or more, from the viewpoint of improving the adhesive force with the rubber. Then, it is preferably 80% by mass or less, more preferably 60% by mass or less, still more preferably 50% by mass or less, still more preferably 40% by mass or less.
- the content of the conjugated diene rubber in the adhesive component is within the above range, it is possible to prevent the viscosity of the adhesive component from becoming extremely high while obtaining sufficient adhesive force.
- the content of the oil in the adhesive component is preferably 20% by mass or more, more preferably 40% by mass or more, still more preferably 50% by mass or more, still more preferably 60% by mass or more, and preferably. Is 99% by mass or less, more preferably 95% by mass or less, still more preferably 90% by mass or less.
- the mass ratio of the conjugated diene rubber to the oil in the adhesive component is preferably 0.1: 9.9 to 8: 2, more preferably 0. It is 5: 9.5 to 6: 4, more preferably 1: 9 to 5: 5, and even more preferably 1: 9 to 4: 6. It is generally known that oil deteriorates the adhesiveness of rubber, but when conjugated diene rubber and oil are mixed and used in the specific mass ratio, the adhesiveness is maintained while maintaining the adhesiveness. The viscosity can be lowered, the handleability of the adhesive component is improved, and the workability of adhesion to the surface-modified fiber is also improved.
- the adhesive layer may be formed by adhering an adhesive component composed of an emulsion in which the conjugated diene rubber is dispersed in water to the surface-modified fiber.
- an emulsion (latex) of an adhesive component may be prepared in advance by a mechanical method or a chemical method, and used at a predetermined concentration by dilution or the like. preferable.
- Examples of the mechanical method include a method using a homogenizer, a homomixer, a disperser mixer, a colloid mill, a pipeline mixer, a high-pressure homogenizer, an ultrasonic emulsifier, and the like, and these can be used alone or in combination.
- Examples of the chemical method include various methods such as an inversion emulsification method, a D-phase emulsification method, an HLB temperature emulsification method, a gel emulsification method and a liquid crystal emulsification method. Is preferable.
- an emulsion having a fine particle size it may be preferable to carry out the work while heating at an appropriate temperature (for example, 30 to 80 ° C.) for the purpose of lowering the viscosity of the modified conjugated diene rubber.
- an appropriate temperature for example, 30 to 80 ° C.
- the content of the conjugated diene rubber in the adhesive component when the adhesive component is an emulsion is preferably 0.5% by mass or more, more preferably 1% by mass or more, and further, from the viewpoint of improving the adhesive force with the rubber. It is preferably 2% by mass or more, and preferably 60% by mass or less, more preferably 40% by mass or less, still more preferably 30% by mass or less, still more preferably 20% by mass or less.
- the content of the conjugated diene rubber in the adhesive component is within the above range, it is possible to prevent the viscosity of the adhesive component from becoming extremely high while obtaining sufficient adhesive force.
- the conjugated diene rubber may be used alone or in combination of two or more. Further, the oil may be used alone or in combination of two or more.
- the adhesive component in the present invention may contain components other than the conjugated diene rubber and oil as long as the adhesive force with the rubber is not impaired.
- the other components include other polymers (for example, unmodified conjugated diene rubber), acids, alkalis, antioxidants, curing agents, dispersants, pigments, dyes, adhesive aids, carbon black and the like.
- the content thereof is preferably 10,000 parts by mass or less, more preferably 1,000 parts by mass or less, based on 100 parts by mass of the conjugated diene rubber. It is more preferably 100 parts by mass or less, still more preferably 50 parts by mass or less, still more preferably 25 parts by mass or less, and even more preferably 10 parts by mass or less.
- the method for producing the reinforcing fiber of the present invention is not particularly limited, and a step of adhering the conjugated diene rubber to the fiber in a state of being mixed with the oil or adhering to the fiber in a state of dispersing the conjugated diene rubber in water. It can be produced by a method including a step of causing.
- the conjugated diene rubber is mixed with the oil into the fiber.
- a method including a step of adhering is preferable.
- the following method can be mentioned.
- the method (I) is not particularly limited as long as it is a method of forming an adhesive layer composed of the adhesive component on the surface of the surface-modified fiber, but from the viewpoint of improving the adhesiveness with rubber, the following step I-1 The method including is preferable.
- Step I-1 A step of adhering the adhesive component to the surface of the surface-modified fiber.
- step I-1 there is no particular limitation on the method of adhering the adhesive component to the surface-modified fiber, for example, a method of adhering the adhesive component as it is, a method of adding a solvent to the adhesive component as necessary, and adhering the adhesive component. And so on.
- a method for adhering the adhesive component it is preferable to use one or more selected from immersion, roll coater, oiling roller, oiling guide, nozzle (spray) coating, brush coating and the like.
- the amount of the adhesive component adhered is preferably 0.01 part by mass or more, preferably 0.1 part by mass, with respect to 100 parts by mass of the fiber used as a raw material, from the viewpoint of improving the adhesiveness between the reinforcing fiber and the rubber. It is more preferably parts or more, more preferably 1 part by mass or more, and from the viewpoint of the balance between manufacturing cost and effect, it is preferably 10 parts by mass or less, and 5 parts by mass or less. Is more preferable, and 3 parts by mass or less is further preferable.
- Step I-2 Heat treatment of the surface-modified fiber to which the adhesive component obtained in Step I-1 is attached
- the heat treatment in Step I-2 is preferably performed at a treatment temperature of 100 to 200 ° C. for 0.1 seconds to The treatment time is preferably 2 minutes. Since the conjugated diene rubber contained in the adhesive component has a reactive multiple bond, the heat treatment in the presence of oxygen is preferably 200 ° C. or lower, more preferably 175 ° C.
- the adhesive strength can be improved without reducing the amount of reactive multiple bonds in the conjugated diene rubber, the deterioration of the fibers is suppressed, and the quality such as coloring is also improved. It will be good.
- the reinforcing fiber may contain components other than the surface-modified fiber and the adhesive component.
- other components include cross-linking agents, acids, bases, inorganic salts, organic salts, pigments, dyes, antioxidants, polymerization initiators, plasticizers and the like.
- the total content of the hydrophilic fiber and the adhesive component in the reinforcing fiber is preferably 80% by mass or more, more preferably 90% by mass or more, still more preferably 90% by mass or more, from the viewpoint of improving the adhesive force with the rubber and the reinforcing strength. Is 95% by mass or more.
- the reinforcing fiber is preferably a multifilament having a single yarn fineness of 0.1 dtex or more and 30 dtex or less.
- the single yarn fineness may be less than 0.1 dtex, but it is preferably 0.1 dtex or more because it is difficult to manufacture industrially. Further, when the single yarn fineness is 30 dtex or less, the surface area of the fiber when it is used as a reinforcing fiber becomes large, so that the adhesiveness with rubber is improved.
- the reinforcing fiber of the present invention has a single yarn fineness of more preferably 0.3 dtex or more, further preferably 0.5 dtex or more, still more preferably 1 dtex or more, and more preferably 20 dtex or less, still more preferable. Is preferably a multifilament of 15 dtex or less, more preferably 10 dtex or less.
- the rubber adhesive force of the reinforcing fiber of the present invention is preferably 30 N / 25.4 mm or more, more preferably 50 N / 25.4 mm or more, further preferably 70 N / 25.4 mm or more, and more preferably 80 N. It is more preferably / 25.4 mm or more, and usually 200 N / 25.4 mm or less.
- the rubber adhesive strength of the reinforcing fibers is at least the above lower limit value, a woven fabric, a knitted fabric, and a molded product having excellent reinforcing strength can be obtained.
- the rubber adhesive force of the reinforcing fiber of the present invention is preferably 30 N / 3 or more, more preferably 40 N / 3 or more, further preferably 50 N / 3 or more, and 60 N / 3. It is more preferably 3 or more, and usually 200 N / 3 or less.
- the rubber adhesive strength of the reinforcing fibers is at least the above lower limit value, a woven fabric, a knitted fabric, and a molded product having excellent reinforcing strength can be obtained.
- the rubber adhesive force of the reinforcing fiber can be measured by the method described in the examples.
- the reinforcing fiber of the present invention can be used in any shape, but it is preferable to use it in the form of a fiber cord, a woven fabric, a knitted fabric or the like containing the reinforcing fiber in at least a part thereof, and at least one of the reinforcing fibers is used. It is more preferable to use it as a woven fabric or a knitted fabric included in a part. For example, as will be described later, it can be used as a knit that adheres to rubber. It can also be used as a reinforcing fiber to be embedded in resin, cement or the like.
- the molded product of the present invention is not particularly limited as long as it uses the reinforcing fibers.
- a molded body having the reinforcing fiber and the rubber layer (hereinafter, also referred to as “rubber molded body”) is particularly preferable.
- the reinforcing fibers used in the rubber molded body are preferably used as a woven fabric or knitted fabric containing the reinforcing fibers at least in a part thereof, and the woven fabric or a knitted fabric containing the reinforcing fibers in at least a part thereof.
- a preferred embodiment of the molded body of the present invention is a molded body having fibers, a surface modification layer, an adhesive layer, and a rubber layer in this order, and the adhesive force between the adhesive layer and the rubber layer is 25. It is preferably 70 N or more, more preferably 80 N or more per 4 mm, and if the adhesive force is 70 N or more, it can be suitably used for various uses described later.
- the rubber molded body can be used as a member of, for example, tires such as automobile tires, belts such as conveyor belts and timing belts, hoses, and rubber products such as anti-vibration rubber. Among them, tires, belts, or hoses. It is more preferable to use as.
- the automobile tire for example, it can be used for various members made of a composite material of a reinforcing fiber and a rubber component such as a belt, a carcass ply, a breaker, and a bead tape.
- the hose can be used for transporting various fluids in various applications, and is suitable for, for example, a fluid transport hose for automobiles, and in particular, a liquid fuel hose for automobiles and a brake for automobiles. It is preferably used for oil hoses and fluid hoses, and more preferably for brake oil hoses for automobiles.
- the rubber molded body is preferably molded by using the reinforcing fiber and a rubber composition containing a compounding agent usually used in the rubber industry as a rubber component.
- the rubber component is not particularly limited, but for example, NR (natural rubber), IR (polyisoprene rubber), BR (polybutadiene rubber), SBR (styrene-butadiene rubber), NBR (nitrile rubber), EPM (ethylene-).
