Polyurethane adhesive for a surface treatment-free fiber reinforced plastic

Claim 2

A two component urethane adhesive, comprising: a urethane prepolymer component and a curative component, said urethane prepolymer component made from a hydroxyl terminated intermediate and a polyisocyanate, the amount of said polyisocyanate being an equivalent excess of at least 2.0 based upon the hydroxyl terminated intermediate so that said prepolymer component has free NCO groups, said curative component comprising a nitrogen-free polyether polyol having OH groups, a nitrogen-free polyester polyol having OH groups, a nitrogen-free low molecular weight polyol, or combinations thereof and a primary polyamine, the amount of said polyol curative being such that the equivalent ratio of said free NCO groups to said OH groups and NH groups of said curative is from about 1.2 to about 2.0, the two component urethane adhesive being capable of bonding to a surface treatment-free plastic, fiber reinforced plastic, or metal.

Claim 3

A two component urethane adhesive according to claim 1, wherein said hydroxyl terminated intermediate is a polyester polyol or a polyether polyol having a number average molecular weight of from about 400 to about 10,000, wherein said polyisocyanate has the formula R(NCO) n where n is an integer of 2, 3 or 4, wherein R is an aliphatic having from 2 to about 20 carbon atoms, an aromatic or an alkyl substituted aromatic having from 6 to 20 carbon atoms, and combinations of said polyisocyanate.

Claim 4

A two component urethane adhesive according to claim 2, wherein said polyether polyol intermediate is made from an alkylene oxide having from 2 to 10 carbon atoms, wherein said polyester polyol intermediate is made from a polyhydric alcohol having from 2 to 15 carbon atoms and a polycarboxylic acid having from 2 to 14 carbon atoms, wherein R of said polyisocyanate is an aromatic or an alkyl substituted aromatic having from 6 to 15 carbon atoms, and wherein said curative is a liquid.

Claim 5

A two component urethane adhesive according to claim 3, wherein said equivalent excess of said polyisocyanate is from about 5.0 to about 10.0 based upon said hydroxyl terminated intermediate, wherein the equivalent ratio of said free NCO groups to said OH and NH groups of said curative is from about 1.35 to about 1.6, and wherein said nitrogen free low molecular weight polyol curative is alkyl diol having from 2 to 12 carbon atoms, a polyhydric alcohol having from 3 to 15 carbon atoms and from 3 to 8 hydroxyl groups, a carbohydrate having from 5 to 12 carbon atoms and from 4 to 10 hydroxyl groups, or combinations thereof.

Claim 6

A two component urethane adhesive according to claim 4, wherein said polyether polyol intermediate and said polyester polyol intermediate has a number average molecular weight of from about 2,000 to about 4,000, wherein said polyol curative is said alkyl diol, said polyhydric alcohol, or said carbohydrate, or combinations thereof, said urethane prepolymer component including a filler, the amount of said filler being from about 5 parts to about 100 parts by weight for every 100 parts by weight of said prepolymer component, and said curative component including a filler, the amount of said filler being from about 5 parts to about 100 parts by weight for every 100 parts by weight of said polyol curative.

Claim 7

A two component urethane adhesive according to claim 5, wherein said hydroxyl terminated intermediate is polypropylene ether diol, polybutylene ether diol, polytetramethylene ether diol, polycaprolactone diol, and combinations thereof, wherein said equivalent ratio of said free NCO groups to said OH and NH groups of said curative is from about 1.35 to about 1.45, wherein said polyisocyanate is methylene diphenyl diisocyanate or toluene diisocyanate, and wherein said nitrogen free low molecular weight polyol curative is an ethylene or propylene oxide adduct of trimethylol propane, pentaerythritol, glycerol, an alkyl glucoside wherein said alkyl has from 1 to 12 carbon atoms, or combinations thereof.

Claim 8

A two component urethane adhesive according to claim 6, wherein said filler of said prepolymer component and said curative component independently is ground mica, talc, kaolin clay, calcium carbonate, calcium sulfite, colloidal silica, wollastonite, ballotini, hollow glass microspheres, glass, carbon fibers, graphite fibers, zinc oxide, titanium oxide, zirconium oxide, ground quartz, a metallic silicate, lead powder, aluminum powder, bronze powder, or combinations thereof, wherein the amount of said filler in said prepolymer component is from about 20 parts to about 50 parts by weight for every 100 parts by weight of said prepolymer component, and wherein the amount of said filler in said curative component is from about 30 parts to about 60 parts by weight for every 100 parts by weight of said curative component, said prepolymer component including from about 0.1 to about 40 parts by weight for every 100 parts by weight of a polyhydric alcohol having from 2 to 15 carbon atoms, said curative component containing from about 1 part to about 5 parts by weight for every 100 parts by weight of said primary polyamine having from 1 to 14 carbon atoms.

Claim 9

A two component urethane adhesive according to claim 7, wherein said filler of said prepolymer component and said curative component is talc, and wherein the amount of said polyhydric alcohol in said prepolymer component is from about 0.1 to about 10 parts by weight for every 100 parts by weight of said polyol intermediate.

