Moisture-curable, graft-modified resin composition, process for its manufacture and process for bonding substrates employing the resin composition
View Patent ↗A moisture-curable, graft-modified resin composition includes at least one thermoplastic polymer (i) and at least one silyl group containing polymer (ii) possessing at least one hydrolyzable silyl group that is bonded to the polymer through a linking group containing at least one heteroatom selected from the group consisting of oxygen and nitrogen, each of polymers (i) and (ii) having grafted thereto at least one same or different silane (iii) which, prior to being grafted, possesses at least one reactive carbon-carbon unsaturated bond.
1. A moisture-curable, graft-modified resin composition which comprises at least one thermoplastic polymer (i) and at least one silyl group-containing polymer (ii) possessing at least one hydrolyzable silyl group that is bonded to polymer (ii) through a linking group containing at least one heteroatom selected from the group consisting of oxygen and nitrogen, each of polymers (i) and (ii) further having free-radically grafted thereto at least one same or different silane (iii) which, prior to being grafted, possesses at least one reactive carbon-carbon unsaturated bond.
2. The moisture-curable, graft-modified resin composition of claim 1 wherein thermoplastic polymer (i) is an ethylene-vinyl acetate copolymer having a vinyl acetate content of from 10 to 60 weight percent.
3. The moisture-curable, graft-modified resin composition of claim 1 wherein the thermoplastic polymer (i) is an ethylene-vinyl acetate copolymer having a vinyl acetate content of from 18 to 50 weight percent.
4. The moisture-curable, graft-modified resin composition of claim 1 wherein silyl group-containing polymer (ii) is represented by general Formula (1):
wherein:
each occurrence of R 1 is independently a monovalent or polyvalent organic polymer fragment having a number average molecular weight of from 500 to 25,000 grams/mole;
each occurrence of R 2 is independently a divalent hydrocarbyl group containing up to 12 carbon atoms selected from the group consisting of divalent alkylene, alkenylene, arenylene, arylene and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of A 1 is independently selected from divalent oxygen (—O—), sulfur (—S—) or substituted nitrogen of the structure (—) 2 NR 3 wherein R 3 is hydrogen, alkyl, alkenyl, arenyl, aryl, aralkyl or an —R 2 SiX 1 X 2 X 3 group wherein each R 3 , other than hydrogen, contains up to 18 carbon atoms, and with the provisos that when a is 1 and A 1 is oxygen or sulfur, then A 2 is (—) 2 NR 3 and when a is 0, then A 1 is oxygen;
each occurrence of A 2 is independently selected from divalent oxygen (—O—), sulfur (—S—) or substituted nitrogen of the structure (—) 2 NR 3 wherein R 3 is hydrogen, alkyl, alkenyl, arenyl, aryl, aralkyl or —R 2 SiX 1 X 2 X 3 group, wherein each R 3 , other than hydrogen, contains up to 18 carbon atoms, and with the proviso that when A 2 is oxygen or sulfur, then A 1 is (—) 2 NR 3 ;
each occurrence of X 1 is independently selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO— and R 2 NO— wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms;
each occurrence of X 2 and X 3 is independently selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO—, R 2 NO— and R wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms; and,
each occurrence of subscripts a and b is independently an integer wherein a is 0 or 1 and b is 1 to 6.
