Adhesive compositions for bonding and filling large assemblies

Abstract

Adhesive composition for bonding and filling large assemblies, including a mixture of about 5 percent to about 75 percent by weight of a thermoplastic polymer, about 0.5 percent to about 35 percent by weight of a polyester resin or vinyl ester resin, and about 20 percent to about 80 percent by weight of an alkyl acrylate or methacrylate monomer.

The invention claimed is: 
     
       1. A polymerizable adhesive or filling composition comprising
 about 5 to about 75 percent, by weight, of a blend of 
 a) at least one crosslinked or partially crosslinked polymer or elastomer, and 
 b) at least one soluble thermoplastic polymer or elastomer, 
 about 0.5 to about 35 percent, by weight, of a vinyl ester resin derived from the reaction product of a polyepoxide and an unsaturated monocarboxylic acid and the subsequent addition of a styrene monomer, and 
 about 20 to about 80 percent of an alkyl acrylate or methacrylate monomer. 
 
     
     
       2. The polymerizable adhesive or filling composition of  claim 1  wherein the alkyl acrylate or methacrylate monomers comprise a C1-C6 acrylate or methacrylate monomer selected from the group consisting of methyl methacrylate, ethyl methacrylate, hydroxyethyl methacrylate, propyl methacrylate, hydroxypropyl methacrylate, butyl methacrylate, hexyl methacrylate, cyclohexyl methacrylate, methyl acrylate, ethyl acrylate hydroxyethyl acrylate, propyl acrylate, hydroxypropyl acrylate, butyl acrylate, hexyl acrylate, cyclohexyl methacrylate, or mixtures thereof. 
     
     
       3. The polymerizable adhesive or filling composition of  claim 1  further comprising from about 0.01 to about 20 percent by weight of a polymerizable organic acid monomer or oligomer. 
     
     
       4. The polymerizable adhesive or filling composition of  claim 3  wherein the polymerizable organic acid monomer comprises methacrylic acid or acrylic acid or mixtures thereof. 
     
     
       5. The polymerizable adhesive or filling composition of  claim 3  wherein the polymerizable organic acid monomer is selected from the group consisting of maleic acid, fumaric acid, itaconic acid and mixtures thereof. 
     
     
       6. The polymerizable adhesive or filling composition of  claim 3  wherein the polymerizable organic acid monomer or oligomer comprises a vinyl substituted phosphate ester. 
     
     
       7. The polymerizable adhesive or filling composition of  claim 1  further comprising from about 0.1 to about 10 percent by weight of a viscosity control agent. 
     
     
       8. The polymerizable adhesive or filling composition of  claim 1  further comprising one or more materials selected from the group consisting of catalysts, initiators, reducing agents, activators, and promoters and mixtures thereof. 
     
     
       9. The polymerizable adhesive or filling composition of  claim 1  further comprising an organic sulfonyl chloride or a chlorosulfonated polymer and a dihydropyridine. 
     
     
       10. The polymerizable adhesive or filling composition of  claim 1  further comprising at least 0.5 percent, by weight, of a polyester resin. 
     
     
       11. The polymerizable adhesive or filling composition of  claim 10  wherein the polyester resin is selected from the group consisting of orthophthalic, isophthalic, terephthalic, halogenated polyester resins and mixtures thereof. 
     
     
       12. The polymerizable adhesive or filling composition of  claim 1  further comprising at least 0.5 percent, by weight, of a dicyclopentadiene resin. 
     
     
       13. The polymerizable adhesive or filling composition of  claim 1  further comprising at least 0.5 percent, by weight, of an orthophthalic resin. 
     
     
       14. The polymerizable adhesive or filling composition of  claim 1  wherein the crosslinked or partially crosslinked polymer comprises a core-shell impact modifier. 
     
     
       15. The polymerizable adhesive or filling composition of  claim 14  wherein the core-shell impact modifier is selected from the group consisting of methacrylate butadiene styrene (MBS), acrylonitrile butadiene styrene (ABS), and an acrylic based or ethylene propylene core-shell impact modifier. 
     
     
       16. The polymerizable adhesive or filling composition of  claim 1  wherein the crosslinked or partially crosslinked polymer is selected from the group consisting of a crosslinked polychloroprene elastomer, a crosslinked butadiene acrylonitrile elastomer, and a crosslinked acrylate polymer or terpolymer and mixtures thereof. 
     
