WO2022044460A1 - 補強繊維、及びそれを用いた成形体 - Google Patents
補強繊維、及びそれを用いた成形体 Download PDFInfo
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- WO2022044460A1 WO2022044460A1 PCT/JP2021/020032 JP2021020032W WO2022044460A1 WO 2022044460 A1 WO2022044460 A1 WO 2022044460A1 JP 2021020032 W JP2021020032 W JP 2021020032W WO 2022044460 A1 WO2022044460 A1 WO 2022044460A1
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- Prior art keywords
- rubber
- conjugated diene
- group
- fiber
- mass
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- D—TEXTILES; PAPER
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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
- D06M15/693—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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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B25/00—Layered products comprising a layer of natural or synthetic rubber
- B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B25/042—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of natural rubber or synthetic rubber
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B25/00—Layered products comprising a layer of natural or synthetic rubber
- B32B25/10—Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B25/00—Layered products comprising a layer of natural or synthetic rubber
- B32B25/16—Layered products comprising a layer of natural or synthetic rubber comprising polydienes homopolymers or poly-halodienes homopolymers
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- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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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
- C08J5/04—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
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- 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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- D06M13/3255—Vinylamine; Allylamine
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- 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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- D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
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- D06M15/233—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of hydrocarbons, or reaction products thereof, e.g. afterhalogenated or sulfochlorinated aromatic, e.g. styrene
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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
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- D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/263—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof
- D06M15/267—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof of unsaturated carboxylic esters having amino or quaternary ammonium groups
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- 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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- 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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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
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Definitions
- the present invention relates to a reinforcing fiber having excellent adhesiveness to rubber and a molded product using the reinforcing fiber.
- Synthetic organic fibers such as nylon 66, nylon 6, polyethylene terephthalate (PET), 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 brakes. It is used as a reinforcing fiber for hoses.
- an adhesive method a method using an adhesive called RFL containing resorcinol / formaldehyde resin and rubber latex as main components is widely known in Patent Document 1. Further, in Patent Document 2, a device is devised to maintain strength and improve fatigue resistance by impregnating the inside with RFL.
- Patent Document 3 proposes a technique relating to 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 an active functional group layer is provided by applying a blocked isocyanate compound and an epoxy compound in the first stage, and latex and a low molecular weight conjugated diene rubber are used as main components in the second stage.
- a technique using an adhesive component has been proposed.
- Patent Document 5 proposes a technique that does not use RFL by applying a blocked isocyanate compound, an epoxy compound, an amine-based curing material, and a VP latex.
- Patent Document 3 has a problem that the adhesiveness is inferior and the practicality is poor as compared with the conventional method using RFL.
- 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 stages, so that a large amount of energy is required for the treatment.
- the reinforcing performance was deteriorated due to concern about thermal deterioration of the fiber.
- 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 conjugated diene-based rubber as a main component.
- the epoxy compounds used in Patent Documents 3 to 5 have a problem that they are not preferable in terms of working environment because they may cause factors such as mutagenicity and skin sensitization.
- the present invention has been made in view of the above-mentioned conventional problems, and provides a reinforcing fiber having excellent adhesiveness to rubber without using resorcinol, formaldehyde and an epoxy compound, and a molded body using the same. do.
- the present inventors have provided a surface-modified layer on at least a part of the surface of the fiber, and the surface-modified layer contains a polyamine compound having a specific weight average molecular weight.
- the adhesiveness between the fiber and the rubber is improved without using resorcinol, formaldehyde and an epoxy compound, and completed the present invention.
- a reinforcing fiber having a fiber, a surface-modified layer covering at least a part of the surface of the fiber, and an adhesive layer containing a conjugated diene-based rubber covering at least a part of the surface-modified layer.
- the surface-modified layer is characterized by containing a polyamine compound having one or more functional groups selected from 1 to tertiary amino groups and imino groups and having a weight average molecular weight (Mw) of 300 or more. Reinforcing fiber.
- Mn number average molecular weight
- the reinforcing fiber according to any one of [1] to [4] above, wherein the conjugated diene rubber has a monomer unit derived from one or more selected from butadiene, isoprene and farnesene in the molecule. .. [6]
- 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.
- [7] A molded product using the reinforcing fiber according to any one of the above [1] to [6].
- the molded product according to the above [7] further having a rubber layer.
- the present invention can provide a reinforcing fiber having excellent adhesiveness to rubber and a molded body using the reinforcing fiber without using resorcinol, formaldehyde and an epoxy compound.
- the reinforcing fiber of the present invention has a reinforcing having a fiber, a surface-modified layer covering at least a part of the surface of the fiber, and an adhesive layer containing a conjugated diene rubber covering at least a part of the surface-modified layer. It is a fiber, and the surface-modified layer contains a polyamine compound having one or more functional groups selected from 1 to tertiary amino groups and imino groups and having a weight average molecular weight (Mw) of 300 or more. It is characterized by.
- 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 contains 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 "adhesive layer covering at least a part of the surface modified layer” may mean that the entire surface modified layer is covered with the adhesive layer, but at least a part thereof is covered with the adhesive layer. Any aspect may be used, for example, in which an adhesive component is present as a film or a layer.
