Method of Bonding Non-Polar or Highly Crystalline Resin Substrates Employing a Primer and a Cyanoacrylate Adhesive
Method of Bonding Non-Polar or Highly Crystalline Resin Substrates Employing a Primer and a Cyanoacrylate Adhesive
US4818325
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Abstract:
A primer comprising an organometallic compound and an organic polymer, which is useful in bonding non-polar or highly crystalline resin substrates together or bonding said resin substrates and another material, such as a solid material, a coating material, paint or printing ink by using a 2-cyanoacrylate.
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Language:
United States Patent [19]
Hiraiwa et al.
[54] METHOD OF BONDING NON-POLAR OR
HIGHLY CRYSTALLINE RESIN
SUBSTRATES EMPLOYING A PRIMER AND
A CY ANOACRYLATE ADHESIVE
[75] Inventors: Akihiko Hiraiwa; Kenji Ito; Kaoru
Kimura, all of Nagoya, Japan
Toagosei Chemical Industry Co., Ltd.,
Toyko, Japan
[21] Appl. No.: 78,403
[22] Filed: Jul. 27, 1987
[73] Assignee:
Related U.S. Application Data
[62] Division of Ser. No. 818,716, Jan. 14, 1986, abandoned.
[30] Foreign Application Priority Data
Jan. 18,1985 [JP] Japan .................................. .. 60-5936
Jan. 31, 1985 [JP] Japan ................................ .. 60-15486
[51] Int. Cl.4 .............................................. .. C09J 5/04
[52] U.S. Cl. ............................... .. 156/315; 156/331.2;
427/412.1; 427/412.3; 427/412.4; 427/412.5;
524/394
J 1
[11] Patent Number: 4,818,325
[45] Date of Patent: Apr. 4, 1989
[58] Field of Search ........................... .. 156/315, 331.2;
427/4121, 412.3, 412.4, 412.5; 524/394
[56] References Cited
U.S. PATENT DOCUMENTS
3,441,434 4/1969 Jezl ................................. .. 427/412.3
FOREIGN PATENT DOCUMENTS
52-76344 6/1977 Japan .............................. .. 156/331.2
53-57233 5/1978 Japan ................................. .. 156/315
Primary Exam1'ner—John J. Gallagher
Attomey, Agent, or Fz'rm—Cooper & Dunham
[57] ABSTRACI‘
A primer comprising an organometallic compound and
an organic polymer, which is useful in bonding non-
polar or highly crystalline resin substrates together or
bonding said resi.n substrates and another material, such
as a solid material, a coating material, paint or printing
ink by using a 2-cyanoacrylate.
32 Claims, No Drawings
4,818,325
1
METHOD OF BONDING NON-POLAR OR
HIGHLY CRYSTALLINE RESIN SUBSTRATES
EMPLOYING A PRINIER AND A
CYANOACRYLATE ADHESIVE
This is a division of application Ser. No. 818,716 filed
Jan. 14, 1986, now abandoned.
This invention relates to a primer which is used as
such in bonding non-polar or highly crystalline resin
substrates together or bonding other material thereto
with use of a 2-cyanoacrylate.
This invention has its object to provide a primer
satisfactorily useful in bonding together easily, speedily
and surely non-polar or highly crystalline resin sub-
strates or so bonding another material to the resin sub-
strate with use of a 2-cyanoacrylate, the resin substrates
having heretofore been considered as difficult to bond
together, bond the other material thereto, coat, paint
and print thereon and being typified by polyethylene,
polypropylene, polybutene, polyfluoroethylene, their
copolymer and other polyolefm substrates as well as
polyethylene terephthalate, polyacetal, nylon and soft
PVC (having a high content of a plasticizer) substrates.
This invention has its another object to solve the
problems that the primers earlier proposed by the pres-
ent inventors are unsatisfactory in operativeness and
must be severely controlled as to their film thickness to
prevent their performances or properties from being
degraded.
To render these substrates or materials improved in
adhesiveness, there has heretofore been proposed a
surface treating method which comprises subjecting the
substrates, for example polyethylene or polypropylene,
to flame treatment, corona discharge treatment, irradia-
tion treatment or oxidizing treatment with a bichro-
mate, sulfate or the like so as to produce polar groups
such“as a carbonyl group on the surface of the sub-
strates. In addition, to make a resin, such as polyfluoro-
ethylene, which is impossible to oxidize on the surface,
improved in adhesiveness, there has been proposed a
special chemical treatment such as lithium vapor treat-
ment, heating treatment with an alkali in a helium
stream or treatment of metallic sodium with liquid am-
monia.
