Adhesion promoter for cord-reinforced rubber and metal or polymer substrate/rubber composites

Abstract

A rubber composition including a natural or synthetic rubber, and an adhesive resin capable of unexpected adhesion to metal, polymer and glass substrates, particularly cords in radical tires, hoses, conveyor belts, transmission belts, and the like by the addition of long chain esters, including mono, di- and tri-esters.

What is claimed is:  
     
         1 . A rubber composition comprising rubber selected from the group consisting of natural rubber, synthetic rubber, and a combination thereof; an adhesive resin in an amount of about 0.1% to about 15% by weight, based on the weight of rubber in the composition; a vulcanizing agent; and an ester adhesion promoter compound having formula I, II, III, IV or a mixture of any two or more of said adhesion promoter compounds in an amount of about 0.1% to about 15% by weight, based on the weight of rubber in the composition:  
       
         
           
           
               
               
           
         
         wherein R 1  is a C 3 -C 24  alkyl radical, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds; R 2  is a C 3 -C 24  saturated fatty acid residue, or an unsaturated fatty acid residue having 1 to 6 carbon-to-carbon double bonds;  
         
           
             
             
                 
                 
             
           
         
         wherein n=3-24, and R 3  and R 4 , same or different, are a C 3 -C 24  alkyl radical, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds;  
         
           
             
             
                 
                 
             
           
         
         wherein R 5  and R 7 , same or different, are a C 3 -C 24  hydrocarbon chain, straight chain or branched, either saturated or having 1 to 6 carbon-to-carbon double bonds;  
         R 6  and R 8 , same or different, are a C 3 -C 24  alkyl radical, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds; and  
         R 10  and R 11 , same or different, are a C 3 -C 24 , saturated hydrocarbon chain, straight chain or branched; or an unsaturated C 3 -C 24 , hydrocarbon chain, straight chain or branched, having 1 to 6 carbon-to-carbon double bonds;  
         
           
             
             
                 
                 
             
           
         
         wherein R 12 , R 14  and R 18 , same or different, are a C 3 -C 24  hydrocarbon chain, straight chain or branched, either saturated or having 1 to 6 carbon-to-carbon double bonds;  
         R 13 , R 15  and R 19 , same or different, are a C 3 -C 24  alkyl radical, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds; and  
         R 16 , R 17  and R 20 , same or different, are a C 3 -C 24  saturated hydrocarbon chain, straight chain or branched; or unsaturated C 3 -C 24  hydrocarbon chain, straight chain or branched, containing 1 to 6 carbon-to-carbon double bonds.  
       
     
     
         2 . A rubber composition in accordance with  claim 1 , wherein the adhesion promoter is selected from the group consisting of formula I, II, III, IV, and a combination of any two or more of said adhesion promoter compounds:  
       
         
           
           
               
               
           
         
         wherein R 1  is a C 3 -C 18  alkyl radical, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds, and R 2  is a C 8 -C 18  saturated fatty acid residue, or an unsaturated fatty acid residue having 1 to 3 carbon-to-carbon double bonds;  
         
           
             
             
                 
                 
             
           
         
         wherein n=6-18 and R 3  and R 4 , same or different, are a C 3 -C 18  alkyl radical, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds;  
         
           
             
             
                 
                 
             
           
         
         wherein R 5  and R 7 , are a C 6 -C 24  hydrocarbon chain, straight chain or branched; either saturated or having 1 to 3 carbon-to-carbon double bonds;  
         R 6  and R 8 , same or different, are a C 3 -C 18  alkyl radical, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds, and  
         R 10  and R 11 , same or different, are C 3 -C 18  saturated hydrocarbon chain, straight chain or branched; or an unsaturated hydrocarbon chain, straight chain or branched, containing 1 to 3 carbon-to-carbon double bonds;  
         
           
             
             
                 
                 
             
           
         
         wherein R 12 , R 14  and R 18 , same or different, are a C 8 -C 18  hydrocarbon chain, straight chain or branched, either saturated or containing 1 to 3 carbon-to-carbon double bonds;  
         R 13 , R 15  and R 19 , same or different, are a C 6 -C 18  alkyl radical, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds; and  
         R 16 , R 17  and R 20 , same or different, are a C 6 -C 18  saturated hydrocarbon chain, straight chain or branched; or an unsaturated C 6 -C 18  hydrocarbon-chain, straight chain or branched, containing 1 to 3 carbon-to-carbon double bonds.  
       
