Fast underwater bonding to polycarbonate using photoinitiated cyanoacrylate
Fast underwater bonding to polycarbonate using photoinitiated cyanoacrylate
Year:
Abstract:
Rapid underwater bonding of clear polycarbonate to metal or plastic substrates at temperatures approaching 0 °C was studied. Bonding was achieved within minutes using ethyl 2-cyanoacrylate gel cured using the photoinitiator (dibenzoylferrocene) with a blue-LED light source. The optimum initiator concentration varied from 0.3% to 0.1 wt % for adhesive films 0.5 to 1.2 mm thick, respectively. The polymerisation rate shows a negative temperature dependence making it highly suitable for cold environments. The ultimate shear strength of the bonds was temperature independent and ranged from 1 MPa for metallic to 5 MPa for plastic substrates, respectively.
DOI:
10.1016/j.ijadhadh.2010.01.002
Type of document:
Language:
ARTICLE IN PRESS
International Journal of Adhesion & Adhesives 30 (2010) 208–213
Contents lists available at ScienceDirect
International Journal of Adhesion & Adhesives
journal homepage: www.elsevier.com/locate/ijadhadh
Fast underwater bonding to polycarbonate using photoinitiated cyanoacrylate
William E. Cloete, Walter W. Focke Ã
Institute of Applied Materials, Department of Chemical Engineering, University of Pretoria, Lynnwood Road, Pretoria 0001, South Africa
a r t i c l e in f o
a b s t r a c t
Article history:
Accepted 13 January 2010
Available online 25 January 2010
Rapid underwater bonding of clear polycarbonate to metal or plastic substrates at temperatures
approaching 0 1C was studied. Bonding was achieved within minutes using ethyl 2-cyanoacrylate gel
cured using the photoinitiator (dibenzoylferrocene) with a blue-LED light source. The optimum initiator
concentration varied from 0.3% to 0.1 wt % for adhesive films 0.5 to 1.2 mm thick, respectively. The
polymerisation rate shows a negative temperature dependence making it highly suitable for cold
environments. The ultimate shear strength of the bonds was temperature independent and ranged from
1 MPa for metallic to 5 MPa for plastic substrates, respectively.
& 2010 Elsevier Ltd. All rights reserved.
Keywords:
Cyanoacrylates
Destructive testing
Thermal analysis
Cure/hardening
Plastics
1. Introduction
Neat cyanoacrylate reacts rapidly when it comes in contact
with water. It is therefore not generally used for underwater
bonding. However, the cured resin is not much affected by
exposure to water. Consequently, this adhesive finds interesting
underwater applications including tagging of sea mammals [1]
and mussels or scallops [2] and fixing coral to rocks underwater
[3,4]. Numerous other applications are described in the patent
literature [5–7].
This study considered the use of a commercial ethyl cyanoacrylate-based adhesive for underwater bonding of clear polycarbonate
sheets to other substrates for use with a proprietary applicator
system. The key idea of the applicator is to use the adhesive itself to
rapidly displace any water present between the two substrates to be
bonded. This is achieved by extruding the adhesive from a central
application hole. The water displacement is best achieved using a
high-viscosity adhesive. Suitable thickening agent, e.g. fumed silica,
can be used to impart the required consistency. Previous studies [5]
showed that the strongest bonds are achieved with thin adhesive
layers. Thicker adhesive sections take longer time to cure and
sometimes full cure is not achieved.
Since the present application requires rapid bonding of a clear
polycarbonate sheet to flat underwater substrates, photoinitiated
cure was a definite option. Photoinitiated curing of acrylate
adhesives is well established [8–10] and commercial systems are
available [11]. The advantage is that photoinitiated cure can be
initiated on demand and that thicker adhesive sections polymerise to completion. Thus this study considered the addition of an
à Corresponding author. Tel.: + 27 012 420 2588; fax: + 27 012 420 2516.
E-mail address: walter.focke@up.ac.za (W.W. Focke).