However, the proposed method and treatments need
special equipments, are complicated to carry out, are
unable to uniformly treat every part of the surface of a
substrate having a complicated shape and require great
expenses, these being disadvantageous.
Various primers also have been proposed. For exam-
ple, Japanese Patent Appln. Laid-Open Gazettes Nos.
52-98062, 56-141328 and 57-119929 have proposed
primers prepared by dissolving a chlorinated polyethyl-
ene or chlorinated polypropylene or a fatty acid-modi-
fied acrylated alkyd resin in an organic acid.
According to Japanese Pat. Appln. Laid-Open Ga-
zette No. 58-8734, however, the primers so proposed
are unsatisfactory in adhesiveness to a paint although
they are satisfactory in adhesiveness to a polyolefm
substrate, or, even if the paint and the polyolefin are
satisfactory in adhesion to each other, the adhesiveness
there between will undesirably decrease due to repeti-
tion of the cold/hot cycle.
Japanese Pat. Appln. Laid-Open Gazettes Nos.
54-124048, 54-124049 and 54-124095 have proposed a
modified polyolefin prepared by incorporating solid
rubber, an unsaturated carboxylic acid or the derivative
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thereof, and a radical generator in a polyolefm, how-
ever, according to Japanese Pat. Appln. Laid-Open
Gazette No. 57-38827, the modified polyolefin will have
undesirable effects on the adhesiveness of a paint
formed thereon since the unreacted unsaturated carbox-
ylic acid and the radical generator remain in the modi-
fied polyolefin.
Further, Japanese Pat. Appln. Laid-Open Gazettes
Nos. 54-124050, 55-34270 and 55-84271 have proposed
an improved resin composed essentially of a propyle-
ne/styrene/butadiene block copolymer and an inor-
ganic filler, however, the improved resin so proposed
seems to raise various problems as to poor weather-
proofness of unpainted parts and low-temperature fra-
gility due to the incorporation of the filler.
If non-polar or highly crystalline resins such as poly-
olefm can be improved in adhesiveness or they can
allow a coating, painting or print to be satisfactorily
formed on the surface thereof, they would be very
conductive to various fields such as the automobile
industry and electric appliance industry since they have
many merits such as excellent properties, light weight,
rust-proof and low cost as compared with metallic ma-
terial.
In attempts to develop a surface treating method
which is simple and speedy as compared with the con-
ventional methods, in view of the above-mentioned
situations, the present inventors made intensive studies
and, as the result of their studies, they developed de-
sired primers which enable satisfactory adhesion, coat-
ing, painting and printing.
The present inventors previously filed a U.S. patent
application Ser. No. 611,691 in which is disclosed a
primer comprising an organometallic compound as an
effective ingredient.
The primer disclosed in said earlier U.S. Application
have an extremely excellent function and can attain the
desired object, however, it has now been found that
when used, they will raise the following problems. '
The problems are that the primers so disclosed are
not suitable to be stored in aluminum tubes or glass
bottles because of being non-viscous particularly when
in the solution form and they need techniques to be
uniformly applied without sagging thereof, this indicat-
ing their inferiority in capability of application. As is
apparent from the specification of said U.S. Applica-
tion, since said primers vary in performances such as
bond strength depending on the thickness of the primer
to be applied, the performances such as bond strength
will not be stabilized if the thickness of the primer to be
applied is specifically limited; particularly thick primer
layers exhibit their brittleness, cannot be improved in
bond strength and may sometimes be even disadvanta-
geous as a primer layer because of being too thick. Such
inferiority in application operation as above will raise a
serious problem as to the practical use of the primers.
It has further been found that primers will often ex-
hibit different performances as such even though they
are prepared from the same materials, and they will
decrease in performances during their storage or use in
spite of the fact that they exhibit satisfactory perfor-
mances when they have been prepared, the above being
additional problems.
The present inventors made intensive studies in at-
tempts to solve the above-mentioned problems and, as
the result of their studies, accomplished this invention.
The primer of this invention comprises at least one
organometallic compound and at least one organic pol-
4,818,325
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ymer and is used in bonding non-polar or highly crystal-
line resin substrates together or bonding another mate-
rial to the resin substrate with the use of a 2-cyanoacry-
late.
The expression “bonding another material to the resin
substrate with the use of a 2-cyanoacrylate” used herein
is intended to mean, for example, the use of a 2-cyanoa-
crylate in adhesion of a solid material such as a metal,
glass, a synthetic resin, rubber, leather, stone, cloth,
paper, wood or ceramics to the resin substrate or the use
thereof in coating or printing a resin substrate with a
coating material, paint or printing ink.