5. The moisture-curable, graft-modified resin composition of claim 1 wherein silyl group containing polymer (ii) is an acrylic polymer represented by general Formula (11):
wherein:
each occurrence of R 6 is independently hydrogen or a monovalent hydrocarbyl group of up to 12 carbon atoms selected from the group consisting of alkyl, arenyl, aryl and aralkyl optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of R 7 is independently hydrogen or a monovalent hydrocarbyl group of up to 12 carbon atoms selected from the group consisting of alkyl, arenyl, aryl and aralkyl optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of R 8 is a covalent bond or divalent hydrocarbyl group of up to 12 carbon atoms selected from the group consisting of alkylene, arenylene, arylene and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of X 5 is independently an organofunctional group selected from the group consisting of carboxyl (—C(═O)OH), cyano (—CN), hydroxyl (—OH), halo (Cl—, Br— and I—), phenyl (—C 6 H 5 ) and vinyl (—C(R 5 )═CH 2 ) wherein R 5 has the aforestated meaning;
each occurrence of X 6 is independently a monovalent hydrocarbyl group containing an ester linking group, —C(═O)O—R 9 , wherein each occurrence of R 9 is independently a monovalent hydrocarbyl group of up to 12 carbon atoms selected from the group consisting of alkyl, arenyl, aryl and aralkyl optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of X 7 is independently a monovalent hydrocarbyl group containing a hydroxyl and ester linking group, —C(═O)O—R 10 —OH, wherein each occurrence of R 10 is independently a divalent hydrocarbylene group of up to 12 carbon atoms selected from the group consisting of alkylene, arenylene, arylene and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of X 8 is independently a monovalent hydrocarbyl group containing a hydrolyzable silyl group and a urethane linking group represented by general Formula (12):
wherein
R 2 is a divalent hydrocarbyl group containing up to 12 carbon atoms selected from the group consisting of divalent alkylene, alkenylene, arenylene, arylene and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
X 1 is selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO— and R 2 NO— wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms;
X 2 and X 3 is independently selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO—, R 2 NO— and R wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms;
R 11 is a divalent hydrocarbylene group of up to 18 carbon atoms selected from the group consisting of alkylene, arenylene, arylene, and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur,
A 1 is oxygen;
A 3 and A 4 are —NH—, each A 2 is divalent oxygen, sulfur or substituted nitrogen of the structure(—) 2 NR 3 wherein R 3 is hydrogen, alkyl, alkenyl, aryl aralkyl or an —R 2 SiX 1 X 2 X 3 group wherein each R 3 , other than hydrogen, contains up to 18 carbon atoms, and with the proviso that when c is 0, A 2 is —NH—;
each occurrence of X 9 is independently a monovalent hydrocarbyl group containing a hydrolyzable silyl group, a urethane group and an ester linking group as represented by general Formula (13):
wherein
R 2 , R 11 , X 1 , X 2 and X 3 have the aforestated meanings;
each occurrence of R 10 is a divalent hydrocarbyl group of up to 12 carbon atoms selected from the group consisting of alkylene, arenylene, arylene and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
A 1 is oxygen;
A 3 and A 4 are —NH—;
each A 2 is divalent oxygen, sulfur or substituted nitrogen of the structure (—) 2 NR 3 wherein R 3 is hydrogen, alkyl, alkenyl, aryl aralkyl or a —R 2 SiX 1 X 2 X 3 group wherein each R 3 , other than hydrogen, contains up to 18 carbon atoms, and with the proviso that when d is 0, A 2 is —NH—; and,
each occurrence of c, d, m, n, o, p, q and r is an integer wherein c is 0 or 1; d is 0 or 1, m is 0 to 500, n is 0 to 500, o is 0 to 500 and p is 0 to 500, q is 0 to 500 and r is 0 to 500, with the proviso that the sum of q and r is greater than 1, q is less than or equal to n, and r is less than or equal to p.
6. The moisture-curable, graft-modified resin composition of claim 5 wherein in silyl group-containing-acrylic polymer (ii), R 7 is hydrogen or methyl;
R 8 is a covalent bond;
R 9 is an alkyl or aryl group of up to 10 carbon atoms;
R 10 is an alkylene group of up to 12 carbon atoms;
X 5 is phenyl, cyano, chloro or carboxyl (—C(C═O)OH);
m is from 0 to 300;
n is from 0 to 300;
o is from 0 to 300;
q is from 0 to 200; and,
r is from 0 to 200, with the proviso that the sum of q and r is greater than 1.
7. The moisture-curable, graft-modified resin composition of claim 6 wherein
in silyl group-containing acrylic polymer (ii), R 7 is hydrogen;
R 9 is an alkyl or aryl group of up to 8 carbon atoms;
R 10 is an alkylene group of up to 8 carbon atoms;
m is from 10 to 100;
n is from 10 to 100;
o is from 10 to 100;
q is from 1 to 100; and,
r is from 1 to 100.
