Patent Application
20180371213
The present technology relates to a rubber composition, a rubber composition metal laminate, and a vulcanized rubber product, and particularly relates to a rubber composition containing a vulcanizing agent, a rubber composition metal laminate, and a vulcanized rubber product.
Conventionally, chloroprene rubber compositions for manufacturing hydraulic hose and high pressure hose in which a reinforcing layer having a surface plated with a metal such as brass is sandwiched between a pair of rubber layers have been proposed (e.g. see Japanese Unexamined Patent Application Publication No. 2001-279022). Since this rubber composition contains a vulcanization accelerator such as sulfurs and guanidines, crosslinking characteristics of a rubber layer formed from the rubber composition is enhanced, and excellent adhesion between a metal surface of a reinforcing layer and the rubber layer is achieved.
Methods of producing the hose described above include a steam vulcanization method in which the rubber composition is heated and vulcanized by steam, and an oven vulcanization method in which the rubber composition is vulcanized by an oven. Since the oven vulcanization method allows continuous vulcanization, productivity of hose can be enhanced.
However, when vulcanization of a rubber composition is performed by the oven vulcanization method, sufficient adhesion between the rubber layer and the reinforcing layer may not be always obtained due to vaporization of remarkable amount of water during the vulcanization. Therefore, there has been a demand for a rubber composition that can provide a rubber layer having excellent adhesion to a metal surface of a reinforcing layer even when vulcanization is performed by a hot-air vulcanization method such as the oven vulcanization method, besides the steam vulcanization method.
The present technology provides a rubber composition that can provide a rubber layer having excellent adhesion to metal surfaces, a rubber composition metal laminate, and a vulcanized rubber product.
The rubber composition of the present technology contains, per 100 parts by mass of diene polymer that can be vulcanized by sulfur, from 0.5 parts by mass to 4 parts by mass of sulfur, and from 0.004 mol to 0.17 mol of a polyhydric alcohol compound having a molecular weight of 300 or less.
According to this rubber composition, since the content of the sulfur and the equivalent weight of hydroxy groups derived from the polyhydric alcohol compound in the rubber composition are in appropriate ranges, a catalytic function of bond forming reaction between the sulfur and the metal surface due to the polyhydric alcohol compound is efficiently exhibited. As a result, this rubber composition can provide a rubber layer having excellent adhesion to metal surfaces of reinforcing layers even when vulcanization is performed by a hot-air vulcanization method, by which the composition tends to be dried, or a steam vulcanization method.
In the rubber composition of the present technology, the polyhydric alcohol compound is preferably a compound represented by the general formula (1) below.
In Formula (1), R1 represents a hydrogen atom or a mono- or poly-hydroxy alkyl group that may have an ether bond and a branch and that has from 1 to 5 carbons, and R2 represents a mono- or poly-hydroxy alkyl group that may have an ether bond and a branch and that has from 1 to 5 carbons.
The rubber composition metal laminate of the present technology has a reinforcing layer having a metal surface, and a rubber layer containing the rubber composition described above provided on the metal surface.
According to this rubber composition metal laminate, since the content of the sulfur and the equivalent weight of hydroxy groups derived from the polyhydric alcohol compound in the rubber composition are in appropriate ranges, a catalytic function of bond forming reaction between the sulfur and the metal surface due to the polyhydric alcohol compound is efficiently exhibited. Such a catalytic function allows a rubber composition metal laminate to have excellent adhesion between the rubber layer and the metal surface of the reinforcing layer even when vulcanization is performed by a hot-air vulcanization method, by which the composition tends to be dried, or a steam vulcanization method.
In the rubber composition metal laminate of the present technology, the metal surface is preferably brass-plated.
In the rubber composition metal laminate of the present technology, the reinforcing layer preferably has a braided structure in which wires are braided or a spiral structure.
A vulcanized rubber product of the present technology is obtained by using the rubber composition described above.
The vulcanized rubber product of the present technology is preferably a vulcanized rubber product in which the rubber layer of the rubber composition metal laminate described above is adhered to the reinforcing layer by vulcanization in the presence of sulfur.
The vulcanized rubber product of the present technology is preferably a hose.
According to the present technology, a rubber composition that can provide a rubber layer having excellent adhesion to metal surfaces, a rubber composition metal laminate, and a vulcanized rubber product are provided.
Embodiments of the present technology are described in detail below with reference to the accompanying drawings. Note that the present technology is not limited to the embodiment described below and can be performed with suitable modifications.
The rubber composition according to the present embodiment contains, per 100 parts by mass of a diene polymer that can be vulcanized by sulfur, from 0.5 parts by mass to 4 parts by mass of sulfur, and from 0.004 mol to 0.17 mol of a polyhydric alcohol compound having a molecular weight of 300 or less. According to this rubber composition, since a predetermined amount of sulfur and a predetermined amount of polyhydric alcohol compound are blended to the diene polymer, the content of the sulfur and the equivalent weight of hydroxy groups in the rubber composition are in appropriate ranges, and a catalytic function of bond forming reaction between the sulfur and the metal surface due to the polyhydric alcohol compound is efficiently exhibited. As a result, this rubber composition can provide a rubber layer having excellent adhesion between the rubber layer and the metal surface even when vulcanization is performed by a steam vulcanization method or a hot-air vulcanization method, by which the composition tends to be dried and by which the amount of water having the catalytic function of the bond forming reaction between the sulfur and the metal surface decreases. The components of the rubber composition according to the present embodiment are described in detail below.