The organometallic compounds in which the organic
group is combined with a metal may be used in this
invention irrespective of the kind, structure and the like
thereof.
The organic groups contained in the organometallic
compounds include alkyl, cycloalkyl, haloalkyl, alke-
nyl, cycloalkenyl, alkoxy, cycloalkoxy, aryl, aralkyl,
aralkyloxy, acetylacetate, acyloxy and cycloalk-
enyloxy, aryloxy group, with C3 or higher hydrocarbon
groups being preferred. The metals contained in the
organometallic compounds in this invention are in-
tended to include typical metals, transition metals and
metalloids and further include phosphorus, boron and
silicon. The organometallic compounds are illustrated
by the following structural formulae.
(1) M-0-R (wherein M is a metallic element and R an
organic group; these defmitions apply to the following)
which shows metal alcoholates:
organoaluminum compounds such as aluminum iso-
propylate, aluminum mono-sec.-butoxydiisopropylate,
aluminum ethylacetoacetate diisopropylate, aluminum
oleylacetoacetate diisopropylate; organotitanium com-
pounds such as tetrabutyl titanate and tetraisopropyl
titanate; organoboron compounds such as tri-n-butyl
borate, triphenyl borate, tri-n-octadecyl borate and
monobutyldimethyl borate; phosphoric acid esters such
as trioleyl phosphate, tridecyl phosphate, dibutyl phos-
phite, trisisodecyl phosphite, di-2-ethylhexyl phosphite
and tridecyl phosphite; tetraoctyl silicate; triisobutox-
ygallium; and tetrabutyl zirconate.
(2)
which shows 1,3-dicarbonyl complexes:
complex salts of acetylacetonate such as aluminum
trisacetylacetonate, aluminum monoacetylacetonate
bisethylacetoacetate, aluminum trisethylacetoacetate;
acetylacetone lithium, acetylacetone beryllium, acetyl-
acetone sodium, acetylacetone magnesium, acetylace-
tone calcium, acetylacetone titanium, acetylacetone
strontium, acetylacetone barium, acetylacetone thal-
lium, acetylacetone vanadium, acetylacetone manga-
nese (III), acetylacetone iron (III), acetylacetone tho-
. rium, acetylacetone chromium (III), acetylacetone rho-
dium, acetylacetone cobalt (II), acetylacetone cobalt
(III), acetylacetone nickel, acetylacetone copper, ace-
tylacetone zinc, acetylacetone zirconium, acetylacetone
palladium, acetylacetone indium, acetylacetone tin (IV)
and acetylacetone molybdenum; complex salt of aceto-
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acetic acid ester, trifluoroacetylacetone and benzoy-
lacetone.
(3)
M—O—fi.—R
which shows carboxylates:
magnesium stearate, aluminum stearate, calcium stea-
rate, ferric stearate, zinc stearate, barium stearate, lead
stearate, potassium stearate, copper stearate, manganese
stearate, nickel stearate, nickel naphthenate, cobalt
naphthenate, manganese naphthenate, magnesium naph-
thenate, zinc naphthenate, magnesium palrnitate, cad-
mium palmitate, cobalt palmitate, sodium linoleate,
sodium laurate, barium oleate, aluminum laurate, alumi-
num oleate, potassium oleate, aluminum acetate, stan-
nous acetate, staxmous 2-ethylhexanoate, aluminum
formoacetate, zinc tartrate and basic aluminum thiodi-
glycolate.
(4) M-R which shows hydrocarbon group-containing
metals:
alkyl metals such as zinc 2-ethylhexyl, lithium hexa-
decyl, sodium n-hexyl, potassium hexadecyl, aluminum
n-trioctyl, lead n-propylethyl, antimony tri-n-pentyl,
antimony tri-n-decyl and zinc isobutylisoamyl; organo-
tin compounds such as dibutyl tin diacetate, di-n-butyl
tin dimaleate, di-n-butyl tin dioxide, triphenyl tin ace-
tate, tri-n-butyl tin oxide, dioctyl tin dilaurate, tributyl
tin acetate, tributyl tin chloride, tin tetraamyl and dial-
lyl tin dichloride; methylvinyldichlorosilane; octadecyl-
dimethyl[3(trimethoxysilyl)propyl]ammonium chlo-
ride; ferrocene; titanocene dichloride; and nickelocene.
