Primer

Abstract: A primer comprising at least one organo­ metallic compound, which is useful in bonding non-polar or highly crystalline substrates together or bonding another material, such as a solid material, a coating material, paint or printing ink to the resin substrate by α-cyanoacrylate.

Description: This invention relates to a process for bonding non-polar or highly crystalline resin substrates to each other or to another material This invention has its object to provide process for bonding non-polar or highly crystalline resin substrates to each other or to another material with use of an α-cyanoacrylate, the resin substrates having herefore been considered as difficult to bond together, bond the other material thereto, coat, paint and print thereon and being typified by polyethylene, polypropylene, polybutene, polyfluoroethylene, their copolymer and other polyolefin substrates as well as polyethylene terephthalate, polyacetal, nylon and soft PVC film (having a high content of a plasticizer) substrates. To render these substrates or materials improved in adhesiveness, there has heretofore been proposed a surface treating method which comprises subjecting the substrates, for example polyethylene or polypropylene, to flame treatment, corona discharge treatment, irradiation treatment or oxidizing treatment with a bichromate, sulfate or the like so as to produce polar groups such as a carbonyl group on the surface of the substrates. In addition, to make a resin, such as polyfluoroethylene, which is impossible to oxidize on the surface, improved in adhesiveness, there has been proposed a special chemical treatment such as lithium vapor treatment, heating treatment with an alkali in a helium stream or treatment of metallic sodium with liquid ammonia. However, the proposed method and treatments need special equipments, are complicated to carry out, are unable to uniformly treat every part of the surface of a substrate having a complicated shape and require great expenses, these being disadvantageous. GB-A 2 078 763 discloses a bonding method using an a-cyanoacrylate adhesive together with a so-called adhesive assistant; however, the use of a primer comprising at least one organophosphorous compound is not suggested. Various primers also have been proposed. For example, Japanese Patent Appln. Laid-Open Gazettes Nos. 52-98062, 56-141328 and 57-119929 have proposed primers prepared by dissolving a chlorinated polyethylene or chlorinated polypropylene or a fatty acid-modified acrylated alkyd resin in an organic acid. According to Japanese Pat. Appln. Laid-Open Gazette No. 58-8734, however, the primers so proposed are unsatisfactory in adhesiveness to a paint although they are satisfactory in adhesiveness to a polyolefin substrate, or, even if the paint and the polyolefin are satisfactory in adhesion to each other, the adhesiveness therebetween will undesirably decrease due to repetition of the cold/hot cycle. Japanese Pat. Appln. Laid-Open Gazettes Nos. 54-124048, 54-124049 and 54-124095 have proposed a modified polyolefin prepared by incorporating solid rubber, an unsaturated carboxylic acid or the derivative thereof, and a radical generator in a polyolefin, however, according to Japanese Pat. Appln. Laid-Open Gazette No. 57-38827, the modified polyolefin will have undesirable effects on the adhesiveness of a paint formed thereon since the unreacted unsaturated carboxylic acid and the radical generator remain in the modified polyolefin. Further, Japanese Pat. Appln. Laid-Open Gazettes Nos. 54-124050, 55-34270 and 55-84271 have proposed an improved resin composed essentially of a propylene/styrene/butadiene block copolymer and an in organic filler, however, the improved resin so proposed seems to raise various problems as to poor weatherproofness of unpainted parts and low-temperature fragility due to the incorporation of the filler. If non-polar or highly crystalline resins such as polyolefin can be improved in adhesiveness or they can allow a coating, painting or print to be satisfactorily formed on the surface thereof, they would be very conducive to various fields such as the automobile industry and electric appliance industry since they have many merits such as excellent properties, light weight, rust-proof and low cost as compared with metallic material. In attempts to develop a surface treating method which is simple and speedy as compared with the conventional methods, in view of the above-mentioned situations, the present inventors made intensive studies and, as the result of their studies, they developed the desired process for bonding non-polar or highly crystalline resin substrates to each other or to another material. This invention relates to a process using a primer comprising at least one organometallic compound, which is used in bonding