     
     
         3 . The rubber composition of  claim 1 , wherein the adhesive resin is a condensation product of a methylene acceptor and a methylene donor.  
     
     
         4 . The rubber composition in accordance with  claim 3 , wherein the adhesive resin is selected from the group consisting of phenol-formaldehyde; melamine-formaldehyde; naphthol-formaldehyde; polyepoxide; a reaction product of triallyl cyanurate, resorcinol, and formaldehyde; a reaction product of p-chlorophenol, resorcinol, and formaldehyde; a copolymer of styrene, butadiene, and 2-vinlypyridine; and mixtures thereof.  
     
     
         5 . The rubber composition in accordance with  claim 4 , wherein the phenol-formaldehyde resin is resorcinol-formaldehyde.  
     
     
         6 . The rubber composition in accordance with  claim 1 , wherein the adhesive resin is selected from the group consisting of derivatives of melamine, acetoguanamine, benzoguanamine, cyclohexylguanamine and glycoluril monomers and oligomers of these monomers, which have been substituted on average at two or more positions on the monomer or on each unit of the oligomer with vinyl terminated radicals, the vulcanizable rubber composition being free of resorcinol.  
     
     
         7 . The vulcanizable rubber composition in accordance with  claim 6 , wherein at least one of the additives has been further substituted on average at one or more positions with a radical which comprises carbamylmethyl or amidomethyl.  
     
     
         8 . A vulcanizable rubber composition in accordance with  claim 6 , wherein the adhesive resin is selected from compounds of the formulas:  
       
         
           
           
               
               
           
         
         wherein, in each monomer and in each polymerized unit of the oligomers, Y is selected from methyl, phenyl and cyclohexyl, and, on average,  
         at least two R are —CH 2 —R 1 ,  
         and any remaining R are H, and  
         at least 2 R 1  are radicals selected from  
         
           
             
             
                 
                 
             
           
         
         wherein R 2  is hydrogen or C 1 -C 18  alkyl, and Z is a radical selected from  
         
           
             
             
                 
                 
             
           
         
         any remaining R 1  radicals are selected from  
         
           
             
             
                 
                 
             
           
         
         wherein R 3  is hydrogen or R 4 , and  
         R 4  is a C 1 -C 18  alkyl, alicyclic, hydroxyalkyl, alkoxyalkyl or aromatic radical, and in the oligomers,  
         P is 2to about 10, and  
         L is methylene or the radical  
         —CH 2 —O—CH 2 — 
       
     
     
         9 . A vulcanizable rubber composition in accordance with  claim 8 , wherein on average at least one R 1  in each monomer or in each oligomerized unit is  
       —NH—C(O)—OR 4    
       wherein R 4  is as defined in  claim 8 .  
     
     
         10 . A vulcanizable rubber composition in accordance with  claim 9 , wherein the adhesive resin is a compound of the formula  
       
         
           
           
               
               
           
         
       
       wherein P, L and R are as defined in  claim 8;   
     
     
         11 . A vulcanizable rubber composition in accordance with  claim 10 , wherein in the formulas, on average at least one R radical in each monomer or in each oligomerized unit is  
       —CH 2 —NH—C(O)—OR 4    
       wherein R 4  is a C 1 -C 18  alkyl, alicyclic, hydroxyalkyl, alkoxyalkyl or aromatic radical.  
     
     
         12 . A vulcanizable rubber composition in accordance with  claim 10 , wherein on average at least two R radicals are selected from  
       
         
           
           
               
               
           
         
       
       and at least one R radical is selected from  
       —CH 2 —NH—C(O)—O—CH 3 , and —CH 2 —NH—C(O)—O—C 3 H 7    
     
     
         13 . A vulcanizable rubber composition in accordance with  claim 8 , further comprising an additional additive selected from hydroxymethylated and alkoxymethylated (alkoxy having 1-5 carbon atoms) derivatives of melamine, acetoguanamine, benzoguanamine, cyclohexylguanamine and glycoluril and their oligomers.  
     
     
         14 . The composition in accordance with  claim 6 , wherein the adhesive resin is a derivative of melamine or an oligomer of melamine.  
     
     
         15 . The composition in accordance with  claim 6 , wherein the adhesive resin is a derivative of acetoguanamine or an oligomer of acetoguanamine.  
     
     
         16 . The composition in accordance with  claim 6 , wherein the adhesive resin is a derivative of benzoguanamine or an oligomer of benzoguanamine.  
     