As the diene polymer, a diene polymer that can be vulcanized by sulfur is used. Here, “can be vulcanized by sulfur” means having a property that can form a crosslinking structure via sulfur. Examples of the other diene polymer include a natural rubber (NR), chloroprene rubber (CR), isoprene rubber (IR), styrene butadiene rubber (SBR), acrylonitrile-butadiene rubber (NBR), ethylene-propylene-diene rubber (EPDM), chlorinated polyethylene rubber (CM), and chlorosulfonated polyethylene rubber (CSM). By using these, various physical properties required for a rubber composition for hose can be exhibited at a high level. Among these, from the perspective of achieving high adhesion between the metal surface of the reinforcing layer and the rubber layer, chloroprene rubber (CR), styrene butadiene rubber (SBR), acrylonitrile-butadiene rubber (NBR), and ethylene-propylene-diene rubber (EPDM) are preferable. One type of these diene polymers may be used alone, or two or more types of these diene polymers may be used in a combination.
The compounded amount of the diene polymer is preferably from 20 mass % to 70 mass % relative to the total amount of the rubber composition from the perspective of imparting good mixing processability and good appearance to the rubber.
The rubber composition according to the present embodiment contains sulfur as the vulcanizing agent. Examples of the sulfur include powdered sulfur, precipitated sulfur, highly dispersible sulfur, surface treated sulfur, and insoluble sulfur.
The content of sulfur is from 0.5 parts by mass to 4.0 parts by mass per 100 parts by mass of the diene polymer. When the content of the sulfur is from 0.5 parts by mass to 4.0 parts by mass, bonding between the sulfur and the metal surface is sufficiently formed during the vulcanization of the rubber composition, thereby achieving sufficient adhesion between the rubber layer and the metal surface. From the perspective of adhesion between the rubber layer and the metal surface, the content of the sulfur is preferably 0.55 parts by mass or greater, more preferably 0.6 parts by mass or greater, even more preferably 0.65 parts by mass or greater, and yet even more preferably 0.7 parts by mass or greater, but preferably 3.75 parts by mass or less, more preferably 3.5 parts by mass or less, even more preferably 3.25 parts by mass or less, and yet even more preferably 3.0 parts by mass or less, per 100 parts by mass of the diene polymer. Taking these into consideration, the content of sulfur is preferably from 0.55 parts by mass to 3.75 parts by mass, more preferably from 0.6 parts by mass to 3.5 parts by mass, even more preferably from 0.65 parts by mass to 3.25 parts by mass, and yet even more preferably from 0.7 parts by mass to 3.0 parts by mass, per 100 parts by mass of the diene polymer.
The rubber composition according to the present embodiment may contain a vulcanizing agent other than sulfur in a range that the effect of the present technology can be exhibited. Examples of the vulcanizing agent other than sulfur include sulfur-based, organic peroxide-based, metal oxide-based, phenol resin, quinone dioxime, and the like. One type of these may be used alone, or two or more types of these may be used in a combination. Examples of the sulfur-based vulcanizing agent include sulfur-containing organic compounds, such as tetramethylthiuram disulfide (TMTD), tetraethylthiuram disulfide (TETD), tetrabutylthiuram disulfide (TBTD), dipentamethylenethiuram tetrasulfide (DPTT), tetrabenzylthiuram disulfide, dimorpholine disulfide, and alkylphenol disulfide.
Examples of the organic peroxide-based vulcanizing agent include dicumyl peroxide, benzoyl peroxide, t-butyl hydroperoxide, 2,4-dichlorobenzoyl peroxide, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, and 2,5-dimethylhexane-2,5-di(peroxyl benzoate).
Examples of the other vulcanizing agent include zinc oxide, magnesium oxide, resins such as phenol resin, p-quinone dioxime, p-dibenzoylquinone dioxime, poly-p-dinitrosobenzene, methylenedianiline, and the like.
The rubber composition according to the present embodiment preferably further contains a vulcanization accelerator. Examples of the vulcanization accelerator include aldehyde-ammonia-based vulcanization accelerators, aldehyde-amine-based vulcanization accelerators, thiourea-based vulcanization accelerators, guanidine-based vulcanization accelerators, thiazole-based vulcanization accelerators, sulfenamide-based vulcanization accelerators, thiuram-based vulcanization accelerators, dithiocarbamate-based vulcanization accelerators, and xanthogenate-based vulcanization accelerators. These may be used alone, or two or more may be used in combination.
Examples of the thiuram-based vulcanization accelerator include tetramethylthiuram monosulfide (TS), tetramethylthiuram disulfide (TT), and the like. Examples of the guanidine-based vulcanization accelerator include diphenylguanidine and the like. Examples of the sulfenamide-based vulcanization accelerator include N-t-butylbenzothiazole-2-sulfenamide and the like. Examples of the thiourea-based vulcanization accelerator include ethylene thiourea and the like.
