Bonded plastic structures

Claim 2

A bonded plastic structure which comprises plastic parts coated with a primer coat and bonded together by a thermoplastic block copolymer wherein the plastic is a reinforced reaction injection molded polyurethane or a reaction injection molded nylon, 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 30,000.

Claim 3

The bonded structure of claim 1 wherein the primer coating thickness is in the range of about 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 plastic part adapted to be bonded with a hot melt adhesive, wherein the plastic part is a reinforced reaction injection molded polyurethane or a reaction injection molded nylon and wherein the primer coat comprises a moisture-curable polyisocyanate.

Claim 8

A primed plastic part adapted to be bonded with a hot melt adhesive, wherein the plastic part is a reinforced reaction injection molded polyurethane or a reaction injection molded nylon and wherein the primer coat comprises a moisture-curable polyisocyanate.

Claim 9

The primed plastic part of 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 process for bonding a first plastic part to a second 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 plastic part in a fixture adapted to hold the first plastic part, applying a molten thermoplastic adhesive to the primed surface of the first plastic part, mating the second plastic part to the first plastic part to form a bond, retaining the second plastic part in the fixture against the first 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 plastic parts are reinforced reaction injection molded polyurethane or reaction injection molded polyamide, wherein the primer coating comprises a moisture-curable polyisocyanate, 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 above 155° C. and a number average molecular weight in the range of about 8000 to about 30000.

Claim 11

A process for bonding a first plastic part to a second 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 plastic part in a fixture adapted to hold the first plastic part, applying a molten thermoplastic adhesive to the primed surface of the first plastic part, mating the second plastic part to the first plastic part to form a bond, retaining the second plastic part in the fixture against the first 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 plastic parts are reinforced reaction injection molded polyurethane or reaction injection molded polyamide, wherein the primer coating comprises a moisture-curable polyisocyanate, 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 above 155° C. and a number average molecular weight in the range of about 8000 to about 30000.

Claim 12

The process of claim 8 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 13

The process of claim 8 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 14

The process of claim 8 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 15

The process of claim 8 wherein the primed 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 20° to about 170° C. for at least about 30 minutes.

Claim 16

The process of claim 12 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 17

The process of claim 8 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 18

The process of claim 14 wherein the crystalline segments of the block copolymer comprise polyethylene terephthalate.