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  • 专利说明
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    • 专利摘要:
    Phosphate Adhesion Promoters A first aspect of the present invention is an adhesive composition comprising one or more polyisocyanates and one or more phosphate functional polyols. a second aspect of the present invention is a method of bonding two substrates together to form a bonded article, the method comprising the steps of applying a layer of the composition of the first aspect to one of the substrates, contacting the layer of the composition of claim 1 with a second substrate, and curing or allowing the composition of claim 1 to cure, a third aspect of the present invention is a bonded article formed by the method of the second aspect.
    公开号:BR112016024609B1
    申请号:R112016024609-8
    申请日:2015-05-04
    公开日:2022-01-11
    发明作者:David E. Vietti；Joseph J. Zupancic；Jonathan Barrus
    申请人:Rohm And Haas Company；Dow Global Technologies Llc；
    IPC主号:
    专利说明:

    [1] A useful type of adhesive composition is one that contains a polyisocyanate and a polyol. When using such adhesive compositions to adhere to a metal surface, it is often desirable to include a phosphate functional compound as an adhesion promoter. In the past, adhesion promoters have included phosphate esters made from diglycidyl ethers such as, for example, bisphenol A diglycidyl ether. The use of diglycidyl ethers is undesirable for health, safety and environmental reasons. It is desirable to provide a phosphate functional adhesion promoter which is not made using diglycidyl ether. It is desirable to provide such an adhesion promoter for use in adhesive compositions that are used in the manufacture of food-containing packages. It is desirable that adhesives containing such an adhesion promoter retain their adhesive properties even after exposure to a mixture of vinegar, oil and ketchup.
    [2] US 3,309,427 describes polyhydroxy phosphate esters suitable for use in the manufacture of polyurethane foams. In the method disclosed by US 3,309,427, a polyhydric alcohol is reacted with a polyphosphoric acid to form an acid partial ester, which is then reacted with a sufficient amount of a 1,2-alkylene oxide to substantially neutralize the acidity; after the neutralization step, the product is then mixed with polyisocyanate to form rigid polyurethane foam. It is desirable to provide an adhesive composition which contains an adhesion promoter which has hydroxyl functional groups and also one or more phosphate functional groups.
    [3] The following is a statement of the invention.
    [4] A first aspect of the present invention is an adhesive composition comprising one or more polyisocyanates and one or more phosphate functional polyols.
    [5] A second aspect of the present invention is a method of bonding two substrates together to form a bonded article, the method comprising the steps of applying a layer of the composition of the first aspect to one of the substrates, contacting the layer of the composition of claim 1 with a second substrate, and curing or allowing to cure the composition of claim 1.
    [6] A third aspect of the present invention is a bonded article formed by the method of the second aspect.
    [7] The following is a detailed description of the invention.
    [8] As used herein, the following terms have the designated definitions, unless the context clearly indicates otherwise.
    [9] As used herein, a polyisocyanate is a compound that contains two or more isocyanate groups. Polyisocyanates can be monomeric or non-monomeric. As used herein, a "monomeric polyisocyanate" is a compound that has two or more isocyanate groups, that has a molecular weight of less than 500, and that has no urethane bond and no urea bond. Any polyisocyanate that is not a monomeric polyisocyanate is a non-monomeric polyisocyanate.
    [10] As used herein, "MDI" is diphenyl methylene diisocyanate, also called diphenyl methane diisocyanate. MDI exists as one of three isomers (4, 4' MDI, 2.4' MDI and 2.2' MDI) or as a mixture of two or more of these isomers. As used herein, unless specifically mentioned otherwise, "MDI" does not refer to polymeric MDI (sometimes called PMDI). Polymeric MDI is a compound that has a chain of three or more benzene rings connected together by methylene bonds, with an isocyanate group attached to each benzene ring.
    [11] A hydroxyl group has the structure -OH, where the oxygen atom is bonded to a carbon atom, and the -OH group is not part of a carboxyl group. A compound with two or more hydroxyl groups is a polyol. A polyol with exactly two hydroxyl groups is a diol. A polyol with exactly three hydroxyl groups is a triol. As used herein, a "higher polyol" is a polyol having 3 or more hydroxyl groups. An alkyl polyol is a compound that is an alkane with two or more substituent hydroxyl groups and no atoms other than carbon and hydrogen, except for the oxygen atoms that are part of hydroxyl groups. A higher alkyl polyol is an alkyl polyol having three or more substituent hydroxyl groups.
    [12] A compound that contains two or more ether bonds in the same linear chain of atoms is known herein as a polyether. A compound that contains two or more ester bonds in the same linear chain of atoms is known herein as a polyester. A compound which is a polyester and a polyol is a polyester polyol, and a compound which is a polyether and a polyol is a polyether polyol.
    [13] Some non-monomeric polyisocyanates are reaction products of one or more polyisocyanates with one or more compounds with multiple active hydrogen compounds, where such reaction products have two or more unreacted isocyanate groups. Such non-monomeric polyisocyanates may be, for example, the reaction products of one or more polyisocyanates with one or more polyols or the reaction products of one or more polyisocyanates with one or more polyamines or a mixture thereof. . A polyisocyanate which is a reaction product of one or more polyisocyanates with one or more compounds with various active hydrogen compounds and which has a molecular weight of 500 or more is known herein as a prepolymer. As the prepolymer is a polyisocyanate, it is known herein as an isocyanate functional prepolymer.
    [14] A useful method of characterizing the amount of isocyanate groups in a composition is “%NCO,” which is the total weight of all isocyanate groups present in the composition, divided by the total weight of the composition, expressed as a percentage .
    [15] A compound is said here to be phosphate functional if that compound contains structure I:
    A phosphate functional polyol is a compound having two or more hydroxyl groups and one or more structure I. A compound is said herein to be phosphorus-free if that compound does not contain a phosphorus atom.
    [16] Included in Structure I are structures in which one or more of the acidic hydrogen atoms have been abstracted. Acid hydrogen atoms are hydrogen atoms bonded to oxygen atoms that are bonded to a phosphorus atom. When one or more acidic hydrogens has been abstracted, the phosphate group is an anion.