     
         17 . The composition in accordance  claim 6 , wherein the adhesive resin is a derivative of cyclohexylguanamine or an oligomer of cyclohexylguanamine.  
     
     
         18 . A vulcanizable rubber composition in accordance with  claim 1 , wherein the adhesive resin is a self-condensing alkylated triazine resin selected from the group consisting of (i), (ii), and (iii): 
 (i) a self-condensing alkylated traizine resin having at least one of imino or methylol functionality and represented by the formula (I)                          (ii) an oligoner of(i), or    (iii) a mixture of (i) and (ii), wherein 
 Z is —N(R)(CH 2 OR 1 ), aryl having 6 to 10 carbon atoms, alkyl having 1 to 20 carbon atoms or an acetyl group,  
 each R is independently hydrogen or —CH 2 OR 1 , and  
 each R 1  is independently hydrogen or an alkyl group having 1 to 12 carbon atoms,  
 provided that at least one R is hydrogen or —CH 2 OH and at least one R 1  is selected from the alkyl group; and  
   wherein the vulcanizable rubber composition is substantially free of methylene acceptor coreactants.    
     
     
         19 . The vulcanizable rubber composition in accordance with  claim 18 , wherein at least one R group is hydrogen.  
     
     
         20 . The vulcanizable rubber composition in accordance with  claim 19 , wherein at least one R 1  group is a lower alkyl group having 1 to 6 carbon atoms.  
     
     
         21 . The vulcanizable rubber composition in accordance with  claim 20 , wherein the adhesive resin is a derivative of melamine, benzoguanamine, cyclohexylguanamine, or acetoguanamine, or an oligomer thereof.  
     
     
         22 . The vulcanizable rubber composition in accordance with  claim 20 , wherein Z is —N(R)(CH 2 OR 1 ).  
     
     
         23 . The rubber composition in accordance with  claim 4 , wherein the phenol-formaldehyde resin is resorcinol-formaldehyde; and the melamine-formaldehyde resin is N-(substituted oxymethyl) melamine-formaldehyde.  
     
     
         24 . A rubber,composition in accordance with  claim 1 , wherein the adhesion promoter has the formula II and comprises a saturated diester formed by the reaction of sebacic acid and a C 6 -C 24  alcohol, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds.  
     
     
         25 . A rubber composition in accordance with  claim 24 , wherein the alcohol is 2-ethylhexyl alcohol, and the adhesion promoter has the following formula:  
       
         
           
           
               
               
           
         
       
     
     
         26 . A rubber composition in accordance with  claim 1 , wherein the adhesion promoter is an unsaturated diester formed by the reaction of a C 36  dimer acid and a C 3 -C 18  alcohol, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds.  
     
     
         27 . A rubber composition in accordance with  claim 26 , wherein the alcohol is 2-ethylhexyl alcohol.  
     
     
         28 . A rubber composition in accordance with  claim 26 , wherein the alcohol is tridecyl alcohol.  
     
     
         29 . A rubber composition in accordance with  claim 26 , wherein the alcohol is oleyl alcohol.  
     
     
         30 . A rubber composition in accordance with  claim 1 , wherein the adhesion promoter comprises the following dimerate acid reacted with a C 3 -C 24  alcohol:  
       
         
           
           
               
               
           
         
       
     
     
         31 . A rubber composition in accordance with  claim 1 , wherein the adhesion promoter comprises the following dimerate acid reacted with a C 3 -C 24  alcohol:  
       
         
           
           
               
               
           
         
       
     
     
         32 . A rubber composition in accordance with  claim 1 , wherein the adhesion promoter comprises the following dimerate acid reacted with a C 3 -C 24  alcohol:  
       
         
           
           
               
               
           
         
       
     
     
         33 . A rubber composition in accordance with  claim 1 , wherein the adhesion promoter is the reaction product of a C 3 -C 24  alcohol with a tricarboxylic acid, having the following formula;  
       
         
           
           
               
               
           
         
       
     
     
         34 . A rubber composition in accordance with  claim 1  wherein the adhesion promoter is a combination of compounds of formula I, II, III, and IV.  
     
     
         35 . A rubber composition in accordance with  claim 34 , wherein the adhesion promoter is a reaction product of a C 3 -C 24  alcohol straight chain or branched, saturated, or unsaturated having 1 to 3 carbon-to-carbon double bonds, with a dimer acid having CAS #61788-89-4.  
     
     
         36 . A rubber composition in accordance with  claim 35 , wherein the alcohol is 2-ethylhexyl alcohol.  
     