non-polar or highly crystalline resin substrates together or bonding another material to the resin substrate with the use of an α-cyanoacrylate. The expression "bonding another material to the resin substrate with the use of an α-cyanoacrylate" used herein is intended to mean, for example, the use of an α-cyanoacrylate in adhesion of a solid material such as a metal, glass, a synthetic resin, rubber, leather, stone, cloth, paper, wood or ceramics to the resin substrate or the use thereof in coating or printing a resin substrate with a coating material, paint or printing ink. The primer used according to this invention is composed of one or more organometallic compounds in which the organic group is combined with a metal. Such organometallic compounds may be used in this invention irrespective of the kind, structure and the like thereof. The organic groups contained in the organometallic compounds include alkyl, cycloalkyl, haloalkyl, alkenyl, cycloalkenyl, alkoxy, cycloalkoxy, aryl, aralkyl, aralkyloxy, acetylacetate, acyloxy and cycloalkenyloxy, aryloxy group, with C₃ or higher hydrocarbon groups being preferred. The metals contained in the organometallic compounds in this invention are intended to include typical metals, transition metals and metalloids and further include phosphorus, boron and silicon. The organometallic compounds are illustrated by the following structural formulae. (1) M-O-R (wherein M is an elemental metal and R an organic group; these definitions apply to the following) which shows metal alcoholates: organoaluminum compounds such as aluminum isopropylate, aluminum mono-sec.-butoxydiisopropylate, aluminum ethylacetoacetate diisopropylate, aluminum oleylacetoacetate diisopropylate; organotitanium compounds such as tetrabutyl titanate and tetraisopropyl titanate; organoboron compounds such as tri-n-butyl borate, triphenyl borate, tri-n-octadecyl borate and monobutyldimethyl borate; phosphoric acid esters such as trioleyl phosphate, tridecyl phosphate, dibutyl phosphite, trisisodecyl phosphite, di-2-ethylhexyl phosphite and tridecyl phosphite; tetraoctyl silicate; triisobutoxygallium; and tetrabutyl zirconate. (2) which shows 1,3-dicarbonyl complexes: complex salts of acetylacetonate such as aluminum trisacetylacetonate, aluminum monoacetylacetonate bisethylacetoacetate, aluminum trisethylacetoacetate; acetylacetone lithium, acetylacetone beryllium, acetylacetone sodium, acetylacetone magnesium, acetylacetone calcium, acetylacetone titanium, acetylacetone strontium, acetylacetone barium, acetylacetone thallium, acetylacetone vanadium, acetylacetone manganese (III), acetylacetone iron (III), acetylacetone thorium, acetylacetone chromium (III), acetylacetone rhodium, acetylacetone cobalt (II), acetylacetone cobalt (III), acetylacetone nickel, acetylacetone copper, acetylacetone zinc, acetylacetone zirconium, acetylacetone palladium, acetylacetone indium, acetylacetone tin (IV) and acetylacetone molybdenum; complex salt of acetoacetic acid ester, trifluoroacetylacetone and benzoylacetone. (3) which shows carboxylates: magnesium stearate, aluminum stearate, calcium stearate, ferric stearate, zinc stearate, barium stearate, lead stearate, potassium stearate, copper stearate, manganese stearate, nickel stearate, nickel naphthenate, cobalt naphthenate, manganese naphthenate, magnesium naphthenate, zinc naphthenate, magnesium palmitate, cadmium palmitate, cobalt palmitate, sodium linoleate, sodium laurate, barium oleate, aluminum laurate, aluminum oleate, potassium oleate, aluminum acetate, stannous acetate, stannous 2-ethylhexanoate, aluminum formoacetate, zinc tartrate and basic aluminum thiodiglycolate. (4) M-R which shows hydrocarbon group-containing metals: alkyl metals such as zinc 2-ethylhexyl, lithium hexadecyl, sodium n-hexyl, potassium hexadecyl, aluminum n-trioctyl, lead n-propylethyl, antimony tri-n-pentyl, antimony tri-n-decyl and zinc isobutylisoamyl; organotin compounds such as dibutyl tin diacetate, di-n-butyl tin dimaleate, di-n-butyl tin dioxide, triphenyl tin acetate, tri-n-butyl tin oxide, dioctyl tin dilaurate, tributyl tin acetate, tributyl tin chloride, tin tetraamyl and diallyl tin dichloride; methylvinyldichlorosilane; AY43-021 (tradename of Toray Silicon Co., Ltd.); ferrocene; titanocene dichloride; and nickelocene. (5) M-X-R (wherein X is a hetero atom) shows other organometallic compounds: metal thioalcoholates such as n-dodecylmercaptopotassium salt and aluminum trithiobutoxide; thiodicarboxylates such as tin 2-ethylhexanemonothioate and zinc 2-ethylhexanedithioate; dithiocarbamates such as nickel dimethyldithiocarbamate, copper dimethyldithiocarbamate, iron dimethyldithiocarbamate and zinc diethyldithiocarbamate; sulfonic acids such as nickel benzenesulfonate; phosphates such as vanadium dibutylphosphate; and zinc