8. The moisture-curable, graft-modified resin composition of claim 7
wherein in silyl group-containing acrylate polymer (ii), R 9 is an alkyl or aryl group of up to 6 carbon atoms;
R 10 is an alkylene group of from 3 to 6 carbon atoms;
m is from 25 to 50;
n is from 25 to 50;
o is from 25 to 50;
p is from 25 to 50;
q is from 5 to 50; and,
r is from 5 to 50.
9. The moisture-curable, graft-modified resin composition of claim 1 wherein silane (iii) prior to being grafted to polymers (i) and (ii) is represented by general Formula (14):
wherein:
each occurrence of R 11 R 12 and R 13 is independently hydrogen or a monovalent hydrocarbyl group containing up to 12 carbon atoms selected from the group consisting of alkyl, alkenyl, arenyl, aryl and aralkyl;
each occurrence of R 14 is independently a divalent hydrocarbylene group of up to 12 carbon atoms selected from the group consisting of alkylene, alkenylene, arenylene, arylene and aralkylene optionally containing at least one oxygen heteroatom;
each occurrence of A 5 is independently a chemical bond, divalent oxygen (—O—) or substituted nitrogen of the structure (—) 2 NR 15 wherein R 15 is hydrogen, alkyl, arenyl, aryl, aralkyl or an —R 14 SiX 1 X 2 X 3 group wherein each R 15 , other than hydrogen, contains up to 12 carbon atoms;
each occurrence of X 1 is independently selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO— and R 2 NO— wherein each R is independently hydrogen, alkyl, alkenyl, arenyl, aryl or aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, at least one oxygen atom;
each occurrence of X 2 and X 3 is independently selected from the group consisting of RO—, RC(═O )O—, R 2 C═NO—, R 2 NO— and R wherein each R is independently hydrogen, alkyl, alkenyl, arenyl, aryl or aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, at least one oxygen or sulfur atom;
each occurrence of X 10 is independently selected from the group consisting of RO—, RC(═O )O—, R 2 C═NO— and R 2 NO— wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms;
each occurrence of X 11 and X 12 is independently selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO—, R 2 NO— and R wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms; and,
r is 0 or 1.
10. The moisture-curable, graft-modified resin composition of claim 9 wherein silane (iii) is at least one member selected from the group consisting of
6-(methyl-dimethoxy-silanyl)-2-methyl-hex-1-en-3-one;
6-(trimethoxy-silanyl)-2-methyl-hex-1-en-3-one;
7-(methyl-dimethoxy-silanyl)-2,3-dimethyl-hept-2-en-4-one;
2-methyl-acrylic acid 2-(trimethoxy-silanyl)-ethyl ester;
2-methyl-acrylic acid 2-(methyl-dimethoxy-silanyl)-ethyl ester;
2-methyl-acrylic acid 3-(methyl-dimethoxy-silanyl)-propyl ester;
2-methyl-acrylic acid 3-(triethoxy-silanyl)-propyl ester;
2-methyl-acrylic acid 3-(phenyl-dimethoxy-silanyl)-propyl ester;
N-[3-(methyl-dimethoxy-silanyl)-propyl]-2-methyl-acrylamide;
N-[3-(triethoxy-silanyl)-propyl]-2-methyl-acrylamide;
N-[1-(trimethoxy-silanyl)-methyl]-2-methyl-acrylamide;
N-[3-(methyl-dimethoxy-silanyl)-propyl]-acrylamide;
acrylic acid 3-(methyl-dimethoxy-silanyl)-propyl ester;
acrylic acid 3-(trimethoxy-silanyl)-propyl ester; methyl-dimethoxy-vinyl-silane;
trimethoxy-vinyl-silane;
phenyl-dimethoxy-vinyl-silane;
tripropoxy-vinyl-silane;
methyl-diethoxy-vinyl-silane; and,
triethoxy-vinyl-silane.