- Propylene copolymer rubber EPDM (ethylene-propylene-non-conjugated diene copolymer rubber), IIR (butyl rubber), halogenated butyl rubber, CR (chloroprene rubber) and the like can be mentioned.
- NR IR
- BR IR
- SBR IR
- EPDM CR
- CR CR
- EPDM CR
- One of these rubber components may be used alone, or two or more of these rubber components may be used in combination.
- natural rubber alone or in combination with natural rubber and SBR.
- the mass ratio of natural rubber to SBR is in the range of 50/50 to 90/10 from the viewpoint of suppressing deterioration of physical properties due to vulcanization of rubber. It is preferable to do so.
- the natural rubber is generally used in the tire industry such as TSR (Technically Specified Rubber) such as SMR (Malaysia TSR), SIR (Indonesia TSR), STR (Thai TSR) and RSS (Ribbed Smoked Sheet).
- TSR Technicalnically Specified Rubber
- SMR Magnetic Reliable TSR
- SIR Indonesia TSR
- STR Thai TSR
- RSS Rabbed Smoked Sheet
- modified natural rubber such as natural rubber used, high-purity natural rubber, epoxidized natural rubber, hydroxylated natural rubber, hydrogenated natural rubber, and grafted natural rubber.
- the SBR general ones used for tire applications can be used, but specifically, those having a styrene content of 0.1 to 70% by mass are preferable, and those having a styrene content of 5 to 50% by mass are more preferable. It is more preferably 15 to 35% by mass. Further, the vinyl content is preferably 0.1 to 60% by mass, more preferably 0.1 to 55% by mass.
- the weight average molecular weight (Mw) of the SBR is preferably 100,000 to 2,500,000, more preferably 150,000 to 2,000,000, and 200,000 to 1,500,000. Is more preferable. Within the above range, both workability and mechanical strength can be achieved.
- the weight average molecular weight of SBR is a polystyrene-equivalent weight average molecular weight obtained from the measurement of gel permeation chromatography (GPC).
- GPC gel permeation chromatography
- a modified SBR in which a functional group is introduced into the SBR may be used as long as the effects of the present invention are not impaired.
- the functional group include an amino group, an alkoxysilyl group, a hydroxy group, an epoxy group, a carboxy group and the like.
- the rubber composition may further contain a filler in addition to the rubber component.
- a filler include inorganic fillers such as carbon black, silica, clay, mica, calcium carbonate, magnesium hydroxide, aluminum hydroxide, barium sulfate, titanium oxide, glass fiber, fibrous filler, and glass balloon; resin particles, Examples thereof include wood powder and organic fillers such as cork powder.
- carbon black and silica are preferable from the viewpoint of improving physical properties such as improvement of mechanical strength.
- the carbon black examples include furnace black, channel black, thermal black, acetylene black, and Ketjen black. Among these carbon blacks, furnace black is preferable from the viewpoint of improving the cross-linking speed and mechanical strength.
- the average particle size of the carbon black is preferably 5 to 100 nm, more preferably 5 to 80 nm, and even more preferably 5 to 70 nm.
- the average particle size of the carbon black can be obtained by measuring the diameter of the particles with a transmission electron microscope and calculating the average value.
- silica examples include wet silica (hydrous silicic acid), dry silica (silicic anhydride), calcium silicate, aluminum silicate and the like. Among these silicas, wet silica is preferable.
- the average particle size of the silica is preferably 0.5 to 200 nm, more preferably 5 to 150 nm, and even more preferably 10 to 100 nm. The average particle size of the silica can be obtained by measuring the diameter of the particles with a transmission electron microscope and calculating the average value thereof.
- the content of the filler with respect to 100 parts by mass of the rubber component is preferably 20 to 150 parts by mass, more preferably 25 to 130 parts by mass, and 25 to 110 parts by mass. Is more preferable.
- the content thereof is preferably 20 to 120 parts by mass and 20 to 90 parts by mass with respect to 100 parts by mass of the rubber component. Is more preferable, and 20 to 80 parts by mass is further preferable.
- One of these fillers may be used alone, or two or more thereof may be used in combination.
- the rubber composition may further contain a cross-linking agent in order to cross-link the rubber component.
- a cross-linking agent examples include sulfur, sulfur compounds, oxygen, organic peroxides, phenol resins, amino resins, quinone and quinone dioxime derivatives, halogen compounds, aldehyde compounds, alcohol compounds, epoxy compounds, metal halides and organic substances. Examples include metal halides and silane compounds.
- One of these cross-linking agents may be used alone, or two or more thereof may be used in combination.
- the cross-linking agent is usually 0.1 to 10 parts by mass, preferably 0.5 to 10 parts by mass, and more preferably 0.8 to 5 parts by mass with respect to 100 parts by mass of the rubber component. It is contained in parts by mass.
- the rubber composition may further contain a vulcanization accelerator when, for example, sulfur, a sulfur compound, or the like is contained as a cross-linking agent for cross-linking (vulcanizing) the rubber component.
- a vulcanization accelerator examples include guanidine compounds, sulfenamide compounds, thiazole compounds, thiuram compounds, thiourea compounds, dithiocarbamic acid compounds, aldehyde-amine compounds, aldehyde-ammonia compounds, and imidazoline. Examples thereof include system compounds and xanthate compounds.
- One of these vulcanization accelerators may be used alone, or two or more thereof may be used in combination.
- the vulcanization accelerator is usually contained in an amount of 0.1 to 15 parts by mass, preferably 0.1 to 10 parts by mass, based on 100 parts by mass of the rubber component.
- the rubber composition may further contain a vulcanization aid when, for example, sulfur, a sulfur compound, or the like is contained as a cross-linking agent for cross-linking (vulcanizing) the rubber component.
- a vulcanization aid include fatty acids such as stearic acid, metal oxides such as zinc oxide, and fatty acid metal salts such as zinc stearate.
- fatty acids such as stearic acid
- metal oxides such as zinc oxide
- fatty acid metal salts such as zinc stearate.
- One of these vulcanization aids may be used alone, or two or more thereof may be used in combination.
- the vulcanization aid is usually contained in an amount of 0.1 to 15 parts by mass, preferably 1 to 10 parts by mass with respect to 100 parts by mass of the rubber component.
- the rubber composition contains silica as a filler, it is preferable to further contain a silane coupling agent.
- the silane coupling agent include sulfide compounds, mercapto compounds, vinyl compounds, amino compounds, glycidoxy compounds, nitro compounds, chloro compounds and the like. These silane coupling agents may be used alone or in combination of two or more.
- the silane coupling agent is preferably contained in an amount of 0.1 to 30 parts by mass, more preferably 0.5 to 20 parts by mass, and further preferably 1 to 15 parts by mass with respect to 100 parts by mass of silica. When the content of the silane coupling agent is within the above range, the dispersibility, the coupling effect, and the reinforcing property are improved.
- the rubber composition is used for the purpose of improving processability, fluidity, etc., as long as it does not impair the effects of the present invention, and if necessary, silicon oil, aroma oil, TDAE (Treated Distilled Aromatic Extracts), MES (Mild Extracted). Solvates), RAE (Residual Aromatic Extracts), paraffin oil, naphthenic oil and other process oils, aliphatic hydrocarbon resins, alicyclic hydrocarbon resins, C9 resins, rosin resins, kumaron inden resins, phenolic resins
- a resin component such as the above may be contained as a softening agent.
- the content thereof is preferably less than 50 parts by mass with respect to 100 parts by mass of the rubber component.
- the rubber composition contains an antistatic agent, a wax, an antioxidant, a lubricant, and a light stabilizer, if necessary, for the purpose of improving weather resistance, heat resistance, oxidation resistance, etc., as long as the effects of the present invention are not impaired.
- Agents, anti-scorch agents, processing aids, colorants such as pigments and pigments, flame retardants, antistatic agents, matting agents, anti-blocking agents, UV absorbers, mold release agents, foaming agents, antibacterial agents, antifungal agents , Additives such as fragrances may be contained.
- the antioxidant include hindered phenol compounds, phosphorus compounds, lactone compounds, hydroxyl compounds and the like.
- the antiaging agent include amine-ketone compounds, imidazole compounds, amine compounds, phenol compounds, sulfur compounds and phosphorus compounds. These additives may be used alone or in combination of two or more.
- the reinforcing fiber is embedded in the unvulcanized rubber composition, and the rubber composition is vulcanized to obtain the surface-modified fiber and the rubber component.
- a molded product bonded via an adhesive component can be obtained.
- the brake oil hose for an automobile has, for example, an inner rubber layer and an outer rubber layer, and has one or two reinforcing layers made of the reinforcing fibers between the inner rubber layer and the outer rubber layer. Things can be mentioned. Examples of the rubber component constituting the inner rubber layer and the outer rubber layer include those described above. Among them, EPDM, SBR and the like can be mentioned as the rubber component constituting the inner rubber layer, and EPDM, CR and the like can be mentioned as the rubber component constituting the outer rubber layer.
- the reinforcing layer can be formed by braiding reinforcing fibers.
- a reinforcing layer (first reinforcing layer) in which the reinforcing fibers are braided is formed on the outer surface of the inner rubber layer.
- first reinforcing layer in which the reinforcing fibers are braided
- second reinforcing layer an intermediate rubber layer is further formed on the outer surface of the first reinforcing layer, and the reinforcing fibers are braided on the outer surface of the intermediate rubber layer (second reinforcing layer).
- a reinforcing layer) may be formed. Then, it can be produced by forming an outer rubber layer on the outer surface of the reinforcing layer (first reinforcing layer or second reinforcing layer) and vulcanizing it.
- the vulcanization temperature can be appropriately selected depending on the type of constituent material of each layer of the brake oil hose, but from the viewpoint of suppressing deterioration of the rubber and the reinforcing fiber and improving the adhesive force between the rubber and the reinforcing fiber, the vulcanization temperature is 200 ° C. or less. It is preferable to have.