- 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.
- 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 formaldehyde component is contained in the adhesive layer, 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.
- 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 surface-modified layer in the present invention may contain a polyamine compound having one or more functional groups selected from a primary to tertiary amino group and an imino group and having a weight average molecular weight (Mw) of 300 or more.
- Mw weight average molecular weight
- the "polyamine compound” refers to an aliphatic compound containing two or more amino groups in one molecule. Examples of the primary to tertiary amino groups include substituents represented by the following general formulas (I) to (III).
- R 1 is a linear or branched alkylene chain having 1 to 20 carbon atoms which may have a substituent. Further, R 2 and R 3 each independently have a substituent. It is a linear or branched alkyl group having 1 to 20 carbon atoms which may be possessed.)
- the primary amino group represented by the general formula (I) or the secondary amino group represented by the general formula (II) is preferable from the viewpoint of improving the adhesiveness.
- the imino group is not particularly limited as long as it has a carbon-nitrogen double bond, and is, for example, an ethylidene amino group, a 1-methylpropyridene amino group, a 1,3-dimethylbutylidene amino group, 1-.
- examples thereof include a methylethylideneamino group, a 4-N, N-dimethylaminobenzylideneamino group, a cyclohexylideneamino group and the like.
- the weight average molecular weight of the polyamine compound in the present invention is 300 or more. If the weight average molecular weight is less than 300, the affinity with the adhesive layer containing the conjugated diene rubber is not exhibited, and the adhesive strength cannot be improved. From the viewpoint of improving the adhesiveness, the weight average molecular weight of the polyamine compound may be 500 or more, 800 or more, 1,000 or more, or 1,500 or more. May be good.
- the upper limit of the weight average molecular weight of the polyamine compound is generally 1,000,000 or less, and may be 800,000 or less, considering the deterioration of production efficiency due to the deterioration of handleability.
- the weight average molecular weight of the polyamine compound is a polystyrene-equivalent weight average molecular weight obtained from the measurement of gel permeation chromatography (GPC), and can be specifically measured by the method described in Examples.
- the surface modification layer preferably covers the entire surface of the fiber from the viewpoint of improving the adhesiveness to the 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 5.00 parts by mass, preferably 0.05 to 3.00 parts by mass with respect to 100 parts by mass of the fiber used as a raw material.
- the amount is more preferably 0.10 to 2.00 parts by mass, further preferably 0.20 to 1.00 parts by mass.
- the fiber used for the surface-modified fiber of the present invention is not particularly limited, and a hydrophilic fiber or a hydrophobic fiber can be used.
- the term "fiber” includes not only short fibers and long fibers but also non-woven fabrics, woven fabrics, knitted fabrics, felts, sponges and the like.
- 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.
- a thermoplastic resin include polyvinyl alcohol-based resin and polyamide-based resin [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 kind may be used alone, or two or more kinds 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 fiber examples include natural cellulose fibers such as wood pulp such as kraft pulp, cotton pulp, and non-wood pulp such as straw pulp.
- hydrophilic regenerated fiber examples include regenerated cellulose fibers such as rayon, lyocell, cupra, and polynosic. Each of these natural fibers and regenerated fibers may be used alone or in combination of two or more. 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.
- a fiber having a hydrophilic treatment on the surface of the hydrophobic fiber or a core having a hydrophobic resin as a core and a sheath having a hydrophilic resin as a core may be a sheath type composite fiber or the like.
- hydrophilic resins constituting the sheath the description of hydrophilic synthetic fibers is cited.
- the hydrophobic fiber made of a hydrophobic resin include the hydrophobic fiber described later.
- 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.
- a method of modifying with a compound containing a hydrophilic functional group such as a hydroxy 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. It can be carried out.
- hydrophobic fibers that could not 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.
- hydrophobic fiber examples include polyolefin fibers such as polyethylene and polypropylene, polyester fibers such as polyethylene terephthalate, and total aromatic polyester fibers, among which the manufacturing cost is high. Polyester fibers are preferable because they are excellent in strength, heat resistance, durability and the like.
- synthetic fibers and regenerated fibers are preferable among the fibers, and one or more fibers selected from polyamide fibers, polyvinyl alcohol fibers, polyester fibers, and regenerated cellulose fibers are preferable.
- one type of fiber may be used alone, or two or more types may be used in combination.
- the method for producing a fiber having a surface-modified layer on the surface is not particularly limited, but a method of preparing a solution of the polyamine compound with water or an organic solvent, adhering this solution to the fiber, and then drying it by heat treatment or the like.
- the method of adhering the solution of the compound constituting the surface modification layer to the fiber is not particularly limited, and is selected from, for example, dipping, roll coater, oiling roller, oiling guide, nozzle (spray) coating, brush coating and the like 1. It is preferable to carry out by seed or more.
- the heat treatment for drying the solution it is preferable to treat it at a treatment temperature of 100 to 250 ° C. for 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 from the viewpoint of improving the adhesive force with rubber. It is more preferably 5% by mass or less, and further preferably 5% by mass or less.
