Composite and laminate articles and polymerizable systems for producing the same

Abstract

A composite material comprises a reinforcing material carried in a polymer matrix material which is the polymerization product of a polymerizable composition comprising a di-activated vinyl compound, with the proviso that the di-activated vinyl compound is not a cyanoacrylate. The reinforcing materials may be a wide variety of substrates including thermally sensitive materials. Exemplary composites can be molded and cured at ambient temperatures. Also disclosed are laminate materials having layered materials adhered by curing a di-activated vinyl polymerizable composition.

What is claimed is: 
     
         1 . A laminate structure comprising:
 a substrate; and   a plurality of layers adhered to the substrate; and   wherein one or more of the plurality of layers are formed from polymerization of a polymerizable material, the polymerizable material comprising one or more of a methylene malonate monomer, a methylene betaketoester monomer, and a methylene betadiketone monomer.   
     
     
         2 . The laminate structure of  claim 1 , wherein one or more of the methylene malonate monomer, the methylene betaketoester monomer, and the methylene betadiketone monomer comprise multifunctional monomers. 
     
     
         3 . The laminate structure of  claim 1 , wherein the polymerizable material further comprises one or more of a multifunctional methylene malonate monomer, a multifunctional methylene betaketoester monomer, and a multifunctional methylene betadiketone monomer. 
     
     
         4 . The laminate structure of  claim 1 , wherein the substrate comprises a plant-based material, a plastic material, a carbon-based material, a metal material, or a glass-based material. 
     
     
         5 . The laminate structure of  claim 1 , wherein the substrate comprises paper, oak, Douglass fir, balsa, polyphenylene ether (PPE) plastic, polycarbonate (PC), silicon, glass, fiberglass, silver coated copper, copper, steel, polypropylene, biaxially oriented polypropylene, monoaxially oriented polypropylene, polyethylene, polyester, polyethylene terephthalate, biaxially oriented polyethylene terephthalate, and aluminum. 
     
     
         6 . The laminate structure of  claim 1 , wherein the polymerizable material further comprises a formulation additive. 
     
     
         7 . The laminate structure of  claim 6 , wherein the formulation additive comprises one or more of: plasticizers, thixotropic agents, adhesion promoters, antioxidants, light stabilizers, UV stabilizers, fillers, surfactants, wetting agents, viscosity modifiers, extenders, dispersants, anti-blocking agents, defoamers, air release agents, anti-sagging agents, anti-setting agents, matting agents, flattening agents, waxes, anti-mar additives, anti-scratch additives, and inert resins. 
     
     
         8 . The laminate structure of  claim 1  is a flexible composite article. 
     
     
         9 . The laminate structure of  claim 8  is a film, a packaging component, or a construction material. 
     
     
         10 . The laminate structure of  claim 1  is a rigid composite article. 
     
     
         11 . The laminate structure of  claim 10  is a structural article, a furniture article, an aerospace component, a building article, or a construction article. 
     
     
         12 . The laminate structure of  claim 1  is an automotive component. 
     
     
         13 . The laminate structure of  claim 1  is a thermally-sensitive structure. 
     
     
         14 . A method of forming a multi-layer laminate structure comprising:
 providing a substrate; and   forming a plurality of layers on the substrate; and   wherein one or more of the plurality of layers is formed by polymerization of a polymerizable material comprising one or more of a methylene malonate monomer, a methylene betaketoester monomer, and a methylene betadiketone monomer.   
     
     
         15 . The method of  claim 14 , wherein one or more of the methylene malonate monomer, the methylene betaketoester monomer, and the methylene betadiketone monomer comprise multifunctional monomers. 
     
     
         16 . The method of  claim 14 , wherein the polymerizable material further comprises one or more of a multifunctional methylene malonate monomer, a multifunctional methylene betaketoester monomer, and a multifunctional methylene betadiketone monomer. 
     
     
         17 . The method of  claim 14 , wherein the polymerizable material is cured at a temperature of about 100° C. or less. 
     
     
         18 . The method of  claim 14 , wherein the polymerizable material is cured at about ambient temperature. 
     
     
         19 . The method of  claim 14 , wherein the polymerizable material further comprises a formulation additive, the formulation additive comprising one or more plasticizers, thixotropic agents, adhesion promoters, antioxidants, light stabilizers, UV stabilizers, fillers, surfactants, wetting agents, viscosity modifiers, extenders, dispersants, anti-blocking agents, defoamers, air release agents, anti-sagging agents, anti-setting agents, matting agents, flattening agents, waxes, anti-mar additives, anti-scratch additives, and inert resins. 
     
     
         20 . The method of  claim 14 , wherein the multi-layer laminate structure is an automotive structure.