From the perspective of enhancing the adhesion between the rubber layer using the rubber composition and a metal surface by enhancing vulcanization characteristics thereof, the content of the vulcanization accelerator is preferably 0.5 parts by mass or greater, more preferably 0.75 parts by mass or greater, and even more preferably 1.0 part by mass or greater, but preferably 3.5 parts by mass or less, more preferably 3.0 parts by mass or less, and even more preferably 2.5 parts by mass or less, per 100 parts by mass of the diene polymer. Polyhydric alcohol
The rubber composition according to the present embodiment contains a polyhydric alcohol compound having a molecular weight of 300 or less. As the polyhydric alcohol compound, various compounds can be used in the range that achieves the effect of the present technology as long as the polyhydric alcohol compound is a compound having two or more hydroxy groups and a molecular weight of 300 or less. Since the polyhydric alcohol compound has a function to catalyze the bond forming reaction between the sulfur as a vulcanizing agent and the metal atom of the metal surface during the vulcanization of the rubber composition, the adhesion between the rubber layer containing the rubber composition and the metal surface can be enhanced.
In the rubber composition according to the present embodiment, the polyhydric alcohol compound is preferably a polyhydric alcohol compound represented by the general formula (1) below from the perspective of adhesion between the rubber layer containing the rubber composition and a reinforcing layer.
In Formula (1), R1 represents a hydrogen atom or a mono- or poly-hydroxy alkyl group that may have an ether bond and a branch and that has from 1 to 5 carbons, and R2 represents a mono- or poly-hydroxy alkyl group that may have an ether bond and a branch and that has from 1 to 5 carbons.
In the general formula (1) above, examples of R1 include a hydroxymethyl group, a 1-hydroxyethyl group, a 2-hydroxyethyl group, a dihydroxyethyl group, a 1-hydroxypropyl group, a 2-hydroxypropyl group, a 3-hydroxypropyl group, a dihydroxypropyl group, a trihydroxypropyl group, a 1-hydroxybutyl group, a 2-hydroxybutyl group, a 3-hydroxybutyl group, a 4-hydroxybutyl group, a dihydroxybutyl group, a trihydroxybutyl group, a tetrahydroxybutyl group, a pentahydroxybutyl group, a 1-hydroxypentyl group, a 2-hydroxypentyl group, a 3-hydroxypentyl group, a 4-hydroxypentyl group, a 5-hydroxypentyl group, a dihydroxypentyl group, a trihydroxypentyl group, a tetrahydroxypentyl group, a pentahydroxypentyl group, a methoxymethyl group, a hydroxyethoxyethyl group, a dihydroxypropoxymethyl group, a dihydroxypropoxyethyl group, a trihydroxypropoxymethyl group, a trihydroxypropoxyethyl group, and the like.
In the general formula (1) above, examples of R2 include a hydroxymethyl group, a 1-hydroxyethyl group, a 2-hydroxyethyl group, a dihydroxyethyl group, a 1-hydroxypropyl group, a 2-hydroxypropyl group, a 3-hydroxypropyl group, a dihydroxypropyl group, a trihydroxypropyl group, a 1-hydroxybutyl group, a 2-hydroxybutyl group, a 3-hydroxybutyl group, a 4-hydroxybutyl group, a dihydroxybutyl group, a trihydroxybutyl group, a tetrahydroxybutyl group, a pentahydroxybutyl group, a 1-hydroxypentyl group, a 2-hydroxypentyl group, a 3-hydroxypentyl group, a 4-hydroxypentyl group, a 5-hydroxypentyl group, a dihydroxypentyl group, a trihydroxypentyl group, a tetrahydroxypentyl group, a pentahydroxypentyl group, a methoxymethyl group, a hydroxyethoxyethyl group, a dihydroxypropoxymethyl group, a dihydroxypropoxyethyl group, a trihydroxypropoxymethyl group, a trihydroxypropoxyethyl group, and the like.
Examples of the polyhydric alcohol compound represented by the general formula (1) above include ethylene glycol, propylene glycol, butylene glycol, pentylene glycol, diethylene glycol, triethylene glycol, glycerin, 1,2,6-trihydroxyhexane, diglycerin, trimethylolpropane, pentaerythritol, sorbitol, hexanetriol, and the like. Among these, as the polyhydric alcohol compound, from the perspective of obtaining a rubber composition having excellent adhesion between the rubber layer using the rubber composition and a metal surface, at least one type selected from the group consisting of ethylene glycol, diethylene glycol, glycerin, hexanetriol, diglycerin, and sorbitol is preferable.
The content of the polyhydric alcohol compound is from 0.004 mol to 0.17 mol per 100 parts by mass of the diene polymer. When the content of the polyhydric alcohol compound is within the range described above, the equivalent weight of the hydroxy group in the rubber composition is set to the appropriate range, thereby exhibiting sufficient catalytic effect of the bonding reaction between the sulfur and the metal surface and thereby obtaining the composition having excellent adhesion between the rubber layer using the rubber composition and a metal surface. The content of the polyhydric alcohol compound is preferably 0.01 mol or greater, and more preferably 0.02 mol or greater, but preferably 0.165 mol or less, and more preferably 0.155 mol or less, per 100 parts by mass of the diene polymer. Taking these into account, the content of the polyhydric alcohol compound is preferably from 0.01 mol to 0.165 mol, and more preferably from 0.02 mol to 0.155 mol, per 100 parts by mass of the diene polymer.