- the adhesive layer in the reinforcing fiber of the present invention is not particularly limited as long as it contains a conjugated diene-based rubber.
- an adhesive component composed of an emulsion in which the conjugated diene-based rubber is dispersed in water is attached to the surface-modified fiber. It can be formed by.
- 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 is, for example, a whole unit 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.
- conjugated diene monomer examples include butadiene, 2-methyl-1,3-butadiene (hereinafter, also referred to as “isoprene”), 2,3-dimethylbutadiene, 2-phenylbutadiene, 1,3-pentadiene, and the like.
- 2-Methyl-1,3-pentadiene, 1,3-hexadiene, 1,3-octadiene, 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 in combination of two or more. It is more preferable that the conjugated diene rubber has a monomer unit derived from one or more selected from butadiene, isoprene and farnesene from the viewpoint of reactivity at the time of vulcanization.
- the conjugated diene-based 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-binding functional group in a part of the conjugated diene-based rubber, and contains a conjugated diene unit in at least a part of the polymer chain. Moreover, a modified conjugated diene-based rubber having a hydrogen-binding 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.
- hydrogen bond means a hydrogen atom (donor) which is bonded to an atom (O, N, S, etc.) having a large electronegativity and is electrically positively polarized, and a lone electron pair. It means a bond-like 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. Examples of the derivative of the carboxy group include the salt thereof, the esterified product thereof, the amidated product thereof, and the acid anhydride thereof.
- Examples of the derivative of the silanol group include its esterified product.
- Examples of the carboxy group include a group derived from a monocarboxylic acid and a group derived from a dicarboxylic acid. Among these, hydroxy group, epoxy group, aldehyde group, acetalized form of aldehyde group, carbonyl group, carboxy group, salt of carboxy group, esterified form of carboxy group, acid anhydride of carboxy group, silanol group, silanol group.
- One or more selected from the esterified product of the above, an amino group, an imidazole group, and a mercapto group is preferable.
- the weight average molecular weight per epoxy group is 1,000 or more, while the epoxy used in the invention described in the above-mentioned prior art document.
- the compounds have a molecular weight of less than 1,000 per epoxy group, and the two differ in the molecular weight of each epoxy group.
- hydrogen-bonding functional groups hydroxy group, carboxy group, carbonyl group, carboxy group salt, carboxy group esterified product, from the viewpoint of improving adhesiveness and easiness of producing conjugated diene rubber.
- one or more selected from the acid anhydride of the carboxy group is preferable, and one or more selected from the carboxy group, the esterified product of the carboxy group, and the acid anhydride of the carboxy group are more preferable, and the esterified product of maleic anhydride.
- functional groups derived from maleic anhydride are more preferred.
- the number of hydrogen-bonding functional groups in the modified conjugated diene-based rubber is preferably 2 or more, and more preferably 3 or more, on average per molecule from the viewpoint of obtaining reinforcing fibers having excellent rubber adhesiveness. It is preferable, and it is more preferable that the number is four or more. Further, the number of hydrogen-bonding functional groups is preferably 80 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 the handleability. The number is more preferably less than 25, more preferably 25 or less, and even 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 one hydrogen-bonding functional group and other monomers other than the conjugated diene contained as necessary. do.
- Average number of hydrogen-bonding functional groups per molecule [(number average molecular weight (Mn)) / (molecular weight of styrene unit) ⁇ (conjugated diene and, if necessary, average of other monomer units other than conjugated diene) 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-based rubber include a method obtained by adding a modified compound to a polymerized product of the conjugated diene monomer (hereinafter, also referred to as “production method (1)”), and a conjugated diene polymer. (Hereinafter, also referred to as “manufacturing 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 end 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 end 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-based rubber (hereinafter, also referred to as “unmodified conjugated diene-based 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, a solution polymerization method, or the like.
- a known or known method can be applied.
- a Cheegler catalyst e.g., a metallocene catalyst
- an anionic polymerizable active metal or active metal compound e.g., a polar compound.
- the solvent examples include aliphatic hydrocarbons such as n-butane, n-pentane, isopentan, n-hexane, n-heptane and isooctane; alicyclic hydrocarbons such as cyclopentane, cyclohexane and methylcyclopentane; benzene, Examples thereof include aromatic hydrocarbons such as toluene and xylene.
- anion-polymerizable active metal examples include alkali metals such as lithium, sodium and potassium; alkaline earth metals such as beryllium, magnesium, calcium, strontium and barium; and lanthanoid-based rare earth metals such as lanthanum and neodym. .. Among these anionic 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 moiety without inactivating the reaction.
- the polar compound include ether compounds such as dibutyl ether, tetrahydrofuran and ethylene glycol diethyl ether, 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 the 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-based rubber can be isolated by pouring the obtained polymerization reaction solution into a poor solvent such as methanol to precipitate a polymerized product, 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-based 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 by 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 and 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 antiaging 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 if necessary, nitrates, sulfuric acid and the like are used.