    [17] As used herein, the phrase "a phosphoric acid" means orthophosphoric acid or any member of the series of compounds which can be made by condensation of orthophosphoric acid by the elimination of water or any mixture thereof. This series includes, for example, pyrophosphoric acid, tripolyphosphoric acid, and polyphosphoric acids.
    [18] A comopsition is said here as "curing" when chemical reactions occur that desirably cause an increase in the molecular weight of the composition and/or cause crosslinking of the comopsition in order to improve the properties of the comopsition. Such chemical reactions are known as “healing reactions.” The composition is said to be "cured" when such reactions are complete or when the curing reactions have progressed far enough that the properties of the composition are useful and are not changing appreciably over time. A composition that is capable of undergoing one or more curing reactions is a curable composition.
    [19] As used here, when a composition is said to have “little or no” amount of an ingredient, it means that the amount of that ingredient is zero or is 0.01% by weight or less, based on the weight of the ingredient. composition.
    [20] A polymer film is a structure that is made of a polymer or mixture of polymers and that is 0.5 mm or less in one dimension and is 1 cm or more in the other two dimensions. The composition of a polymer film is 80% or more by weight of one or more polymers, based on the weight of the film.
    [21] When a quantity is described here as “X to Y”, it is meant that the quantity is a number that is greater than or equal to X and also less than or equal to Y. when a ratio is described here as “R :1 or greater,” means that the ratio is S:1, where S is a number greater than or equal to R. Similarly, when a ratio is described here as “T:1 or less,” it means that the ratio is U:1, where U is a number less than or equal to T.
    [22] The adhesive composition of the present invention contains one or more polyisocyanates. Preferred polyisocyanates are MDI, polymeric MDI, carbodiimide modified MDI, isocyanate functional prepolymers, and mixtures thereof. More preferred polyisocyanates are carbodiimide modified MDI, isocyanate functional prepolymers, and mixtures thereof. Even more preferred polyisocyanates are isocyanate functional prepolymers. carbodiimide-modified MDI has one or more carbodiimide bonds that stabilize the compound against hydrolytic degradation; the carbodiimide bond is reversible; dissociation of the carbodiimide bond generates an additional isocyanate function. Preferred isocyanate functional prepolymers are reaction products of one or more isomers of MDI with one or more polyols. In making the prepolymer, the preferred MDI is a mixture of isomers in which the amount of 4,4'-MDI is 90% or greater by weight based on the weight of all MDI isomers. In making the prepolymer, preferred polyols include one or more polyester polyols, one or more epolyether polyols, or a mixture thereof, polyester polyols are more preferred. Preferred prepolymers have % NCO of 0.5% or more; more preferably 1% or more; more preferably 2% or more. Preferred prepolymers have % NCO of 30% or less; more preferably, 25% or less.
    [23] The composition of the present invention contains one or more phosphate functional polyols. A phosphate functional polyol can be represented by structure II:
    where R1is any organic group. In addition to the pendant groups shown in structure II, R1 may or may not have one or more pendant -OH groups, and R1 may or may not have one or more additional pendant groups of structure I. Any two or more of the -OH groups and the do(s) ) group(s) of structure I may or may not be bonded to the same atom of R1. Preferably, each -OH group and each group of structure I is bonded to a separate atom of R1.
    [24] A convenient way to characterize R1 is to describe the compound having structure III:
    where R1 is equal to structure II. The co-wort having structure III is shown here as a “polyol precursor.”
    [25] Preferred precursor polyols have a molecular weight of 90 or higher; more preferably 200 or higher; more preferably 400 or higher. Preferred precursor polyols have a molecular weight of 4000 or less; more preferably 2000 or less; more preferably 1200 or less; more preferably 900 or less; more preferably 500 or less.
    [26] Preferred precursor polyols are higher alkyl polyols, monosaccharides, disaccharides, and compounds having structure IV:
    where each of R2, R3, R4 and R5 is, independently of the other, any organic group; each ofn1, n2 and n3 is, independently of the other, an integer from 0 to 10. In addition to the pendant groups shown in structure IV, R2 may or may not have one or more additional pendant groups. It is further understood that any two or more of the pendant groups may or may not be attached to the same R2 atom. In some embodiments, a mixture of compounds having structure IV is present, where compounds of structure IV differ from each other in the value of one or more of n1, n2, and n3; such mixtures are described here by mentioning a non-integer value for the parameter n1, n2, or n3, where the non-integer value represents the numerical average of that parameter. When it is desired to assess the molecular weight of such a mixture, the number average molecular weight is used.
    [27] Among precursor polyols having structure IV, preferably each pendant group is bonded to a separate atom of R2.
    [28] Among precursor polyols having structure IV, preferably one or more of R3 , R4 and R5 is a hydrocarbon group having 1 to 4 carbon atoms; more preferably 2 to 3 carbon atoms; more preferably 3 carbon atoms. Among precursor polyols having structure IV, preferably one or more of R3 , R4 and R5 is an alkyl group, which may be linear or cyclic or branched or a combination thereof, more preferably one or more of R3 , R4 and R5 is a group straight or branched alkyl; more preferably, one or more of R3 , R4 and R5 is a branched alkyl group. Preferably, R3 , R4 and R5 are identical to each other.
    [29] Among precursor polyols having structure IV, preferably one or more of n1, n2 and n3 is from 0 to 8. Among precursor polyols having structure IV, preferably one or more of n1, n2 and n3 is 1 or more. Among precursor polyols having structure IV, preferably one or more of n1, n2 and n3 is 6 or less. Among precursor polyols having structure IV, n2 and n3 are equal to each other.
    [30] A preferred group of precursor polyols having structure IV are compounds in which each of R2 , R3 , R4 and R5 is an alkyl group; such precursor polyols are known herein as alkoxylated alkyl triols. In a triol, when at least one of n1, n2 and n3 is 1 or more and R2 has the structure V:
    so the triol is known here as an alkoxylated glycerol. In alkoxylated triols, when each of R3, R4 and R5 is a branched alkyl group with exactly 3 carbon atoms, the alkoxylated triol is known herein as a propoxylated triol. A propoxylated triol in which R2 has the structure V is known herein as propoxylated glycerol.