mercaptobenzothiazole. Among these organometallic compounds, the carboxylates (3) and the hydrocarbon group-containing metals (4) are preferred, and the metal alcoholates (1) and the 1,3-dicarbonyl complex salts (2) are more preferred. More particularly, the preferred organometallic compounds include acetylacetone lithium, acetylacetone sodium, acetylacetone magnesium, acetylacetone titanium, acetylacetone iron (III), acetylacetone palladium, acetylacetone indium, tri-n-octadecyl borate, sodium linoleate, magnesium stearate, aluminum stearate, aluminum acetate, aluminum laurate, basic aluminum thiodiglycolate, calcium stearate, ferric stearate, ferrocene, copper dimethyldithiocarbamate, zinc stearate, zinc 2-ethylhexyl, zinc tartrate, stannous acetate, di-n-butyl tin maleate, di-n-butyl tin oxide, triphenyl tin acetate, barium stearate, lead stearate, dibutyl phosphite, tridecyl phosphate and trioleyl phosphate. The more preferred organometallic compounds include acetylacetone calcium, acetylacetone zinc, potassium oleate, nickel naphthenate and dioctyl tin dilaurate. The most preferred organometallic compounds include aluminum isopropylate, aluminum mono-sec.-butoxydiisopropylate, aluminum ethylacetoacetate diisopropylate, aluminum oleylacetoacetate diisopropylate, aluminum trisacetylacetonate, aluminum monoacetylacetonate bisethylacetoacetate, aluminum trisethylacetoacetate, acetylacetone manganese (III), acetylacetone cobalt (II), acetylacetone nickel, acetylacetone zinc, acetylacetone zirconium, tetrabutyl titanate, tetraisopropyl titanate, dibutyl tin diacetate, tri-n-butyl tin oxide, tin 2-ethylhexanoate, AY43-021 (tradename of a certain silicon compound produced by Toray Silicon Co., Ltd) and trisisodecyl phosphite. The primer composed of the organometallic compound or compounds is used for coating on a non-polar or highly crystalline resin substrates in bonding the resin substrates together or bonding another material thereto with use of α-cyanoacrylate. In this case, it is desired to control the thickness of the organometallic compounds coated so that the full effects of this invention are attained as described later. For this purpose, it is preferred that the compounds be used in solution. The solvents used herein are preferably a usual one which is capable of completely dissolving or dispersing the organometallic compound therein, has suitable volatility and is industrially easily available. The solvents are also preferably such that a resin, such as polyolefin, can be fully wetted on the surface therewith, in order to allow the primers to exercise their performance more efficiently. For this purpose, it is further preferable to selectively use an organic solvent which has a surface tension lower than the critical surface tension γc of the resin. The following Table indicates the surface tension and the critical surface tension of typical solvents to help one skilled in the art in selecting a solvent to be used. Critical surface γc of resin (dyne/cm. 20°C) Surface tension of organic solvent (dyne/cm. 20°C) Polytrifluoroethylene 22 1,1,2-trichloro-1,1,2-trifluoroethane 19 Polyethylene 31 Ethanol 22 Polypropylene 31 Acetone 23 Polyacetal 40 Ethyl acetate 24 Polyvinylidene chloride 40 1,1,1-trichloroethane 26 Polyethylene terephthalate 43 Tetrahydrofuran 26 6-6 nylon 46 1,4-dioxane 27 Toluene 28 It is preferable that a solution of the organometallic compound in a solvent be in a concentration by weight of 0.001-10% for the reason that the organometallic compound may be coated to nearly thickness of monomolecular layer thereof whereby the compound can exhibit its best performance as described later. The α-cyanoacrylate used in this invention is represented by the following general formula wherein R is alkyl, alkenyl, cycloalkyl, aryl, alkoxyalkyl, aralkyl, haloalkyl or the like and more particularly it is illustrated by methyl, ethyl, n-propyl, n-butyl, isobutyl, n-pentyl, allyl, cyclohexyl, benzyl or methoxypropyl. The α-cyanoacrylates used herein are the main component of commercially available cyanoacrylate-based instant adhesives which may be used as they are, as α-cyanoacrylate in this invention. The commercially available cyanoacrylate-based adhesives are composed mainly of α-cyanoacrylate and may be further incorporated with various ingredients as illustrated below: (1) Stabilizer (2) Thickener (3) Modifier (4) Dyestuff The stabilizer is for enhancing the storage stability of the cyanoacrylate-based adhesives and is illustrated by sulfur dioxide, an aromatic sulfonic acid or a sultone as an anion polymerization inhibitor and by hydroquinone or hydroquinone monomethyl ether as a radical polymerization inhibitor. The thickener used herein is for increasing the viscosity of the cyanoacrylate-based adhesives to several ten to several thousand cp since