- 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, by washing with water, dehydrating, and then drying, an unmodified conjugated diene-based rubber can be obtained.
- latex and extended 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 fiber.
- 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 the 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 such as maleic anhydride, citraconic anhydride, 2,3-dimethylmaleic anhydride, and itaconic anhydride.
- Carboxylic acid anhydrides unsaturated carboxylic acid esters such as maleic acid ester, fumaric acid ester, citraconic acid ester, and itaconic acid ester
- unsaturated carboxylic acid amides such as maleic acid amide, fumaric acid amide, citraconic acid amide, and itaconic acid amide.
- Saturated carboxylic acid imides such as maleic acid 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 -Mercaptpropyldimethoxymethylsilane, 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 1 to 1 to 50 parts by mass with respect to 100 parts by mass of the unmodified conjugated diene rubber. It is more preferably 30 parts by mass.
- 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, a compound such as water, etc. There is a method of reacting.
- the amount of the modified compound added to the modified conjugated diene rubber is preferably 0.5 to 40 parts by mass, 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 rubber is not particularly limited, and is selected from, for example, a liquid unmodified conjugated diene rubber, an unsaturated carboxylic acid, an unsaturated carboxylic acid derivative, a silane compound, and the like.
- examples thereof include a method of adding one or more modified compounds and, if necessary, a radical generator, and heating 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 a hydrocarbon solvent and a halogenated hydrocarbon solvent.
- 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.
- Anti-aging agents include 2,6-di-butyl-4-methylphenol (BHT), 2,2'-methylenebis (4-methyl-6-t-butylphenol), and 4,4'-thiobis (3-methyl).
- Phosphoric acid-based antioxidant N-phenyl-N'-(1,3-dimethylbutyl) -p-phenylenediamine (Nocrack 6C), bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate (LA-77Y), N, N-dioctadecyl hydroxylamine (IrgastabFS042), bis (4-t-octylphenyl) amine (Irganox5057) and other amine-based antioxidants; dioctadecyl 3,3'-dithiobispropio Nate, didodecyl-3,3'-thiodipropionate (IrganoxPS800), bis [3- (dodecylthio) propionic acid-2,2-bis [3- (dodecylthio) -1-oxopropyloxy] methyl] -1, Sulfur-based antioxidants such as 3-propanediyl (
- One type of antiaging agent may be used alone, or two or more types may be used in combination. Among these, it is effective and versatile to use 2,6-di-butyl-4-methylphenol, N-phenyl-N'-(1,3-dimethylbutyl) -p-phenylenediamine (Nocrack 6C) and the like. It is preferable in terms of.
- 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, 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 more than 2,000, more preferably 5,000 or more, and more preferably 10,000, 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 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 the viscosity of the conjugated diene rubber is small and the 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-based 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, still more 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 units having bonds other than 1,4-bonds).
- the vinyl content is derived from the signal derived from the conjugated diene unit bonded by 1,2-bond or 3,4-bond using 1 H-NMR and the conjugated diene unit bonded by 1,4-bond. It can be calculated from the integrated value ratio of the signals of.
- an adhesive layer by adhering an adhesive component composed of an emulsion in which the conjugated diene rubber is dispersed in water to a 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.
- emulsifier examples include fatty acid soaps such as potassium or sodium salts such as oleic acid, lauric acid, myristic acid, palmitic acid and stearic acid, resin soaps such as potassium or sodium salts such as rosin and disproportionated rosin, alkylbenzene sulfonic acids and alkyls.
- fatty acid soaps such as potassium or sodium salts such as oleic acid, lauric acid, myristic acid, palmitic acid and stearic acid
- resin soaps such as potassium or sodium salts such as rosin and disproportionated rosin, alkylbenzene sulfonic acids and alkyls.
- Sulfonic acid soap such as sodium or potassium salt such as naphthalene sulfonic acid, sulfate ester soap such as sodium salt such as oleyl sulfate ester, lauryl sulfate ester, polyoxyethylene alkyl sulfate ester, hexadecyl phosphate, polyoxyethylene lauryl ether phos.
- Anionic soaps such as phosphate soaps such as fate, polyoxyethylene tridecyl ether phosphate and polyoxyethylene nonylphenyl phosphate, nonion soaps such as polyoxyethylene nonylphenyl ether, polyethylene glycol laurate and polyethylene glycol oleate, Examples thereof include aliphatic amine hydrochlorides such as dodecylamine hydrochloride, cation soaps such as octyltrimethylammonium chloride, dioctyldimethylammonium chloride, benzyldimethyloctylammounium salt, and alkylpyridium salts such as dodecylpyridium chloride. These may be used alone or in combination.
- the amount of the emulsifier used is preferably 0.5 to 15 parts by mass, more preferably 1 to 10 parts by mass with respect to 100 parts by mass of the conjugated diene rubber.
- the amount of the emulsifier used is not more than the above upper limit, the emulsion can be stably produced while suppressing the production cost. Further, when the amount of the emulsifier used is at least the above lower limit, it is possible to suppress an increase in the emulsion particle size and suppress the occurrence of creaming and separation phenomena.