0143-7496/$ - see front matter & 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijadhadh.2010.01.002
anionic photoinitiator to the cyanoacrylate adhesives to act as the
primary cure initiator.
Ferrocene is a transition metal complex that has been the
subject of numerous investigations [12]. The photochemical
characteristics of ferrocene and several of its derivatives have
been studied exhaustively [13–15]. Kutal and Yamaguchi [16]
identified dibenzoylferrocene as a preferred anionic photoinitiator
for cyanoacrylates. It is insoluble in water and has a maximum
absorption peak at 485 nm. This closely matches the 470 nm blue
LED light sources used in underwater camphorquinone initiated
acrylate systems [8–10]. This light source was therefore selected
for used in the present study.
2. Materials and methods
2.1. Adhesives and substrates
A commercial ethyl cyanoacrylate gel (Loctite 454) was used
without modification. Dibenzoylferrocene was supplied by Sigma
Aldrich Chemicals and used without further purification as a
solution in hexane. Sea water was simulated using the aquarium
product ‘‘Ocean Fish’’ supplied by Prodac. All other chemicals used
were obtained from Sigma Aldrich. Metal sheets (hot-rolled mild
steel sheet (12% carbon), stainless steel 304, and aluminium) were
cut into squares measuring 10 Â 100 Â 100 mm in accordance
with ASTM D 4501. The bonding surfaces of the different
metal substrates were sanded with 100 grit sandpaper and then
cleaned with a lint-free cloth soaked in isopropyl alcohol. The
sulphuric-acid anodised aluminium was used as supplied. All
thermoplastic sheets were supplied by Maizeys. The fibreglassreinforced polyester (FRP) sheet was cast using glass fibre and
polyester resin supplied by Plastocure.
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2.2. Light sources and calibration
The light source unit was custom-designed and consisted of
144 LED’s in a 12 Â 12 array. Nichia Corporation (Model: NSPB
500S) 5 mm blue ultra-bright LED’s were used. The whole system
was sealed inside an acrylic box to allow underwater illumination
of the substrates. The light source was powered by a Vanson
Deluxe Universal Regulated DC Power Supply (Model RC-1200).
The output was set at 12 V DC and the overall current measured
was 750 mA. The light source was calibrated by the National
Metrology Institute of South Africa (NMISA) by comparing the
spectral irradiance of the blue light LED array against the spectral
irradiance of a standard lamp, traceable to the national measuring
standard for spectral irradiance. In this investigation the adhesive
was illuminated with the light source placed at a distance of
50 mm away. This distance was chosen to ensure overlapping of
the individual LED light beams and to allow sufficient space to fit
the experimental equipment between the light source and the
adhesive samples. All adhesive samples were irradiated at an
effective light intensity of 5 mW/cm2.
2.3. Photodifferential scanning calorimetry (Photo-DSC)
Isothermal photopolymerisation studies were performed on a
Perkin-Elmer DSC-7 differential scanning calorimeter and analyzed using Pyris software. An indium standard was used for
calibration. The DSC head was modified with a single polycarbonate window covering both the sample and the reference cells as
described by Pappas [17]. The polycarbonate window was
regularly replaced because, over time, vapours from the cyanoacrylate samples affected its transparency. The blue LED light
source was positioned at a distance of 50 mm above the measuring
pans. The light source was switched on and off using a timer.
Cylindrical aluminium sample pans were used with depths of
0.5, 0.8, and 1.2 mm to control the sample thickness. Nitrogen was
used as the purge gas. The instrument was allowed to stabilize at
every set isothermal temperature before photocuring experiments commenced.
2.4. Tensile testing
The shear strength of the adhesive bonds between the rigid
substrates was measured according to the ASTM D4501 shear
block testing standard on an Instron 4303 tensile tester. The load
cell had a maximum capacity of 25 kN in tension. Shear strength
values reported here are averages of at least five replicates in
accordance with the ASTM specification.