The rubber composition may contain other additives, if necessary, in a range that the effect of the present technology can be exhibited. Examples of the other additive include fillers, plasticizers, softeners, anti-aging agents, organic activators, antioxidants, antistatic agents, flame retardants, crosslinking-accelerating auxiliaries, vulcanization retarders, antiozonants, process oils (aroma oils), and adhesive auxiliaries.
Examples of the fillers include carbon black, silica (white carbon black), clay, talc, iron oxide, zinc oxide (ZnO), titanium oxide, barium oxide, magnesium oxide, calcium carbonate, magnesium carbonate, zinc carbonate, barium sulfate, mica, diatomaceous earth, and the like. One type of these may be used alone, or two or more types of these may be used in a combination. As the carbon black, any carbon black can be suitably selected and used depending on the purpose. ISAF (Intermediate Super Abrasion Furnace) grade and FEF (Fast Extruding Furnace) grade carbon blacks are preferable. Examples of the silica include crystallized silica, precipitated silica, amorphous silica (e.g. high temperature treated silica), fumed silica, calcined silica, pulverized silica, molten silica, and the like. In particular, silica is known to generate a carbon gel (bound rubber) in the similar manner as in carbon black and can be suitably used if necessary. Examples of the clay include hard clay, pyropyllite clay, kaolin clay, calcined clay, and the like.
Examples of the plasticizer include dioctyl phthalate (DOP), dibutyl phthalate (DBP), dioctyl adipate (DOA), isodecyl succinate, di(ethylene glycol) dibenzoate, pentaerythritol ester, butyl oleate, methyl acetyl ricinoleate, tricresyl phosphate, trioctyl phosphate, trimellitic acid ester, propylene glycol adipate polyester, butylene glycol adipate polyester, naphthenic oil, and the like. One type of these may be used alone, or two or more types of these may be used in a combination.
Specific examples of the softener include aromatic oil, naphthenic oil, paraffinic oil, petroleum resin, vegetable oil, liquid rubber, and the like. One type of these may be used alone, or two or more types of these may be used in a combination.
Examples of the anti-aging agent include N-(1,3-dimethylbutyl)-N′-phenyl-p-phenylenediamine (6PPD), N,N′-dinaphthyl-p-phenylenediamine (DNPD), N-isopropyl-N′-phenyl-p-phenylenediamine (IPPD), styrenated phenol (SP), 2,2,4-trimethyl-1,2-dihydroquinoline polymer (RD), and the like. One type of these may be used alone, or two or more types of these may be used in a combination.
Examples of the organic activator include stearic acid, oleic acid, lauric acid, zinc stearate, and the like. One type of these may be used alone, or two or more types of these may be used in a combination.
Examples of the antioxidant include butylhydroxytoluene (BHT) and butylhydroxyanisole (BHA).
Examples of the antistatic agent include quaternary ammonium salts; and hydrophilic compounds such as polyglycols and ethylene oxide derivatives.
Examples of the flame retardant include chloroalkyl phosphates, dimethyl-methyl phosphonates, bromine-phosphorus compounds, ammonium polyphosphates, neopentyl bromide polyethers, brominated polyethers, and the like. Examples of non-halogen-based flame retardant include aluminum hydroxide, magnesium hydroxide, tricresyl phosphate, and diphenyl cresyl phosphate.
A conventional auxiliary for rubber can be used together as a cross-linking promoter. As the auxiliary for rubber, zinc oxide; stearic acid, oleic acid, and Zn salts of these can be used.
Examples of the vulcanization retarder include organic acids such as phthalic anhydride, benzoic acid, salicylic acid, and acetylsalicylic acid; nitroso compounds such as N-nitroso-diphenylamine, N-nitroso-phenyl-β-naphthylamine, and N-nitroso-trimethyl-dihydroquinoline polymer; halides such as trichloromelanine; 2-mercaptobenzimidazole, N-(cyclohexylthio)phthalimide (PVI), and the like. One type of these may be used alone, or two or more types of these may be used in a combination.
Examples of the adhesive auxiliary include triazine thiol compounds (e.g. 2,4,6-trimercapto-1,3,5-triazine and 6-butylamino-2,4-dimercapto-1,3,5-triazine), resorcin, cresol, resorcin-formalin latex, monomethylol melamine, monomethylol urea, ethylene maleimide, cobalt naphthenate, cobalt stearate, cobalt versatate, cobalt dodecanoate, and the like. One type of these adhesive auxiliaries may be used alone, or two or more types of these adhesive auxiliaries may be used in a combination.
The rubber composition according to the present embodiment can be produced by a conventionally known production method. An example of the method of producing the rubber composition according to the present embodiment is a production method including compounding the diene polymer described above, and as necessary, another diene polymer, a polymer other than the diene polymer, and various additives described above; and kneading the mixture using an internal mixer such as a Banbury mixer or a kneader, a roll kneader such as a roll, an extruder, a twin screw extruder, or the like. Rubber composition metal laminate
The rubber composition metal laminate according to the present embodiment is a laminate of the rubber composition and a wire reinforcing layer having a metal-plated surface. Examples of the laminate include high pressure hoses, hydraulic hoses, and the like.