- alkaline substances such as sodium hydroxide, potassium hydroxide and amines can be added as needed to adjust the pH before use.
- 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, from the viewpoint of improving the adhesive force with the rubber. It is 10% by mass or more, and 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 conjugated diene rubber 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-based rubber as long as the adhesive force with the rubber is not impaired.
- the other components include other polymers (for example, unmodified conjugated diene-based rubber), acids, alkalis, antioxidants, curing agents, dispersants, pigments, dyes, adhesive aids, carbon black and the like.
- the adhesive component contains another component, the content thereof is preferably 10,000 parts by mass or less, and 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, further preferably 50 parts by mass or less.
- the method for producing the reinforcing fiber is not particularly limited, and the fiber can be produced by a method including a step of adhering the conjugated diene rubber to the fiber in a state of being dispersed in water.
- the above-mentioned is made from the viewpoint of efficiently adhering the conjugated diene rubber to the surface-modified fiber (fiber having a surface-modified layer on the surface) and from the viewpoint of suppressing contamination of the manufacturing equipment.
- a method including a step of adhering the conjugated diene rubber to the fiber in a state of being mixed with the oil may be adopted.
- 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 dipping, 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 10 parts by mass or less, 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 8 parts by mass or less. Is more preferable, and 7 parts by mass or less is further preferable.
- the reinforcing fiber of the present invention can be obtained by adhering the adhesive component to the surface-modified fiber and then blending it at room temperature of about 20 ° C. for about 3 to 10 days.
- Step I-2 may be carried out.
- 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 or more. It is preferable to carry out the treatment with a processing time of 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. or lower.
- 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 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 industrially produce it. Further, when the single yarn fineness is 30 dtex or less, the surface area of the fiber when it is made into 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 even more preferably 20 dtex or less, still more preferable. Is preferably a multifilament having 15 dtex or less, more preferably 10 dtex or less.
- the rubber adhesive strength of the reinforcing fiber of the present invention is preferably 30N / 3 or more, more preferably 40N / 3 or more, further preferably 50N / 3 or more, and 60N / 3 or more.
- the above is more preferable, and it is usually 200 N / 3 or less.
- the rubber adhesive strength of the reinforcing fiber is at least the above lower limit value, a woven fabric, a knitted fabric, and a molded body having excellent reinforcing strength can be obtained.
- the rubber adhesive strength of the reinforcing fiber can be measured by the method described in Examples.
- the reinforcing fiber may have a fiber strength of 4 cN / dtex or more and 20 cN / dtex or less.
- PET or nylon fiber having a strength of 6 cN / dtex or more is preferable.
- vinylon or PET having a strength of 6 cN / dtex or more is preferable.
- 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 at least in 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 contained in a part. For example, as 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. It is more preferable to use it as a laminated body in which a reinforcing layer made of a knitted fabric and a rubber layer are laminated.
- the rubber molded body can be used, for example, as a member of a tire such as an automobile tire, a belt such as a conveyor belt or a timing belt, a hose, and a rubber product such as a vibration-proof rubber.
- a tire, a belt, or a hose It is more preferable to use it as a tire.
- 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, particularly a liquid fuel hose for automobiles and a brake for automobiles. It is preferably used for oil hoses and fluid hoses, and more preferably used 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 NR
- BR BR
- SBR SBR
- One of these rubber components may be used alone, or two or more of them may be used in combination.
- those commonly used in the tire industry can be used.
- natural rubber alone or a combination of natural rubber and SBR, natural rubber and BR, and SBR and BR.
- the natural rubber is generally used in the tire industry such as TSR (Technically Specified Rubber) such as SMR (Malaysia TSR), SIR (Indonesian TSR), STR (Thai TSR) and RSS (Ribbed Smoked Sheet).
- TSR Technicalnically Specified Rubber
- SMR Magnetic Reliable TSR
- SIR Indonesian 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, a vinyl content of 0.1 to 60% by mass is preferable, and a vinyl content of 0.1 to 55% by mass is more preferable.
- 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 effect of the present invention is 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 examples include inorganic fillers such as carbon black, silica, clay, mica, calcium carbonate, magnesium hydroxide, aluminum hydroxide, barium sulfate, titanium oxide, glass fibers, fibrous fillers, and glass balloons; resin particles, Examples thereof include organic fillers such as wood flour and cork flour.
- 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 the 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 (anhydrous silicic acid), 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.
- 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, phenolic resins, amino resins, quinone and quinonedioxime derivatives, halogen compounds, aldehyde compounds, alcohol compounds, epoxy compounds, metal halides and organics. Examples thereof 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, for example, when sulfur, a sulfur compound, or the like is contained as a cross-linking agent for cross-linking (vulcanizing) the rubber component.
- a vulcanization accelerator for example, when sulfur, a sulfur compound, or the like is contained as a cross-linking agent for cross-linking (vulcanizing) the rubber component.
