A novel one-step eco-friendly dipping system for PA66 fiber/rubber composites with excellent interfacial adhesion and its adhesion mechanism

Fiber-reinforced rubber composites (FRRC) are widely used in tires, hoses, conveyor belts and other fields. Currently, the industry heavily relies on the resorcinol-formaldehyde-latex (RFL) system to enhance interfacial adhesion performance of FRRC; however, both resorcinol (R) and formaldehyde (F) pose significant risks to human health and the environment. Thus, some two-step RF-free dipping systems have been developed to replace RFL system. Nevertheless, these complex two-step systems face challenges during industrialization. In this study, we proposed a novel one-step eco-friendly dipping system (PCGL) for polyamide66 (PA66)fibers. By using the new system, a solid transition bridge between PA66 fiber and rubber matrix can be formed, due to the bonding between PA66 and isocyanate, the interaction among polyacrylic acid resin, isocyanate and epoxy, the catalytic effect of triethanolamine, as well as the co-crosslinking of styrene-butadiene-vinyl-pyridine latex and rubber. The interfacial adhesion performance of PA66 fiber/rubber composites treated by PCGL with optimized ratio of epoxy groups/isocyanate groups can reach more than 90% of RFL level, meeting industry requirements for high interfacial bonding performance, while maintaining strength and safety of composites. The mechanism of largely enhanced interfacial adhesion was revealed through the analysis of modulus transition and co-crosslinking at the composite interface.