As described above, the inner rubber layer 11 and/or the outer rubber layer 13 are rubber layers using the rubber composition according to the present embodiment. From the perspective of weather resistance of the hose, it is preferable to form at least the outer rubber layer 13 using the rubber composition according to the present embodiment. The inner rubber layer 11 is preferably formed by using a rubber composition containing an acrylonitrile butadiene rubber (NBR) having excellent oil resistance as a main component.
The thickness of the inner rubber layer 11 is, for example, preferably from 0.2 mm to 4.0 mm, and more preferably from 0.5 mm to 2.0 mm. Similarly, the thickness of the outer rubber layer 13 is, for example, preferably from 0.2 mm to 4.0 mm, and more preferably from 0.5 mm to 2.0 mm. Reinforcing layer
The reinforcing layer 12 is a wire braid in which steel wires having a surface plated with brass are braided. From the perspective of maintaining the strength of the hydraulic hose 1, the reinforcing layer 12 is a layer provided in between the inner rubber layer 11 and the outer rubber layer 13. Note that, in the example illustrated in
Examples of the wire materials include piano wires (carbon steel), hard steel wires, and stainless steel wires. From the perspective of processability and strength, piano wires (carbon-steel) and hard steel wires are particularly preferable as the wire materials.
In order to enhance the adhesion to the rubber layer, the surface of the reinforcing layer 12 is plated with a metal. This metal plating is a brass coating applied on piano wires and hard steel wires. The brass coating is formed by plating a steel wire with copper, plating with zinc over the copper, and then subjecting the wire to thermal diffusion processing.
In the rubber composition metal laminate of the rubber composition and the reinforcing layer 12, molecules of the rubber constituting the inner rubber layer 11 and the outer rubber layer 13 are crosslinked by sulfur by being subjected to crosslinking, i.e. vulcanization, in the presence of sulfur. This crosslinking imparts elasticity and tensile strength to the inner rubber layer 11 and the outer rubber layer 13, and adheres the inner rubber layer 11 and the outer rubber layer 13 to the reinforcing layer 12 due to the bond formed between the metal (copper, zinc) constituting the brass coating and the sulfur, at the interface between the rubber layers and the reinforcing layer 12.
Sulfur is preferably blended together with other materials when a compound of the rubber composition is formed. Note that the time at which sulfur is blended is not limited to the time when the compound is prepared as long as molecules forming the diene polymer are crosslinked each other by the sulfur, and as long as the inner rubber layer 11 and the outer rubber layer 13 are adhered to the reinforcing layer 12 due to the bond formed between the metal (copper, zinc) and the sulfur at the interface between the inner rubber layer 11 and the reinforcing layer 12, and the interface between the outer rubber layer 13 and the reinforcing layer 12, and the like.
An example of the method of vulcanization is a method in which the rubber composition is heat treated at a predetermined temperature for a predetermined time period in the presence of sulfur. The vulcanization temperature is preferably from 130° C. to 180° C. The vulcanization time is preferably from 30 minutes to 240 minutes. By a combination of the temperature and the time in these ranges, desired physical properties as a vulcanized rubber product such as elasticity, tensile strength, appearance, adhesion at the interface between the rubber and the metal, and rubber sticking at the interface between the rubber and the metal can be imparted.
The vulcanized rubber product in the present embodiment can be suitably used as hydraulic hose and the like. Examples of the method of producing a hydraulic hose or the like include a steam vulcanization method in which the rubber composition metal laminate is placed in a high pressure container and is crosslinked in a boiler, and an oven vulcanization method in which the rubber composition metal laminate is covered by nylon cloth or the like and vulcanized in a hot-air drying furnace. In general, the steam vulcanization method is a batch type treatment, and the oven vulcanization method is a continuous type treatment. The method of producing a hydraulic hose is preferably an oven vulcanization method which is a continuous type treatment.
A method of producing a vulcanized rubber product according to the present embodiment will be described below. Here, an example of the case where a hydraulic hose is produced as the vulcanized rubber product will be described.
The method of producing a hydraulic hose according to the present embodiment will be described with reference to
As illustrated in
In the step S101, the outer circumferential surface of a mandrel 101 that is sent out from an unwinding machine 100 is covered by an unvulcanized inner rubber layer 11 via a first extruder 102. A hose 103 which is covered by the inner rubber layer 11 is wound by a winding-unwinding machine 104.
Next, in the step S102, a reinforcing layer 12 is braided by a braiding machine 105 in a manner that the inner rubber layer 11 constituting the hose 103 sent out from the winding-unwinding machine 104 is covered, to form a hose 106, and then the hose 106 is wound by the winding-unwinding machine 107. A metal wire is used as the code of this reinforcing layer 12. As the metal wire, a steel wire plated with brass is used in order to impart excellent adhesion to rubber. Note that the reinforcing layer 12 may be formed by spirally winding the metal wire around the inner rubber layer 11 formed around the mandrel 101.