    [31] Among the precursor polyols which are higher alkyl polyols, those with 10 or fewer carbon atoms are preferred; more preferred are those with 6 or fewer carbon atoms; more preferred are those with 3 or fewer carbon atoms; most preferred is glycerol.
    [32] More preferred precursor polyols are higher alkyl polyols and compounds having the structure IV; more preferred are compounds having the structure IV. It is observed that if n1 = n2 = n3 = 0 and if R2 is an alkyl group or an alkyl group having hydroxyl groups, then the compound having structure IV is a higher alkyl polyol.
    [33] A preferred group of precursor polyols are alkyl triols and alkoxylated alkyl triols. Among these, glycerol and alkoxylated glycerols are more preferred; more preferred are alkoxylated glycerols. Among alkoxylated glycerols, propoxylated glycerols are preferred.
    [34] Another class of suitable phosphate functional polyols are those that contain urethane linkages. Preferably, members of that class are made by reacting one or more suitable phosphate functional polyols with one or more polyisocyanates, preferably including one or more diisocyanates. Preferably, the amount of polyisocyanate is kept low enough that some or all of the reaction products are phosphate functional polyols. Alternatively, the polyol can be first reacted with the polyisocyanate to make an OH-terminated prepolymer which is then reacted with polyphosphoric acid.
    [35] A preferred method of making the phosphate functional polyol of the present invention is to react a precursor polyol with phosphoric acid to produce the compound having structure II.
    [36] Preferably, the amounts of phosphoric acid and precursor polyol are chosen to determine the Mp:Mx ratio as follows: Mhy = number of hydroxyl groups per molecule of the precursor polyol Nx = Mhy=2 Mx = (moles of precursor polyol) x Nx Mp = moles of phosphorus atoms contained in the phosphoric acid Preferably, the ratio of Mp:Mx is 0.1:1 or higher; more preferably 0.2:1 or higher; more preferably 0.5:1 or higher; more preferably 0.75:1 or higher. Preferably, the Mp:Mx ratio is 1:1 or less.
    [37] Preferably, the weight ratio of phosphoric acid to polyol precursor is 0.005:1 or higher; more preferably 0.01:1 or higher; more preferably 0.02:1 or higher. Preferably, the weight ratio of phosphoric acid to polyol precursor is 0.3:1 or lower; more preferably 0.2:1 or lower; more preferably 0.12:1 or lower.
    [38] Preferably, the phosphoric acid type contains polyphosphoric acid. Preferably, the amount of polyphosphoric acid in the phosphoric acid is, by weight based on the weight of the phosphoric acid, 75% or more; more preferably 80% or more; more preferably 90% or more. Polyphosphoric acid is available in various grades; each grade is characterized by a percentage. To determine the grade, it is first recognized that pure monomeric orthophosphoric acid, the phosphorus pentoxide content is taken to be 72.4%. Any grade of polyphosphoric acid can also be analyzed to consider that one mole of polyphosphoric acid (weight of formula labeled “Fppa”) contains the number of moles of phosphorus pentoxide labeled “Nppo”, and the percentage of phosphorus pentoxide (“ PCppo”) is given by PCppo = (Nppo X 142)/Fppa, expressed as a percentage. So, the grade of that polyphosphoric acid is the ratio, expressed as a percentage: grade = PCppo / 72.4.
    [39] Preferably, polyphosphoric acid is used which is 100% grade or higher; more preferably, 110% or higher. Preferably, polyphosphoric acid is used which is 150% grade or lower; more preferably 125% or lower.
    [40] Preferably, the adhesive composition of the present invention contains one or more non-phosphorus polyols in addition to one or more phosphate functional polyols.
    [41] A preferred method (herein "method A") including a phosphorus-free polyol in the composition is as follows. A phosphate functional polyol is made by reacting a precursor polyol which is a phosphorus-free polyol with phosphoric-type acid. An amount of phosphoric-like acid is used such that even if every phosphorus atom in the phosphoric-like acid were to react with a hydroxyl group in the phosphorus-free polyol, the amount of phosphorus-free polyol that remained phosphorus-free at the end of the reaction would be, by weight based on the weight of the phosphorus-free polyol prior to reaction, preferably 50% or more; more preferably 75% or more. An amount of phosphoric-type acid is used such that, even if every phosphorus atom in the phosphoric-type acid were to react with a hydroxyl group in the phosphorus-free polyol, the amount of phosphorus-free polyol that remained phosphorus-free at the end of the reaction would be, by weight based on the weight of the phosphorus-free polyol before the reaction, preferably 99% or less; more preferably 95% or less.
    [42] Preferably, method A is used.
    [43] Regardless of the method used to make the phosphate-functional polyol, in some embodiments the adhesive composition of the present invention contains a phosphorus-free polyol (herein called "precursor-type" polyol) that has the same structure as a phosphate-functional polyol. phosphate present in the composition, except that at each position where a phosphate group is present in the phosphate-functional polyol, a hydroxyl group is present in the phosphorus-free polyol. A precursor-type polyol may be present because it is left over from the process that made the phosphate-functional polyol, or a precursor-type polyol may be present because it is added to the composition after formation of the phosphate-functional polyol or a combination thereof.
    [44] In addition to method A or instead of method A, one or more phosphorus-free polyols in addition to one or more phosphate-functional polyols can be introduced by adding one or more phosphorus-free polyols (herein called a “non-precursor” polyol). ”) which is not a precursor-type polyol. Suitable non-precursor polyols include polyether polyols, polyester polyols, polyether-polyester polyols, alkyl polyols, polyols that have a single ether bond, polyols that have a single ester bond, and mixtures thereof.
    [45] Preferably, the total amount of polyols in the adhesive composition of the present invention is, in parts by weight based on 100 parts by weight of the total of all polyisocyanate compounds in the composition, 1 part or more; more preferably 2 parts or more. Preferably, the total amount of polyols in the adhesive composition of the present invention is, in parts by weight based on 100 parts by weight of the total of all polyisocyanate compounds in the composition, 800 parts or less; more preferably 600 pieces or less.