     
         37 . A rubber composition in accordance with  claim 35 , wherein the alcohol is a tridecyl alcohol.  
     
     
         38 . A rubber composition in accordance with  claim 35 , wherein the alcohol is a oleyl alcohol.  
     
     
         39 . A method of increasing the adhesion of a rubber composition to a polymer, glass, or metal substrate, said rubber composition including a natural or synthetic rubber, a rubber vulcanizing agent, and an adhesive resin, comprising adding to said rubber composition, in an amount of about 0.1% to 15% by weight, based on the weight of the rubber, an ester adhesion promoter additive of formula I, II, III, IV, or mixtures thereof:  
       
         
           
           
               
               
           
         
         wherein R 1  is a C 3 -C 24  alkyl radical, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds; R 2  is a C 3 -C 24  saturated fatty acid residue, or an unsaturated fatty acid residue having 1 to 6 carbon-to-carbon double bonds;  
         
           
             
             
                 
                 
             
           
         
         wherein n=3-24 and R 3  and R 4 , same or different, are a C 3 -C 24  alkyl radical, straight chain or branched;  
         
           
             
             
                 
                 
             
           
         
         wherein R 5  and R 7 , same or different, are a C 3 -C 24  hydrocarbon chain, straight chain or branched, either saturated or having 1 to 6 carbon-to-carbon double bonds;  
         R 6  and R 8 , same or different, are a C 3 -C 24  alkyl radical, straight chain or branched; and  
         R 10  and R 11 , same or different, are a C 3 -C 24 , saturated hydrocarbon chain, straight chain or branched; or an unsaturated C 3 -C 24 , hydrocarbon chain, straight chain or branched, having 1 to 6 carbon-to-carbon double bonds;  
         
           
             
             
                 
                 
             
           
         
         wherein R 12 , R 14  and R 18 , same or different, are a C 3 -C 24  hydrocarbon chain, straight chain or branched, either saturated or having 1 to 6 carbon-to-carbon double bonds;  
         R 13 , R 15  and R 19 , same or different, are a C 3 -C 24  alkyl radical, straight chain or branched, saturated, or unsaturated containing 1 to 3 carbon-to-carbon double bonds; and  
         R 16 , R 17  and R 20 , same or different, are a C 3 -C 24  saturated hydrocarbon chain, straight chain or branched; or unsaturated C 3 -C 24  hydrocarbon chain, straight chain or branched, containing 1 to 6 carbon-to-carbon double bonds.  
       
     
     
         40 . A method in accordance with  claim 39 , wherein the substrate is a plurality of cords.  
     
     
         41 . A method in accordance with  claim 39 , wherein the substrate is a polymeric sheet or fabric.  
     
     
         42 . A method in accordance with  claim 39 , wherein the substrate is metal flat stock material.  
     
     
         43 . A cord-reinforced article of manufacture comprising a plurality of cords selected from polymeric cords, metal cords, glass cords, and a combination thereof, adhered to the rubber composition of  claim 1 .  
     
     
         44 . The rubber composition in accordance with  claim 1 , wherein the R 2 , R 5 , R 7 , R 12 , R 14  are fatty acid residues derived from animal or vegetable fatty acids.  
     
     
         45 . The rubber composition of  claim 44 , wherein the fatty acids are selected from the group consisting of butter; lard; tallow; grease; herring; menhaden; pilchard; sardine; babassu; castor; coconut; corn; cottonseed; jojoba; linseed; oiticia; olive; palm; palm kernel; peanut; rapeseed; safflower; soya; sunflower; tall; tung; and mixtures thereof.  
     
     
         46 . The rubber composition of  claim 45 , wherein the fatty acid residues are selected from the group consisting of hexanoic; octanoic; decanoic; dodecanoic; 9-dodecenoic; tetradecanoic; 9-tetradecenoic; hexadecanoic; 9-hexadecenoic; octadecanoic; 9-octadecenoic; 9-octadecenoic, 12-hydroxy; 9,12-octadecadienoic; 9,12,15-octadecatrienoic; 9,11,13-octadecatrienoic; 9,11,13-octadecatrienoic; 4-oxo; octadecatetrenoic; eicosanoic; 11-eicosenoic; eicosadienoic; eicosatrienoic; 5,8,11,14-eicosatetraenoic; eicosapentaenoic; docosanoic; 13-docosenoic; docosatetraenoic; 4,8,12,15,19-docosapentaenoic; docosahexaenoic; tetracosenoic; and 4,8,12,15,18,21-tetracosahexaenoic.