Next, in the step S103, a hose body 109 is formed by covering the reinforcing layer 12 of the hose 106 sent out from the winding-unwinding machine 107 with an unvulcanized outer rubber layer 13 using a second extruder 108, and the formed hose body 109 is wound by a winding machine 110. In the present embodiment, a vulcanized hose 112 obtained by a vulcanization step performed by a vulcanization device 111 is wound by the winding machine 110 after the hose body 109 is sent out from the second extruder 108 but before being wound by the winding machine 110; however, the vulcanization step can be performed after the hose body 109 is wound by the winding machine 110. Furthermore, before and after the vulcanization device 111, a wrapping device 113 and an unwrapping device 114 are provided in order to wrap or unwrap a protective cloth such as a nylon cloth around the hose body 109. Note that, in
Next, in the step S104, a hose 118 is completed by removing the mandrel 101, using a mandrel removing device 117, from the hose 116 that is sent out from the winding machine 110 and unwrapped after the vulcanization.
As illustrated in
As described above, the vulcanization temperature is preferably from 130° C. to 180° C., and the vulcanization time (that is, the vulcanization time in the vulcanization device 111) is preferably from 30 minutes to 240 minutes. Using this temperature range and the vulcanization time, a hydraulic hose having excellent adhesion between the inner rubber layer 11 and the reinforcing layer 12 and between the outer rubber layer 13 and the reinforcing layer 12 is obtained. Here, a hydraulic hose having excellent adhesion between an inner rubber layer 11 and/or an outer rubber layer 13 and a metal reinforcing layer 12 can be produced by forming the inner rubber layer 11 and/or the outer rubber layer 13 using the rubber composition according to the embodiment described above.
Note that, according to the rubber composition of the present technology, since a suitable water content can be stably maintained in the composition until immediately before the vulcanization, adhesion failure and decrease in adhesion due to insufficient water content can be suppressed in an oven vulcanization method that causes great amount of water evaporation. The rubber composition according to the embodiment can be, needless to say, suitably used in a production of rubber products using conventionally known another vulcanization method. Examples of another vulcanization method include press vulcanization, steam vulcanization, hot water vulcanization, and the like.
Furthermore, in the embodiment described above, the production steps of continuous treatment are exemplified; however, the vulcanized rubber products can be also produced by a method in which the rubber layer and the reinforcing layer are produced in separate steps and then adhered.
The hydraulic hose produced by the production method according to the present embodiment can be used for various applications. The hydraulic hose can be suitably used as, for example, air conditioner hose for vehicles, power steering hose, hydraulic hose for hydraulic systems of construction vehicles, and the like.
Furthermore, the present embodiment was described using a hydraulic hose as the rubber composition metal laminate and the vulcanized rubber product; however, the present technology is not limited to this. For example, the present embodiment can be similarly employed in other rubber laminates such as conveyor belts.
As described above, according to the rubber composition metal laminate, the vulcanized rubber product, and the method of producing the vulcanized rubber product, a vulcanized rubber product having excellent adhesion between a rubber layer and a reinforcing layer can be provided even by a continuous production method using an oven vulcanization method. In particular, a composition that forms a rubber product having excellent adhesion to a reinforcing layer can be provided even in the case where the vulcanized rubber product is stored in a hot and humid conditions for a long period of time and then used. This vulcanized rubber product can be suitably used for hydraulic hose, high pressure hose, and the like.
Embodiments of the present technology are described in further detail with reference to the examples performed in order to clearly show the effect of the present technology. Note that the present technology is not limited by the examples and comparative examples described below.
In 100 parts by mass of diene polymer containing 40 mass % of acrylonitrile-butadiene rubber (trade name: Nancar 3345, manufactured by Nantex Industry Co., Ltd.; acrylonitrile content: 34 mass %; Mooney viscosity (ML1+4, 100° C.): 45), 30 mass % of ethylene-propylene-diene rubber (trade name: EPT 4070, manufactured by Mitsui Chemicals, Inc.; ethylene content: 56 mass %; ethylidene norbornene content: 8 mass %; Mooney viscosity (ML1+4, 125° C.): 47), and 30 mass % of styrene butadiene rubber (trade name: Nipol 1502, manufactured by Zeon Corporation; emulsion polymerization SBR; bonding styrene content: 23.5 mass %; Mooney viscosity (ML1+4, 100° C.): 52), 2.3 parts by mass of sulfur (manufactured by Hosoi Chemical Industry Co., Ltd.), 0.05 mol of ethylene glycol (manufactured by Nippon Shokubai Co., Ltd.), 1.7 parts by mass of sulfenamide-based vulcanization accelerator (N-t-butylbenzothiazole-2-sulfenamide; trade name: NOCCELER NS-P, manufactured by Ouchi Shinko Chemical Industrial Co., Ltd.), 0.3 parts by mass of antiscorching agent (N-cyclohexylthiophthalimide, manufactured by Flexsys), 62 parts by mass of ISAF grade carbon black (trade name: Sho Black N220, manufactured by Showa Cabot K.K.), 15 parts by mass of hard clay (trade name: Suprex Clay, manufactured by Kentucky-Tennessee Clay Company), 5 parts by mass of Zinc Oxide III (manufactured by Seido Chemical Industry Co., Ltd.), 1 part by mass of stearic acid (manufactured by Nippon Oil & Fats Co., Ltd.), 2.4 parts by mass of antiozonant (trade name: Ozonone 6C, manufactured by Seiko Chemical Co., Ltd.), 10 parts by mass of plasticizer (dioctyl adipate; trade name: DIACIZER DOA, manufactured by Mitsubishi Kasei Vinyl Company), and 12 parts by mass of process oil (aroma oil; trade name: A-OMIX, manufactured by Sankyo Yuka Kogyo K.K.) were blended and kneaded by a Banbury mixer to produce a rubber composition. The adhesion of the produced rubber composition was evaluated. The compounded amount of each of the components is shown in Table 1 below.