- Production Example 1 Production of Modified Conjugated Diene Rubber (A-1) A sufficiently dried 5 L autoclave is replaced with nitrogen, and 756 g of hexane and 122.3 g of n-butyllithium (17 mass% hexane solution) are charged and heated to 50 ° C. After raising the temperature, 1344 g of butadiene was sequentially added under stirring conditions while controlling the polymerization temperature to be 50 ° C., and polymerization was carried out for 1 hour. Then, methanol was added to stop the polymerization reaction to obtain a polymer solution. Water was added to the obtained polymer solution, the mixture was stirred, and the polymer solution was washed with water.
- A-1 A sufficiently dried 5 L autoclave is replaced with nitrogen, and 756 g of hexane and 122.3 g of n-butyllithium (17 mass% hexane solution) are charged and heated to 50 ° C. After raising the temperature, 1344 g of butadiene was sequentially
- Butyl) -p-phenylenediamine (trade name "Nocrack 6C", manufactured by Ouchi Shinko Kagaku Kogyo Co., Ltd.) was added and reacted at 170 ° C. for 24 hours to modify maleic anhydride-modified liquid polybutadiene (A-1). ) was obtained.
- Production Example 2 Production of Modified Conjugated Diene Rubber (A-2) A sufficiently dried 5 L autoclave was substituted with nitrogen, and 1260 g of hexane and 36.3 g of n-butyllithium (17 mass% hexane solution) were charged and brought to 50 ° C. After raising the temperature, 1260 g of butadiene was sequentially added under stirring conditions while controlling the polymerization temperature to be 50 ° C., and polymerization was carried out for 1 hour. Then, methanol was added to stop the polymerization reaction to obtain a polymer solution. Water was added to the obtained polymer solution, the mixture was stirred, and the polymer solution was washed with water.
- A-2 Modified Conjugated Diene Rubber
- Butyl) -p-phenylenediamine (trade name "Nocrack 6C", manufactured by Ouchi Shinko Kagaku Kogyo Co., Ltd.) was added and reacted at 170 ° C. for 24 hours to modify maleic anhydride-modified liquid polybutadiene (A-2). ) was obtained.
- Production Example 3 Production of Modified Conjugated Diene Rubber (A-3) A sufficiently dried 5 L autoclave is replaced with nitrogen, and 1140 g of hexane and 20.9 g of n-butyllithium (17 mass% hexane solution) are charged and brought to 50 ° C. After raising the temperature, 1390 g of butadiene was sequentially added under stirring conditions while controlling the polymerization temperature to be 50 ° C., and polymerization was carried out for 1 hour. Then, methanol was added to stop the polymerization reaction to obtain a polymer solution. Water was added to the obtained polymer solution, the mixture was stirred, and the polymer solution was washed with water.
- A-3 Modified Conjugated Diene Rubber
- Butyl) -p-phenylenediamine (trade name "Nocrack 6C", manufactured by Ouchi Shinko Kagaku Kogyo Co., Ltd.) was added and reacted at 170 ° C. for 24 hours to modify maleic anhydride-modified liquid polybutadiene (A-3). ) was obtained.
- Production Example 4 Production of Modified Conjugated Diene Rubber (A-4) To 525 g of the obtained maleic anhydride-modified liquid polybutadiene (A-3), 9.0 g of methanol is added and reacted at 80 ° C. for 6 hours. Obtained monomethyl maleate-modified liquid polybutadiene (A-4).
- Production Example 5 Production of Modified Conjugated Diene Rubber (A-5) To 525 g of the obtained maleic anhydride-modified liquid polybutadiene (A-2), 8.5 g of methanol is added and reacted at 80 ° C. for 6 hours. Obtained monomethyl maleate-modified liquid polybutadiene (A-5).
- the methods for measuring and calculating the physical properties of the modified conjugated diene rubber are as follows. The results are shown in Table 1. ⁇ Measurement method of weight average molecular weight, number average molecular weight and molecular weight distribution> The weight average molecular weight (Mw), number average molecular weight (Mn), and molecular weight distribution (Mw / Mn) of the modified conjugated diene rubber were determined by GPC (gel permeation chromatography) as standard polystyrene-equivalent values. The measuring device and conditions are as follows.
- GPC device GPC device "GPC8020” manufactured by Tosoh Corporation -Separation column: "TSKgelG4000HXL” manufactured by Tosoh Corporation -Detector: "RI-8020” manufactured by Tosoh Corporation -Eluent: tetrahydrofuran-Eluent flow rate: 1.0 ml / min-Sample concentration: 5 mg / 10 ml -Column temperature: 40 ° C
- melt viscosity The melt viscosity of the modified conjugated diene rubber at 38 ° C. was measured with a Brookfield viscometer (manufactured by BROOKFIELD ENGINEERING LABS. INC.).
- DSC differential scanning calorimetry
- the vinyl content was calculated from the area ratio of the peak of the double bond derived from the vinylized diene compound and the peak of the double bond derived from the non-vinylized diene compound in the obtained spectrum.
- the average number of hydrogen-bonding functional groups per molecule of the modified conjugated diene-based rubber was calculated from the equivalent of hydrogen-bonding functional groups (g / eq) of the modified conjugated diene-based rubber and the number average molecular weight Mn in terms of styrene from the following formula. ..
- Average number of hydrogen-bonding functional groups per molecule [(number average molecular weight (Mn)) / (molecular weight of styrene unit) ⁇ (average of conjugated diene and other monomer units other than conjugated diene contained as needed) Molecular weight)] / (equivalent to hydrogen-bonding functional group)
- the method for calculating the equivalent of the hydrogen-bonding functional group can be appropriately selected depending on the type of the hydrogen-bonding functional group.
- the average number of hydrogen-bonding functional groups per molecule of maleic anhydride-modified conjugated diene-based rubber and monomethyl maleate-modified conjugated diene-based rubber is calculated for the maleic anhydride-modified conjugated diene-based rubber and monomethyl maleate-modified conjugated diene-based rubber.
- the acid value of the rubber was determined, and the equivalent (g / eq) of the hydrogen-bonding functional group was calculated from the acid value.
- the sample after the denaturation reaction was washed 4 times with methanol (5 mL per 1 g of the sample) to remove impurities such as antioxidants, and then the sample was dried under reduced pressure at 80 ° C. for 12 hours.
- the mass of the hydrogen-bonding functional group contained in 1 g of the maleic anhydride-modified conjugated diene-based rubber and the monomethyl-modified conjugated diene-based rubber maleate was calculated by the following formula, and further, the maleic anhydride-modified conjugated diene-based rubber was calculated.
- the mass other than the functional group (polymer main chain mass) contained in 1 g of monomethyl-modified conjugated diene-based rubber maleate was calculated.
- the equivalent (g / eq) of the hydrogen-bonding functional group was calculated from the following formula.
- ⁇ Diluted solution of conjugated diene rubber> A solution was prepared by diluting each of the modified conjugated diene rubbers shown in Table 1 with fatty acid ester or mineral oil to 25% by mass.
- the fatty acid ester is a polyol fatty acid ester (trimethylolpropane tricaprylate), which has a vapor pressure of 1.7 ⁇ 10-7 Pa at 20 ° C., a flash point of 258 ° C., and is not volatile. I used the one.
- As the mineral oil a mineral oil having a vapor pressure of 7.0 ⁇ 10 -3 Pa at 20 ° C., a flash point of 158 ° C., and no volatility was used.
- PET fibers (total fineness 1100 dtex, single yarn fineness 6.10 dtex), which are polyester fibers, were immersed in the surface modifier (B-1) and then squeezed with a roller. Then, the obtained fiber was dried at 140 ° C. for 60 seconds and further heat-treated at 240 ° C. for 60 seconds to prepare a surface-modified fiber. Next, a diluted solution of the modified conjugated diene rubber was prepared so as to have the composition and the amount of adhesion shown in Table 3, and then the diluted solution was applied to the surface-modified fiber using an oiling guide and wound up. Then, after acclimatizing at room temperature (20 ° C.) for 3 days, the reinforcing fibers were twisted at a twist number of 80 T / m to prepare reinforcing fibers.
- Liquid B SBR latex (effective content 40% by mass): 207 parts by mass Vinyl pyridine-modified SBR latex (effective content 40% by mass): 233 parts by mass After mixing the above liquid B and the aged liquid A, the temperature is 25 ° C. The RFL solution was produced by aging for 16 hours.
- EPDM rubber 100 parts by mass Filler (carbon black): 60 parts by mass Softener (paraffin-based process oil): 20 parts by mass Crossing agent (sulfur powder): 1.5 parts by mass Vulcanization aid (2 types of zinc oxide, stearer) Acid): 6 parts by mass Vulcanization accelerator (thiazole type, thiuram type): 1.5 parts by mass
- NR rubber 70 parts by mass SBR rubber: 41.25 parts by mass Filler (carbon black): 45 parts by mass Vulcanizing agent (sulfur powder): 3.5 parts by mass Vulcanization aid (zinc oxide, stearic acid): 6 parts by mass Part Vulcanization accelerator (thiazole type): 1 part by mass
- Example 17 Processing method of twisted cord> Two PET fibers (total fineness 1100 dtex, single yarn fineness 6.10 dtex), which are polyester fibers, were multiplied by 470 times / m of upper twist and 470 times / m of lower twist to prepare a twisted fiber cord. ..
- the twisted cord was immersed in the surface modifier (B-1) and then squeezed with a roller.
- the obtained fiber cord was dried at 140 ° C. for 60 seconds and further heat-treated at 240 ° C. for 60 seconds to prepare the fiber cord. Then, it was immersed in the emulsion composition containing the modified conjugated diene rubber as the main component shown in Table 5, squeezed with a roller, dried at 140 ° C. for 60 seconds, and then wound up.
- the content of the modified conjugated diene rubber in the emulsion composition was 10% by mass.