- the brewing accelerator include guanidine-based compounds, sulfenamide-based compounds, thiazole-based compounds, thiuram-based compounds, thiourea-based compounds, dithiocarbamic acid-based compounds, aldehyde-amine-based compounds, aldehyde-ammonia-based compounds, and imidazoline. Examples thereof include system compounds and xantate 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
- 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, process oils such as naphthenic oil, aliphatic hydrocarbon resins, alicyclic hydrocarbon resins, C9 resins, rosin resins, kumaron-inden resins, phenolic resins, etc.
- the resin component of 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 is used as an antioxidant, 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, phosphorus compounds and the like. 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 body 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 is formed on the outer surface of the inner rubber layer.
- second reinforcing layer an intermediate rubber layer is further formed on the outer surface of the first reinforcing layer, and the reinforcing fiber is woven on the outer surface of the intermediate rubber layer (second reinforcing layer).
- a reinforcing layer) may be formed. Then, it can be manufactured 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 strength 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 substituted with nitrogen, 1140 g of hexane and 20.9 g of n-butyllithium (17 mass% hexane solution) are charged, and the temperature is adjusted to 50 ° C. After raising the temperature, 1390 g of butadiene was sequentially added and polymerized for 1 hour under stirring conditions while controlling the polymerization temperature to be 50 ° C. 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 substituted with nitrogen, 1140 g of hexane and 20.9 g of n-butyllithium (17 mass% hexane solution) are charged, and the temperature is adjusted to 50 ° C. After raising the temperature, 1390 g of butadiene
- 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 is substituted with nitrogen, and 1260 g of hexane and 36.3 g of n-butyllithium (17 mass% hexane solution) are charged and heated 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 the mixture was polymerized 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
- Production Example 3 Production of Modified Conjugated Diene Rubber (A-3) 9.0 g of methanol was added to 525 g of maleic anhydride-modified liquid polybutadiene (A-1) obtained in Production Example 1 and 6 at 80 ° C. The reaction was carried out for a period of time to obtain monomethyl maleate-modified liquid polybutadiene (A-3).
- the methods for measuring and calculating the physical properties of the polyamine compound and the modified conjugated diene rubber are as follows. The results are shown in Tables 1 and 2. ⁇ Measurement method of weight average molecular weight, number average molecular weight and molecular weight distribution>
- the weight average molecular weight (Mw) of the polyamine compound, the weight average molecular weight (Mw), the number average molecular weight (Mn) and the molecular weight distribution (Mw / Mn) of the modified conjugated diene rubber are determined by standard polystyrene by GPC (gel permeation chromatography). Obtained as a converted value.
- 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 modified conjugated diene-based rubber was calculated from the following formula 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. ..
- Average number of hydrogen-bonding functional groups per molecule [(number average molecular weight (Mn)) / (molecular weight of styrene unit) ⁇ (conjugated diene and, if necessary, average of other monomer units other than conjugated diene) 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-modified conjugated diene-based rubber maleate was calculated for the maleic anhydride-modified conjugated diene-based rubber and monomethyl-modified conjugated diene-based maleate.
- the acid value of the rubber was determined, and the equivalent amount (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 is calculated by the following formula, and further, the maleic anhydride-modified conjugated diene-based rubber is 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 of the hydrogen-bonding functional group (g / eq) was calculated from the following formula.
- Table 2 shows the compounds used for the surface modification layer and their characteristics.
- a twisted fiber cord was prepared by multiplying two nylon fibers (total fineness 1400 dtex, single yarn fineness 6.86 dtex), which are polyamide fibers, at an upper twist of 470 times / m and a lower twist of 470 times / m.
- the twisted fiber cord was immersed in an aqueous solution containing a 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 210 ° C. for 60 seconds to prepare a surface-modified fiber.
- A-2 modified conjugated diene rubber
- the fiber was squeezed with a roller, dried at 140 ° C. for 60 seconds, and then wound to prepare a reinforcing fiber.
- Example 8 Reinforcing fibers were produced in the same manner as in Example 1 except that the fibers were changed to vinylon fibers (total fineness 1200 dtex, single yarn fineness 6.00 dtex) which are polyvinyl alcohol-based 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.
- 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 flower, stealic acid): 6 parts by mass Vulcanization accelerator (thiazole type): 1 part by mass
- the fiber and the rubber can be firmly adhered without using resorcinol, formaldehyde and an epoxy compound.