A rubber composition was produced in the same manner as in Example 1 except for changing the compounded amount of the ethylene glycol to 0.16 mol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 1 below.
A rubber composition was produced in the same manner as in Example 1 except for compounding 0.03 mol of diethylene glycol in place of the ethylene glycol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 1 below.
A rubber composition was produced in the same manner as in Example 1 except for compounding 0.0043 mol of glycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.) in place of the ethylene glycol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 1 below.
A rubber composition was produced in the same manner as in Example 4 except for changing the compounded amount of the glycerin to 0.043 mol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 1 below.
A rubber composition was produced in the same manner as in Example 4 except for changing the compounded amount of the glycerin to 0.155 mol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 1 below.
A rubber composition was produced in the same manner as in Example 1 except for compounding 0.15 mol of 1,2,6-hexanetriol (manufactured by Tokyo Chemical Industry Co., Ltd.) in place of the ethylene glycol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 1 below.
A rubber composition was produced in the same manner as in Example 1 except for compounding 0.04 mol of diglycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.) in place of the ethylene glycol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 1 below.
A rubber composition was produced in the same manner as in Example 1 except for compounding 0.03 mol of sorbitol (manufactured by Kao Corporation) in place of the ethylene glycol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 1 below.
A rubber composition was produced in the same manner as in Example 4 except for changing the compounded amount of the sulfur to 4 parts by mass, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 1 below.
In 100 parts by mass of diene polymer containing 40 mass % of styrene butadiene rubber (trade name: Nipol 1502, manufactured by Zeon Corporation; emulsion polymerized SBR; bonded styrene content: 23.5 mass %; Mooney viscosity (ML1+4, 100° C.): 52) and 60 mass % of chloroprene rubber (trade name: Denka Chloroprene S-41, manufactured by Denki Kagaku Kogyo K.K; non-sulfur-modified chloroprene rubber; Mooney viscosity (ML1+4, 125° C.): 47), 0.043 mol of glycerin (manufactured by Sakamoto Yakuhin Kogyo Co., Ltd.), 0.55 parts by mass of sulfur (manufactured by Hosoi Chemical Industry Co., Ltd.), 0.8 parts by mass of thiuram-based vulcanization accelerator (tetramethylthiuram monosulfide; trade name: Sanceller TS-G, manufactured by Sanshin Chemical Industry Co., Ltd.), 0.8 parts by mass of guanidine-based vulcanization accelerator (diphenylguanidine; trade name: Soxinol D-G, manufactured by Sumitomo Chemical Co., Ltd.), 95 parts by mass of FEF grade carbon black (trade name: HTC#100, manufactured by NSCC Carbon Co., Ltd.), 5 parts by mass of Zinc Oxide III (manufactured by Seido Chemical Industry Co., Ltd.), 3 parts by mass of magnesium oxide (trade name: Kyowa Mag 150, manufactured by Kyowa Chemical Industry Co., Ltd.), 2 parts by mass of stearic acid (manufactured by Nippon Oil & Fats Co., Ltd.), 2.0 parts by mass of antiozonant (trade name: Ozonone 6C, manufactured by Seiko Chemical Co., Ltd.), and 22 parts by mass of process oil (aroma oil; trade name: A-OMIX, manufactured by Sankyo Yuka Kogyo K.K.) were blended and kneaded by a Banbury mixer to produce a rubber composition. The adhesion of the produced rubber composition was evaluated. Compounded amount of each of the components is shown in Table 1 below.
A rubber composition was produced in the same manner as in Example 1 except for compounding no ethylene glycol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 2 below.
A rubber composition was produced in the same manner as in Example 4 except for changing the compounded amount of the glycerin to 0.003 mol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 2 below.
A rubber composition was produced in the same manner as in Example 4 except for changing the compounded amount of the glycerin to 0.174 mol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 2 below.
A rubber composition was produced in the same manner as in Example 1 except for changing the compounded amount of the ethylene glycol to 0.18 mol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 2 below.
A rubber composition was produced in the same manner as in Example 4 except for changing the compounded amount of the glycerin to 0.10 mol and the compounded amount of the sulfur to 4.5 parts by mass, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 2 below.
A rubber composition was produced in the same manner as in Example 4 except for changing the compounded amount of the glycerin to 0.10 mol and the compounded amount of the sulfur to 0.45 parts by mass, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 2 below.
A rubber composition was produced in the same manner as in Example 1 except for compounding 0.02 mol of polyglycerin A (molecular weight: 330) in place of the ethylene glycol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 2 below.
A rubber composition was produced in the same manner as in Example 1 except for compounding 0.02 mol of polyglycerin B (molecular weight: 500) in place of the ethylene glycol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 2 below.