usually α-cyanoacrylate is a low viscous liquid having a viscosity of about several cp. The thickener used herein includes a polymethylmethacrylate, acryl rubber or cellulose derivative. The modifier used herein is for improving the impact resistance or heat resistance which are drawbacks of conventional cyanoacrylate-based adhesives and is illustrated by maleic anhydride or a derivative thereof as an improver of heat resistance as indicated in Japanese Pat. Appln. Gazette No. 52-12737. To enable a porous and acidic sap-containing woody material which has heretofore been considered difficult to bond, to be bonded, crown compounds and the like may be used as indicated in, for example, Japanese Pat. Appln. Publication Gazette No. 55-2238. Further, to provide a flexible adhesive layer, the original adhesive may be incorporated with a plasticizer such as tricresyl phosphate, dioctyl phthalate or dimethyl sebacate. The dyestuff used herein is for, for example, rendering a bonded portion easily identifiable, the original adhesive may be incorporated with, for instance, an acidic salt of basic dye as indicated in Japanese Pat. Appln. Laid-Open Gazette No. 53-37260 or the like. Furthermore, the original adhesive may further be incorporated with a perfume such as an ester derivative as indicated in Pat. Appln. Laid-Open Gazette No. 53-58541 or the like, in order to provide the adhesive with fragrance. In the practice of this invention, the α-cyanoacrylate may be used in the form of a diluted solution in a specific organic solvent. The organic solvent should be such that it is compatible with the α-cyanoacrylate and does not impair the stability thereof, and it includes toluene, butyl acetate or methylchloroform. It is preferred that the organic solvent contains none of moisture and other impurities. In a case where two substrates to be bonded together are each a non-polar or highly crystalline resin, coating of the organometallic compound may be effected by immersing the both of the substrate in a solution of the primer for several seconds or coating it with the solution of the use of a brush or spray gun and then air drying, while in a case where one of substrates to be bonded together is a non-polar or highly crystalline resin, the substrate may be treated only in the same manner as above. The primer coated non-polar or highly crystalline resin substrates together or another material and the substrate are bonded using the α-cyanoacrylate by a usual means, thus obtaining a bonded body having very excellent bond strength. In the coating method of the primer, there may also be used a method which comprises coating a mixture of the α-cyanoacrylate and the organometallic compound on a substrate with or without using organic solvent, or a method which comprises ejecting an α-cyanoacrylate and a solution of the organometallic compound simultaneously by the use of spray gun having two nozzles. In the former method, full care must be taken to prevent moisture, amines, alcohols and other foreign matters from mixing in the mixture since the α-cyanoacrylate specifically has a strong anionic activity. In a process for forming a coating, painting or printing on a non-polar or highly crystalline resin substrate, the primer is coated on the resin substrate by the above-mentioned coating method, and then an α-cyanoacrylate is coated and polymerized to form a polymer film thereof, thus producing a resin substrate having satisfactory receptivity and bond strength to coating materials, paints and printing ink. The thus produced resin substrates may be coated or printed by a conventional means to form an excellent coating, painting and printing thereon. In the coating steps the following steps will show more excellent effects in coatings. In a first step, a primer prepared by dissolving the organometallic compound in an organic solvent, is coated on a substrate on which a coating, painting or printing is to be formed by an immersing or spraying method and being laid usually 5-60 minutes at room temperature or several days depending on the operational steps taken. In a second step, the α-cyanoacrylate is coated on the primer-coated substrate to form a poly-α-cyanoacrylate film, by a coating method using a preliminarily acid-treated brush, an immersing method, a spraying method, or the like. In a case there the spraying method is used, it is preferred to use a diluted solution of α-cyanoacrylate in an organic solvent in order to prevent the nozzles of spray gun from being clogged. In addition, in a case there a commercially available cyanoacrylate-based adhesive is used, it is preferable to choose the low viscosity one. The substrate on which the α-cyanoacrylate has been coated is allowed to stand at room temperature for at least 12 hours to form a poly-α-cyanoacrylate film. The