    [46] Preferably, the composition of the present invention contains one or more solvents. A solvent is a liquid at 25°C and is capable of providing a continuous medium in which each of the other ingredients in the composition is dissolved or dispersed. Preferably, each of the one or more polyisocyanate ingredient(s) is soluble in the solvent in an amount, by weight based on the weight of the solvent, of 10% or more; more preferably 50% or more; more preferably 100% or more. Preferably, each of the one or more polyol ingredient(s) is soluble in the solvent in an amount, by weight based on the weight of the solvent, of 10% or more; more preferably 50% or more; more preferably 100% or more. Also considered are modalities ("solvent-free modalities") in which little or no solvent is used. It is envisaged that, in solvent-free embodiments, the ingredients are chosen so that the composition of the present invention is liquid at 25°C.
    [47] When a solvent is used, preferred solvents are hydrocarbon solvents, polar aprotic solvents, polar protic solvents, and mixtures thereof; polar aprotic solvents are more preferred, ethyl acetates, acetone, and methyl ethyl ketone are more preferred; ethyl acetate is more preferred.
    [48] When a solvent is used, the preferred amount of solvent, by weight based on the total weight of the composition, is 10% or more; more preferably 20% or more; more preferably 40% or more. When a solvent is used, the preferred amount of solvent, by weight based on the total weight of the composition, is 80% or less; more preferably 60% or less.
    [49] The composition of the present invention optionally contains one or more silane adhesion promoters. Preferred silane adhesion promoters contain one or more reactive organic epoxide group and one or more alkoxy silyl group, more preferably one or more methoxy silyl or ethoxy silyl group. When a silane adhesion promoter is used, a preferred amount, in parts by weight based on 100 parts by weight of the total weight of all polyols, is 0.05 part or more; more preferably 0.1 part or more; more preferably 0.2 part or more. When a silane adhesion promoter is used, a preferred amount, in parts by weight based on 100 parts by weight of the total weight of all polyols, is 5 parts or less; more preferably 2 parts or less; more preferably 1 part or less.
    [50] The adhesive composition may optionally contain one or more additional conventional ingredients such as fillers, pigments, tackifiers, plasticizers, rheology modifiers, polymers (including, for example, thermoplastic resins other than those discussed above), dehydrating agents (including, e.g. silanes), benzoyl chloride, other polyols (including e.g. fatty polyols), ultraviolet indicators, etc.
    [51] Preferably, the adhesive composition of the present invention is curable. Preferably, the adhesive composition of the present invention is subjected to one or more chemical reactions that desirably effect an increase in the molecular weight of the composition and/or effect crosslinking of the composition in order to improve the properties of the composition. Preferably, the curing chemical reactions involve reaction of isocyanate groups with hydroxyl groups to form urethane bonds.
    [52] In embodiments involving application of the adhesive composition of the present invention to at least one substrate, application is preferably effected by conventional means such as, for example, spray applicator, bead applicator, nozzle, blade, extrusion, or roll coating, to form a continuous or discontinuous film of the adhesive composition.
    [53] The composition is preferably applied at a level, in grams of dry composition per square meter, of 0.5 or greater; more preferably 1 or greater. The composition is preferably applied at a level, in grams of dry composition per square meter, of 10 or less; more preferably 7 or less.
    [54] Preferably, the curable adhesive composition of the present invention is used as an adhesive to bond a first substrate to at least one subsequent substrate. In such embodiments, the adhesive composition is applied to a first substrate and subsequently or simultaneously, the applied adhesive composition is contacted by at least one subsequent substrate to provide a bonded assembly.
    [55] In preferred embodiments of the present invention, the curable adhesive composition of the present invention is applied to, or otherwise contacted with, one or more substrates. Some suitable substrates include, for example, wood (including natural wood, plywood, lauan wood, and chipboard), metal, plastic (including rigid plastic, flexible plastic, plastic film and plastic foam), composite materials, cloth ( including fabric and non-woven), paper, oriented particle board, and combinations thereof. If more than one substrate is used, any combination of suitable substrates is also suitable. In some embodiments, all substrates will be made of the same material; in other embodiments, two or more different materials will be used as substrates.
    [56] Preferably, one or more of the substrates is metal.
    [57] Preferably, one or more substrates is a polymer film. Preferred polymer films contain organic polymer. Preferred organic polymers are polyesters, polyolefins (including copolymers of olefins with other monomers), polyamides and mixtures thereof. More preferred organic polymers are polyethylene terephthalate, polyethylene, polypropylene and nylon.
    [58] A preferred use of the composition of the present invention is as an adhesive in a laminate. A laminate is a structure that contains two films bonded together with an adhesive layer. The “flat face” of the film is the surface that is perpendicular to the thickness direction. In a laminate, the adhesive is in contact with a flat face of one film and a flat face of the other film. A laminate of the present invention contains a film that is bonded to another film using a composition of the present invention as the adhesive. Laminates of the present invention may contain additional layers of bonded films, each of which may be bonded to its adjacent layer with the composition of the present invention or with a different adhesive.
    [59] A preferred method of making a laminate is to apply a layer of the composition of the present invention to a flat face of a film, then remove solvent (if any) preferably by evaporation, then place the flat face of the second substrate in contact with the layer of the composition of the present invention to form the laminate, and then heating the entire laminate to cure the composition of the present invention.
    [60] It is to be understood that for the purposes of the present examples that each operation disclosed herein is carried out at 25°C unless otherwise specified.
    [61] The following are examples of the present invention.