2.5. Bonding process
The application process is a vital factor that determines the
ultimate strength of underwater bonds. In this study the top
substrate was always a clear polycarbonate sheet. This allowed
facile illumination of the adhesive sandwiched between the
two substrates.
A 19 mm diameter pencil ring was drawn in the centre of the
polycarbonate sheet used as the top substrate. A quantity of 0.50 g
( 70.01 g) of adhesive was placed on this demarcated area. This
was done to keep the surface area of the adhesive, exposed to
water, constant. The bottom substrate was first submerged in
water. It was left in the water bath for at least 5 min to allow
temperature equilibration. The top substrate was then submersed
into the water bath and pressed firmly onto the bottom substrate.
This action caused the adhesive to flow radially outward and
cover the entire bond area. Next, the light source was submersed.
209
It was positioned at a distance of 50 mm away from the bond line
and switched on to initiate cure.
It should be noted that rapid polymerisation of the cyanoacrylate resin ensues as soon as it comes in contact with water.
However, this gives rise to a protective skin layer that acts as a
barrier for further water ingress by diffusion [5,6]. Thus only the
adhesive’s outer surface (inside the 19 mm ring on the top
substrate) is instantly affected by the exposure to water. This part
of the cyanoacrylate adhesive, cured by the reaction with water,
assumes a white colour. This contrasts with the orange tint of
cyanoacrylate cured by the blue light radiation. Since the whitecoloured skin represents already polymerised material, it does not
contribute to the bonding of the bottom substrate. When the two
sheets are pressed together, the protective skin ruptures and
adhesive is squeezed out. The uncured adhesive displaces the
water as it travels radially outwards between the two substrates.
Only this part of the surface is responsible for the measured bond
strength. The non-bonded water-cured skin region trapped
between the two substrates had an average diameter of 21 mm.
This inactive bond area (346 mm2) was subtracted from the total
bond area (2 500 mm2) to give, on average, an active bond area of
2154 mm2 for calculating the shear bond strength. The average
bond line thickness was measured at 0.2 mm.
The effect of illumination time and water temperature on the
ultimate bond shear strength was determined using polycarbonate
as top and bottom substrates. The sheets were bonded in potable
water. The effect of illumination time was determined using a water
temperature of 15 1C. Next, the illumination time was kept constant
at 1 min and the water temperature varied from 1.5 to 40 1C. Bond
strength measurements to various other substrate materials were
done on samples bonded in 15 1C potable water as well as in
simulated sea water. The different materials tested are categorised
as metals (mild steel, aluminium, anodised aluminium, stainless
steel 304) and other polymers including ABS (Acrylonitrilebutadiene-styrene), poly(vinyl chloride) (PVC), poly(methyl methacrylate) (PMMA), polycarbonate (PC), and fibreglass-reinforced
polyester (FRP). Substrate preparation was the same in each case
and an illumination time of 1 min was used throughout.
The effect of the length of time for which the adhesive was
exposed to water before bonding studied by delaying the pressing
together of the sheets for predetermined times. These tests were
performed in potable and in artificial sea water at a temperature
of 15 1C.
In all cases the actual shear bond strengths were measured at
room temperature. The averages of at least five replications are
reported.
3. Results and discussion
3.1. Thermal analysis
3.1.1. Experimental problems with Photo-DSC
The cure reaction of cyanoacrylates is highly exothermic and
calorimetric techniques seem ideal to study the polymerisation
kinetics. Cyanoacrylates are among the most reactive monomers to
be examined kinetically. Pepper and co-workers [18,19] studied their
cure kinetics and the mechanism of polymerisation. Despite the fact
that they employed carefully controlled experimental conditions,
problems were experienced with respect to reproducibility. Similar
problems were experienced in this study where the polymerisation of
cyanoacrylate adhesives was followed using photo-DSC.