11. The moisture-curable, graft-modified resin composition of claim 1 further comprising at least one optional component (v) selected from the group consisting of tackifying agents, fillers, reinforcements, ultra-violet stabilizers, antioxidants, antiozonants, catalysts, adhesion promoters, cure accelerators, rheology modifiers, solvents, surfactants, corrosion inhibitors, hydrolyzable silicon compounds, flame retardants, waxes, moisture scavengers, pigments, dyes, colorants, surfactant, solvents, fungicides, biocides, free-radical inhibitors, free-radical stabilizers and free radical scavengers.
12. The moisture-curable, graft-modified resin composition of claim 1 possessing an open time of from 2 to 90 seconds, wherein the open time is the time which begins at the point when an adhesive is applied at ambient conditions to a first substrate until it is bonded to a second substrate.
13. The moisture-curable, graft-modified resin composition of claim 1 possessing an open time of from 3 to 75 seconds, wherein the open time is the time which begins at the point when an adhesive is applied at ambient conditions to a first substrate until it is bonded to a second substrate.
14. The moisture-cured resin obtained from the moisture curing of the moisture-curable, graft-modified resin composition of claim 1 .
15. The moisture-cured resin of claim 14 possessing a tensile strength of from 750 to 10,000 psi and a bond strength of from 70 to 1000 lbf.
16. The moisture-cured resin of claim 14 possessing a tensile strength of from 1,000 to 7,500 psi and a bond strength of from 100 to 500 lbf.
17. A process for preparing a moisture-curable, graft-modified resin composition comprising:
free-radically grafting at least one same or different silane (iii) possessing at least one reactive carbon-carbon unsaturated bond onto at least one thermoplastic polymer (i) and at least one silyl group-containing polymer (ii) possessing at least one hydrolyzable silyl group that is bonded to polymer (ii) through a linking group containing at least one heteroatom selected from the group consisting of oxygen and nitrogen, to provide a moisture-curable, graft-modified resin composition; and, optionally, moisture-curing the moisture-curable, graft-modified resin composition.
18. The process of claim 17 which comprises:
a) heating at least one thermoplastic polymer (i) to a temperature at or above the melt temperature but not exceeding the degradation temperature thereof to provide molten thermoplastic polymer(s)(i);
b) combining molten thermoplastic polymer(s)(i) from step (a) with at least one silyl group-containing polymer (ii) possessing at least one hydrolyzable silyl group that is bonded to polymer (ii) through a linking group containing at least one heteroatom selected from the group consisting of oxygen and nitrogen to provide a substantially uniform mixture of molten thermoplastic(s) (i) and silyl group-containing polymer(s) (ii);
c) combining the substantially uniform mixture of molten thermoplastic polymer(s) (i) and silyl group-containing polymer(s) (ii) from step (b) with at least one silane (iii) possessing at least one reactive carbon-carbon unsaturated bond, and at least one free radical-generating agent (iv) under reactive-mechanical conditions to provide a moisture-curable, graft-modified resin composition; and,
d) optionally, moisture-curing the moisture-curable, graft-modified resin composition from step (c).
19. The process of claim 17 wherein thermoplastic resin (i) is an ethylene-vinyl acetate copolymer having a vinyl acetate content of from 10 to 60 weight percent.
20. The process of claim 17 wherein the thermoplastic resin (i) is an ethylene-vinyl acetate copolymer which has a vinyl acetate content of from 18 to 50 percent.