(5) M-X-R (where X is a hetero atom) shows other
organometallic compounds:
metal thioalcoholates such as n-dodecylmercap-
topotassium salt and aluminum trithiobutoxide; thi-
odicarboxylates such as tin 2-ethylhexanemonothioate
and zinc 2-ethylhexanedithioate; dithiocarbamates such
as nickel dimethyldithiocarbamate, copper dimethyldi-
thiocarbamate, iron dimethyldithiocarbamate and zinc
diethyldithiocarbamate; sulfonic acids such as nickel
benzenesulfonate; phosphates such as vanadium dibu-
tylphosphate; and zinc mercaptobenzothiazole.
Among these organometallic compounds, the carbox-
ylates (3) and the hydrocarbon group-containing metals
(4) are preferred, and the metal alcoholates (1) and the
1,3-dicarbonyl complex salts (2) are more preferred.
More particularly, the preferred organometallic com-
pounds include acetylacetone lithium, acetylacetone
sodium, acetylacetone magnesium, acetylacetone tita-
nium, acetylacetone iron (III), acetylacetone palladium,
acetylacetone indium, tri-n-octadecyl borate, sodium
linoleate, magnesium stearate, aluminum stearate, alu-
minum acetate, aluminum laurate, basic _a1uminum thi-
odiglycolate, calcium stearate, ferric stearate, ferro-
cene, copper dimethyldithiocarbamate, zinc stearate,
zinc 2-ethylhexyl, zinc tartrate, stannous acetate, di-n-
butyl tin maleate, di-n-butyl tin oxide, triphenyl tin
acetate, barium stearate, lead stearate, dibutyl phos-
phite, tridecyl phosphate and trioleyl phosphate. The
more preferred organometallic compounds include ace-
tylacetone calcium, acetylacetone zinc, potassium ole-
ate, nickel naphthenate and dioctyl tin dilaurate. The
most preferred organometallic compounds include alu-
minum isopropylate, aluminum mono-sec.-butoxydiiso-
proylate, aluminum ethylacetoacetate diisopropylate,
4,818,325
5
aluminum oleylacetoacetate diisopropylate, aluminum
trisacetylacetonate, aluminum monoacetylacetonate
bisethylacetoacetate, aluminum trisethylacetoacetate,
acetylacetone manganese (III), acetylacetone cobalt
(II), acetylacetone nickel, acetylacetpne zinc, acetylac-
etone zirconium, tetrabutyl titanate, tetraisopropyl tita-
nate, dibutyl tin diacetate, tri-n-butyl tin oxide, tin 2-
ethylhexanoate, octadecyldimethyl[3(trimethoxysilyl)-
propyl]ammonium chloride and trisisodecyl phosphite.
The organic polymers used in- this invention may be
those generally known in the art. It is preferable, how-
ever, that they be soluble in organic solvents since the
primers of this invention are used preferably in the
dispersion or solution form.
The organic polymers used herein include olefinic
copolymers such as ethylene/vinyl acetate copolymers,
ethylene/acrylic acid ester copolymers and a-olefin/-
maleic acid copolymers; chlorinated olefmic polymers
such as chlorinated polyethylene, chlorinated polypro-
pylene, chlorinated ethylene/propylene copolymers
and chlorinated ethylene/vinyl acetate copolymers;
vinylic polymers such as polyvinyl chloride, polyvinyl
acetate, poly(meth)acrylic acid ester, polyvinyl ethers
and vinyl chloride/vinylidene chloride copolymers;
and synthetic rubbers such as polychloroprene, NBR,
SBR and chlorinated rubbers.
Of the above-mentioned various organic polymer,
those which are preferred for attaining the objects of
this invention are chlorinated olefinic polymers pre-
pared by chlorination of propylene, ethylene or the like
polymers or copolymers; chlorinated rubbers; olefinic
copolymers such as copolymers of propylene, ethylene
or the like; and methyl methacrylate/chloroprene co-
polymers with chlorinated polypropylene and methyl
methacrylate/chloroprene copolymers being particu-
larly preferred.
The primer gf this invention is used for coating on a
non-polar or highly crystalline resin substrates in bond-
ing the resin substrates together or bonding another
material thereto with use of a 2-cyanoacrylate. In this
case, it is desired to control the thickness of the organo-
metallic compounds coated so that the full effects of this
invention are attained as described later. For this pur-
pose, it is preferred that the compounds be used in solu-
tion.