3.1.2. Effect of photoinitiator concentration
It is conventional to assume that the DSC-measured heat flux is
proportional to the rate of polymerisation. The amount of
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0.5
240
210
-0.5
0.50 mm
-1.5
Cure time, t95 (s)
Heat flow (W/g)
180
0.05% PI
0.10% PI
-2.5
0.20% PI
0.30% PI
-3.5
Light on at
30 seconds
0.40% PI
0.80 mm
150
1.20 mm
120
90
60
0.50% PI
-4.5
30
Cure temperature 15ºC
-5.5
0
0
50
100
150
Time (s)
200
250
0
0.1
0.2
0.3
0.4
0.5
Concentration Initiator (% m/m)
0.6
0.7
Fig. 1. Effect of the photoinitiator concentration on the isothermal cure exotherms
for Loctite 454.
Fig. 2. Effect of photoinitiator concentration and adhesive film thickness on the
cure time (t95).
photoinitiator (PI) present affects the rate of polymerisation. Thus
experiments were conducted varying both the concentration of
dibenzoylferrocene and the adhesive film thickness. Since the idea
was to simulate actual underwater bonding conditions, relatively
thick films (0.5–1.2 mm) were tested in order to determine the
optimum photoinitiator concentration. The photoinitiated DSC
cure studies revealed complex cure behaviour. The measured cure
rates were not sufficiently repeatable to allow a proper kinetic
analysis of the data. Consequently, the cure time was simply
characterized by the time required to attain 95% of the full
conversion time (t95). For a given experiment, this was calculated
as the time point where 95% of the total heat release, due to the
reaction exotherm, was reached. The optimum photoinitiator
concentration was associated with the shortest cure time.
Fig. 1 shows DSC exotherms measured at a film thickness of
0.8 mm. The peak in the exotherm corresponds to the maximum
rate of polymerisation. Fig. 1 reveals that the maximum cure rate
first increases and then decreases with increasing photoinitiator
concentration. This counterintuitive behaviour can be rationalized
as follows: Cure initiation is hampered by the acidic stabilizer. This
means that the stabilizer neutralization reaction competes with the
cure initiation reaction. Consequently, it takes an even longer time
to reach the maximum cure rate when the concentration of
initiator is low. At intermediate photoinitiator concentrations the
maximum cure rate is reached in a very short time. However, at
higher concentrations the exotherm ‘‘tails out’’, i.e. takes a longer
time to return to the base line. This is attributed to excessive light
absorption by the outer layers hampering photoinitiation of the
deeper layers, the so-called ‘‘the inner filter effect’’. Similar
exotherm trends were observed for experiments conducted with
adhesive film thicknesses of 0.5 and 1.2 mm. Nevertheless, the
overall heat of reaction was independent of initiator concentration
and film thickness and amounted to 26274 J/g.
Fig. 2 shows the effect of initiator concentration and film
thickness, at a temperature of 20 1C, on the cure time. As
mentioned, this was taken as the time to reach 95% conversion
(t95). Generally and unsurprisingly, the thicker the film, the longer
is the cure time (t95). The cure time curves obtained by a plot
against the initiator concentration show shallow minima. The
minimum cure time and corresponding initiator concentration
increases with increasing film thickness in accordance with
expectations considering the ‘‘inner-filter’’ effect [20]. The optimum
concentration of dibenzoylferrocene for the polymerisation of films of
0.5, 0.8, and 1.2 mm are approximately 0.28, 0.2, and 0.14 wt %,
respectively.
In the current underwater adhesion tests, the average bond
line thickness was observed to be slightly less than 0.2 mm. This
means that a photoinitiator concentration of 0.3 wt % or a little
higher would probably provide the fastest cure. It was, however,
decided to standardize on 0.2 wt % photoinitiator in all further
testing because real-life underwater surfaces are generally rather
rough and one would therefore expect that thicker adhesive lines
may be encountered.
3.1.3. Effect of photopolymerisation temperature
Isothermal photopolymerisation experiments were performed at
temperatures of À10, 20 and 50 1C. Owing to the poor reproducibility of the data, each curve in Fig. 3 actually represents the average
of ten separately measured exotherms. The exotherms in Fig. 3
show that the cure advances faster at lower reaction temperatures
in agreement with previous studies dealing with ferrocene
derivatives [21,22], or aliphatic amines and pyridine derivatives
[19] as initiators.