A rubber composition was produced in the same manner as in Example 11 except for changing the compounded amount of the glycerin to 0.003 mol and the compounded amount of the sulfur to 0.8 parts by mass, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 2 below.
A rubber composition was produced in the same manner as in Comparative Example 9 except for changing the compounded amount of the glycerin to 0.174 mol, and the rubber composition was evaluated. The compounded amount of each of the components is shown in Table 2 below.
Details of each of the components listed in Tables 1 and 2 are as described below.
Using each of the rubber compositions obtained in Examples 1 to 11 and Comparative Examples 1 to 10, a hose-shaped test piece having a rubber outer layer formed from each of the rubber compositions and a reinforcing layer formed from brass-plated wires was produced in the manner described below.
Brass-plated wires were first wounded in a braided manner around a mandrel having an outer diameter of 34 mm to form a reinforcing layer. An unvulcanized sheet having a thickness of 2.5 mm prepared by using each of the obtained rubber compositions was then adhered on the reinforcing layer to obtain an unvulcanized hose-shaped test piece. Thereafter, curing tape (protective cloth) formed from nylon 66 was wound around to cover the outer side of the unvulcanized hose-shaped test piece, and then vulcanization was performed.
The vulcanization was performed under the two types of conditions described below, and adhesive strength and rubber sticking of the obtained vulcanized hose-shaped test piece were evaluated. Note that each of the adhesive strength and the rubber sticking was shown as an average value obtained from 10 measured values.
Each of the vulcanized hose-shaped test pieces obtained by the vulcanization conditions 1 described above was evaluated for the adhesive strength (kN/m) and the rubber sticking (%). Note that the adhesive strength (kN/m) is a degree of force (kN) per unit width (m) that is required when an outer side rubber layer is peeled off from the interface between the outer side rubber layer and a reinforcing layer at the peeling rate of 50 mm/min. Note that the rubber sticking is a proportion of residues of the outer side rubber layer of the vulcanized hose-shaped test piece remaining on the surface of the reinforcing layer, and is a percentage showing the proportion of the area of the residual rubber layer relative to the total surface area of the reinforcing layer. Each of values of the adhesive strength (kN/m) and the rubber sticking (%) is an average value obtained from 10 measurements. The evaluation results are shown in Tables 3 and 4. The evaluation result is shown as an index with the result of the adhesion test of Comparative Example 1 expressed as an index of 100.
Adhesion was evaluated in the same manner as in Adhesion test 1 except for using each of the vulcanized hose-shaped test pieces obtained by the vulcanization conditions 2.
Adhesion was evaluated in the same manner as in Adhesion test 1 after each of the vulcanized hose-shaped test pieces obtained by the vulcanization conditions 1 was stored in a thermo-hygrostat at 50° C. and 95% relative humidity (% RH) for one week.
Adhesion was evaluated in the same manner as in Adhesion test 1 after each of the vulcanized hose-shaped test pieces obtained by the vulcanization conditions 2 was stored in a thermo-hygrostat at 50° C. and 95% relative humidity (% RH) for one week.
As is clear from Tables 3 and 4, excellent evaluation results of adhesion were obtained in both the cases of the steam vulcanization method and the oven vulcanization method for Examples 1 to 11, in which the polyhydric alcohol compound was blended in a manner that the equivalent weight of the hydroxy group became a predetermined amount in the diene polymer. On the other hand, when the polyhydric alcohol compound was not compounded, the adhesive strength was significantly deteriorated in the case of the oven vulcanization method while sufficient adhesive strength was achieved in the case of the steam vulcanization method (Comparative Example 1). Furthermore, when the equivalent weight of the hydroxy group of the polyhydric alcohol compound was less than the predetermined range, the adhesive strength was significantly deteriorated especially after the storage in hot and humid conditions in the case of the oven vulcanization method while sufficient adhesive strength was achieved in the case of the steam vulcanization method (Comparative Examples 2 and 9). Furthermore, when the equivalent weight of the hydroxy group of the polyhydric alcohol compound was greater than the predetermined range, the adhesive strength was significantly deteriorated in the case of the steam vulcanization method while sufficient adhesive strength was achieved in the case of the oven vulcanization method (Comparative Examples 3, 4 and 10). It is conceived that these results were due to deterioration in balance of the catalytic function of the bonding reaction of the sulfur and the metal surface by the polyhydric alcohol compound. Furthermore, when the content of sulfur was greater than the predetermined range, it was found that the evaluation result of the adhesion tended to be inferior in both the vulcanization methods (Comparative Example 5), and when the content of sulfur was less than the predetermined range, it was found that the adhesive strength was significantly deteriorated in both the vulcanization methods (Comparative Example 6). It is conceived that these results were due to deterioration in balance of the catalytic function of the bonding reaction of the sulfur and the metal surface by the polyhydric alcohol compound. Furthermore, when the polyhydric alcohol compound having a molecular weight of greater than 300 was used, it was found that the adhesive strength, especially, in the case of the steam vulcanization method was deteriorated (Comparative Examples 7 and 8). It is conceived that this result is because the catalytic function was not exhibited in the bonding reaction of the sulfur and the metal surface in the rubber composition due to the excessively large molecular weight of the polyhydric alcohol compound.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2015/071007 | 7/23/2015 | WO | 00 |