21. The process of claim 17 wherein silyl group-containing polymer (ii) is represented by general Formula (1):
wherein:
each occurrence of R 1 is independently a monovalent or polyvalent organic polymer fragment having an number average molecular weight of from 500 to 25,000 grams/mole;
each occurrence of R 2 is independently a divalent hydrocarbyl group containing up to 12 carbon atoms selected from the group consisting of divalent alkylene, alkenylene, arenylene, arylene and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of A 1 is independently selected from divalent oxygen (—O—), sulfur (—S—) or substituted nitrogen of the structure (—) 2 NR 3 wherein R 3 is hydrogen, alkyl, alkenyl, arenyl, aryl, aralkyl or an —R 2 SiX 1 X 2 X 3 group wherein each R 3 , other than hydrogen, contains up to 18 carbon atoms, and with the provisos that when a is 1 and A 1 is oxygen or sulfur, then A 2 is (—) 2 NR 3 and when a is 0, then A 1 is oxygen;
each occurrence of A 2 is independently selected from divalent oxygen (—O—), sulfur (—S—) or substituted nitrogen of the structure (—) 2 NR 3 wherein R 3 is hydrogen, alkyl, alkenyl, arenyl, aryl, aralkyl or —R 2 SiX 1 X 2 X 3 group, wherein each R 3 , other than hydrogen, contains up to 18 carbon atoms, and with the proviso that when A 2 is oxygen or sulfur, then A 1 is (—) 2 NR 3 ;
each occurrence of X 1 is independently selected from the group consisting of RO—, RC(═O)O— and R 2 NO— wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms;
each occurrence of X 2 and X 3 is independently selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO—, R 2 NO— and R wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms; and,
each occurrence of subscripts a and b is independently an integer wherein a is 0 or 1 and b is 1 to 6.
22. The process of claim 17 wherein silyl group containing polymer (ii) is an acrylic polymer represented by general Formula (11):
wherein:
each occurrence of R 6 is independently hydrogen or a monovalent hydrocarbyl group of up to 12 carbon atoms selected from the group consisting of alkyl, arenyl, aryl and aralkyl optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of R 7 is independently hydrogen or a monovalent hydrocarbyl group of up to 12 carbon atoms selected from the group consisting of alkyl, arenyl, aryl and aralkyl optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of R 8 is a covalent bond or divalent hydrocarbyl group of up to 12 carbon atoms selected from the group consisting of alkylene, arenylene, arylene and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of X 5 is independently an organofunctional group selected from the group consisting of carboxyl (—C(═O)OH), cyano (—CN), hydroxyl (—OH), halo (Cl—, Br— and I—), phenyl (—C 6 H 5 ) and vinyl (—C(R 5 )═CH 2 ) wherein R 5 has the aforestated meaning;
each occurrence of X 6 is independently a monovalent hydrocarbyl group containing an ester linking group, —C(═O)O—R 9 , wherein each occurrence of R 9 is independently a monovalent hydrocarbyl group of up to 12 carbon atoms selected from the group consisting of alkyl, arenyl, aryl and aralkyl optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of X 7 is independently a monovalent hydrocarbyl group containing a hydroxyl and ester linking group, —C(═O)O—R 10 —OH, wherein each occurrence of R 10 is independently a divalent hydrocarbylene group of up to 12 carbon atoms selected from the group consisting of alkylene, arenylene, arylene and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
each occurrence of X 8 is independently a monovalent hydrocarbyl group containing a hydrolyzable silyl group and a urethane linking group represented by general Formula (12):
wherein
R 2 is a divalent hydrocarbyl group containing up to 12 carbon atoms selected from the group consisting of divalent alkylene, alkenylene, arenylene, arylene and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
X 1 is selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO— and R 2 NO— wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms;
X 2 and X 3 is independently selected from the group consisting of RO—, RC(═O )O—, R 2 C═NO—, R 2 NO— and R wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms;
R 11 is a divalent hydrocarbylene group of up to 18 carbon atoms selected from the group consisting of alkylene, arenylene, arylene, and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur,
A 1 is oxygen;
A 3 and A 4 are —NH—, each A 2 is divalent oxygen, sulfur or substituted nitrogen of the structure (—) 2 NR 3 wherein R 3 is hydrogen, alkyl, alkenyl, aryl aralkyl or an —R 2 SiX 1 X 2 X 3 group wherein each R 3 , other than hydrogen, contains up to 18 carbon atoms, and with the proviso that when c is 0, A 2 is —NH—;
each occurrence of X 9 is independently a monovalent hydrocarbonyl group containing a hydrolyzable silyl group, a urethane group and an ester linking group as represented by general Formula (13):
wherein
R 2 , R 11 , X 1 , X 2 and X 3 have the aforestated meanings;
each occurrence of R 10 is a divalent hydrocarbyl group of up to 12 carbon atoms selected from the group consisting of alkylene, arenylene, arylene and aralkylene optionally containing at least one heteroatom selected from the group consisting of oxygen, nitrogen and sulfur;
A 1 is oxygen;
A 3 and A 4 are —NH—;
each A 2 is divalent oxygen, sulfur or substituted nitrogen of the structure (—) 2 NR 3 wherein R 3 is hydrogen, alkyl, alkenyl, aryl aralkyl or a —R 2 SiX 1 X 2 X 3 group wherein each R 3 , other than hydrogen, contains up to 18 carbon atoms, and with the proviso that when d is 0, A 2 is —NH—; and,
each occurrence of c, d, m, n, o, p, q and r is an integer wherein c is 0 or 1; d is 0 or 1, m is 0 to 500, n is 0 to 500, o is 0 to 500 and p is 0 to 500, q is 0 to 500 and r is 0 to 500, with the proviso that the sum of q and r is greater than or equal to 1, q is less than or equal to n, and r is less than or equal to p.