These results indicate that this adhesive system will cure faster
in cold water conditions. This gives it an advantage over epoxybased underwater adhesives which often fail to cure properly
under such cold conditions. If it is assumed that the 95%
conversion state is controlled by a single reaction with its
associated Arrhenius activation energy, the effective cure time
(in seconds) for 0.80 mm thick adhesive containing 0.20% initiator
is given by the expression
t95 ¼ 1495eÀ782=T
ð1Þ
3.2. Bond strength results
3.2.1. Illumination time
Fig. 4 shows the effect of illumination time on ultimate bond
shear strength obtained in potable water at 15 1C with
polycarbonate as both top and bottom substrate. The bond
strength increases with increased illumination time but reaches
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1.0
Steel
Light source on at 30 s
0.0
Al anodized
-1.0
Heat flow (W/g)
211
Aluminium
SS 304
-2.0
-10ºC
ABS
20ºC
-3.0
PVC
50ºC
-4.0
PMMA
0.20 wt % PI
Film thickness 0.8 mm
-5.0
-6.0
PC
FRP
0
50
100
150
Time (s)
200
250
0
Fig. 3. Averaged DSC cure exotherms obtained at different temperatures.
2
4
6
Shear bond strength (MPa)
8
Fig. 5. Shear strength for polycarbonate bonded to other substrate materials.
7
Shear bond strength (MPa)
6
5
4
3
2
Shear bond strength without illumination
(kept in position for 60 s and then tested)
1
0
0
25
50
75
Illumination time (s)
100
125
Fig. 4. Effect of illumination time on the shear strength of polycarbonatee bonded
to polycarbonate.
a plateau value beyond 50 s. An advantage offered by the
cyanoacrylates over standard acrylic adhesives [8–10] is that a
useful level of bond strength develops even in the absence of
illumination.
3.2.2. Substrate material
Fig. 5 shows the shear bond strengths achieved for bonds of
polycarbonate to other substrates. It is clear that the adhesive
bonds to polymeric substrates were much stronger than those to
metals. For mild steel and aluminium the failure mode was
adhesive failure at the metal surface. Visual inspection revealed
the presence of patchy moisture films on the bared metal. This
implies that the adhesive was unable to completely and
effectively remove water from the metal surface during the
bonding process.
Low shear bond strengths of 0.86 and 0.49 MPa were recorded
for mild steel and aluminium, respectively. Bonding was more
effective with the anodised aluminium averaging 1.27 MPa, i.e.
more than double the strength obtained with untreated aluminium. In this case the failure mode was mixed. It occurred mainly
between the anodised layer and the metal surface, revealing the
shiny metal surface underneath the grey anodised layer. In minor
parts cohesive failure in the adhesive layer was also observed.
Kinloch [23] also reported this type of failure mode for aluminium
surfaces anodised with sulphuric acid. Adhesion to stainless steel
304 was somewhat better than that to anodised aluminium. The
failure mode was mixed with small amounts of adhesive present
on the stainless steel surface after bond failure. All the bonds
made to polymers showed varying degrees of cohesive failure,
except for the FRP which showed massive substrate failure. The
average shear bond strength to polymers was in the order of
5 MPa. Drain et al. [24,25] found that cyanoacrylates dissolve
polycarbonate to form a type of ‘‘solvent’’ welded interface that is
able to withstand moisture over long periods. Whether cyanoacrylate adhesives have the ability to do the same to other
polymers like ABS, PVC, PMMA, and FRP is not clear, but very high
bond strengths are measured on these materials. The large
difference in shear bond strength between metallic and polymeric
materials could be attributed to their respective hydrophilicities.