Claim 10

A urethane adhesive composite containing treatment-free substrates therein, comprising: the urethane adhesive, said urethane adhesive being the reaction product of a two component system of a urethane prepolymer component and a urethane curative component, said urethane prepolymer component made from a hydroxyl terminated intermediate and a polyisocyanate, the equivalent ratio of said polyisocyanate to said hydroxyl terminated intermediate being from about 2 to 20 so that said prepolymer component contains free NCO groups, said urethane curative component containing a polyol curative having OH groups therein and a primary polyamine containing NH groups therein, the equivalent ratio of said free NCO groups to said OH groups of said polyol curative and said NH groups of said primary polyamine being at least 1.2, at least two surface treatment-free substrate, said substrates bonded together by said urethane adhesive.

Claim 11

A urethane adhesive composite containing treatment-free substrates therein, comprising: the urethane adhesive, said urethane adhesive being the reaction product of a two component system of a urethane prepolymer component and a urethane curative component, said urethane prepolymer component made from a hydroxyl terminated intermediate and a polyisocyanate, the equivalent ratio of said polyisocyanate to said hydroxyl terminated intermediate being from about 2 to 20 so that said prepolymer component contains free NCO groups, said urethane curative component containing a polyol curative having OH groups therein and a primary polyamine containing NH groups therein, the equivalent ratio of said free NCO groups to said OH groups of said polyol curative and said NH groups of said primary polyamine being at least 1.2, at least two surface treatment-free substrate, said substrates bonded together by said urethane adhesive.

Claim 12

A urethane adhesive composite according to claim 9, wherein said hydroxyl terminated intermediate is a polyester polyol or a polyether polyol having a number average molecular weight of from about 400 to about 10,000, wherein said polyisocyanate has the formula R(NCO) n where n is an integer of 2, 3 or 4, wherein R is an aliphatic having from 2 to about 20 carbon atoms, an aromatic or an alkyl substituted aromatic having from 6 to 20 carbon atoms, and combinations of said polyisocyanate.

Claim 13

A urethane adhesive composite according to claim 10, wherein said substrate is a treatment-free fiberglass reinforced plastic, a treatment-free metal, or a treatment-free plastic substrate.

Claim 14

A urethane adhesive composite according to claim 11, wherein said polyether polyol intermediate is made from an alkylene oxide having from 2 to 10 carbon atoms, wherein said polyester polyol intermediate is made from a polyhydric alcohol having from 2 to 15 carbon atoms and a polycarboxylic acid having from 2 to 14 carbon atoms, wherein R of said polyisocyanate is an aromatic or an alkyl substituted aromatic having from 6 to 15 carbon atoms, wherein said equivalent ratio of said polyisocyanate to said hydroxyl terminated intermediate is from about 5.0 to about 10.0, wherein the equivalent ratio of said free NCO groups and said NH groups to said OH groups of said curative is from about 1.35 to about 1.6, and wherein said polyol curative is alkyl diol having from 2 to 12 carbon atoms, a polyhydric alcohol having from 3 to 15 carbon atoms and from 3 to 8 hydroxyl groups, a carbohydrate having from 5 to 12 carbon atoms and from 4 to 10 hydroxyl groups, or combinations thereof.

Claim 15

A urethane adhesive composite according to claim 12, wherein said polyether polyol intermediate and said polyester polyol intermediate has a number average molecular weight of from about 2,000 to about 4,000, wherein said hydroxyl terminated intermediate is polypropylene ether diol, polybutylene ether diol, polytetramethylene ether, polycaprolactone diol, and combinations thereof, wherein said equivalent ratio of said free NCO groups and said OH groups to said OH groups of said curative is from about 1.35 to about 1.45, wherein said polyisocyanate is methylene diphenyl diisocyanate or toluene diisocyanate, and wherein said polyol curative is an ethylene or propylene oxide adduct of trimethylol propane, pentaerythritol, glycerol, an alkyl glucoside wherein said alkyl has from 1 to 12 carbon atoms, or combinations thereof.

Claim 16

A urethane adhesive composite according to claim 13, including a filler is said urethane prepolymer component, the amount of said filler being from about 5 parts to about 100 parts by weight for every 100 parts by weight of said prepolymer component, and including a filler in said curative component, the amount of said filler being from about 5 parts to about 100 parts by weight for every 100 parts by weight of said polyol curative.

Claim 17

A urethane adhesive composite according to claim 14, wherein said filler of said prepolymer component and said curative component independently is ground mica, talc, kaolin clay, calcium carbonate, calcium sulfite, colloidal silica, wollastonite, ballotini, hollow glass microspheres, glass, carbon fibers, graphite fibers, zinc oxide, titanium oxide, zirconium oxide, ground quartz, a metallic silicate, lead powder, aluminum powder, bronze powder, or combinations thereof, wherein the amount of said filler in said prepolymer component is from about 20 parts to about 50 parts by weight for every 100 parts by weight of said prepolymer component, and wherein the amount of said filler in said curative component is from about 30 parts to about 60 parts by weight for every 100 parts by weight of said polyol curative, said prepolymer component including from about 0.1 to about 40 parts by weight for every 100 parts by weight of a polyhydric alcohol having from 2 to 15 carbon atoms, said curative component containing from about 1 part to about 5 parts by weight for every 100 parts by weight of said primary polyamine having from 1 to 14 carbon atoms.