poly-α-cyanoacrylate film is not particularly limited in thickness, but it is preferable that the thickness be in the range of 0.1-100 µ, preferably 10-50 µ to eliminate defective coated portions. The substrate on which the primer and α-cyanoacrylate have been coated as indicated above, is then coated with a usual coating material, painted with a paint or printed with a usual printing ink. There are various kinds of coating materials, paints or printing inks which may be classified in various ways, however, they may be enumerated from the view-point of the kind of vehicle resin used, as follows: rosin derivatives, nitrocellulose resins, vinylic resins, acrylic resins, polyester resins, polyamide resins, polyurethane resins, phenolic resins, epoxy resins, aminoalkyd resins, melamine resins and UV-curable acryl oligomers. From the view-point of use, particularly preferred coating materials, paints or printing inks for use in applying to a polyolefin substrate are those containing a polyurethane resin, an epoxy resin, or an alkyd resin. As to thermosetting coating materials, those which may be cured at a baking temperature of not higher than 90°C are preferred. A coating material or a paint may be applied by a usual method such as a coating method using a brush, a bar coater, a roller coater or a spray gun, while a printing ink may be applied by a usual method such as a silk screen printing method, a gravure printing method or a flexographic printing method. It is not clear why the adhesiveness of a non-polar or highly crystalline resin to another material is improved by using the organometallic compound according to this invention as the primer and the α-cyanoacrylate, however, the organometallic compounds will exhibit their best primer performance when they are very thinly coated to an extent that the amount thereof coated reaches 0.001 to 1 g/m² although the optimum thickness varies depending on the kind of the organometallic compound used. Bonding tests were made by using a polypropylene plate (2 mm thick) as the resin substrate, acetylacetone zirconium (used as solutions of various concentrations in methylchloroform) as the primer, and an α-cyanoacrylate-based adhesive (produced under the tradename of Aron Alpha No. 201 by Toagosei Chemical Industrial Co., Ltd.), to obtain bonded products which were measured for tensile shear strength at the bonded portion. The following Table A indicates the differences in tensile shear strength due to the differences in amount of the primer coated. The bonded products were aged at 23°C under a relative humidity (RH) of 60% for one day. Conc. of primer (wt.%) Amount of primer coated (g/m²) Tensile shear strength (Kgf/cm²) 5 0.5-2.5 3 3 0.3-1.5 10 1 0.1-0.5 15 0.5 0.05-0.25 36 0.25 0.025-0.125 55* 0.05 0.005-0.025 60* 0.025 0.0025-0.0125 27 0.01 0.001-0.005 11 0.001 0.0001-0.0005 3 Note: The symbol, *, indicates the destruction of plate. It is seen from the results in Table A that the primer will exhibit its best performance then it is coated in nearly the thickness of its monomolecular layer. From the above results and the fact that the organometallic compounds have a polar segment and non-polar segment in structure, it is surmised that the effects of this invention are produced under the following mechanism. The organometallic compound, that is, the primer according to this invention is present in approximately the monomolecular layer between the surface of the non-polar or highly crystalline resin substrate and the α-cyanoacrylate layer (monomer or polymer film layer) whereby the groups highly compatible with the α-cyanoacrylate layer, in other words, the lipophilic groups and the polar groups are arranged in order and these groups act as a bonding agent to obtain the effects of this invention. To obtain the best results in accordance with this invention, it is necessary to determine an organometallic compound to be used, the concentration of the compound, the amount thereof applied, and the like in view of the nature of the organometallic compound, a substrate and a material to be bonded thereto. As to the amount of the organometallic compound (primer) applied, the use of the primer in such a small amount that the resulting primer layer does not cover all the surface of the substrate which is needed, will naturally not give good results, whereas the use thereof in such a large amount that the resulting primer layer is thicker than the monomolecular layer, will result in forming a fragile primer layer whereby the results of this invention are not obtained. Thus, the concentration of solution of an organometallic compound (primer solution) is preferably 0.001-10% by weight and the amount of the primer coated is in the range of preferably 0.001-1 g/m², more preferably 0.01-0.1 g/m². A secure bond is effected between a non-polar