Metallic surfaces tend to be more hydrophilic and polymeric
surfaces more hydrophobic. It is more difficult for the cyanoacrylate adhesive to completely displace the water from immersed
metal surfaces and ensure the good initial contact necessary for
the development of strong bonds.
3.2.3. Effect of temperature
Fig. 6 shows that varying the water temperatures between 1.5
and 40 1C did not significantly influence the bond strength.
Although photo-DSC data revealed negative temperature
dependence, i.e. a lower rate of cure at high temperatures, this
did not affect the ultimate bond strength obtained at 40 1C. It can
therefore be concluded that the 1-min illumination time on a
bond of 0.2 mm thick adhesive layer cured at 40 1C was sufficient
to achieve the full bonding.
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5
environments. The reduction in bond strength is due to a
combination of two factors: the reduction in the amount of
adhesive available for bonding and therefore a smaller bonding
area, and the increase in bond line thickness due to the PECA
skin which becomes thicker over time causing the bond line to
be thicker.
4
4. Conclusions
3
Clear polycarbonate sheets can be bonded rapidly to underwater
substrates using the commercial cyanoacrylate adhesive Loctite 454
spiked with the photoinitiator dibenzoylferrocene. In this regard the
application process is critical. First a bead of the viscous adhesive is
placed on the polycarbonate plate. On submersion a protective skin
forms on the adhesive’s surface owing to water-initiated polymerisation. When the plate is pressed against the underwater substrate,
the squeezing action causes unreacted adhesive to ooze out from
the broken protective skin. It spreads radially outward to fill the gap
between the two substrates. Simultaneously it displaces the water
initially present. Full cure, throughout the adhesive layer, is
guaranteed by photochemical polymerisation. Initiation is triggered
by illumination with a suitable blue light source, e.g. blue LED’s
(wavelength: 467 nm). More specifically, a one minute exposure to
this blue light with an intensity of ca. 5 mW/cm2 was sufficient to
reach the full ultimate bond strength of adhesive films with a
thickness of 0.2 mm when the resin contained 0.2 wt % benzoylferrocene. Bond strength development was insensitive to the water
temperature in the range of 1 – 40 1C. Best adhesion performance,
with the shear strength exceeding 5 MPa, was obtained when
bonding one polycarbonate sheet to another. Strong bonds were
also obtained when using other plastics but bonds to metal
substrates were substantially weaker. Bond strengths were ca. 1
and 2 MPa to anodised aluminium and stainless steel, respectively.
Finally, care should be taken to minimize the exposure time to
water to avoid loss of bonding strength.
7
Shear bond strength (MPa)
6
2
1
0
0
10
20
Temperature (°C)
30
40
Fig. 6. Effect of temperature on shear bond strength.
6
Potable Water
Shear bond strength (MPa)
5
Sea Water
4
3
2
Acknowledgements
1
Financial and technical support from the Council for Scientific
and Industrial Research is acknowledged with gratitude.
0
0
10
20
30
40
Work time (min)
50
60
Fig. 7. Effect of underwater work time on shear bond strength.
3.2.4. Effect of water exposure time
Unlike acrylate-based adhesives, cyanoacrylates react when
coming in contact with water. On submersion, the outer layer of
the cyanoacrylate adhesive (clear with a light orange tint) rapidly
polymerises to form a white protective barrier skin. This skin is
permeable and water ingress via diffusion will slowly cause
polymerisation of the remaining adhesive on the inside until all of
it has been converted. Preliminary measurements indicate that in
room temperature potable water the polymerised cyanoacrylate
skin grew to a thickness of about 1.5 mm in one hour. It is
therefore imperative that the bond should be made as soon as
possible after submersion, i.e. contact with water. Fig. 7 shows the
effect of water exposure time on the shear bond strength. It shows
a linear decline in bond strength with water exposure time. The
bond strength decays slightly faster in artificial sea water,
possibly due to the pH being higher than that of potable water.
This accords with the findings of Katti and Krishnamurti [26] who
found that alkyl cyanoacrylates polymerise faster in higher pH
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