The solvents used herein are preferably a usual one
which is capable of completely dissolving or dispersing
the organometallic compound and organic polymer
therein, has suitable volatility and is industrially easily
available. The solvents are also preferably such that a
resin, such as polyolefin, can be fully wetted on the
surface therewith, in order to allow the primers to exer-
cise their performance more efficiently. For this pur-
pose, it is further preferable to selectively use an or-
ganic solvent which has a surface tension lower than the
critical surface tension (')'c) of the resin. The following
Table 1 indicates the surface tension and the critical
surface tension of typical solvents to help one skilled in
the art in selecting a solvent to be used.
TABLE I
Critical surface tension
(ye) of resin
(dyne/cm. 20° C.)
Surface tension of
organic solvent
(dyne/cm. 20° C.)
Polytrifluoroethylene 22 1, l,2-trichloro- l,2,2- 19
tiitluoroethane
Polyethylene 3 l Ethanol 22
Polypropylene 3 l Acetone 23
Polyacetal 4-0 Ethyl acetate 24
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TABLE I-continued
Critical surface tension
(yo) of resin
(dyne/cm. 20° C.)
Surface tension of
organic solvent
(dyne/cm. 20° C.)
Polyvinylidene chloride 40 1,1,1-trichloroethane 26
Polyethylene terephthalate 43 Tetrahydrofuran 2
6-6 nylon 46 lkdioxane 27
Toluene 28
It is preferable that the organometallic compound in
solution be in a concentration by weight of 0.001-10%
for the reason that the organometallic compound may
be coated to nearly thickness of monomolecular layer
thereof whereby the compound can exhibit its best per-
formance as described later.
The concentration of organic polymer used will vary
depending on the kind of the polymer and is preferably
in the range of 0.1-20% by weight. If the concentration
used is less than 0.1% by weight then it will be difficult
to attain the objects of this invention, whereas the use of
a concentration of more than 20% by weight will hin-
der the action of the organometallic compound, which
plays a principal part as a primer, whereupon the primer
decreases in performance as such. Further, it is pre-
ferred that the amount of kind of the organic polymers
contained in a primer be determined so that when the
primer is made to be a primer solution, the primer solu-
tion will have a viscosity in the range of 2-5000 cp at
25° C. It will be difficult to attain the objects of this
invention when the viscosity of primer solution used is
outside of said range. In addition, when the primer is
used in the solution form, it is possible to add to the
primer solution a small amount of a viscosity improver
such as fused silica in order to use the solution as a
thixotropic one.
It has been found by the present inventors that the
variation of the primer of this invention in quality and
properties as well as the degradation thereof in quality
during its use or storage, is caused by the presence of
water in the primer and that it is desirable to limit the
water content of the primer to a certain amount, that is,
500 ppm or less in order to solve one of the above-men-
tioned problems.
To limit the water content of the primer to within 500
ppm, it is desired to limit not only the water contents of
the organometallic compound and organic polymer as
the ingredients of the primer but also the water content
of an organic solvent used together with said ingredi-
ents if necessary. .
It is also desired to prepare a primer from the above
ingredients in a dehumidified chamber or using 2. mois-
ture-preventing apparatus.
The primer will absorb moisture from air during its
use or storage even if it is free of water just after it has
been prepared. The primer will further absorb moisture
for a‘ long period of time to an extent that the water
content of the primer exceeds 500 ppm, whereby the
primer lowers in primer performance. Thus, it is desir-
able that the primer be treated so that its water content
does not exceed 500 ppm even a long time after its
preparation.
To prevent the primer from absorbing moisture dur-
ing the storage thereof, the primer may be stored in
glass- or metal-made containers as well as in nonperme-
able material-made containers such as plastics-made
containers having a polyvinylidene chloride layer.
However, it is unavoidable that the primer will absorb
4,818,325
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moisture during its use, and it is undesirable that the
containers for the primer are limited to specific ones.
Therefore, it is preferable to prevent the water content
in the primer from exceeding 500 ppm by moisture
absorption.
To this end, a desiccating agent or an adsorbent may
be housed in a space within a container or under the lid
thereof, the space being so defined as to prevent contact
of the primer with the desiccating agent or adsorbent. A
simple method for limiting the water content in the
primer, comprises allowing a solid desiccating agent or
adsorbent to coexist with the primer thereby rendering
it possible to remove the water absorbed or the water
derived from the ingredients of which the primer is
composed and keep the water content in the primer at a
level of not more than 500 ppm.
