PLASTICS BONDING SYSTEMS AND METHODS

• US 20150210894A1
• Filed: 04/03/2015
• Published: 07/30/2015
• Est. Priority Date: 11/16/2012
• Status: Active Grant

• Current Assignee: Nippon Shokubai Company Limited
• Original Assignee: Sirrus, Inc (Nippon Shokubai Company Limited)
• Inventors: Malofsky, Bernard Miles, Malofsky, Adam Gregg, Ellison, Matthew McBrayer, Desousa, Joseph D.
• Granted Patent: US 9,752,059 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B32B 2038/0016 Abrading
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/14 next to a particulate layer
• CPC Class Codes: B32B 27/26 using curing agents
• CPC Class Codes: B32B 37/0038 involving application of liquid to the layers prior to lamination, e.g. wet laminating B32B37/12 takes precedence
• CPC Class Codes: B32B 37/182 one or more of the layers being plastic
• CPC Class Codes: B32B 38/0012 Mechanical treatment, e.g. roughening, deforming, stretching
• CPC Class Codes: B32B 7/10 at least one layer having inter-reactive properties
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C09J 11/06 organic
• CPC Class Codes: C09J 2400/20 Presence of organic materials
• CPC Class Codes: C09J 2400/226 in the substrate
• CPC Class Codes: C09J 4/00 Adhesives based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; adhesives, based on monomers of macromolecular compounds of groups C09J183/00 - C09J183/16
• CPC Class Codes: C09J 5/00 Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
• CPC Class Codes: C09J 5/04 involving separate application of adhesive ingredients to the different surfaces to be joined
• CPC Class Codes: Y10T 428/287 including epoxy group or epoxy polymer
• CPC Class Codes: Y10T 428/2891 including addition polymer from alpha-beta unsaturated carboxylic acid [e.g., acrylic acid, methacrylic acid, etc.] Or derivative thereof
• CPC Class Codes: Y10T 428/31645 Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31692 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31895 : Paper or wood
• CPC Class Codes: Y10T 428/31938 : Polymer of monoethylenically unsaturated hydrocarbon

Abstract

Reactive composition includes a reactive component able to form an adhesive bond between two substrates, at least one of which comprises a plastic material. The substrate may include an initiator on or near the surface thereof. The initiator may be present in the plastic material inherently, by blending in an additive package, through injection molding, or other process. The reactive component may comprise a methylene malonate, a reactive multifunctional methylene, a methylene beta ketoester, a methylene beta diketone. A carrier component for the reactive component may be selected to interact with the plastic substrate to soften and/or penetrate the surface to be bonded. The surface of the plastic may be abraded or otherwise treated to expose the initiator. The reactive component, upon contact with a suitable initiator, is able to polymerize to form an interpenetrating polymer weld.

Claims

1. A system comprising:

a reactive component curable after exposure to a reaction initiator, wherein the reactive component comprises one or more members selected from the group consisting of a methylene malonate component, a methylene beta-ketoester component, a methylene beta-diketone component, and an oligomer or resin thereof; and

a first substrate formed of a plastic material and comprising the reaction initiator, the reaction initiator on or near a surface of the first substrate.

2. The system according to claim 1, wherein the reactive component further comprises a carrier component, and the carrier component is partially soluble with the first substrate.

3. The system according to claim 2, wherein the carrier component comprises an additional reactive component.

4. The system according to claim 1, wherein the reactive component comprises one or more of a mono-functional and a multifunctional methylene malonate component.

5. The system according to claim 1, wherein the reactive component further comprises one or more members selected from the group consisting of cyanoacrylates, epoxies, urethanes, polyurethanes, acrylics, and silicones.

6. The system according to claim 1, wherein the reactive component further comprises a formulation additive.

7. The system according to claim 6, wherein the reactive component comprises the methylene malonate component, the methylene malonate component comprises diethyl methylene malonate and the formulation additive comprises poly(methyl methacrylate).

8. The system according to claim 1, wherein the reaction initiator is formed of the plastic material.

9. The system according to claim 1, wherein the reaction initiator comprises spheres, fibers, chopped fibers, particles, or a combination thereof.

10. The system according to claim 1, wherein the reactive component is cured.

11. A bonded article formed from the cured system of claim 1, further comprising a second substrate, wherein the reactive component is disposed between the first substrate and the second substrate.

12. The bonded article according to claim 11, is an automotive interior component.

13. The bonded article according to claim 11, wherein the first substrate is 3D printed.

14. The bonded article according to claim 11, wherein the second substrate is formed of a glass material, a metal material, a wood material, or another plastic material.

15. The bonded article according to claim 11, wherein the first substrate and the second substrate are formed of the same material.

16. The bonded article according to claim 11, wherein the first substrate and the second substrate are formed of different materials.

17. A method for bonding a first substrate formed of a plastic material to a second substrate, wherein the first substrate comprises a reaction initiator on or near a surface of the first substrate, the method comprising:

a) providing a reactive component on the surface of the first substrate;

b) exposing the reactive component to the reaction initiator; and

c) engaging at least a portion of the first substrate with the second substrate to create a bonding engagement; and

wherein the reactive component comprises one or more members selected from the group consisting of a methylene malonate component, a methylene beta-ketoester component, a methylene beta-diketone component, and an oligomer or resin thereof.

18. The method according to claim 17, further comprises:

abrading the surface of the first substrate prior to step (a).

19. A kit comprising:

a first substrate formed of a plastic material and comprising a reaction initiator, the reaction initiator on or near a surface of the first substrate;

a second substrate; and

a reactive component effective to bond the first substrate to the second substrate upon exposure to the reaction initiator, wherein the reactive component comprises one or more members selected from the group consisting of a methylene malonate component, a methylene beta-ketoester component, a methylene beta-diketone component, and an oligomer or resin thereof.

20. The kit according to claim 19, wherein the kit further comprises an abrasive component capable of exposing the reaction initiator.