Bonded reinforced plastic structures

Claim 2

A bonded reinforced plastic structure which comprises reinforced plastic parts coated with a primer coat and bonded together by a thermoplastic block copolymer wherein the reinforced plastic is formed from sheet molding compound or bulk molding compound, wherein the primer coat comprises a moisture-curable polyisocyanate, wherein the block copolymer comprises from 40 to 80% by weight of crystalline polyester or polyamide segments and from 20 to 60% by weight of amorphous polyamide or polyether segments, and wherein the block copolymer has a crystalline melting point above about 155° C. and a number average molecular weight in the range of about 8000 to about 30000.

Claim 3

The bonded structure of claim 1 wherein the primer coating thickness is in the range of 5 to about 25 microns.

Claim 4

The bonded structure of claim 1 wherein the moisture-curable polyisocyanate has an isocyanate functionality in the range of about 2.2 to about 6 and is selected from the group consisting of isocyanate terminated urethane prepolymers of number average molecular weight in the range of about 400 to about 4000, polymethylene polyphenyl isocyanates, isocyanurate polyisocyanates of number average molecular weight in the range of about 500 to about 2000 and oligomeric polyisocyanate-biurets of number average molecular weight in the range of about 400 to about 2000.

Claim 5

The bonded structure of claim 1 wherein the crystalline segments of the block copolymer are polyethylene terephthalate or polybutylene terephthalate and the amorphous segments comprise a polyamide condensation product of a dimer acid containing from 75 to 98 weight percent dimer and an aliphatic primary diamine containing from 2 to 10 carbon atoms.

Claim 6

The bonded structure of claim 4 wherein the crystalline segments of the block copolymer comprise polyethylene terephthalate.

Claim 7

A primed reinforced plastic part adapted to be bonded with a hot melt adhesive, wherein the reinforced plastic part is formed from a sheet molding compound or a bulk molding compound and wherein the primer coat comprises a moisture-curable polyisocyanate.

Claim 8

A primed reinforced plastic part adapted to be bonded with a hot melt adhesive, wherein the reinforced plastic part is formed from a sheet molding compound or a bulk molding compound and wherein the primer coat comprises a moisture-curable polyisocyanate.

Claim 9

A primed reinforced plastic part according to claim 6 wherein the moisture-curable polyisocyanate has an isocyanate functionality in the range of about 2.2 to about 6 and is selected from the group consisting of isocyanate terminated urethane prepolymers of number average molecular weight in the range of about 400 to about 4000, polymethylene polyphenyl isocyanates, isocyanurate polyisocyanates of number average molecular weight in the range of about 500 to about 2000 and oligomeric polyisocyanate-biurets of number average molecular weight in the range of about 400 to about 2000.

Claim 10

A primed reinforced plastic part according to claim 6 wherein the primer coating thickness is in the range of about 5 to 25 about microns.

Claim 11

A process for bonding a first reinforced plastic part to a second reinforced plastic part, which comprises applying a primer coating solution to the bonding surfaces, evaporating solvent from the primer coating to provide a film of dry primer, placing the first reinforced plastic part in a fixture adapted to hold the first reinforced plastic part, applying a molten thermoplastic adhesive to the primed surface of the first reinforced plastic part, mating the second reinforced plastic part to the first reinforced plastic part to form a bond, retaining the second reinforced plastic part in the fixture against the first reinforced plastic part by application of a pressure of at least 20 kPa substantially uniformly over the bond, and cooling the bonded parts to allow the bond to set, wherein the reinforced plastic parts are prepared from sheet molding compound or bulk molding compound, wherein the primer coating comprises a moisture-curable polyisocyanate, and wherein the thermoplastic adhesive is a block copolymer comprising 40 to 80 wt % crystalline polyester or polyamide segments and from 20 to 60 wt % amorphous polyamide or polyether segments, and has a crystalline melting point in the range of 155° to 225° C. and a number average molecular weight in the range of about 8000 to about 30000.

Claim 12

A process for bonding a first reinforced plastic part to a second reinforced plastic part, which comprises applying a primer coating solution to the bonding surfaces, evaporating solvent from the primer coating to provide a film of dry primer, placing the first reinforced plastic part in a fixture adapted to hold the first reinforced plastic part, applying a molten thermoplastic adhesive to the primed surface of the first reinforced plastic part, mating the second reinforced plastic part to the first reinforced plastic part to form a bond, retaining the second reinforced plastic part in the fixture against the first reinforced plastic part by application of a pressure of at least 20 kPa substantially uniformly over the bond, and cooling the bonded parts to allow the bond to set, wherein the reinforced plastic parts are prepared from sheet molding compound or bulk molding compound, wherein the primer coating comprises a moisture-curable polyisocyanate, and wherein the thermoplastic adhesive is a block copolymer comprising 40 to 80 wt % crystalline polyester or polyamide segments and from 20 to 60 wt % amorphous polyamide or polyether segments, and has a crystalline melting point in the range of 155° to 225° C. and a number average molecular weight in the range of about 8000 to about 30000.

Claim 13

The process of claim 9 wherein the moisture-curable polyisocyanate has an isocyanate functionality in the range of about 2.2 to about 6 and is selected from the group consisting of isocyanate terminated urethane prepolymers of number average molecular weight in the range of about 400 to about 4000, polymethylene polyphenyl isocyanates, isocyanurate polyisocyanates of number average molecular weight in the range of about 500 to about 2000 and oligomeric polyisocyanate-biurets of number average molecular weight in the range of about 400 to about 2000.

Claim 14

The process of claim 9 wherein the primer coating thickness is in the range of about 5 to about 25 microns and wherein the thickness of the thermoplastic adhesive bond is in the range of about 200 to about 1500 microns.

Claim 15

The process of claim 9 wherein the moisture-curable polyisocyanate has an isocyanate functionality in the range of about 2.2 to about 6 and is selected from the group consisting of isocyanate terminated urethane prepolymers of number average molecular weight in the range of about 400 to about 4000, polymethylene polyphenyl isocyanates, isocyanurate polyisocyanates of number average molecular weight in the range of about 500 to about 2000 and oligomeric polyisocyanate-biurets of number average molecular weight in the range of about 400 to about 2000, wherein the crystalline segments of the block copolymer comprise polyethylene terephthalate and the amorphous segments comprise a polyamide condensation product of a dimer acid containing from 90 to 98 weight percent dimer and an aliphatic primary diamine containing from 2 to 10 carbon atoms, wherein the primed plastic parts are preheated to at least 105° C. before the molten thermoplastic adhesive is applied, wherein the applied pressure is in the range of about 28 to about 85 kPa, and wherein the bond is aged at a temperature in the range of about 90° to about 135° C. for at least about 30 minutes.

Claim 16

The process of claim 9 wherein the primed reinforced plastic parts are preheated to at least 65° C. before the molten thermoplastic adhesive is applied, wherein the applied pressure is in the range of about 28 to about 85 kPa and wherein the bond is aged at a temperature in the range of about 65° to about 170° C. for at least about 30 minutes.

Claim 17

The process of claim 13 wherein the preheat temperature is at least about 105° C. and the aging temperature is in the range of about 90° to about 135° C.

Claim 18

The process of claim 9 wherein the crystalline segments of the block copolymer comprise polyethylene terephthalate or polybutylene terephthalate and the amorphous segments comprise a polyamide condensation product of a dimer acid containing from 75 to 98 weight percent dimer and an aliphatic primary diamine containing from 2 to 10 carbon atoms.

Claim 19

The process of claim 15 wherein the crystalline segments of the block copolymer comprise polyethylene terephthalate.