The desiccating agents used herein include various
kinds of desiccating agents such as phosphorus pentox-
ide, activated alumina, anhydrous calcium sulfate, mag-
nesium oxide, calcium oxide, calcium chloride, magne-
sium sulfate, diatomaceous earth, anhydrous zinc chlo-
ride, anhydrous copper (III) sulfate, silica gel and silica
alumina. The adsorbents used herein include molecular
sieve and activated carbon. The desiccating agents or
adsorbents which are allowed to exist in the primer, are
preferably those which meet the following require-
ments:
(1) They are solid materials,
(2) They are neutral or nearly neutral,
(3) They do not react with the primer,
(4) They are not dissolved in the primer, and
(5) They do not hinder the primer performance or activ-
ity of the primer.
Thus, they include activated alumina, magnesium
oxide, magnesium sulfate, diatomaceous earth, silica
aluminum with silica gel and molecular sieves being
morepreferable
The desiccating agents and adsorbents to be added to
‘the primer are preferably particulate in shape and the
particle size thereof is preferably in the range of about
0.5-10 m. If they have a particle size of smaller than
0.5 mm then they will run out of the primer and be
attached to the surface to be coated during the use of
the primer, whereas if they have too large a particle size
then they will come to be large in volume and unsuit-
able in shape as merchandise. The amount of such desic-
cating agents or adsorbents used may be determined
taking into consideration the expected amount of mois-
ture to be adsorbed and the capability of the agents or
adsorbents to absorb moisture.
The 2-cyanoacrylate used -in this invention is repre-
sented by the following general formula
CN
/
CI-I2=C
COOR
wherein R.is alkyl, alkenyl, cycloalkyl, aryl, alkoxyal-
kyl, aralkyl, haloalkyl or the like and more particularly
it is illustrated by methyl, ethyl, n-propyl, n-butyl, iso-
butyl, n-pentyl, allyl, cyclohexyl, benzyl or methoxy-
propyl.
The 2-cyanoacrylates used herein are the main com-
ponent of commercially available cyanoacrylate-based
instant adhesives which may be used as they are as the
2-cyanoacrylate in this invention.
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The commercially available cyanoacrylate-based
adhesives are composed mainly of a 2-cyanoacrylate
and may be further incorporated with various ingredi-
ents as illustrated below:
(1) Stabilizer
(2) Thickener
(3) Modifier
(4) Dyestuff
The stabilizer is for enhancing the storage stability of
the cyanoacrylate-based adhesives and is illustrated by
sulfur dioxide, an aromatic sulfonic acid or a sultone as
an anion polymerization inhibitor and by hydroquinone
or hydroquinone monomethyl ether as a radical poly-
merization inhibitor.
The thickener used herein is for increasing the viscos-
ity of the cyanoacrylate-based adhesives to several ten
to several thousand cp since usually a 2-cyanoacrylate is
a low viscous liquid having a viscosity of about several
op. The thickener used herein includes a polymethyl-
methacrylate, acryl rubber or cellulose derivative.
The modifier used herein is for improving the impact
resistance or heat resistance which are drawbacks of
conventional cyanoacrylate-based adhesives and is illus-
trated by maleic anhydride or a derivative thereof as an
improver of heat resistance as indicated in Japanese Pat.
Appln. Gazette No.52-12737. To enable a porous and
acidic sap-containing woody material which has hereto-
fore been considered difficult to bond, to be bonded,
crown compounds and the like may be used as indicated
in, for example, Japanese Pat. Appln. Publication Ga-
zette No. 55-2238.
Further, to provide a flexible adhesive layer, the
original adhesive may be incorporated with a plasticizer
such as tricresyl phsphate, dioctyl phthalate or dimethyl
sebacate.
The dyestuff used herein is for, for example, render-
ing a bonded portion easily identifiable, the original
adhesive may be incorporated with, for instance, an
acidic salt of basic dye as indicated in Japanese Pat.
Appln. Laid-Open Gazette No. 53-37260 or the like.
Furthermore, the original adhesive may further be
incorporated with a perfume such as an ester derivative
as indicated in Pat. Appln. Laid-Open Gazette No.
53-58541 or the like, in order to provide the adhesive
with fragrance.
In the practice of this ‘invention, the 2-cyanoacrylate
-may be used in the form of a diluted solution in a spe-
cific organic solvent. The organic solvent should be
such that it is compatible with the 2-cyanoacrylate and
does not impair the stability thereof, and it includes
toluene, butyl acetate or methylchloroform. It is pre-
ferred that the organic solvent contains none of mois-
ture and other impurities.