Claim 18

A urethane adhesive composite according to claim 14, wherein said substrate is said treatment-free fiberglass reinforced plastic.

Claim 19

A process for adhering at least one treatment-free substrate to another substrate, comprising the steps of: applying a two component urethane adhesive to at least a first treatment-free substrate, said urethane adhesive being the reaction product of a two component system of a urethane prepolymer component and a urethane curative component, said urethane prepolymer component being made from a hydroxyl terminated intermediate and a polyisocyanate, the equivalent ratio of said polyisocyanate to said hydroxyl terminated intermediate being from about 2 to 20 so that said prepolymer component contains free NCO groups, said urethane curative component containing a polyol curative having OH groups therein and a primary polyamine containing NH groups therein, the equivalent ratio of said free NCO groups to said OH groups and said NH groups of said polyol curative being at least 1.2, applying said two component urethane adhesive to at least a second substrate, and curing said two component urethane adhesive by heating.

Claim 20

A process for adhering at least one treatment-free substrate to another substrate, comprising the steps of: applying a two component urethane adhesive to at least a first treatment-free substrate, said urethane adhesive being the reaction product of a two component system of a urethane prepolymer component and a urethane curative component, said urethane prepolymer component being made from a hydroxyl terminated intermediate and a polyisocyanate, the equivalent ratio of said polyisocyanate to said hydroxyl terminated intermediate being from about 2 to 20 so that said prepolymer component contains free NCO groups, said urethane curative component containing a polyol curative having OH groups therein and a primary polyamine containing NH groups therein, the equivalent ratio of said free NCO groups to said OH groups and said NH groups of said polyol curative being at least 1.2, applying said two component urethane adhesive to at least a second substrate, and curing said two component urethane adhesive by heating.

Claim 21

A process according to claim 17, wherein said second substrate is a treatment-free substrate, wherein said hydroxyl terminated intermediate is a polyester polyol or a polyether polyol having a number average molecular weight of from about 400 to about 10,000, wherein said polyisocyanate has the formula R(NCO) n where n is an integer of 2, 3 or 4, wherein R is an aliphatic having from 2 to about 20 carbon atoms, an aromatic or an alkyl substituted aromatic having from 6 to 20 carbon atoms, and combinations of said polyisocyanate, and wherein said first and said second substrate is a treatment-free fiberglass reinforced plastic, a treatment-free metal, or a treatment-free plastic substrate.

Claim 22

A process according to claim 18, including curing said two component urethane adhesive by heating said adhesive to a temperature above 50° C., wherein said polyether polyol intermediate is made from an alkylene oxide having from 2 to 10 carbon atoms, wherein said polyester polyol intermediate is made from a polyhydric alcohol having from 2 to 15 carbon atoms and a polycarboxylic acid having from 2 to 14 carbon atoms, wherein R of said polyisocyanate is an aromatic or an alkyl substituted aromatic having from 6 to 15 carbon atoms, wherein said equivalent ratio of said polyisocyanate to said hydroxyl terminated intermediate is from about 5.0 to about 10.0, wherein the equivalent ratio of said free NCO groups to said OH groups and said NH groups of said curative is from about 1.35 to about 1.6, and wherein said polyol curative is alkyl diol having from 2 to 12 carbon atoms, a polyhydric alcohol having from 3 to 15 carbon atoms and from 3 to 8 hydroxyl groups, a carbohydrate having from 5 to 12 carbon atoms and from 4 to 10 hydroxyl groups, or combinations thereof.

Claim 23

A process according to claim 19, wherein said first and said second treatment free substrates are a fiberglass reinforced plastic.

Claim 24

A urethane adhesive capable of bonding to a treatment-free surface of plastic, fiber reinforced plastic, or metal comprising: a urethane prepolymer component made from a hydroxyl terminated intermediate and a polyisocyanate, the equivalent ratio of said polyisocyanate to said hydroxyl terminated intermediate being at least 2.0 so that said prepolymer component has free NCO groups, and a curative component having OH groups, the equivalent ratio of said free NCO groups of said prepolymer to said OH groups of said polyol curative being at least 1.2.

Claim 25

A urethane adhesive capable of bonding to a treatment-free surface of plastic, fiber reinforced plastic, or metal comprising: a urethane prepolymer component made from a hydroxyl terminated intermediate and a polyisocyanate, the equivalent ratio of said polyisocyanate to said hydroxyl terminated intermediate being at least 2.0 so that said prepolymer component has free NCO groups, and a curative component having OH groups, the equivalent ratio of said free NCO groups of said prepolymer to said OH groups of said polyol curative being at least 1.2.