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Abstract
Description
しかしながら、RFLに含まれるホルムアルデヒドは発がん性の疑いがあり、また、レゾルシノールは環境ホルモンの疑いがあることから、これらの原料を使用しない代替材料の開発が望まれている。
[1]繊維と、前記繊維の表面の少なくとも一部を覆う表面改質層とを有し、前記表面改質層の表面における固体表面ゼータ電位が-20.0~30.0mVである表面改質繊維。
[2]前記繊維が、ポリエステル系繊維、ポリアミド系繊維、ポリビニルアルコール系繊維、及び再生セルロース系繊維から選ばれる1種以上の繊維である、前記[1]に記載の表面改質繊維。
[3]前記表面改質層が含窒素官能基を有する化合物を含む、前記[1]又は[2]に記載の表面改質繊維。
[4]前記表面改質層が、オキサゾリン基、オキサゾリジノン基、カルボジイミド基、カルバミド基、アミノ基、及びアジリジン基から選ばれる1種以上に由来する官能基を有する化合物を含む、前記[1]~[3]のいずれかに記載の表面改質繊維。
[5]前記表面改質層の量が、原料として用いた繊維100質量部に対して0.01~5.0質量部である、前記[1]~[4]のいずれかに記載の表面改質繊維。
[6]前記[1]~[5]のいずれかに記載の表面改質繊維と、前記表面改質繊維の表面の少なくとも一部を覆う共役ジエン系ゴムを含有する接着層とを有する補強繊維。
[7]前記共役ジエン系ゴムの数平均分子量(Mn)が2,000超120,000以下である、前記[6]に記載の補強繊維。
[8]前記共役ジエン系ゴムが、分子内にブタジエン、イソプレン、及びファルネセンから選ばれる1種以上に由来する単量体単位を有する、前記[6]又は[7]に記載の補強繊維。
[9]前記共役ジエン系ゴムが、共役ジエン系ゴムの一部に水素結合性官能基を有する変性共役ジエン系ゴムであり、該水素結合性官能基が、ヒドロキシ基、エポキシ基、アルデヒド基、アルデヒド基のアセタール化体、カルボキシ基、カルボキシ基の塩、カルボキシ基のエステル化体、カルボキシ基の酸無水物、シラノール基、シラノール基のエステル化体、アミノ基、イミダゾール基、及びメルカプト基から選ばれる1種以上である、前記[6]~[8]のいずれかに記載の補強繊維。
[10]前記接着層が更にオイルを含有し、該オイルの20℃における蒸気圧が10Pa以下である、前記[6]~[9]のいずれかに記載の補強繊維。
[11]前記[6]~[10]のいずれかに記載の補強繊維を用いた、成形体。
[12]更にゴム層を有する、前記[11]に記載の成形体。
[13]前記成形体がタイヤ、ベルト又はホースである、前記[11]又は[12]に記載の成形体。
[14]繊維、表面改質層、接着層、及びゴム層をこの順に有する成形体であって、前記接着層と前記ゴム層との接着力が幅25.4mmあたり70N以上である、成形体。
本発明の表面改質繊維は、繊維と、前記繊維の表面の少なくとも一部を覆う表面改質層とを有し、前記表面改質層の表面における固体表面ゼータ電位が-20.0~30.0mVであることを特徴とするものである。
本発明によれば、固体表面のゼータ電位を前記範囲に調整しているため、接着成分に含まれる変性共役ジエン系ゴムと繊維との間に強い親和性が発現する。そして、繊維と接着成分とゴムとがそれぞれ強固に接着し、結果として繊維とゴムとの接着性が向上する。
なお、本発明において「繊維の表面の少なくとも一部を覆う表面改質層」とは、繊維の表面の少なくとも一部に、例えば、膜や層として表面改質層が存在する態様であってもよく、繊維の原料に表面改質層に相当する成分が含まれており、繊維そのものの表面の一部に表面改質層の成分が存在する態様であってもよい。
本発明における表面改質層は、前記固体表面ゼータ電位を前記範囲内に調整することができる化合物で構成されていれば特に制限はないが、例えば、含窒素官能基を有する化合物を含む層であることが好ましく、具体的には、オキサゾリン基、オキサゾリジノン基、カルボジイミド基、カルバミド基、アミノ基、及びアジリジン基から選ばれる1種以上に由来する官能基を有する化合物を含む層であることが好ましい。
本発明の表面改質繊維に用いる繊維に特に制限はないが、従来の技術ではゴムに対して強固に接着することができなかった疎水性樹脂からなる疎水性繊維に好適に用いることができる。疎水性繊維は一般的に繊維表面に極性の官能基を有しないため、後述する接着成分との親和性に乏しく、ゴムと強固に接着することができなかった。しかしながら、本発明のように繊維表面に表面改質層を設けることにより、疎水性繊維であってもゴムと強固に接着することが可能になる。なお、本発明において「繊維」とは、単繊維や長繊維だけでなく、不織布、織物、編物、フェルト及びスポンジ等の形態を含むものとする。
このような熱可塑性樹脂の具体例は、ポリビニルアルコール系樹脂、ポリアミド系樹脂〔ポリアミド6、ポリアミド66、ポリアミド11、ポリアミド12、ポリアミド610、ポリアミド612、ポリアミド9C(ノナンジアミンとシクロヘキサンジカルボン酸からなるポリアミド)等の脂肪族ポリアミド;ポリアミド9T(ノナンジアミンとテレフタル酸からなるポリアミド)等の芳香族ジカルボン酸と脂肪族ジアミンとから合成される半芳香族ポリアミド;ポリパラフェニレンテレフタルアミド等の芳香族ジカルボン酸と芳香族ジアミンとから合成される全芳香族ポリアミド等〕、ポリアクリルアミド系樹脂等が挙げられる。
これらの中でも、ポリビニルアルコール系樹脂、及びポリアミド系樹脂が好ましい。親水性の合成繊維は、1種を単独で用いてもよく、2種以上を併用してもよい。また、これらの親水性の合成繊維は、親水性をより高めるべく、後述する親水化処理を更に施してもよい。
親水性の再生繊維としては、レーヨン、リヨセル、キュプラ、及びポリノジック等の再生セルロース繊維が挙げられる。
これらの天然繊維及び再生繊維は、それぞれ1種を単独で用いてもよく、2種以上を併用してもよい。また、これらの親水性の天然繊維及び再生繊維は、親水性をより高めるべく、後述する親水化処理を更に施してもよい。
なお、本発明において、繊維は1種を単独で用いてもよく、2種以上を併用してもよい。
本発明の表面改質繊維の製造方法に特に制限はないが、前述の表面改質層を構成する化合物の水又は有機溶媒による溶液を調製し、この溶液を前記繊維に付着させ、その後、熱処理等により乾燥させる方法により製造することができる。
前記表面改質剤の溶液を繊維に付着させる方法に特に制限はなく、例えば、浸漬、ロールコーター、オイリングローラー、オイリングガイド、ノズル(スプレー)塗布、及び刷毛塗り等から選ばれる1種以上により行うことが好ましい。
表面改質層が前記他の成分を含有する場合、表面改質層中の他の成分の含有量は、ゴムとの接着力を向上させる観点から、好ましくは20質量%以下、より好ましくは10質量%以下、更に好ましくは5質量%以下である。
本発明の補強繊維は、前記本発明の表面改質繊維と、前記表面改質繊維の表面の少なくとも一部を覆う共役ジエン系ゴムを含有する接着層とを有するものである。本発明においては、前記表面改質繊維と接着層との親和性が高いため、繊維と接着層、該接着層とゴムとを強固に接着することが可能になる。
本発明の補強繊維は、表面改質繊維の表面の全体が接着層で覆われていてもよいが、少なくとも一部が接着層で覆われていればよく、例えば、膜や層として接着成分が存在する態様であってもよい。
本発明の補強繊維における接着層は共役ジエン系ゴムを含有するものであれば特に制限はなく、例えば、共役ジエン系ゴムをオイルに溶解させた溶液からなる接着成分、又は共役ジエン系ゴムを水に分散させたエマルションからなる接着成分を表面改質繊維に付着させることにより形成することができる。以下、接着層の態様について具体的に説明する。
本発明において用いる共役ジエン系ゴムは、分子内に少なくとも共役ジエンに由来する単量体単位(以下、「共役ジエン単位」とも称する)を含むものであり、例えば、共役ジエン系ゴム中の全単量体単位中に共役ジエンに由来する単量体単位を50モル%以上含有するものが好ましい。
前記共役ジエン単量体としては、例えば、ブタジエン、2-メチル-1,3-ブタジエン(以下、「イソプレン」とも称する)、2,3-ジメチルブタジエン、2-フェニルブタジエン、1,3-ペンタジエン、2-メチルー1,3-ペンタジエン、1,3-ヘキサジエン、1,3-オクタジエン、1,3-シクロヘキサジエン、2-メチル-1,3-オクタジエン、1,3,7-オクタトリエン、β-ファルネセン(以下、「ファルネセン」とも称する)、ミルセン、及びクロロプレン等が挙げられる。これら共役ジエンは、1種を単独で用いてもよく、2種以上を併用してもよい。共役ジエン系ゴムは、加硫時の反応性の観点から、ブタジエン、イソプレン、及びファルネセンから選ばれる1種以上に由来する単量体単位を有することがより好ましい。
前記エチレン性不飽和単量体としては、例えば、エチレン、1-ブテン、及びイソブチレン等のオレフィン等が挙げられる。
前記芳香族ビニル化合物としては、例えば、スチレン、α-メチルスチレン、2-メチルスチレン、3-メチルスチレン、4-メチルスチレン、4-プロピルスチレン、4-t-ブチルスチレン、4-シクロヘキシルスチレン、4-ドデシルスチレン、2,4-ジメチルスチレン、2,4-ジイソプロピルスチレン、2,4,6-トリメチルスチレン、2-エチル-4-ベンジルスチレン、4-(フェニルブチル)スチレン、1-ビニルナフタレン、2-ビニルナフタレン、ビニルアントラセン、N,N-ジエチル-4-アミノエチルスチレン、ビニルピリジン、4-メトキシスチレン、モノクロロスチレン、ジクロロスチレン、及びジビニルベンゼン等が挙げられる。これらは、1種を単独で用いてもよく、2種以上を併用してもよい。
共役ジエン系ゴムが共役ジエン単量体以外の他の単量体に由来する単量体単位を含有する場合、その含有量は30モル%以下であることが好ましく、10モル%以下であることがより好ましく、5モル%以下であることが更に好ましい。