    [62] The following terms and abbreviations are used: OHN = OH number, measured by ASTM D 4274-88 AV = acid value, measured by ASTM D 3644-83 (synonymous with “acid number”) VISC = viscosity, measured with a Brookfield DVII+ viscometer with a small sample adapter with thermostat, using an SC-27 shaft. Rotation speed varied from 6 to 60 rpm as needed to obtain viscosity readings. Viscosity (C&P) = viscosity measured with TA INSTRUMENTS AR 2000 rheometer using a 40 mm cone and Peltier plate for temperature control, cone angle = 0° 30 min 4 s, shear rate = 10 s-1 % NCO is measured per ASTM 2572-70 Molecular weights are measured by liquid size exclusion chromatography ASTM D3536-76 or D3593-80 Tg = glass transition measured by Differential Scanning Calorimetry using the midpoint method and ramp rate of 10°C/ min. Pbw = parts by weight PPA = polyphosphoric acid, grade 115% PA = phosphoric acid, 100% (solid) DPG = dipropylene glycol (ALDRICH Chemical Co.) EtAc = ethyl acetate Laminate preparation:
    [63] The films tested were: . PET = 24 micrometer thick polyethylene terephthalate (92LBT); . pre-laminated film made of a polyethylene terephthalate (PET, 12 microns (μm) thick) laminated to MACOR aluminum foil of the soft lamination type (9 μm thick) with ADCOTE™ 550/COREACTANT F (Dow Chemical Co .). This laminated structure was obtained from AMPAC Company, Cary, IL, and is referred to as “Prelam” or “PET-A1; . Pliant 808.24 = Polyethylene sealing film from Berry Plastics. . GF-19 = Polyethylene sealing film containing high amount of slip additive from Berry Plastics. PET = polyethylene terephthalate.
    [64] Film samples were cut into sections approximately 23 x 30 cm (9 inches x 12 inches). Polyethylene and PET films were corona treated to obtain a surface energy of 38 dynes or higher. The secondary film was placed on the rubber block of the laminator (treated side up). A strip of paper approximately 5 cm wide and 20 cm long was arranged across the center of the sheet to provide an unlaminated strip area to separate the films for the peel test. The two adhesive components were combined and diluted to 35-50% solids (typically 40% solids).
    [65] The primer film was fixed to a flat hard surface (treated side up). The adhesive was applied to the aluminum side of the PET-Al laminate or to the polyester film with a coiled rod of #6 Meyer wire (primer film). The coating weight was approximately 3.25 g/m 2 (2.0 lbs/ream). If necessary, the adhesive concentration was adjusted or a more suitable rod was selected to obtain the target coating weight. The solvent was evaporated from the adhesive by placing the coated film in a forced air oven at 80°C for approximately 30 seconds. The primary film was removed from the plate and the top edge of the film (sticky side down) married to the top of the secondary film on the laminator block. The oil heated roller (approximately 82°C) from the laminator was passed over the films bringing the primary film into contact with the secondary film and laminating the two films together. The laminate sheets were placed between two hard surfaces (eg steel plates) with sufficient weight (about 500 kg) on the top sheet to hold the laminate sheets pressed together until cured.
    [66] Test of laminates
    [67] The T 90° detachment test was performed on laminated samples cut into 15 mm or 25.4 mm (2 inch) wide strips and pulled through the Thwing Albert™ tensile tester at a speed of 25.4 cm/ min. (10 in./min.) for 25.4 mm (1 inch) strips or 10.2 cm (4 inches)/min for 15 mm strips. When the two films on the laminate separated (slapped off), the average force during traction was recorded. If one of the films stretched or broke, the maximum force or breaking force was recorded. Values were the average of three separate sample strips. The failure mode (“FM”) was recorded as follows: FS = film stretching PFS = partial film stretching (film stretches and at the same time comes off to some extent) FT = film tears or breaks 1° = primary weft ( the adhesive is coated onto the primary film or web) 2° = secondary weft (film that is laminated to the primary weft, often a sealing film such as polyethylene) AF = adhesive failure (adhesive is on the primary film, fails to adhere to the secondary film) AT = adhesive transfer (adhesive fails to adhere to primary film and is transferred to secondary film) AS = cohesive failure or adhesive splitting (adhesive is found in both primary and secondary films) Delam = laminated films separated during testing (e.g. , during boiling in the bag test), little or no adhesion between films. Initial or “green” bonds were tested as soon as possible after the laminate was made. Additional T-detachment tests were performed at the indicated time intervals (typically after 1 day, and 7 days).
    [68] Bag boil test procedure (“BB 1:1:1”):
    [69] Laminates were made from PET-A1 “prelam” film that was bonded to polyethylene sealing film (Pliant 808.24 from Berry Plastics) as described above. One of the 9” x 12” (23 cm x 30.5 cm) sheets of laminate was folded to provide a 9” x 6” (23 cm x 15.25 cm) throne double layer. The edges were trimmed on a paper cutter to provide a folded piece measuring approximately 5” x 7” (12.7 x 17.8 cm). Two long sides and one short side have been heat-veined at the edges to provide a finished bag with an inner size of 10.2 cm x 15.2 cm (4 inches x 6 inches). Heat sealing was done at 177°C (350°F) for 1 second at a hydraulic pressure of 276 kPa (40 PSI). Two or three bags were made for each test. Pouches were filled through the open edge with 100 ± 5 ml of 1:1:1 dressing (mixture of equal parts by weight of ketchup, vinegar and vegetable oil). Splashing of filler over the heat seal area was avoided as this could cause the heat seal to fail during testing. After filling, the top of the bag was sealed in a way that minimized air retention within the bag. Seal integrity was inspected on all four sides of the bags to ensure there were no seal failures that would cause the bag to leak during testing. Any suspicious bags were discarded and replaced. In some cases laminate flaws were marked to identify whether additional flaws were generated during testing.
    [70] A vessel was 2/3 filled with water and brought to a boil. The boiling vessel was covered with a lid to minimize steam and water loss. The vessel was observed during the test to ensure there was enough water present to maintain boiling. The bag(s) were placed in boiling water and kept there for 30 minutes. The pockets were removed and the extent of tunneling, blistering, delamination, or leakage was compared to any of the pre-existing flaws marked. Observations were recorded. The bags were cut open, emptied and rinsed with soap and water. One or more 2.54 cm (one inch) strips were cut from the pouches and the laminate bond strength was measured in a tensile tester. This was done as soon as possible after removing the contents of the bag. The interior of the pouches was examined and any other visual defects noted.
