METHODS AND ARTICLES IN HAVING A FRINGED MICROPROTRUSION SURFACE STRUCTURE

• US 20070261224A1
• Filed: 05/10/2007
• Published: 11/15/2007
• Est. Priority Date: 05/11/2006
• Status: Abandoned Application

• Current Assignee: Dow Global Technologies, Inc. (Dow, Inc.)
• Original Assignee: Dow Global Technologies, Inc. (Dow, Inc.)
• Inventors: McLeod, David
• Application Number:
  US11/746,977
• Publication Number:
  US 20070261224A1
• Time in Patent Office: Days
• US Class Current: 29/428
• CPC Class Codes: B29C 37/0053 Moulding articles characterised by the shape of the surface, e.g. ribs, high polish mould construction therefor B29C33/42; surface shaping of articles B29C59/00; by incorporating filler in or near the surface B29C70/64
• CPC Class Codes: B29C 37/0082 Mechanical anchoring B29C66/303 takes precedence
• CPC Class Codes: B29C 65/04 Dielectric heating, e.g. high-frequency welding , i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
• CPC Class Codes: B29C 65/06 using friction, e.g. spin welding non-plastics elements to plastic elements B29C65/645
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 66/21 said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
• CPC Class Codes: B29C 66/30221 said melt initiators being point-like
• CPC Class Codes: B29C 66/30321 making use of protrusions belonging to at least one of the parts to be joined
• CPC Class Codes: B29C 66/45 Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/712 the composition of one of the parts to be joined being different from the composition of the other part
• CPC Class Codes: B29C 66/7212 characterised by the composition of the fibres
• CPC Class Codes: B29C 66/72141 Fibres of continuous length
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29K 2009/06 SB polymers, i.e. butadiene-styrene polymers
• CPC Class Codes: B29K 2021/003 Thermoplastic elastomers
• CPC Class Codes: B29K 2023/00 Use of polyalkenes or derivatives thereof as moulding material
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/10 Polymers of propylene
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2025/06 : PS, i.e. polystyrene
• CPC Class Codes: B29K 2027/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2027/12 : containing fluorine
• CPC Class Codes: B29K 2033/08 : Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
• CPC Class Codes: B29K 2033/12 : Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
• CPC Class Codes: B29K 2033/20 : PAN, i.e. polyacrylonitrile
• CPC Class Codes: B29K 2055/02 : ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2069/00 : Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/12 : PPO, i.e. polyphenylene oxide; PPE, i.e. polyphenylene ether
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2081/06 : PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
• CPC Class Codes: B29K 2105/04 : cellular or porous
• CPC Class Codes: B29K 2309/08 : Glass
• CPC Class Codes: B29K 2995/0002 : insulating
• CPC Class Codes: B29K 2995/0091 : Damping, energy absorption
• CPC Class Codes: B29L 2031/14 : Filters optical filters B29L2011/0066, sieves or screens B29L2031/737
• CPC Class Codes: B29L 2031/26 : Sealing devices, e.g. packaging for pistons or pipe joints
• CPC Class Codes: B29L 2031/265 : Packings, Gaskets
• CPC Class Codes: B29L 2031/3005 : Body finishings
• CPC Class Codes: B29L 2031/3008 : Instrument panels
• CPC Class Codes: B29L 2031/3026 : Arm-rests
• CPC Class Codes: B29L 2031/3044 : Bumpers
• CPC Class Codes: B29L 2031/3047 : Steering wheels
• CPC Class Codes: B29L 2031/3468 : Batteries, accumulators or fuel cells battery cases B29L2031/7146
• CPC Class Codes: B29L 2031/44 : Furniture or parts thereof
• CPC Class Codes: B29L 2031/463 : Grips, handles handgrips as part of the body finishing of the vehicles B29L2031/3029
• CPC Class Codes: B29L 2031/5272 : Surf boards
• CPC Class Codes: B29L 2031/7322 : Carpets
• CPC Class Codes: Y10T 29/49826 : Assembling or joining

Abstract

Composite articles and a method for making the same, wherein the articles include at least two bodies that are attached at an interface that includes a fringed microprotrusion surface structure. The method generally includes the steps of providing a first body that includes a fringed microprotrusion surface structure on one or more surfaces; and attaching to the first body, a second body for defining the interface that includes at least a portion of the fringed microprotrusion surface structure.

Claims

1. A method for making a composite article, comprising the steps of:

a. providing a first body that includes a fringed microprotrusion surface structure; and

b. attaching to the first body, a second body for defining an interface that includes at least a portion of the fringed microprotrusion surface structure.

2. The method of claim 1, wherein the fringed surface structure is characterized by a plurality of generally conical microprotrusions that project from a surface of the first body.

3. The method of claim 2, wherein the generally conical microprotrusions are generally closed at their distal ends.

4. The method of claim 2, wherein the generally conical microprotrusions include a curved distal end for defining a hook.

5. The method of claim 2, wherein the generally conical microprotrusions generally have an aspect ratio (height to diameter) in the range of about 0.5:

1 to 7;

1.

6. The method of claim 5, wherein the generally conical microprotrusions generally have an aspect ratio (height to diameter) in the range of about 2:

1.

7. The method of claim 2, wherein over at least 20% by area of the fringed surface portion of the first body, the generally conical microprotrusions are present in a concentration of at least about 225 protrusions per cm².

8. The method of claim 2, wherein the generally conical microprotrusions have an average diameter of from about 40 to about 350 microns.

9. The method of claim 2, wherein the generally conical microprotrusions have an average height of about 25 to 500 microns.

10. The method of claim 2, wherein the first body is plastic and the polymer of the first plastic body includes at least 40 wt % of a polyolefin polymer.

11. The method of claim 7, wherein the first body is plastic and the polymer of the first plastic body includes at least 60 wt % of a polypropylene.

12. The method of claim 11, wherein the first body is plastic and the polymer of the first plastic body consists essentially of a polypropylene.

13. The method of claim 2, wherein the first body includes glass fiber reinforcement.

14. The method of claim 13, wherein the first body includes long glass fiber reinforcement.

15. The method of claim 2, wherein the first body is plastic and the first plastic body has a melt index per ASTM D1238 of at least about 20.

16. The method of claim 2, wherein the second body is plastic and includes at least 40 wt % of a polyurethane foam, and further wherein the attaching step occurs when the polyurethane is foamed.

17. The method of claim 1, wherein the step of providing a first body includes injecting molding or die casting the first body.

18. The method of claim 1, wherein cohesive failure of the second body is observed upon separating the first body from the second body.

19. The method of claim 1, wherein the resulting lap shear, or peel strength observed upon separating the first body from the second body is at least three times greater than that which would be observed if compared with a lap shear, or peel strength of a joint formed by a comparable structure that omits the fringed surface structure from the first body, substituting in its place a surface that has only been mechanically roughened to increase surface area by 40%.

20. The method of claim 1, wherein the composite article is an instrument panel that is substantially free of an adhesion promoter between the first body and the second body.