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Abstract
Description
従来、かかる接着方法として、特許文献1ではレゾルシノール・ホルムアルデヒド樹脂とゴムラテックスとを主成分とするRFLと呼ばれる接着剤を用いる方法が広く知られている。また、特許文献2ではRFLを内部まで含浸させることで強度の保持や耐疲労性の改善を行う工夫がなされている。
また、特許文献3~5において使用されているエポキシ化合物は、変異原性や皮膚感作性等の要因になる可能性があるため作業環境上好ましくないという問題がある。
[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、前記表面改質層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であり、
前記表面改質層が、1~3級アミノ基、及びイミノ基から選ばれる1種以上の官能基を有し、重量平均分子量(Mw)が300以上であるポリアミン化合物を含むことを特徴とする補強繊維。
[2]前記繊維が、ポリアミド系繊維、ポリビニルアルコール系繊維、ポリエステル系繊維、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]に記載の補強繊維。
[3]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0.01~5.00質量部である、前記[1]又は[2]に記載の補強繊維。
[4]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[1]~[3]のいずれかに記載の補強繊維。
[6]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、カルボニル基、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[1]~[5]のいずれかに記載の補強繊維。
[7]前記[1]~[6]のいずれかに記載の補強繊維を用いた、成形体。
[8]更にゴム層を有する、前記[7]に記載の成形体。
[9]前記成形体がタイヤ、ベルト又はホースである、前記[7]又は[8]に記載の成形体。
本発明の補強繊維は、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、前記表面改質層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であり、前記表面改質層が、1~3級アミノ基、及びイミノ基から選ばれる1種以上の官能基を有し、重量平均分子量(Mw)が300以上であるポリアミン化合物を含むことを特徴とするものである。
本発明によれば、繊維表面の少なくとも一部に特定のポリアミン化合物を含む表面改質層を設けているため、共役ジエン系ゴムと、ポリアミン化合物の置換基と、繊維との間でそれぞれ強い親和性が発現し、その結果、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。
また、本発明において「表面改質層の少なくとも一部を覆う接着層」とは、表面改質層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。
本発明における表面改質層は、1~3級アミノ基、及びイミノ基から選ばれる1種以上の官能基を有し、重量平均分子量(Mw)が300以上であるポリアミン化合物を含むものであれば特に制限はない。なお、本発明において「ポリアミン化合物」とは1分子中にアミノ基を2つ以上含む脂肪族化合物を指す。
前記1~3級アミノ基としては、下記一般式(I)~(III)で表される置換基が挙げられる。
-R1-NH2 (I)
-R1-NR2H (II)
-R1-NR2R3 (III)
(R1は、置換基を有していてもよい炭素数が1~20である直鎖状又は分岐状アルキレン鎖である。また、R2及びR3は、それぞれ独立して、置換基を有していてもよい炭素数1~20である直鎖状又は分岐状アルキル基である。)
これらのアミノ基の中でも、接着性を向上させる観点から、前記一般式(I)で表される1級アミノ基又は前記一般式(II)で表される2級アミノ基が好ましい。
また、前記イミノ基としては、炭素-窒素二重結合を有する基であれば特に制限はなく、例えばエチリデンアミノ基、1-メチルプロピリデンアミノ基、1,3-ジメチルブチリデンアミノ基、1-メチルエチリデンアミノ基、4-N,N-ジメチルアミノベンジリデンアミノ基、シクロヘキシリデンアミノ基等が挙げられる。
なお、接着性を向上させる観点から、ポリアミン化合物の重量平均分子量は500以上であってもよく、800以上であってもよく、1,000以上であってもよく、1,500以上であってもよい。
なお、ポリアミン化合物の重量平均分子量の上限値は、取り扱い性の低下に伴う生産効率の悪化を考慮すると、一般的に1,000,000以下であり、800,000以下であってもよい。
なお、ポリアミン化合物の重量平均分子量は、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。
本発明の表面改質繊維に用いる繊維に特に制限はなく、親水性繊維や疎水性繊維を用いることができる。なお、本発明において「繊維」とは、短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。
表面改質層を表面に有する繊維の製造方法に特に制限はないが、前記ポリアミン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。
前記表面改質層を構成する化合物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、20質量%以下であることが好ましく、10質量%以下であることがより好ましく、5質量%以下であることが更に好ましい。
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、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。
なお、本発明において共役ジエン系ゴムがエポキシ基を有する場合、エポキシ基1個当たりの重量平均分子量は1,000以上であり、一方、前述の先行技術文献に記載の発明で用いられているエポキシ化合物は、エポキシ基1個当たりの分子量が1,000未満であり、両者はエポキシ基1個当たりの分子量の点で相違するものである。
これらの水素結合性官能基の中でも、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、及び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、及び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。
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、及びキシレン等の炭化水素系溶媒が好ましい。
これらの中でも、2,6-ジ-ブチル-4-メチルフェノール、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(ノクラック6C)等を用いることが効果や汎用性の面で好ましい。
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。
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。
エマルションの安定性を高める目的で、必要に応じて水酸化ナトリウム、水酸化カリウム、アミン類のようなアルカリ性物質を添加し、pHを調整して使用することもできる。
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、10,000質量部以下であることが好ましく、1,000質量部以下であることがより好ましく、100質量部以下であることが更に好ましく、50質量部以下であることがより更に好ましい。
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。なお、本発明においては、前記表面改質繊維(表面に表面改質層を有する繊維)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を採用してもよい。
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。
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。
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、BR、SBR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、天然ゴムとBR、SBRとBRとを組み合わせて使用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。