In a case where two substrates to be bonded together
are each a non-polar or highly crystalline resin, coating
of the organometallic compound may be effected by
immersing the both of the substrate in a solution of the
primer for several seconds or coating it with the solu-
tion of the use of a brush or spray gun and then air
drying, while in a case where one of substrates to be
bonded together is a non-polar or highly crystalline
resin, the substrate may be treated only in the same
manner as above. '
The primer coated non-polar or highly crystalline
resin substrates together or another material and the
substrate are bonded using the 2-cyanoacrylate by a
usual means, thus obtaining a bonded body having very
excellent bond strength.
4,818,325
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In the coating method of the primer, there may also
be used a method which comprises ejecting a 2-cyanoa-
crylate and a solution of the organometallic compound
simultaneously by the use of spray gun having two
nozzles.
In a process for forming a coating, painting or print-
ing on a non-polar or highly crystalline resin substrate,
the primer is coated on the resin substrate by the above-
mentioned coating method, and then a 2-cyanoacrylate
is coated and polymerized to form a polymer film
thereof, thus producing a resin substrate having satisfac-
tory receptivity and bond strength to coating materials,
paints and printing ink. The thus produced resin sub-
strates may be coated or printed by a conventional
means to form an excellent coating, painting and print-
ing thereon.
In the coating steps the following steps will show
more excellent effects in coatings.
In a first step, a primer prepared by dissolving the
organometallic compound and organic polymer in an
organic solvent, is coated on a substrate on which a
coating, painting or printing is to be formed by an im-
mersing or spraying method and being laid usually 5-60
minutes at room temperature or several days depending
on the operational steps taken.
In a second step, the 2-cyanoacrylate is coated on the
primer-coated substrate to form a poly-2-cyanoacrylate
film, by a coating method using a preliminarily acid-
treated brush, an immersing method, a spraying
method, or the like. In a case where the spraying
method is used, it is preferred to use a diluted solution of
l0
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a 2-cyanoacrylate in an organic solvent in order to pre-
vent the nozzles of spray gun from being clogged.
In addition, in a case where a commercially available
cyanoacrylate-based adhesive is used, it is preferable to
choose the low viscosity one.
The substrateon which the 2-cyanoacrylate has been
coated is allowed to stand at room temperature for at
least 12 hours to form a poly-2-cyanoacrylate film.
The poly-2-cyanoacrylate film is not particularly
limited in thickness, but it is preferable that the thick-
ness be in the range of 0.l—lO01.L, preferably 10-50;; to
eliminate defective coated portions.
The substrate on which the primer and a 2-cyanoa-
crylate have been coated as indicated above, is then
coated with a usual coating material, painted with a
paint or printed with a usual printing ink.
There are various kinds of coating materials, paints or
printing inks which may be classified in various ways,
however, they may be enumerated from the view-point
of the kind of vehicle resin used, as follows:
rosin derivatives, nitrocellulose resins, vinylic resins,
acrylic resins, polyester resins, polyamide resins, poly-
urethane resins, phenolic resins, epoxy resins, ami-
noalkyd resins, melamine resins and UV-curable acryl
oligomers.
From the view-point of use, particularly preferred
coating materials, paints or printing inks for use in ap-
plying to a polyolefin substrate are those containing a
polyurethane resin, an epoxy resin, or an alkyd resin.
As to thermosetting coating materials, those which
may be cured at a baking temperature of not higher than
90° C. are preferred.
A coating material or a paint may be applied by a
usual method such as a coating method using a brush, a
bar coater, a roller coater or a spray gun, while a print-
ing ink may be. applied by a usual method such as a silk
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65
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screen printing method, a gravure printing method or a
flexographic printing method.
It is not clear why the adhesiveness of a non-polar or
highly crystalline resin to another material is improved
by using the organometallic compound of this invention
as the primer and the 2-cyanoacrylate, however, the
organometallic compounds will exhibit their best
primer performance when they are very thinly coated
to an extent that the amount thereof coated reaches
0.001 to 1 g/m2 although the optimum thickness varies
depending on the kind of the organometallic compound
used.
Bonding tests were made by using a polypropylene
plate (2 mm thick) as the resin substrate, acetylacetone
zirconium (used as solutions of various concentrations
in methylchloroform) as the primer, and a 2-cyanoacry-
late-based adhesive (produced under the tradename of
Aron Alpha No. 201 by Toagosei Chemical Industrial
Co., Ltd.), to obtain bonded products which were mea-
sured for tensile shear strength at the bonded portion.
The following Table A indicates the differences in ten-
sile shear strength due to the differences in amount of
the primer coated. The bonded products were aged at
23° C. under a relative humidity (RH) of 60% for one
day.