    [71] The Water Soak test was performed as follows: After allowing the laminates to cure for 7 days, three strips one inch (2.54 cm) wide and approximately 6 inches (15 cm) were cut from the laminate sheets. These strips were placed in a jug of water and kept fully submerged by attaching a weight (such as a heavy paper clip) to the strips. After standing overnight at room temperature, the strips were removed and the T-peel test was performed within a few minutes.
    [72] The Heat Seal Test was performed as follows: an approximately 30 cm x 20 cm sample was cut from a sheet of laminate. The sample was folded and the long edge of the sheet was placed in a heat sealer at approximately 177°C (350°F) for one second at a pressure of 276 kPa (40 PSI). This sealed edge sheet was cut into strips 1 inch (2.54 cm) wide. The loop edge opposite the heat-sealed edge has been cut to provide a strip with the heat-sealed portion in between. The ends of the strip were placed in the grips of an INSTRON tensile tester and pulled at 10 inches (25.4 cm) per minute. The force required to break the film on the heat seal was recorded. Also, any delamination that may have occurred during the test was noted. Heat seal results are reported in units of Nepesoons per 25.4mm wide.
    [73] Adhesive preparation
    [74] The samples in the Examples below were prepared by combining the polyol portion of the adhesive with the additives shown in the tables followed by addition of solvent (where shown) to obtain the desired final concentration, then adding the isocyanate functional portion and mixing for approximately 15 minutes.
    [75] Example 1. ADCOTE™ 577 (available from the Dow Chemical Company) is an isocyanate functional prepolymer comprised of approximately 72-74% polyurethane resin, 2-3% methylene bis(4-phenylisocyanate) and 23- 25% ethyl acetate. Typical viscosity (Technical Data Sheet) is 3900 mPa*s.
    [76] Example 2. Polyether-polyester polyol The method described in WO 2013/053555 was used. 2011.0 g (7.89 mol) of VORANOL™ CP260 polyether triol polyol, 1520.4 g (10.25 mol) of phthalic anhydride and 0.20 g of 2-ethyl-4-methyl-imidazole (EMI, 41 ppm based on product weight) were mixed with stirring at 50 rpm in a 5 L stainless steel alkoxylation reactor. The reaction mixture was cleaned 10 times with 600 kPa (6 bar) nitrogen (N2) pressure. The reactor was thermostated at 130°C with 600 kPa (6 bar) of N2 pressure. The obtained slurry gradually dissolved in the reactor, becoming mostly liquid after 0.5 h at this temperature. The stirring rate was gradually increased from 50 to 200 rpm. The reactor content was stirred for an additional 1.5 h. The N2 pressure in the reactor was reduced to 1.0 bar, and the stirring rate was increased to 300 rpm. PO (1246.0 g, 21.46 mol) was fed into the reactor at a feed rate of 15 g/min. for 85 min. The immediate onset of the reaction was accompanied by an exotherm. At the end of the feed, the total pressure in the reactor had reached 490 kPa (4.9 bar). 3.0 h additional digestion time was allowed. The total pressure in the reactor dropped to 430 kPa (4.3 bar). The reactor temperature was lowered to 100°C. 6.80 g of a 10% solution of triflic acid (TFA, 142 ppm based on product weight) in ethanol was injected into the reactor with the aid of a pressurized stainless steel pump connected to the reactor. An immediate pressure drop in the reactor and an exotherm were observed, 30 min. of additional digestion time was allowed. Residual nitrogen pressure was bled, the reaction mixture was cleaned 10 times with 600 kPa (6 bar) N2 pressure. Potassium hydroxide (7.16 g, 0.5 mol/l solution in ethanol) was injected into the reactor with the aid of a pressurized stainless steel pump, connected to the reactor, to neutralize the remaining triflic acid. The product was then vacuum extracted for 1 h at 120°C. A colorless viscous liquid was obtained.
    [77] The hybrid polyether-polyester polyol produced had the following properties: OHN: 276 mg KOH/g; plate and cone viscosity (40 mm diameter, 0.5° cone, 10 s-1) at 25°C: 31700 mPa*s (density at 25°C: 1.156 g/cm3; pH: 5.9; Mn = 460 g/mol, Mw/Mn = 1.17.
    [78] Example 3: MOR-FREE™ C411 (Dow Chemical Company) is a solvent-free blend containing polyester polyol with typical viscosity reported as 1100 mPa*s.
    [79] Example 4: Preparation of Polyether Phosphates
    [80] Reagent amounts are shown in the table below. A 1 L multi-neck round bottom flask was dried in an oven, cleaned with dry N2 for 30 minutes, then charged with polyether polyol and placed under an N2 sweep of 70 mL/min. A syringe was loaded with 115% polyphosphoric acid (PPA) from ALDRICH CHEMICAL Company. PPA was added dropwise from the syringe to the polyether polyol with vigorous stirring. A minimal rise in temperature was observed. The reactor contents were then heated to 100°C for 1 hour, cooled (significant increase in viscosity was observed), and the clear, colorless product was packaged.
    [81] For comparison, sample 4F was prepared by adding 100% phosphoric acid (PA) crystals to VORANOL™ CP 450. The mixture was heated to 50°C and stirred until the crystals were fully dissolved.
    [82] Results

    (1) The Dow Chemical Company, average molecular weight = 450 (2) The ARCH Chemical Company, average molecular weight = 700 (3) The Dow Chemical Company, average molecular weight = 1055

    [83] Example 5: Polyether-urethane preparation
    [84] Reagent amounts are in the table below. A 1 L multi-necked round bottom flask was dried in an oven, cleaned with dry N2 for 30 minutes, then charged with VORANOL™ CP 450 polyether polyol and placed under an N2 sweep of 70 mL/min. A syringe was loaded with 115% polyphosphoric acid (PPA) from ALDRICH CHEMICAL Col. The PPA was added dropwise to the polyether polyol with intense agitation. A minimal temperature rise was observed. The reactor contents were heated to 100°C for 1 hour, then cooled to 45°C. ISONATE™ 125M Polyisocyanate was added. The temperature rose to approximately 95°C from the heat of reaction. Also, there was an increase in viscosity and development of a yellow color. The reactor was then brought to 65°C, and ethyl acetate was added to cut viscosity and improve agitation. After 1 hour, the reactor was cooled and the contents packed.