<変性共役ジエン系ゴムの製造>
・下記式(1a)で表される単量体単位を有する変性共役ジエン系ゴムの製造
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、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’-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)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-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525gに対し、メタノールを8.5g添加し、80℃で6時間反応させて、マレイン酸モノメチル変性液状ポリブタジエン(A-2)を得た。
製造例1で得られた無水マレイン酸変性液状ポリブタジエン(A-1)525gに対し、メタノールを9.0g添加し、80℃で6時間反応させて、マレイン酸モノメチル変性液状ポリブタジエン(A-3)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>
ポリアミン化合物の重量平均分子量(Mw)、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〕)
〔B-1〕
ポリエチレンイミン(株式会社日本触媒製 SP-200)
〔B-2〕
ポリアリルアミン(ニットーボーメディカル株式会社製 PAA-15)
〔B-3〕
ポリアリルアミン(ニットーボーメディカル株式会社製 PAA-01)
〔B-4〕
ポリエチレンイミン(株式会社日本触媒製 SP-006)
〔B-5〕
ポリアリルアミン(ニットーボーメディカル株式会社製 PAS-21)
〔B-6〕
ポリエチレンイミン(BASFジャパン株式会社製 Lupasolシリーズ)
4級アンモニウム含有アクリルポリマー(大成ファインケミカル株式会社1WX-1020)
〔X-2〕
エチレンジアミン(富士フィルム和光純薬株式会社製)
〔X-3〕
トリエチレンテトラミン(富士フィルム和光純薬株式会社製)
〔X-4〕
ペンタエチレンヘキサミン(富士フィルム和光純薬株式会社製)
表1に記載の各変性共役ジエンゴム300gに非イオン性界面活性剤18gを添加し、均一に混合した。次いで、撹拌を継続しながら水酸化ナトリウム水溶液682gを徐々に添加し、固形分30質量部のエマルションを得た。
表2に記載の化合物5gと、水955gとを混合することにより、表面改質層を構成する水溶液をそれぞれ調製した。
ポリアミド系繊維であるナイロン繊維(総繊度1400dtex、単糸繊度6.86dtex)2本を、上撚470回/m、下撚470回/mで掛けることにより、撚り合わせ繊維コードを作製した。
前記撚り合わせ繊維コードを、表面改質剤(B-1)を含む水溶液中に浸漬した後、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210℃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、変性共役ジエン系ゴム(A-2)を含むエマルションに浸漬した後、ローラーで搾液し140℃で60秒間乾燥処理した後に巻き取ることにより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。
繊維を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1200dtex、単糸繊度6.00dtex)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。
参考例1としてポリアミド系繊維であるナイロン6繊維(繊度1400dtex、単糸繊度6.86dtex)2本、参考例2としてポリビニルアルコール系繊維であるビニロン繊維(繊度1200dtex、単糸繊度6.00dtex)2本を、それぞれ、上撚470回/m、下撚470回/mを掛けることにより撚り合わせ繊維コードを作製した。これを後述のRFL液に浸漬した後、ローラーで搾液し付与し140℃で60秒間乾燥し、更に210℃で60秒間熱処理することにより参考例1及び2の補強繊維を作製した。
なお、使用したRFL液は下記の方法にて調製した。
A液
水 :1727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、比較例及び参考例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た。この評価用試供体をゴムから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。
前述の実施例、比較例及び参考例で作製した補強繊維を、後述の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評価用供試体を作製した。
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
Claims (9)
- 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、前記表面改質層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であり、
前記表面改質層が、1~3級アミノ基、及びイミノ基から選ばれる1種以上の官能基を有し、重量平均分子量(Mw)が300以上であるポリアミン化合物を含むことを特徴とする補強繊維。 - 前記繊維が、ポリアミド系繊維、ポリビニルアルコール系繊維、ポリエステル系繊維、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に記載の補強繊維。
- 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0.01~5.00質量部である、請求項1又は2に記載の補強繊維。
- 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1~3のいずれかに記載の補強繊維。
- 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1~4のいずれかに記載の補強繊維。
- 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、カルボニル基、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1~5のいずれかに記載の補強繊維。
- 請求項1~6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7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7又は8に記載の成形体。
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JPS60209071A (ja) * | 1984-03-26 | 1985-10-21 | 株式会社クラレ | 繊維処理剤 |
EP3258006A1 (de) | 2016-06-14 | 2017-12-20 | Continental Reifen Deutschland GmbH | Verfahren zur herstellung einer festigkeitsträgerlage, festigkeitsträgerlage und fahrzeugreifen |
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JP3157587B2 (ja) | 1991-03-13 | 2001-04-16 | 株式会社ブリヂストン | ゴム補強用ポリアミド繊維コード |
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JPS4017131B1 (ja) * | 1962-01-09 | 1965-08-04 | ||
JPS4927440B1 (ja) * | 1969-01-14 | 1974-07-17 | ||
JPS60209071A (ja) * | 1984-03-26 | 1985-10-21 | 株式会社クラレ | 繊維処理剤 |
EP3258006A1 (de) | 2016-06-14 | 2017-12-20 | Continental Reifen Deutschland GmbH | Verfahren zur herstellung einer festigkeitsträgerlage, festigkeitsträgerlage und fahrzeugreifen |
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