共役ジエン系ゴムとして前記変性共役ジエン系ゴムを用いた場合、変性共役ジエン系ゴムが被着体であるゴム及び表面改質繊維のそれぞれと相互作用することによって、両者を接着させることができる。変性共役ジエン系ゴムと被着ゴムとを加硫し、共有結合を形成させた場合は、強い凝集力が生じるため、より一層接着性が向上する。
また、変性共役ジエン系ゴムに含まれる水素結合性官能基が表面改質繊維の表面改質層と水素結合を形成することにより接着性が向上すると考えられる。
これらの中でも、接着性を向上させる観点、共役ジエン系ゴムの製造容易性の観点から、ヒドロキシ基、カルボキシ基、カルボニル基、カルボキシ基の塩、カルボキシ基のエステル化体、カルボキシ基の酸無水物から選ばれる1種以上が好ましく、カルボキシ基、カルボキシ基のエステル化体、カルボキシ基の酸無水物から選ばれる1種以上がより好ましく、無水マレイン酸のエステル化体及び無水マレイン酸由来の官能基が更に好ましい。
1分子当たりの平均水素結合性官能基数=[(数平均分子量(Mn))/(スチレン単位の分子量)×(共役ジエン及び必要に応じて含まれる共役ジエン以外の他の単量体単位の平均分子量)]/(水素結合性官能基の当量)
なお、水素結合性官能基の当量の算出方法は、水素結合性官能基の種類により適宜選択することができる。
製造方法(1)は、共役ジエン単量体の重合化物、すなわち未変性の共役ジエン系ゴム(以下、「未変性共役ジエン系ゴム」とも称する)に変性化合物を付加する方法である。
未変性共役ジエン系ゴムは、共役ジエン及び必要に応じて共役ジエン以外の他の単量体を、例えば、乳化重合法、又は溶液重合法等により重合して得ることができる。
溶媒としては、例えば、n-ブタン、n-ペンタン、イソペンタン、n-ヘキサン、n-ヘプタン、イソオクタン等の脂肪族炭化水素;シクロペンタン、シクロヘキサン、メチルシクロペンタン等の脂環式炭化水素;ベンゼン、トルエン、キシレン等の芳香族炭化水素等が挙げられる。
アニオン重合可能な活性金属化合物としては、有機アルカリ金属化合物が好ましい。有機アルカリ金属化合物としては、例えば、メチルリチウム、エチルリチウム、n-ブチルリチウム、sec-ブチルリチウム、t-ブチルリチウム、ヘキシルリチウム、フェニルリチウム、スチルベンリチウム等の有機モノリチウム化合物;ジリチオメタン、ジリチオナフタレン、1,4-ジリチオブタン、1,4-ジリチオ-2-エチルシクロヘキサン、1,3,5-トリリチオベンゼン等の多官能性有機リチウム化合物;ナトリウムナフタレン、カリウムナフタレン等が挙げられる。これら有機アルカリ金属化合物の中でも有機リチウム化合物が好ましく、有機モノリチウム化合物がより好ましい。
前記有機アルカリ金属化合物は、ジブチルアミン、ジヘキシルアミン、ジベンジルアミン等の第2級アミンと反応させて、有機アルカリ金属アミドとして使用することもできる。
溶液重合の温度は、通常-80~150℃の範囲、好ましくは0~100℃の範囲、より好ましくは10~90℃の範囲である。重合様式は回分式あるいは連続式のいずれでもよい。
重合反応は、重合停止剤の添加により停止できる。重合停止剤としては、例えば、メタノール、イソプロパノール等のアルコールが挙げられる。得られた重合反応液をメタノール等の貧溶媒に注いで、重合化物を析出させるか、重合反応液を水で洗浄し、分離後、乾燥することにより未変性共役ジエン系ゴムを単離できる。
未変性共役ジエン系ゴムの製造方法としては、前記方法の中でも、溶液重合法が好ましい。
乳化剤としては、例えば炭素数10以上の長鎖脂肪酸塩及びロジン酸塩等が挙げられる。長鎖脂肪酸塩としては、例えば、カプリン酸、ラウリン酸、ミリスチン酸、パルミチン酸、オレイン酸、ステアリン酸等の脂肪酸のカリウム塩又はナトリウム塩等が挙げられる。
分散溶媒としては通常、水が使用され、重合時の安定性が阻害されない範囲で、メタノール、エタノール等の水溶性有機溶媒を含んでいてもよい。
ラジカル重合開始剤としては、例えば過硫酸アンモニウムや過硫酸カリウムのような過硫酸塩、有機過酸化物、過酸化水素等が挙げられる。
得られる未変性共役ジエン系ゴムの分子量を調整するため、連鎖移動剤を使用してもよい。連鎖移動剤としては、例えば、t-ドデシルメルカプタン、n-ドデシルメルカプタン等のメルカプタン類;四塩化炭素、チオグリコール酸、ジテルペン、ターピノーレン、γ-テルピネン、α-メチルスチレンダイマー等が挙げられる。
製造方法(1)で用いる変性化合物に特に制限はないが、補強繊維の接着性を向上させる観点から、水素結合性官能基を有しているものが好ましい。水素結合性官能基としては、前述と同様のものが挙げられる。それらの中でも、水素結合力の強さの観点から、アミノ基、イミダゾール基、ウレア基、ヒドロキシ基、エポキシ基、メルカプト基、シラノール基、アルデヒド基、カルボキシ基及びその誘導体が好ましい。カルボキシ基の誘導体としては、その塩、そのエステル化体、そのアミド化体、又はその酸無水物が好ましい。これらの水素結合性官能基を有する変性化合物は、1種を単独で用いてもよく、2種以上を併用してもよい。
反応温度は通常0~200℃の範囲が好ましく、50~200℃の範囲がより好ましい。
また、未変性共役ジエン系ゴムに前記変性化合物をグラフト化し水素結合性官能基を導入した後、更に該官能基と反応し得る変性化合物を添加して別の水素結合性官能基を重合体中に導入してもよい。具体的には、例えば、リビングアニオン重合して得られる未変性共役ジエン系ゴムに対し、無水マレイン酸をグラフト化した後、2-ヒドロキシエチルメタクリレートやメタノール等の水酸基を有する化合物、水等の化合物を反応させる方法が挙げられる。
前記方法で使用される有機溶媒としては、一般的には炭化水素系溶媒、ハロゲン化炭化水素系溶媒が挙げられる。これら有機溶媒の中でも、n-ブタン、n-ヘキサン、n-ヘプタン、シクロヘキサン、ベンゼン、トルエン、キシレン等の炭化水素系溶媒が好ましい。
老化防止剤の添加量は、未変性共役ジエン系ゴム100質量部に対して、0.01~10質量部であることが好ましく、0.05~5質量部であることがより好ましい。老化防止剤の添加量が前記範囲内であると、副反応を抑制することができ、収率よく変性共役ジエン系ゴムを得ることができる。
共役ジエン系ゴムの重量平均分子量(Mw)は特に制限はないが、接着性を向上させる観点から、2,000超であることが好ましく、5,000以上であることがより好ましく、10,000以上であることが更に好ましく、15,000以上であることがより更に好ましく、20,000以上であることがより更に好ましく、25,000以上であることが特に好ましく、取り扱い性の観点から、120,000以下であることが好ましく、100,000以下であることがより好ましく、75,000以下であることが更に好ましく、55,000以下であることがより更に好ましい。
共役ジエン系ゴムのMw及びMnは、ゲルパーミエーションクロマトグラフィー(GPC)の測定から求めたポリスチレン換算の重量平均分子量及び数平均分子量であり、具体的には実施例に記載の方法により測定することができる。
本明細書において「液状」とは、共役ジエン系ゴムの38℃で測定した溶融粘度が4,000Pa・s以下であることを示す。該溶融粘度は接着性を向上させる観点から、0.1Pa・s以上であることが好ましく、1Pa・s以上であることがより好ましく、10Pa・s以上であることが更に好ましく、30Pa・s以上であることがより更に好ましく、50Pa・s以上であることがより更に好ましく、取り扱い性の観点から、2,500Pa・s以下であることが好ましく、2,100Pa・s以下であることがより好ましい。前記溶融粘度が前記範囲内であると、共役ジエン系ゴムの接着性を向上させつつ、取り扱い性を良好にすることができる。
なお、共役ジエン系ゴムの溶融粘度は、ブルックフィールド型粘度計(B型粘度計)を用いて38℃にて測定した粘度を意味する。
本明細書において「ビニル含量」とは、変性液状ジエン系ゴムに含まれる、共役ジエン単位の合計100モル%中、1,2-結合又は3,4-結合で結合をしている共役ジエン単位(1,4-結合以外で結合をしている共役ジエン単位)の合計モル%を意味する。ビニル含量は、1H-NMRを用いて1,2-結合又は3,4-結合で結合をしている共役ジエン単位由来のシグナルと1,4-結合で結合をしている共役ジエン単位由来のシグナルの積分値比から算出することができる。
本発明における接着層は、例えば、共役ジエン系ゴムをオイルに溶解させた溶液からなる接着成分を表面改質繊維に塗布することにより形成することができる。
本発明においては、例えば20℃における蒸気圧が10Pa以下である、いわゆる不揮発性のオイルを用いることが好ましい。このようなオイルを用いることにより、接着成分を繊維の表面に塗布した後もオイルが長期間揮発しないので、接着成分の塗り斑が生じにくくなり、接着性が向上する。また、製造時の製造設備の汚染を抑制することができる。これらの観点から、オイルとしては、20℃におけるオイルの蒸気圧が、8Pa以下であることが好ましく、5Pa以下であることがより好ましく、1Pa以下であることが更に好ましく、0.1Pa以下であることがより更に好ましく、0.01Pa以下であることがより更に好ましい。
なお、本発明において20℃におけるオイルの蒸気圧は、気体流通法により測定した測定値にアントワン(Antoine)式を適用して得られた最適曲線によって算出した値をいう。
本発明においてオイルを用いた場合、RFLを用いる従来技術と比較して樹脂化のための加熱工程が不要であり、更に希釈剤として水等の溶媒を用いる従来技術と比較して水等を除去するための蒸発工程も不要である。よって、従来と比較して簡易な設備で効率的に製造することが可能であり、環境にも優しい。
