Methods and formulations for bonding dissimilar materials
The present disclosure is directed to a formulations of cements and methods for bonding dissimilar materials. The formulations and methods can bond a Non-polyvinyl chloride (PVC) containing first polyolefin that is amorphous or has low crystallinity to a second material that is a rigid material or a hard PVC. The methods and formulations can work by co-dissolution at an interface, or activation of a one of the materials prior to bonding.
1 . A method of bonding a first material to a second material, the first and second materials being dissimilar, wherein
the first material comprises a non-polyvinyl chloride (Non-PVC) polyolefin polymer, wherein the Non-PVC polyolefin polymer is amorphous or has a degree of crystallinity in the range of about 0.1% to about 50% crystallinity;
the second material comprises a rigid amorphous material having a tensile modulus in the range of about 1800 to about 3000 MPa, a PVC having a Shore A hardness in the range of about 70 to about 85, or a combination thereof;
the method comprising:
i.) modifying the first material with a polar functional group, the polar functional group increasing an affinity of the first material to the second material, wherein modifying the first material comprises:
grafting the polar functional group to the first material via a reactive extrusion, wherein the reactive extrusion comprises activating the first material with an initiator to provide an activated material;
ii.) bonding the first material to the second material, wherein bonding the first material to the second material comprises integrating the modified first material to the second material by applying a solvent at an interface between the modified first material and the second material.
2 . The method of claim 1 , wherein the initiator is selected from the group consisting of benzyl peroxide, dicumyl peroxide, and 2,2′-Azobisisobutyronitrile.
3 . The method of claim 1 , wherein the polar functional group is formed from reacting with a monomeric compound comprising at least one ester group.
4 . The method of claim 3 , wherein the monomeric compound comprises a carbon-carbon double bond capable of reacting with the activated material.
5 . The method of claim 3 , wherein the monomeric compound is selected from the group consisting of methyl methacrylate, glycidyl methacrylate, and vinyl acetate.
6 . The method of claim 1 , wherein modifying the first material comprises grafting the polar functional group to the first material using one or more tackifiers selected from the group consisting of a terpene phenol, a styrenated terpene, a rosin ester, a terpene resin, and a hydrocarbon resin.
7 . The method of claim 1 , wherein the solvent is selected from the group consisting of cyclohexanone, methyl ethyl ketone, cyclohexane, ethyl acetate, isobutyl acetate, n-butyl acetate, methyl isobutyl ketone, tetrahydrofuran, heptane, and any combination thereof.
8 . The method of claim 1 , wherein modifying the first material further comprises combining the first material with up to about 10 wt % of a secondary compatibilizer selected from polyether amine, ethylene-vinyl acetate (EVA), or both, wherein the secondary compatibilizer increases the polarity of the first material.
9 . The method of claim 1 , wherein modifying the first material further comprises combining the first material with up to about 1 wt % of an antioxidant, up to about 1 wt % of a processing aid, or both.
10 . The method of claim 9 , wherein the antioxidant is selected from the group consisting of penterythritol tetrakis (3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate), or 1, 3, 5-trimethyl-2,4,6-tris (3,5-di-tert-butyl-4-hydroxybenzyl) benzene.
11 . The method of claim 1 , wherein modifying the first material further comprises combining the first material with up to about 10 wt % of an isoprene-based tackifier.
12 . The method of claim 11 , wherein the isoprene-based tackifier is a terpene.
13 . The method of claim 1 , wherein the non-PVC polyolefin polymer is a styrenic based thermoplastic elastomer (TPE) or a styrenic based thermoplastic olefin (TPO).
14 . The method of claim 1 , wherein the rigid amorphous material comprises a polycarbonate or copolymer thereof, a polyacrylate or copolymer thereof, or an acrylonitrile butadiene styrene (ABS) or copolymer thereof.
15 . The method of claim 1 , wherein an adhesive is not utilized in bonding the first material to the second material.