     
       17. The polymerizable adhesive or filling composition of  claim 1  wherein the soluble thermoplastic polymer or elastomer comprises a diene based polymer comprising butadiene or isoprene, including liquid polymers and copolymers of butadiene. 
     
     
       18. The polymerizable adhesive or filling composition of  claim 17  wherein the diene based polymer or elastomer comprises a copolymer of butadiene, isoprene, or a combination of butadiene or isoprene with styrene, acrylonitrile or an acrylic monomer. 
     
     
       19. The polymerizable adhesive or filling composition of  claim 1  wherein the soluble thermoplastic polymer or elastomer comprises a block copolymer of butadiene, isoprene, or mixtures of butadiene and isoprene, ethylene-propylene or ethylene-butylene with styrene. 
     
     
       20. The polymerizable adhesive or filling composition of  claim 1  wherein the alkyl acrylate monomer comprises a higher molecular weight monofunctional or polyfunctional monomer. 
     
     
       21. The polymerizable adhesive or filling composition of  claim 20  wherein the monomer comprises lauryl methacrylate. 
     
     
       22. A polymerizable adhesive or filling composition comprising
 1) from about 5 percent to about 75 percent, by weight, of a blend of polymers comprising
 a. a soluble component comprising non-crosslinked thermoplastic polymers selected from the group consisting of polychloroprene elastomers, nitrile elastomers, acrylic elastomers and copolymers, copolymers and multipolymers containing acrylonitrile, styrenic and acrylic monomers, acrylonitrile butadiene styrene resins, diene-based polymers, copolymers and multipolymers based on butadiene, isoprene, ethylene-propylene and ethylene-butylene in combination with styrene, acrylonitrile and acrylic monomers, block copolymers, chlorinated polyethylenes, chlorosulfonated polyethylenes, and reactive liquid polymers, and 
 b. an insoluble or partially soluble core shell impact modifier, 
   2) from 0.5 to 35 percent by weight of a component selected from the group consisting of
 a. an unsaturated polyester resin derived from maleic acid, fumaric acid, phthalic acid, orthophthalic acid and isophthalic acid, 
 b. a terminally unsaturated vinyl ester resin derived from a polyepoxide, and 
 c. mixtures of the above, and 
   3) from 20 to 80 percent by weight of an alkyl acrylate or methacrylate monomer.   
     
     
       23. The polymerizable adhesive or filling composition of claim 22, comprising from 10 to 60 percent by weight of the blend, from 1 to 25 percent by weight of the unsaturated polyester resin or vinyl ester resin and from 30 to 80 percent by weight of the alkyl acrylate or methacrylate monomer. 
     
     
       24. The polymerizable adhesive or filling composition of claim 22, comprising from 15 to 50 percent by weight of the blend, from 2 to 20 percent by weight of the unsaturated polyester resin or vinyl ester resin and from 40 to 70 percent by weight of the alkyl acrylate or methacrylate monomer. 
     
     
       25. The polymerizable adhesive or filling composition of claim 22, further comprising from 0.01 to 20 percent by weight of a polymerizable organic acid monomer or oligomer. 
     
     
       26. The polymerizable adhesive or filling composition of claim 25, wherein the polymerizable organic acid monomer comprises methacrylic acid or acrylic acid or a mixture thereof. 
     
     
       27. The polymerizable adhesive or filling composition of claim 25, wherein the polymerizable organic acid monomer is selected from the group consisting of maleic acid, fumaric acid, itaconic acid and mixtures thereof. 
     
     
       28. The polymerizable adhesive or filling composition of claim 25, wherein the polymerizable organic acid monomer comprises a vinyl substituted phosphate ester. 
     
     
       29. The polymerizable adhesive or filling composition of claim 22, further comprising from 0.1 to 10 percent by weight of a viscosity control agent. 
     
     
       30. The polymerizable adhesive or filling composition of claim 22, further comprising one or more materials selected from the group consisting of catalysts, initiators, reducing agents, activators, promoters and mixtures thereof. 
     
     
       31. The polymerizable adhesive or filling composition of claim 22, further comprising a component selected from the group consisting of a chlorosulfonated polymer, an organic sulfonyl chloride and a dihydropyridine. 
     
     
       32. The polymerizable adhesive or filling composition of claim 22, further comprising a component selected from the group consisting of a hydroperoxide, a chelator, an organometallic salt and an aromatic amine.