鉱物油としては、溶剤精製、水添精製等の通常の精製法により得られた、パラフィン系鉱物油、芳香族系鉱物油及びナフテン系鉱物油、更にフィッシャートロプシュプロセス等により製造されたワックス(ガストゥリキッドワックス)、ワックスを異性化することによって製造された鉱物油等が挙げられる。
パラフィン系鉱物油の市販品としては、出光興産株式会社製の「ダイアナプロセスオイル」シリーズ、JXエネルギー株式会社製の「スーパーオイル」シリーズ等が挙げられる。
植物油としては例えば、亜麻仁油、ツバキ油、マカダミアナッツ油、トウモロコシ油、ミンク油、オリーブ油、アボカド油、サザンカ油、ヒマシ油、紅花油、ホホバ油、ヒマワリ油、アーモンド油、菜種油、ゴマ油、大豆油、ピーナッツ油、綿実油、ココヤシ油、パーム核油、米ぬか油等が挙げられる。
合成油としては、炭化水素系合成油、エステル系合成油、エーテル系合成油等が挙げられる。炭化水素系合成油としては、ポリブテン、ポリイソブチレン、1-オクテンオリゴマー、1-デセンオリゴマー、及びエチレン-プロピレン共重合体等のα-オレフィンオリゴマー又はその水素化物、アルキルベンゼン、及びアルキルナフタレン等が挙げられる。エステル系合成油としては、トリグリセリン脂肪エステル、ジグリセリン脂肪酸エステル、モノグリセリン脂肪酸エステル、モノアルコール脂肪酸エステル、多価アルコール脂肪酸エステル等が挙げられる。エーテル系合成油としては、ポリオキシアルキレングリコール、及びポリフェニルエーテル等が挙げられる。合成油の市販品としては、出光興産株式会社製の「リニアレン」シリーズ、ANDEROL製、「FGC32」、「FGC46」、「FGC68」等が挙げられる。
本発明においては、接着成分の粘度を適切な範囲とし、作業性を向上させる観点から、鉱物油が好ましく、パラフィン系鉱物油、及びナフテン系鉱物油から選ばれる少なくとも1種がより好ましい。
また、前記接着成分中のオイルの含有量は、好ましくは20質量%以上、より好ましくは40質量%以上、更に好ましくは50質量%以上、より更に好ましくは60質量%以上であり、そして、好ましくは99質量%以下、より好ましくは95質量%以下、更に好ましくは90質量%以下である。
共役ジエン系ゴムを水に分散させて水中油滴型エマルションとして用いる場合、機械的方法又は化学的方法により接着成分のエマルション(ラテックス)を予め調製し、希釈等により所定の濃度で使用することが好ましい。
機械的方法としてはホモジナイザー、ホモミキサー、ディスパーサーミキサー、コロイドミル、パイプラインミキサー、高圧ホモジナイザー、超音波乳化機等を用いる方法が挙げられ、これらを単独又は組み合わせて使用できる。
化学的方法としては、反転乳化法、D相乳化法、HLB温度乳化法、ゲル乳化法及び液晶乳化法等種々の方法が挙げられ、簡便に粒子径の細かいエマルションが得られる観点から反転乳化法が好ましい。また粒子径の細かいエマルションを得るためには、変性共役ジエン系ゴムの粘度を下げる目的で適当な温度(例えば30~80℃)で加熱しながら作業を実施することが好ましい場合もある。
前記他の成分としては、他のポリマー(例えば未変性共役ジエン系ゴム)、酸、アルカリ、酸化防止剤、硬化剤、分散剤、顔料、染料、接着助剤、カーボンブラック等が挙げられる。
前記接着成分が他の成分を含有する場合、その含有量は、共役ジエン系ゴム100質量部に対して、好ましくは10,000質量部以下であり、より好ましくは1,000質量部以下であり、更に好ましくは100質量部以下であり、より更に好ましくは50質量部以下であり、より更に好ましくは25質量部以下であり、より更に好ましくは10質量部以下である。
本発明の補強繊維の製造方法に特に制限はなく、前記共役ジエン系ゴムを前記オイルと混合した状態で繊維に付着させる工程や、前記共役ジエン系ゴムを水に分散させた状態で繊維に付着させる工程を含む方法で製造することができる。
本発明においては、表面改質繊維に対して共役ジエン系ゴムを効率的に付着させる観点、及び製造設備の汚染を抑制する観点から、前記共役ジエン系ゴムを前記オイルと混合した状態で繊維に付着させる工程を含む方法が好ましい。
本発明の補強繊維のより具体的な製造方法としては、下記方法が挙げられる。
方法(I)としては、表面改質繊維の表面に前記接着成分からなる接着層を形成する方法であれば特に制限はないが、ゴムとの接着性を向上させる観点から、下記工程I-1を含む方法が好ましい。
工程I-1:前記接着成分を表面改質繊維の表面に付着させる工程
前記接着成分を付着させる方法として、浸漬、ロールコーター、オイリングローラー、オイリングガイド、ノズル(スプレー)塗布、及び刷毛塗り等から選ばれる1種以上により行うことが好ましい。
工程I-2:工程I-1で得られた前記接着成分が付着した表面改質繊維を熱処理する工程
工程I-2における熱処理は、好ましくは100~200℃の処理温度で0.1秒~2分の処理時間で行うことが好ましい。前記接着成分に含まれる共役ジエン系ゴムは反応性多重結合を有しているため、酸素存在下での熱処理は200℃以下であることが好ましく、175℃以下であることがより好ましい。熱処理の温度が前記範囲内であると、共役ジエン系ゴム中の反応性多重結合量が減少することなく、接着力を向上させることができ、更に繊維の劣化も抑制し、着色等の品質も良好となる。
前記補強繊維中の前記親水性繊維及び前記接着成分の合計含有量は、ゴムとの接着力の向上及び補強強度の観点から、好ましくは80質量%以上、より好ましくは90質量%以上、更に好ましくは95質量%以上である。
前記補強繊維は、単糸繊度が0.1dtex以上30dtex以下のマルチフィラメントであることが好ましい。単糸繊度は0.1dtex未満であってもよいが工業的に製造することが難しいことから0.1dtex以上が好ましい。また、単糸繊度が30dtex以下であると、補強繊維とした場合における繊維の表面積が大きくなるため、ゴムとの接着性が向上する。当該観点から、本発明の補強繊維は、単糸繊度がより好ましくは0.3dtex以上、更に好ましくは0.5dtex以上、より更に好ましくは1dtex以上であり、そして、より好ましくは20dtex以下、更に好ましくは15dtex以下、より更に好ましくは10dtex以下であるマルチフィラメントであることが好ましい。
また、本発明の補強繊維のゴム接着力は、30N/3本以上であることが好ましく、40N/3本以上であることがより好ましく、50N/3本以上であることが更に好ましく、60N/3本以上であることがより更に好ましく、通常、200N/3本以下である。補強繊維のゴム接着力が前記下限値以上であると、補強強度に優れた織物、編み物及び成形体を得ることができる。
なお、補強繊維のゴム接着力は、実施例に記載の方法により測定することができる。
本発明の成形体は、前記補強繊維を用いたものであれば特に限定されない。中でも、前記補強繊維がゴムとの優れた接着性を有することから、特に前記補強繊維とゴム層とを有する成形体(以下、「ゴム成形体」とも称する)が好ましい。前記ゴム成形体に用いられる補強繊維は、ゴムの形態保持という観点からは、該補強繊維を少なくとも一部に含む織物又は編物として用いられることが好ましく、該補強繊維を少なくとも一部に含む織物又は編物からなる補強層とゴム層とを積層した積層体として用いられることがより好ましい。
本発明の成形体の好適な態様としては、繊維、表面改質層、接着層、及びゴム層をこの順に有する成形体であって、前記接着層と前記ゴム層との接着力が幅25.4mmあたり70N以上、より好ましくは80N以上であることが好ましく、前記接着力が70N以上であれば、後述する各種用途に好適に用いることができる。
前記自動車用タイヤとしては、例えばベルト、カーカスプライ、ブレーカー、ビードテープ等の補強繊維とゴム成分との複合材からなる各種部材に使用できる。
前記ホースとしては、種々の用途における各種流体の輸送を目的に使用することができ、例えば、自動車用の流体輸送用ホースに好適であり、特に、自動車用の液体燃料用ホース、自動車用のブレーキオイルホース、及び冷媒用ホースに用いることが好ましく、自動車用のブレーキオイルホースに用いることがより好ましい。
ゴム成分としては、特に限定はされないが、例えば、NR(天然ゴム)、IR(ポリイソプレンゴム)、BR(ポリブタジエンゴム)、SBR(スチレン-ブタジエンゴム)、NBR(ニトリルゴム)、EPM(エチレン-プロピレン共重合体ゴム)、EPDM(エチレン-プロピレン-非共役ジエン共重合体ゴム)、IIR(ブチルゴム)、ハロゲン化ブチルゴム、CR(クロロプレンゴム)等が挙げられる。これらの中でも、NR、IR、BR、SBR、EPDM、CRを用いることが好ましく、EPDMを用いることがより好ましい。これらのゴム成分は1種を単独で用いてもよく、2種以上を組み合わせて用いてもよい。タイヤ用途においては、タイヤ工業において一般的に用いられるものが使用できる。中でも、天然ゴム単独、あるいは天然ゴムとSBRとを組み合わせて使用することが好ましい。天然ゴムとSBRとを組み合わせる際は、ゴムの加硫戻りによる物性低下を抑制する観点から、天然ゴムとSBRとの質量比(天然ゴム/SBR)は、50/50~90/10の範囲とすることが好ましい。
前記SBRの重量平均分子量(Mw)は100,000~2,500,000であることが好ましく、150,000~2,000,000であることがより好ましく、200,000~1,500,000であることが更に好ましい。前記範囲である場合、加工性と機械強度を両立することができる。なお、SBRの重量平均分子量とは、ゲルパーミエーションクロマトグラフィー(GPC)の測定から求めたポリスチレン換算の重量平均分子量である。
前記SBRとしては、本発明の効果を損ねない範囲であれば、SBRに官能基が導入された変性SBRを用いてもよい。官能基としては、例えばアミノ基、アルコキシシリル基、ヒドロキシ基、エポキシ基、カルボキシ基等が挙げられる。
機械強度の向上等の物性の改善等の観点からは、前記フィラーの中でも、カーボンブラック及びシリカが好ましい。