TABLE A
Amount of Tensile shear
Cone. of primer primer coated strength
(wt. %) (g/m2) (kgf/cmz)
5 0.5-2.5 3
3 0.3-1.5 10
1 0.1-0.5 15
0.5 0.05-0.25 36
0.25 0.025—O.l25 55*
0.05 0005-0025 60*
0.025 00025-00125 27
0.01 0.001—0.005 11
0.001 0.0001-0.0005 3
Note:
The symbol, ‘, indicates the destruction of plate.
It is seen from the results in Table A that the primer
will exhibit its best performance when it is coated in
nearly the thickness of its monomolecular layer. From
the above results and the fact that the organometallic
compounds have a polar segment and non-polar seg-
ment in structure, it is surmised that the effects of this
invention are produced under the following mecha-
msm. —
The organometallic compound, that is, the primer ‘of
this invention is present in approximately the monomo-
lecular layer between the surface of the non-polar or
highly crystalline resin substrate and the 2-cyanoacry-
late layer (monomer or polymer film layer) whereby the
groups highly compatible with the 2-cyanoacrylate
layer, in other words, the lipophilic groups and the
polar groups are arranged in order and these groups act
as a bonding agent to obtain the effects of this invention.
To obtain the best results in accordance with this
invention, it is necessary to determine an organometal-
lic compound and organic polymer to be used, the con-
centration of the compound, the amount thereof ap-
plied, and the like in view of the nature of the organo-
metallic compound, the organic polymer, a substrate
and a material to be bonded thereto. As to the amount
of the organometallic compound (primer) applied, the
use of the primer in such a small amount that the result-
ing primer layer does not cover all the surface of the
substrate which is needed, will naturally not give good
4,818,325
11
results, whereas the use thereof in such a large amount
that the resulting primer layer is thicker than the mono-
molecular layer, will result in forming a fragile primer
layer whereby the results of this invention are not ob-
tained. Thus, the concentration of an organometallic
compound in solution (primer solution) is preferably
0.001-10% by weight and the amount of the primer
coated is in the-range of preferably 0.00l—l g/m2, more
preferably 0.0l—0.l g/m3.
A secure bond is effected between a non-polar or
highly crystalline resin substrate and a 2-cyanoacrylate
with aid of the organometallic compound present there-
between whereby the resin substrate is much improved
in adhesiveness and, further, a usual coating material or
printing ink can easily be applied to the treated resin
substrate without causing any problems owing to the
presence of a poly-2-cyanoacrylate film formed
thereon.
The excellent effects obtained by the practice of this
invention are those which may be attained by the com-
bined use of the 2-cyanoacrylate, organometallic com-
pound and non-polar or highly crystalline resin sub-
strate. On the other hand, in cases where a bond is
attempted to be effected between polyolefin (such as
polyethylene) and something, an organotitanium com-
pound was once studied to fmd whether it is useful as a
primer or preliminary treatment; in these cases, how-
ever, excellent effects were not appreciated since an
epoxy, urethane, rubber or acrylic adhesive was used.
These conventional means do not anticipate at all the
present invention which will unexpectedly excellent
effects when practiced.
The effects of this invention will be exhibited only
when a non-polar or highly crystalline resin is used as
the substrate, whereas they will not be exhibited when
other materials (such as a metal, wood or porcelain) are
used as the substrate.
TE: primerzof this invention is effective for a non-
polar or highly crystalline resin such as olefinic poly-
mers typified by polyethylene, polypropylene, polybu-
tene and polymethylpentene; composite materials com-
posed of the olefinic polymers incorporated with talc,
alumina, mica, glass fibers and the like; polyethylene
terephthalate; polyacetal; polyurethane; silicone rub-
bers; and soft-type PVC (polyvinyl chloride). It is for
olefmic polymers such as polyethylene and polypropyl-
ene that the primer of this invention is the most effec-
tive.
This invention will be better understood by the fol-
lowing Examples and Comparative Examples wherein
all parts and percentages are by weight unless otherwise
specified.
EXAMPLE 1
0.5 parts of Manganese (III) acetylacetonate and 2
parts of chlorinated polypropylene (produced under the
tradename of SUPERCHLON l06H by Sanyo
Kokusaku Pulp Co., Ltd.) were dissolved in 97.5 parts
of toluene to obtain a primer. In accordance with JIS
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50
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K6861-1977, the thus obtained primer was applied to
polypropylene resin-made test pieces (25X l0O>
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