or highly crystalline resin substrate and an α-cyanoacrylate with aid of the organometallic compound present therebetween whereby the resin substrate is much improved in adhesiveness and, further, a usual coating material or printing ink can easily be applied to the treated resin substrate without causing any problems owing to the presence of a poly-α-cyanoacrylate film formed thereon. The excellent effects obtained by the practice of this invention are those which may be attained by the combined use of the α-cyanoacrylate, organometallic compound and non-polar or highly crystalline resin substrate. On the other hand, in cases where a bond is attempted to be effected between polyolefin (such as polyethylene) and something, an organotitanium compound was once studied to find whether it is useful as a primer or preliminary treatment; in these cases, however, excellent effects were not appreciated since an epoxy, urethane, rubber or acrylic adhesive was used. These conventional means do not anticipate at all the present invention which will unexpectedly excellent effects when practiced. The effects of this invention will be exhibited only when a non-polar or highly crystalline resin is used as the substrate, whereas they will not be exhibited when other materials (such as a metal, wood or porcelain) are used as the substrate. Using the primer according to this invention is effective for a non-polar or highly crystalline resin such as polyethylene terephthalate, polyacetal or nylon and is particularly effective for polyolefin such as polyethylene and polypropylene. This invention will be better understood by the following Examples and Comparative Examples. Example 1 and Comparative Example 1 0.3 g of each of aluminum mono-sec. butoxydiisopropylate, aluminum monoacetylacetonate diethylacetoacetate and aluminium trisethylacetoacetate were dissolved in 99.7 g of 1,1,1-trichloroethane to prepare a primer solution. Two pieces, 25 x 100 x 0.2 mmt, of a polyethylene film were each brushed on one face with each of the thus prepared primer solutions and air dried for about 5 minutes. Thus the primer coated film pieces were bonded together about one half (1/2) of its length with Aron Alpha No. 221 (Trade name, cyanoacrylate-based adhesive produced by Toagosei Chemical Industrial Co., Ltd.), and were then aged under a compressive load of 0.1 Kgf/cm² at room temperature for 24 hours to obtain a test piece. The test pieces so obtained were each measured for peel bond strength at a pulling rate of 100 mm/min. using a Strograph W-type tester in accordance with JIS K6854-1977 (Example 1). For comparison, the above procedure was followed except that the primer was not used (Comparative Example 1). The results are as shown in Table 1. Example 2 and Comparative Example 2 One gram of each of aluminum isopropylate and aluminum ethylacetoacetate diisopropylate was dissolved in 99 g of toluene to prepare a primer solution. Two pieces, 12.7 mm square x 38 mm, of each of polyethylene, polypropylene and polyacetal were ground with a smooth-cut plain file to obtain pieces having a smooth ground face. The thus obtained pieces were brushed with the primer solution and air dried for about 10 minutes. In each of the polymers coated with different primers, the two primer coated pieces were bonded together with Aron Alpha No. 201 (cyanoacrylate-based adhesive produced by Toagosei Chemical Industrial Co., Ltd.), and were then aged under a compressive load of 0.1 Kgf/cm² at room temperature for 24 hours. The thus obtained test pieces were measured for tensile bond strength at a pull rate of 20 mm/min. using a Strograph W-type tester in accordance with JIS K6861-1977. For comparison, the above procedure was followed except that the primer was not used (Comparative Example 2). The results are as shown in Table 2. Example 3 and Comparative Example 3 0.5 g of each of aluminum oleylacetoacetate diisopropylate, aluminum isopropylate and aluminum ethylacetoacetate diisopropylate were dissolved in 99.5 g of 1,1,2-trichloro-1,2,2-trifluoroethane to prepare a primer solution. The two film pieces were treated and tested in the same manner as in Example 1 except using 25 x 100 x 0.1 mmt of a polytrifluoroethylene and Aron Alpha No. 221F (cyanoacrylate-based adhesive produced by Toagosei Chemical Industrial Co., Ltd.). For comparison, the above procedure was followed except that the primer was not used (Comparative Example 3). The results are as shown in Table 3. Example 4 and Comparative Example 4 0.5 g of aluminum oleylacetoacetate diisopropylate were dissolved in 99.5 g of each of ethanol, ethyl acetate and tetrahydrofuran to prepare a primer solution. Thereafter, the two film pieces were treated and tested in the same manner as in Example 1 except using 25 x 100 x 0.5 mmt of a PVC film and Aron Alpha No. 201. For comparison, the above procedure was followed except that a primer was not used (Comparative Example 4). The results are as indicated in Table 4. Example 5 and Comparative Example 5 The primers, polyolefin substrates and α-cyanoacrylate used were as follows: 1. Primers (1) Acetylacetone zirconium (2) Acetylacetone manganese (III) (3) Acetylacetone nickel 0.2 g of each of the above compounds, that is primers, were dissolved in 99.8 g of toluene to prepare a primer solution. 