前記カーボンブラックの平均粒径としては、5~100nmであることが好ましく、5~80nmであることがより好ましく、5~70nmであることが更に好ましい。なお、前記カーボンブラックの平均粒径は、透過型電子顕微鏡により粒子の直径を測定してその平均値を算出することにより求めることができる。
前記シリカの平均粒径は、0.5~200nmであることが好ましく、5~150nmであることがより好ましく、10~100nmであることが更に好ましい。
なお、前記シリカの平均粒径は、透過型電子顕微鏡により粒子の直径を測定して、その平均値を算出することにより求めることができる。
また、前記フィラーとして、シリカ及びカーボンブラック以外のフィラーを用いる場合には、その含有量は、前記ゴム成分100質量部に対して、20~120質量部であることが好ましく、20~90質量部であることがより好ましく、20~80質量部であることが更に好ましい。
これらフィラーは1種を単独で用いてもよく、2種以上を併用してもよい。
これらシランカップリング剤は、1種を単独で用いてもよく、2種以上を併用してもよい。前記シランカップリング剤は、シリカ100質量部に対して好ましくは0.1~30質量部、より好ましくは0.5~20質量部、更に好ましくは1~15質量部含有される。シランカップリング剤の含有量が前記範囲内であると、分散性、カップリング効果、補強性が向上する。
内側ゴム層と外側ゴム層を構成するゴム成分としては、前述のものが挙げられる。中でも、内側ゴム層を構成するゴム成分としては、EPDM、SBR等が挙げられ、外側ゴム層を構成するゴム成分としては、EPDM、CR等が挙げられる。前記補強層は、補強繊維を編組して形成することができる。
前記ブレーキオイルホースの製造方法としては、内側ゴム層の外表面上に、前記補強繊維を編組した補強層(第1補強層)を形成する。2層の補強層を形成する場合には、第1補強層の外表面上に更に中間ゴム層を形成し、該中間ゴム層の外表面上に、前記補強繊維を編組した補強層(第2補強層)を形成してもよい。そして、補強層(第1補強層又は第2補強層)の外表面上に外側ゴム層を形成し、加硫することにより製造することができる。
加硫温度は、ブレーキオイルホースの各層の構成材料の種類等により適宜選択できるが、ゴムと補強繊維の劣化を抑制し、ゴムと補強繊維との接着力を向上させる観点から、200℃以下であることが好ましい。
十分に乾燥した5Lオートクレーブを窒素置換し、ヘキサン756g及びn-ブチルリチウム(17質量%ヘキサン溶液)122.3gを仕込み、50℃に昇温した後、撹拌条件下、重合温度が50℃となるように制御しながら、ブタジエン1344gを逐次添加して、1時間重合した。その後メタノールを添加して重合反応を停止させ、重合体溶液を得た。得られた重合体溶液に水を添加して撹拌し、水で重合体溶液を洗浄した。撹拌を終了し、重合体溶液相と水相とが分離していることを確認した後、水を分離した。洗浄終了後の重合体溶液を70℃で24時間真空乾燥することにより、未変性液状ポリブタジエン(A’-1)を得た。
続いて、窒素置換を行った容量1Lのオートクレーブ中に、得られた未変性液状ポリブタジエン(A’-1)600gを仕込み、無水マレイン酸30gとN-フェニル-N’-(1,3-ジメチルブチル)-p-フェニレンジアミン(商品名「ノクラック6C」、大内新興化学工業株式会社製)0.6gを添加し、170℃で24時間反応させて、無水マレイン酸変性液状ポリブタジエン(A-1)を得た。
十分に乾燥した5Lオートクレーブを窒素置換し、ヘキサン1260g及びn-ブチルリチウム(17質量%ヘキサン溶液)36.3gを仕込み、50℃に昇温した後、撹拌条件下、重合温度が50℃となるように制御しながら、ブタジエン1260gを逐次添加して、1時間重合した。その後メタノールを添加して重合反応を停止させ、重合体溶液を得た。得られた重合体溶液に水を添加して撹拌し、水で重合体溶液を洗浄した。撹拌を終了し、重合体溶液相と水相とが分離していることを確認した後、水を分離した。洗浄終了後の重合体溶液を70℃で24時間真空乾燥することにより、未変性液状ポリブタジエン(A’-2)を得た。
続いて、窒素置換を行った容量1Lのオートクレーブ中に、得られた未変性液状ポリブタジエン(A’-2)500gを仕込み、無水マレイン酸25gとN-フェニル-N’-(1,3-ジメチルブチル)-p-フェニレンジアミン(商品名「ノクラック6C」、大内新興化学工業株式会社製)0.5gを添加し、170℃で24時間反応させて、無水マレイン酸変性液状ポリブタジエン(A-2)を得た。
十分に乾燥した5Lオートクレーブを窒素置換し、ヘキサン1140g及びn-ブチルリチウム(17質量%ヘキサン溶液)20.9gを仕込み、50℃に昇温した後、攪拌条件下、重合温度を50℃となるように制御しながら、ブタジエン1390gを逐次添加して、1時間重合した。その後メタノールを添加して重合反応を停止させ、重合体溶液を得た。得られた重合体溶液に水を添加して撹拌し、水で重合体溶液を洗浄した。撹拌を終了し、重合体溶液相と水相とが分離していることを確認した後、水を分離した。洗浄終了後の重合体溶液を70℃で24時間真空乾燥することにより、未変性液状ポリブタジエン(A’-3)を得た。
続いて、窒素置換を行った容量1Lのオートクレーブ中に、得られた未変性液状ポリブタジエン(A’-3)500gを仕込み、無水マレイン酸25gとN-フェニル-N’-(1,3-ジメチルブチル)-p-フェニレンジアミン(商品名「ノクラック6C」、大内新興化学工業株式会社製)0.5gを添加し、170℃で24時間反応させて、無水マレイン酸変性液状ポリブタジエン(A-3)を得た。
得られた無水マレイン酸変性液状ポリブタジエン(A-3)525gに対し、メタノールを9.0g添加し、80℃で6時間反応させることにより、マレイン酸モノメチル変性液状ポリブタジエン(A-4)を得た。
得られた無水マレイン酸変性液状ポリブタジエン(A-2)525gに対し、メタノールを8.5g添加し、80℃で6時間反応させることにより、マレイン酸モノメチル変性液状ポリブタジエン(A-5)を得た。
<重量平均分子量、数平均分子量及び分子量分布の測定方法>
変性共役ジエン系ゴムの重量平均分子量(Mw)、数平均分子量(Mn)及び分子量分布(Mw/Mn)は、GPC(ゲルパーミエーションクロマトグラフィー)により標準ポリスチレン換算値として求めた。測定装置及び条件は、以下の通りである。
・装置 :東ソー株式会社製GPC装置「GPC8020」
・分離カラム :東ソー株式会社製「TSKgelG4000HXL」
・検出器 :東ソー株式会社製「RI-8020」
・溶離液 :テトラヒドロフラン
・溶離液流量 :1.0ml/分
・サンプル濃度:5mg/10ml
・カラム温度 :40℃
変性共役ジエン系ゴムの38℃における溶融粘度をブルックフィールド型粘度計(BROOKFIELD ENGINEERING LABS. INC.製)により測定した。
変性共役ジエン系ゴム10mgをアルミパンに採取し、示差走査熱量測定(DSC)により10℃/分の昇温速度条件においてサーモグラムを測定し、DDSCのピークトップの値をガラス転移温度とした。
変性共役ジエン系ゴムのビニル含量を、日本電子株式会社製1H-NMR(500MHz)を使用し、サンプル/重クロロホルム=50mg/1mLの濃度、積算回数1024回で測定した。得られたスペクトルのビニル化されたジエン化合物由来の二重結合のピークと、ビニル化されていないジエン化合物由来の二重結合のピークとの面積比から、ビニル含量を算出した。
変性共役ジエン系ゴム1分子当たりの平均水素結合性官能基数は、変性共役ジエン系ゴムの水素結合性官能基の当量(g/eq)とスチレン換算の数平均分子量Mnから、下記式より算出した。
1分子当たりの平均水素結合性官能基数=[(数平均分子量(Mn))/(スチレン単位の分子量)×(共役ジエン及び必要に応じて含まれる共役ジエン以外の他の単量体単位の平均分子量)]/(水素結合性官能基の当量)
なお、水素結合性官能基の当量の算出方法は、水素結合性官能基の種類により適宜選択することができる。
変性反応後の試料をメタノールで4回洗浄(試料1gに対して5mL)して酸化防止剤等の不純物を除去した後、試料を80℃で12時間、減圧乾燥した。変性反応後の試料3gにトルエン180mL、エタノール20mLを加え溶解した後、0.1N水酸化カリウムのエタノール溶液で中和滴定し、下記式より酸価を求めた。
酸価(mgKOH/g)=(A-B)×F×5.611/S
A:中和に要した0.1N水酸化カリウムのエタノール溶液滴下量(mL)
B:試料を含まないブランクでの0.1N水酸化カリウムのエタノール溶液滴下量(mL)
F:0.1N水酸化カリウムのエタノール溶液の力価
S:秤量した試料の質量(g)
〔1g当たり水素結合性官能基質量〕=〔酸価〕/〔56.11〕×〔水素結合性官能基分子量〕/1000
〔1g当たり重合体主鎖質量〕=1-〔1g当たり水素結合性官能基質量〕
〔水素結合性官能基の当量〕=〔1g当たり重合体主鎖質量〕/(〔1g当たり水素結合性官能基質量〕/〔水素結合性官能基分子量〕)
・ブロックドイソシアネート化合物
メイカネートDM-3031 CONC(明成化学工業株式会社製、純分54質量%)
・エポキシ化合物
デナコールEX-614B(ナガセケムテック株式会社製、純分100質量%)
・オキサゾリン基含有化合物
エポクロスWS-700(株式会社日本触媒製、純分25質量%)
・カルボジイミド基含有化合物
カルボジライトPrototype(日清紡ケミカル株式会社製、純分40質量%)
・アクリル酸ナトリウム化合物
アクアリックDL-453(株式会社日本触媒製、純分35質量%)
・エチレンイミン化合物
エポミンSP-200(株式会社日本触媒製、純分100質量%)
・ジアミド型カチオン系化合物
アデカミンSF-201(株式会社ADEKA製、純分80質量%)