    [85] Example 6: Testing Adhesives
    [86] The samples in the following tables were prepared by combining the polyol portion of the adhesive with the additives shown in the tables followed by adding solvent to obtain the desired final concentration, then adding the isocyanate functional portion and mixing for approximately 15 minutes. minutes.
    [87] The tables below summarize T-peel test results for PET-Al/Pliant 808.24 laminates. The adhesive coating weight (dry) was approximately 3.26 g/m 2 (2.0 lbs/ream). T-detachment results are shown at various times. Also shown are the results of the bag boil test with the 1:1:1 sauce (mixture of equal parts by weight of vinegar, oil and ketchup). The data show that most laminates made with phosphate functional polyol provided cured bonds comparable to the control adhesive, but green bonds (ie, short-time T-detachment values) were significantly better than controls. Higher green bonds are desirable because this simplifies the laminating process which helps to avoid defects that can result from the two films moving before the laminate has cured. After the adhesive cures, the desired failure mode is film stretch (FS) or film tear (FT). The control adhesive was made with the isocyanate functional prepolymer of example 1 as one component and the polyol co-agent ADCOTE™ 577B (herein "polyol COM") as the second component. ADCOTE™ 577B is a blend containing polyether and polyester polyols and 28-30% ethyl acetate with a typical viscosity (Technical Data Sheet 130 mPa*s. Available from the Dow Chemical Company.
    [88] Samples made with VORANOL™ CP 1055 polyol provided poor green bonds due to limited miscibility of polyether CP 1055 with the prepolymer from example 1. For all samples 4A-4E, T-loosening bonds after testing bag boil were as good as or better than the control adhesive and better than the comparative examples without PPA. Some defects (“bubbles”) were seen in some samples with higher concentrations (4-10%) of PPA in VORANOL™ CP 450 (eg 4A and 4B). “Bubbles” refers to small bubbles that appear on the laminate surface after exposure to the boil-in-bag test. Table 5 shows that 100% phosphoric acid (PA) does not provide the 1/1/1 sauce strength benefit that is seen with PPA-reacted polyols. “Tunneling” refers to channels that form from areas of delamination where the two films separated during testing. This is a major defect. The following tables 1-9 show results of laminates of PET-A1 prelam (primary substrate) with Pliant 808.24 (secondary substrate). Table 1A: Formulations

    Table 1B: T-Detachment Results (grams per 2.54 cm (g/inch))
    Table 1C: Additional T-Detachment Results (grams per 2.54 cm (g/inch))

    Table 2A: Formulations
    Table 2B: T-Detachment Results (grams per 2.54 cm (g/inch))

    Table 2C: Additional T-Detachment Results (grams per 2.54 cm (g/inch))
    Table 3A: Formulations

    Table 3B: T-Detachment Results (grams per 2.54 cm (g/inch))
    Table 4A: Formulations
    Table 4B: T-Detachment Results (grams per 2.54 cm (g/inch))
    Table 4C: Additional T-Detachment Results (grams per 2.54 cm (g/inch))
    Table 5A: Formulations

    Table 5B: T-Detachment Results (grams per 2.54 cm (g/inch))
    Table 6A: Formulations

    Table 6B: T-Detachment Results (grams per 2.54 cm (g/inch))
    Table 7A: Formulations
    Table 7B: T-Detachment Results (grams per 2.54 cm (g/inch))
    (4) Laminate showed some defects before the BB 1:1:1 test because it was difficult to make good laminates with low green bonds. However, no new defects appeared during the 1:1:1 BB test. Table 8A: Formulations
    Table 8B: T-Detachment Results (grams per 2.54 cm (g/inch))
    (5) Example is not fully miscible with Voranol™ CP 1055 polyol. This is responsible for the bad green links. Table 9A: Formulations
    Table 9B: T-Detachment Results (grams per 2.54 cm (g/inch))
    (6) The example is not fully miscible with Voranol™ CP 1055 polyol. This is responsible for the bad green bonds.
    [89] Example 7: ADCOTE™ 795 is the hydroxyl component of a two-part polyurethane adhesive. It is a blend containing hydroxyl functional polyester and hydroxyl functional acrylic polymers (70-80%), glycols (1-5%) and 20-25% ethyl acetate. It is available from the Dow Chemical Company. Typical viscosity (from data sheet) 825 mPa*s.
    [90] Example 8: Preparation of Isocyanate Functional Prepolymer
    [91] The ingredients were as follows:
    [92] Item 1 was loaded into a dry reactor at 50°C. The reactor was kept under an atmosphere of dry nitrogen throughout the process. Item 2 was loaded into the reactor and the resin mixture was heated to 80°C. Item 3 was added for 30 min. at a rate to maintain the temperature at 80-85°C. The resin mixture was kept at 80°C for 2 hours. The % NCO was monitored until it was 15.0 ± 0.3%. The resin was cooled to 50°C - 60°C, item 4 was added; the solution was mixed well, then packed.
    [93] The final resin had the following properties: 14.8% NCO. The plate and cone viscosity results (40 mm diameter, 0.5° cone, 10 s-1) are shown in the table below.
    Dry ethyl acetate (30g) was added to 170g of the resin. The resin dissolved with stirring to provide a solution with 85% solid resin and a viscosity of 325 mPa*s at 25°.
    [94] Example 9: Preparation of Glycerin Phosphate
    [95] Polyphosphoric acid (40 grams of 115% from Aldrich Chemical Co.) was placed in a three-neck flask with stirrer, thermometer, and nitrogen inlet/outlet. A slow stream of dry nitrogen was passed through the reactor throughout the reaction time. Glycerin (69.4 grams, Aldrich) was added with stirring. The heat of reaction caused the temperature to rise from 24°C to 69°C in 10 minutes. The solution was kept at 60-70°C for 45 minutes. The clear, colorless viscous liquid product was cooled and packed in a glass container.