2. Substrates to be bonded (1) Polyethylene plate (25 x 100 x 2 mm) (2) Polypropylene plate (25 x 100 x 2 mm) (3) Polybutene plate (25 x 100 x 2 mm) 3. α-cyanoacrylate Aron Alpha No. 201 The procedure of Example 2 was followed except that different primers were used (Example 5). For comparison, the above procedure was followed except that a primer was not used (Comparative Example 5). The results are as shown in Table 5. Example 6 and Comparative Example 6 The primers, substrates to be bonded, and α-cyanoacrylate used were as follows: 1. Primers (1) di-n-butyltin diacetate (2) ferric stearate (3) trisisodecyl phosphite 0.3 g of each of the above compounds (1) to (3) was dissolved in 99.7 g of methylchloroform to prepare a primer solution. 2. Substrates to be bonded (1) polyacetal plate (25 x 100 x 3 mm) (2) Polyurethane plate (25 x 100 x 3 mm) (3) Ethylene-propylene-terpolymer (25 x 100 x 3 mm) 3. α-cyanoacrylate Aron Alpha No. 221 The procedure of Example 5 was followed, but varying the materials used (Example 6). For comparison, the above procedure was followed except that the primer was not used (Comparative Example 6). The results are as shown in Table 6. Example 7 and Comparative Example 7 The primers, substrate to be bonded, and α-cyanoacrylate used were as follows: 1. Primers (1) Acetylacetone cobalt (III) (2) Acetylacetone zinc 0.5% of each of the above primers was dissolved in 99.5 g of 1,1,2-trichloro-1,1,2-trifluoroethane to prepare a primer solution. 2. Substrates to be bonded Teflon film 25 x 100 x 0.1 mm 3. α-cyanoacrylate Aron Alpha No. 221F The procedure of Example 5 was followed, but varying the materials used (Example 7). For comparison, the above procedure was followed except that a primer was not used (Comparative Example 7). The results are as shown in Table 7. Example 8 and Comparative Examples 8-9 The primers, substrate to be bonded, and α-cyanoacrylate used were as follows: 1. Primers (1) Tetraisopropyl titanate (2) Tetrabutyl titanate 0.5 g of each of the above primers were dissolved in 99.5 g of methylchloroform to obtain a primer solution. 2. Substrate to be bonded (1) Polypropylene plate (25 x 100 x 2 mm) 3. α-cyanoacrylate Aron Alpha No. 201 The procedure of Example 5 was followed, but varying the materials used (Example 8). For comparison, the above procedure was followed except that a two-liquid type epoxy adhesive (commercially available) was substituted for the Aron Alpha No. 201 (Comparative Example 8) and it was also followed except that a primer was not used (Comparative Example 9). The results are as indicated in Table 8. Comparative Examples 10-12 The procedures of Example 8 and Comparative Examples 8 and 9, were each followed except that a chromium-plated steel plate, 25 x 100 x 1.6 mm, was substituted for the polypropylene plate. The results are as shown in Table 9. Example 9 and Comparative Examples 13-15 The primers, α-cyanoacrylate, substrate and paints used were as follows: 1. Primers (1) Acetylacetone magnesium (2) Acetylacetone copper (3) Di-n-butyltin dimaleate (4) Aluminum oleinate (5) Cobalt palmitinate 0.1 g of each of the above primers was dissolved in 99.9 g of tetrahydrofuran to obtain a primer solution. 2. α-cyanoacrylate Fifty (50) grams of ethyl α-cyanoacrylate were uniformly dissolved in 50 g of n-butyl acetate to prepare a solution of α-cyanoacrylate. Note: This solution also contained 100 ppm of sulfur dioxide gas and 500 ppm of hydroquinone. 3. Paints (1) Nitrocellulose lacquer enamel (blue color) spray type (produced by Nippon Paint Co., Ltd.) (2) Acryl resin-based paint (yellow color) (produced by Toagosei Chemical Industrial Co., Ltd.) (3) Polyurethane-based paint, two-liquid type (brown color) (produced by Chugoku Paint Co., Ltd.) 4. Substrate Polypropylene plate (100 x 100 x 2 mm) First of all, the substrate was brushed on the surface with each of the primer solutions and air dried for 10 minutes. The primer coated substrate was further coated uniformly with the α-cyanoacrylate solution by the use of a spray gun and allowed to stand at room temperature for 24 hours. The obtained substrate was uniformly painted by spraying method with each of the paints then allowed to stand at room temperature for three days. The adhesion of the paint was evaluated by a cross-cut peel test in accordance with JIS K5400-1979 after