表1に記載の各変性共役ジエンゴムを脂肪酸エステル又は鉱物油を用いて25質量%に希釈した溶液を調製した。
なお、脂肪酸エステルとしては、ポリオール脂肪酸エステル(トリメチロールプロパントリカプリレート)であって、20℃蒸気圧が1.7×10-7Paであり、引火点が258℃であり、揮発性がないものを用いた。また、鉱物油としては、20℃蒸気圧が7.0×10-3Paであり、引火点が158℃であり、揮発性がないものを用いた。
表面改質剤(B-1)中にポリエステル系繊維であるPET繊維(総繊度1100dtex、単糸繊度6.10dtex)を浸漬した後、ローラーで搾液した。
その後、得られた繊維を140℃で60秒間乾燥処理し、更に240℃で60秒間熱処理することにより表面改質繊維を作製した。
次いで、表3に示す組成及び付着量になるように変性共役ジエン系ゴムの希釈溶液を調製した後、オイリングガイドを用いて前記希釈溶液を表面改質繊維に付与し、巻き取った。その後、室温(20℃)で3日間なじませた後、撚り数80T/mで撚って補強繊維を作製した。
表面改質層、接着層及びそれらの付着量を表3に記載のとおりに変更したこと以外は実施例1と同様の方法で補強繊維を作製した。
後述の前処理液にポリエステル系繊維であるPET繊維(総繊度1100dtex、単糸繊度6.10dtex)を浸漬した後、ローラーで搾液し付与し140℃で60秒間乾燥し、更に240℃で60秒間熱処理した。
次いでRFLを付与した後に140℃で60秒間乾燥し、更に240℃で60秒間熱処理することにより処理糸を得た。得られた処理糸を撚り数80T/mで撚り補強繊維を作製した。なお、使用した前処理液及びRFL液は下記の方法にて調製した。
水 :96.96質量部
ブロックドイソシアネート : 2.29質量部
エポキシ化合物 : 0.75質量部
前処理液はブロックドイソシアネートとエポキシ樹脂を用いて調製した。なお、ブロックドイソシアネートとして、明成化学工業株式会社製の「メイカノートDM-3031 CONC」を、エポキシ樹脂として、ナガセケムテックス株式会社製の「デナコールEX-614B」を用いた。
A液
水 :524質量部
レゾルシノール : 15質量部
ホルムアルデヒド(有効分37質量%) : 16質量部
水酸化ナトリウム水溶液(有効分10質量%): 4質量部
上記A液を25℃の温度で6時間熟成した。
SBRラテックス(有効分40質量%) :207質量部
ビニルピリジン変性SBRラテックス(有効分40質量%):233質量部
上記B液と熟成済みのA液とを混合した後、25℃の温度で16時間熟成してRFL液を製造した。
実施例1~7及び比較例1~4で得られた表面改質繊維の繊維表面のゼータ電位は、ゼータ電位・粒径測定システムELSZ-1000(大塚電子株式会社製)にてpH=7、温度25℃で平板用セルを用いて測定した。
具体的には、繊維を平板用セルに隙間無く並べ密着させ、平板用セル内にモニタ用粒子(ヒドロキシプロピルセルロースでコーティングしたポリスチレン粒子〔大塚電子株式会社製〕)を10mMの塩化ナトリウム(NaCl)溶液中に分散させた分散液を注入した。電気泳動は印加電圧80Vの条件で行った。
実施例1~7、比較例1~4及び参考例1で得られた補強繊維について、下記方法で評価用シートを作製し、補強繊維をゴムからT型剥離させるときに要した力(N/25.4mm)を測定し、ゴム接着力として評価した。結果を表3に示す。
ゴム接着力の評価結果は、数値が大きいほど補強繊維とゴムとの接着力が大きいことを示す。なお、接着用シートは下記のように作製した。
実施例、比較例及び参考例で作製した補強繊維を、補強繊維同士が重ならないようにスダレ状にマスキングテープ上に並べて固定した後、これと、別途EPDMゴムを用い、下記配合組成により調製した未加硫のゴム組成物とを重ね合わせた。次いで、150℃、圧力20kg/cm2の条件で30分間プレス加硫することにより評価用シートを作製した。
EPDMゴム :100質量部
フィラー(カーボンブラック) : 60質量部
軟化剤(パラフィン系プロセスオイル) : 20質量部
架橋剤(硫黄粉) :1.5質量部
加硫助剤(亜鉛華2種、ステアリン酸) : 6質量部
加硫促進剤(チアゾール系、チウラム系) :1.5質量部
繊維、表面改質層、接着層及びそれらの付着量を表4に記載のとおりに変更したこと以外は実施例1と同様の方法で補強繊維を作製した。なお繊維種はポリエステル系繊維に加え、ポリアミド系繊維であるナイロン繊維(総繊度1100dtex、単糸繊度6.10dtex)、及びポリビニルアルコール系繊維であるビニロン繊維(総繊度1330dtex、単糸繊度6.65dtex、株式会社クラレ製「クラロン1239」)を用いた。
最終的に撚りをかけないこと以外は参考例1と同様に処理し補強繊維を作製した。
実施例8~16、比較例5~9及び参考例2で得られた補強繊維について、下記方法で評価用シートを作製し、補強繊維をゴムからT型剥離させるときに要した力(N/25.4mm)を測定し、ゴム接着力として評価した。結果を表4に示す。ゴム接着力の評価結果は、数値が大きいほど補強繊維とゴムとの接着力が大きいことを示す。なお、接着用シートは下記の様に作製した。
前述の実施例、比較例及び参考例で作製した補強繊維を、補強繊維同士が重ならないようにスダレ状にマスキングテープ上に並べて固定した後、これと、別途NR/SBRゴムを用い、下記配合組成により調製した未加硫のゴム組成物とを重ね合わせた。次いで、150℃、圧力20kg/cm2の条件で30分間プレス加硫することにより評価用シートを作製した。
NRゴム : 70質量部
SBRゴム :41.25質量部
フィラー(カーボンブラック) : 45質量部
加硫剤(硫黄粉) : 3.5質量部
加硫助剤(亜鉛華、ステアリン酸) : 6質量部
加硫促進剤(チアゾール系) : 1質量部
ポリエステル系繊維であるPET繊維(総繊度1100dtex、単糸繊度6.10dtex)2本を、上撚470回/m、下撚470回/mを掛けたものを作製し撚り合わせ繊維コードを作製した。
前記撚り合わせコードを表面改質剤(B-1)中に浸漬した後、ローラーで搾液した。得られた繊維コードを140℃で60秒間乾燥処理し、更に240℃で60秒間熱処理して作製した。次いで表5に記載の変性共役ジエン系ゴムを主成分とするエマルション組成物に浸漬した後、ローラーで搾液し140℃で60秒乾燥処理した後巻き取った。なお、エマルション組成物中の変性共役ジエン系ゴムの含有量は10質量%であった。
表面改質層、接着層及びそれらの付着量を表5に記載のとおりに変更したこと以外は実施例17と同様にして補強繊維を作製した。
撚り合わせたPET繊維コードを用いたこと以外は参考例1と同様にして補強繊維を作製した。
実施例17~19、比較例10及び参考例3で得られた補強繊維について、下記方法で評価用供試体を作製し、補強繊維をゴムからT型剥離させるときに要した力(N/3本)を測定し、ゴム接着力として評価した。結果を表5に示す。ゴム接着力の評価結果は、数値が大きいほど補強繊維とゴムとの接着力が大きいことを示す。なお、接着用供試体は下記の様に作製した。
前述の実施例、比較例及び参考例で作製した補強繊維を、前記配合により調製したNR/SBR未加硫のゴム組成物に一定の間隔を空け3本並べた。次いで、150℃、圧力20kg/cm2の条件で30分間プレス加硫することにより接着供試体を作製した。
Claims (14)
- 繊維と、前記繊維の表面の少なくとも一部を覆う表面改質層とを有し、前記表面改質層の表面における固体表面ゼータ電位が-20.0~30.0mVである表面改質繊維。
- 前記繊維が、ポリエステル系繊維、ポリアミド系繊維、ポリビニルアルコール系繊維、及び再生セルロース系繊維から選ばれる1種以上の繊維である、請求項1に記載の表面改質繊維。
- 前記表面改質層が含窒素官能基を有する化合物を含む、請求項1又は2に記載の表面改質繊維。
- 前記表面改質層が、オキサゾリン基、オキサゾリジノン基、カルボジイミド基、カルバミド基、アミノ基、及びアジリジン基から選ばれる1種以上に由来する官能基を有する化合物を含む、請求項1~3のいずれかに記載の表面改質繊維。
- 前記表面改質層の量が、原料として用いた繊維100質量部に対して0.01~5.0質量部である、請求項1~4のいずれかに記載の表面改質繊維。
- 請求項1~5のいずれかに記載の表面改質繊維と、前記表面改質繊維の表面の少なくとも一部を覆う共役ジエン系ゴムを含有する接着層とを有する補強繊維。
- 前記共役ジエン系ゴムの数平均分子量(Mn)が2,000超120,000以下である、請求項6に記載の補強繊維。
- 前記共役ジエン系ゴムが、分子内にブタジエン、イソプレン、及びファルネセンから選ばれる1種以上に由来する単量体単位を有する、請求項6又は7に記載の補強繊維。
- 前記共役ジエン系ゴムが、共役ジエン系ゴムの一部に水素結合性官能基を有する変性共役ジエン系ゴムであり、該水素結合性官能基が、ヒドロキシ基、エポキシ基、アルデヒド基、アルデヒド基のアセタール化体、カルボキシ基、カルボキシ基の塩、カルボキシ基のエステル化体、カルボキシ基の酸無水物、シラノール基、シラノール基のエステル化体、アミノ基、イミダゾール基、及びメルカプト基から選ばれる1種以上である、請求項6~8のいずれかに記載の補強繊維。
- 前記接着層が更にオイルを含有し、該オイルの20℃における蒸気圧が10Pa以下である、請求項6~9のいずれかに記載の補強繊維。
- 請求項6~10のいずれかに記載の補強繊維を用いた、成形体。
- 更にゴム層を有する、請求項11に記載の成形体。
- 前記成形体がタイヤ、ベルト又はホースである、請求項11又は12に記載の成形体。
- 繊維、表面改質層、接着層、及びゴム層をこの順に有する成形体であって、前記接着層と前記ゴム層との接着力が幅25.4mmあたり70N以上である、成形体。
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