23. The process of claim 22 wherein in silyl group-containing-acrylic polymer (ii), R 7 is hydrogen or methyl; R 8 is a covalent bond; R 9 is an alkyl or aryl group of up to 10 carbon atoms; R 10 is an alkylene group of up to 12 carbon atoms; X 5 is phenyl, cyano, chloro or carboxyl (—C(C═O)OH); m is from 0 to 300; n is from 0 to 300; o is from 0 to 300; q is from 0 to 200; and, r is from 0 to 200, with the proviso that the sum of q and r is equal to or greater than 1.
24. The process of claim 23 wherein in silyl group-containing acrylic polymer (ii), R 7 is hydrogen; R 9 is an alkyl or aryl group of up to 8 carbon atoms; R 10 is an alkylene group of up to 8 carbon atoms; m is from 10 to 100; n is from 10 to 100; o is from 10 to 100; q is from 1 to 100; and, r is from 1 to 100.
25. The process of claim 24 wherein in silyl group-containing acrylate polymer (ii), R 9 is an alkyl or aryl group of up to 6 carbon atoms; R 10 is an alkylene group of from 3 to 6 carbon atoms; m is from 25 to 50; n is from 25 to 50; o is from 25 to 50; p is from 25 to 50; q is from 5 to 50; and, r is from 5 to 50.
26. The process of claim 17 wherein silane (iii) is represented by general Formula (14):
wherein:
each occurrence of R 11 , R 12 and R 13 is independently hydrogen or a monovalent hydrocarbyl group containing up to 12 carbon atoms selected from the group consisting of alkyl, alkenyl, arenyl, aryl and aralkyl;
each occurrence of R 14 is independently a divalent hydrocarbylene group of up to 12 carbon atoms selected from the group consisting of alkylene, alkenylene, arenylene, arylene and aralkylene optionally containing at least one oxygen heteroatom;
each occurrence of A 5 is independently a chemical bond, divalent oxygen (—O—) or substituted nitrogen of the structure (—) 2 NR 15 wherein R 15 is hydrogen, alkyl, arenyl, aryl, aralkyl or an —R 14 SiX 1 X 2 X 3 group wherein each R 15 , other than hydrogen, contains up to 12 carbon atoms;
each occurrence of X 1 is independently selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO— and R 2 NO— wherein each R is independently hydrogen, alkyl, alkenyl, arenyl, aryl or aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, at least one oxygen atom;
each occurrence of X 2 and X 3 is independently selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO—, R 2 NO— and R wherein each R is independently hydrogen, alkyl, alkenyl, arenyl, aryl or aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, at least one oxygen or sulfur atom;
each occurrence of X 10 is independently selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO— and R 2 NO— wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms;
each occurrence of X 11 and X 12 is independently selected from the group consisting of RO—, RC(═O)O—, R 2 C═NO—, R 2 NO— and R wherein each R is independently selected from the group consisting of hydrogen, alkyl, alkenyl, arenyl, aryl, and aralkyl wherein each R, other than hydrogen, contains up to 18 carbon atoms and, optionally, one or more oxygen and/or sulfur atoms; and,
r is 0 or 1.