    [96] Example 10: Adhesive formulations were prepared by adding phosphate esters to example 7 and combining it with the isocyanate functional co-agent (example 8). Laminates were made from these blends as described above. The results were as follows. For each laminate, the first substrate listed was the primary substrate. Table 10A: formulations
    (7) Comparative sample, (without phosphate functional polyol) Table 10B: T-Detachment Results (grams of force per 2.54 cm (g/inch))
    (8) Comparative sample, (without phosphate functional polyol) Table 10C: Additional results (g/2.54 cm)

    (9) Comparative samples (without phosphate functional polyol)
    [97] Example 11: Preparation of isocyanate functional prepolymer
    Item 1 was loaded into a dry reactor at 50°C. the reactor was kept under an atmosphere of dry nitrogen throughout the process. Item 2 was charged to the reactor and the resin mixture was heated to 80°C. Item 3 was added for 30 min. at a rate to maintain the temperature at 80-85°C. The resin mixture was held at 80°C for 2 hours. The % NCO was monitored until it was 15.0 ± 0.3%. The resin was cooled to 50°C - 60°C, item 4 was added; the solution was mixed well, then packaged (12.4% NCO, Brookfield viscosity 810 mPa*s).
    [98] Example 12. Polycarbodiimide-modified MDI prepolymer
    Items loaded 1-6 with shaking. Gradually heated to 50-55°C over 30 minutes. Heating was continued at 75°C for 30 minutes. Kept at 73-77°C for 90 minutes. Light yellow product collected: 12.3% NCO; Brookfield viscosity 1620 mPa*s (axis #5 at 20 rpm).
    [99] Example 13. Preparation of Polyester Resin


    [100] Items 1-3 are loaded into a reactor equipped with an agitator, thermocouple, nitrogen inlet, a steam jacketed fractionation column, and a condenser to collect water that has distilled from the reactor. A very slow flow of nitrogen was passed through the reactor height space throughout this reaction time.
    [101] The heterogeneous mixture was heated to 100-120°C. the external heat was reduced and the heat of reaction brought the temperature up to approximately 130°C. The temperature was maintained at 120-130°C for 0.25 - 0.50 h.
    [102] The resin mixture was gradually heated to 225°C. At approximately 190°C the water began to distill. After 85-95% of the theoretical amount of water was collected, samples were periodically extracted from the reactor and tested for viscosity (cone & plate at 100°C) and acid number. When the acid number was less than 20 mg KOH/g sample, vacuum was applied and distillation continued under reduced pressure. Initially, the pressure was set at 450 torr. The vacuum was gradually decreased to approximately 25 torr. The pressure was maintained at approximately 20-20 torr and the temperature maintained at 225°C until the acid number was less than 2.0 mg KOH/g sample.
    [103] The product was cooled and combined with the ethyl acetate. The resin had the following properties: 74.7% solids, OHN 24 mg KOH/g; acid value 1.4, OHN 25; viscosity (C&P) 814 mPa*s at 25°C.
    [104] Example 14: Adhesive formulations
    [105] The samples in the following tables were prepared by combining the polyol portion of the adhesive with the additives, mixing thoroughly and allowing the resulting solution to stand for at least 24 hours at room temperature. When preparing laminates, the polyol blend was combined with the co-agent (NCO-terminated prepolymer) in the proportion mustard in the tables. Ethyl acetate was added to the mixtures in sufficient quantity to obtain a 3540% solids solution and laminates were prepared and tested as described above. For all samples in Table 14, the NCO equivalent/OH equivalent ratio was approximately 1.4. Table 14A Formulations
    Table 14B Results

    [106] Both 66-1A and 66-2B use example 12 as the polyisocyanate. Sample 66-1A shows delamination in the 1:1:1 BB test, while sample 66-2B does not. Both 66-1C and 66-2A use example 11 as the polyisocyanate. Sample 66-1C shows delamination in the 1:1:1 BB test, while sample 66-2A does not. These results demonstrate the benefit of the phosphate functional polyol, which is only present in samples 66-2A and 66-2B.
    权利要求:
    Claims (9)
    [0001]
    1. An adhesive composition comprising one or more polyisocyanates and one or more phosphate-functional polyols, characterized in that said one or more phosphate-functional polyols comprise urethane linkages.
    [0002]
    2. Adhesive composition according to claim 1, characterized in that said phosphate functional polyol is a reaction product of one or more polyisocyanates with a phosphate functional polyol which is a phosphate ester of a precursor polyol .
    [0003]
    3. Adhesive composition according to claim 2, characterized in that said phosphate functional polyol is a phosphate ester of a precursor polyol and is prepared by reacting said precursor polyol with polyphosphoric acid.
    [0004]
    4. Adhesive composition according to claim 3, characterized in that the polyphosphoric acid has a grade of 100% or higher.
    [0005]
    5. Adhesive composition according to claim 2, characterized in that said precursor polyol is an alkyl triol or alkoxylated alkyl triol.
    [0006]
    6. Adhesive composition according to claim 2, characterized in that said precursor polyol is glycerol or alkoxylated glycerol.
    [0007]
    7. Adhesive composition according to claim 2, characterized by the fact that said precursor polyol is a propoxylated glycerol.
    [0008]
    8. Adhesive composition according to claim 2, characterized by the fact that said one or more phosphate functional polyols contains the structure I
    [0009]
    9. A method of bonding two substrates together to form a bonded article, the method comprising the steps of applying a layer of the adhesive composition as defined in claim 1 to one of the substrates, contacting said layer of the composition of adhesive with a second substrate, and curing or allowing the adhesive composition to cure as defined in claim 1.
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    法律状态:
    2020-01-07| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-06-29| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2021-08-03| B350| Update of information on the portal [chapter 15.35 patent gazette]|
    2021-10-26| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2022-01-11| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 04/05/2015, OBSERVADAS AS CONDICOES LEGAIS. |
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    US201461987530P| true| 2014-05-02|2014-05-02|
    US61/987,530|2014-05-02|
    PCT/US2015/028981|WO2015168670A1|2014-05-02|2015-05-04|Phosphate adhesion promoters|
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