27. The process of claim 26 wherein silane (iii) is at least one member selected from the group consisting of
6-(methyl-dimethoxy-silanyl)-2-methyl-hex-1 -en-3-one;
6-(trimethoxy-silanyl)-2-methyl-hex-1-en-3-one;
7-(methyl-dimethoxy-silanyl)-2,3-dimethyl-hept-2-en-4-one;
2-methyl-acrylic acid 2-(trimethoxy-silanyl)-ethyl ester;
2-methyl-acrylic acid 2-(methyl-dimethoxy-silanyl)-ethyl ester;
2-methyl-acrylic acid 3-(methyl-dimethoxy-silanyl)-propyl ester;
2-methyl-acrylic acid 3-(triethoxy-silanyl)-propyl ester;
2-methyl-acrylic acid 3-(phenyl-dimethoxy-silanyl)-propyl ester;
N-[3-(methyl-dimethoxy-silanyl)-propyl]-2-methyl-acrylamide;
N-[3-(triethoxy-silanyl)-propyl]-2-methyl-acrylamide;
N-[1-(trimethoxy-silanyl)-methyl]-2-methyl-acrylamide;
N-[3-(methyl-dimethoxy-silanyl)-propyl]-acrylamide;
acrylic acid 3-(methyl-dimethoxy-silanyl)-propyl ester;
acrylic acid 3-(trimethoxy-silanyl)-propyl ester;
methyl-dimethoxy-vinyl-silane;
trimethoxy-vinyl-silane;
phenyl-dimethoxy-vinyl-silane;
tripropoxy-vinyl-silane;
methyl-diethoxy-vinyl-silane; and,
triethoxy-vinyl-silane.
28. The process of claim 18 further comprising adding at least one component (v) selected from the group consisting of tackifying agents, fillers, reinforcements, ultra-violet stabilizers, antioxidants, antiozonants, catalysts, adhesion promoters, cure accelerators, rheology modifiers, solvents, surfactants, corrosion inhibitors, hydrolyzable silicon compounds, flame retardants, waxes, moisture scavengers, pigments, dyes, colorants, surfactant, solvents, fungicides, biocides, free-radical inhibitors, free-radical stabilizers and free radical scavengers prior to, or following at least one of steps (a), (b) and (c).
29. A moisture-cured, graft-modified resin obtained from the moisture curing of the moisture-curable, graft-modified resin composition in accordance with the process of claim 17 .
30. A moisture-curable, graft-modified resin-forming composition which comprises:
(i) at least one thermoplastic polymer;
(ii) at least one silyl group-containing polymer possessing at least one hydrolyzable silyl group that is bonded to the polymer through a linking group containing at least one heteroatom selected from the group consisting of oxygen and nitrogen;
(iii) at least one silane possessing at least one reactive carbon-carbon unsaturated bond;
(iv) at least one free radical-generating agent; and,
(v) optionally, one or more additional components.
31. The moisture-curable, graft-modified composition obtained from the grafting reactions of the moisture-curable, graft-modified resin-forming composition of claim 30 , wherein the thermoplastic polymer (i) and the silyl group-containing polymer (ii) react with the silane (iii) under reactive-mechanical conditions.
32. A process for bonding substrates which comprises:
a) applying to a first substrate the moisture-curable, graft-modified resin composition of claim 1 heated to the flowable state;
b) applying a second substrate to exposed surface of the moisture-curable, graft-modified resin composition while said resin composition is in the flowable state; and,
c) moisture-curing the moisture-curable, graft-modified resin composition to provide a moisture-cured resin adhesively bonding the first substrate to the second substrate.
33. The process of claim 32 wherein the surface of the first substrate and/or second substrate to which the moisture-curable, graft-modified resin composition is applied possesses reactive functional groups for silanol groups.
34. The process of claim 33 wherein the first substrate and/or second substrate has a metal surface possessing hydroxyl groups.
35. The process of claim 34 wherein the metal surface is one of aluminum or aluminum alloy.
36. The bonded substrates obtained from the process of claim 32 .
37. The bonded substrates obtained from the process of claim 33 .
38. The bonded substrates obtained from the process of claim 34 .
39. The bonded substrates obtained from the process of claim 35 .