the paint had been subjected to an exposure test at room temperature and under the following specific environmental conditions. Environmental exposure conditions: (1) UV/Wet cycle A cycle of UV-60°C/4 hours and Steam-40°C/4 hours was repeated 25 times. Apparatus: UVCON Tester (manufactured by Toyo Seiki Co., Ltd.) (2) Heat resistance Heated in air at 80°C for 24 hours. Apparatus: Labooven (manufactured by Tabai Seisakusho Co., Ltd.) (3) Waterproofness Immersed in tap water at room temperature for 24 hours. (4) Hot/cold impact A cycle of -20°C/l hr and 60°C/l hr was repeated 30 times. Apparatus: TSC-10A Model (manufactured by Tabai Seisakusho Co., Ltd.) The results are as indicated in Table 10. The performance of the overcoat in Example 9 was compared as follows. The procedure of Example 9 was followed except that a primer and α-cyanoacrylate were not used (Comparative Example 13). The procedure of Example 9 was followed except that a primer was not used (Comparative Example 14) and it was also followed except that an α-cyanoacrylate was not used (Comparative Example 15). The adhesion of the paints of Comparative Examples 13-15 are shown in comparison with that of Example 9 in Table 10. Example 10 and Comparative Examples 16-18 The primer, α-cyanoacrylate, paints and substrate used were as follows: 1. Primer A solution of 0.2 g aluminum isopropylate in 99.8 g toluene. 2. α-cyanoacrylate Ethyl α-cyanoacrylate (containing a stabilizer, 50 ppm of sulfur dioxide gas and 100 ppm of hydroquinone) 3. Paints (1) Nitrocellulose-based lacquer enamel (blue color) spray type (produced by Nippon Paint Co., Ltd.) (2) Nitrocellulose-based lacquer enamel (white color) spray type (produced by Kansai Paint Co., Ltd.) (3) Nitrocellulose-based lacquer enamel (yellow color) spray type (produced by Kansai Paint Co., Ltd.) 4. Substrate Polyethylene plate 100 x 100 x 2 mm The procedure of Example 9 was followed except for immersion in the α-cyanoacrylate and being allowed to stand for 7 days after painted. The painted bodies so obtained were measured for strength of bond between the paint and polyethylene substrate by a cross-cut peel test in accordance with JIS D0202. Comparative Example 16 The procedure of Example 10 was followed except that neither a primer nor an α-cyanoacrylate was used. Comparative Example 17 The procedure of Example 10 was followed except that the use of a primer was omitted. Comparative Example 18 The procedure of Example 10 was followed except that the use of an α-cyanoacrylate was omitted. The results are as indicated in Table 11. Example 11 The primers, α-cyanoacrylate, paints and substrate used were as follows: 1. Primers Aluminum monoacetylacetonate bis-ethylacetoacetate Aluminum ethylacetoacetate diisopropylate Aluminum trisethylacetoacetate Aluminum oleylacetoacetate diisopropylate 0.3 g of each of the above primers was dissolved in 99.7 g of methylchloroform to prepare a primer solution. 2. α-cyanoacrylate Isopropyl α-cyanoacrylate (containing 50 ppm of sulfur dioxide gas and 100 ppm of hydroquinone as a stabilizer) 3. Paint Acryl resin-based paint (yellow color) (produced by Toagosei Chemical Industrial Co., Ltd.) 4. Substrate Polypropylene plate, 100 x 100 x 2 mm The polypropylene plate was coated with each of the primers by the use of a brush and air dried for 5 minutes. The thus primer coated plate was immersed in the α-cyanoacrylate, soon withdrawn and allowed to stand at room temperature for 24 hours. Thereafter, the thus treated plate was brushed with the paint and then allowed to stand at room temperature for 7 days. The results are as shown in Table 12. Coating on Polypropylene Plate Primer Paint Cross-cut peel test 0.3% solution of aluminum monoacetylacetonate bisethylacetoacetate in methylchloroform Acryl resin-based paint (yellow color) 100/100 0.3% solution of aluminum ethylacetoacetate diisopropylate in methylchloroform Ditto 100/100 0.3% solution of aluminum trisethylacetoacetate in methylchloroform Ditto 100/100 0.3% solution of aluminum oleylacetoacetate diisopropylate in methylchloroform Ditto 100/100 Example 12 The primers, α-cyanoacrylate, paint and substrate used were as follows: 1. Primer A solution of 0.5 g aluminum mono-sec. butoxydiisopropylate in 99.5 g ethyl acetate. 2. α-cyanoacrylate A uniform mixture of 50 g isobutyl α-cyanoacrylate and 50 g ethyl acetate which contained 100 ppm of sulfur dioxide gas and 200 ppm of hydroquinone as stabilizers. 3. Paint Polyurethane-based paint, two-liquid type (brown color) (produced by Chugoku Paint Co., Ltd.) 4. Substrate Polypropylene plate, 100 x 100 x 2 mm The substrate, the polypropylene plate, gas brushed with the primer and air dried for 5 minutes. The plate so treated was uniformly coated with α-cyanoacrylate by a spray gun and allowed to stand at room temperature for 24 hours. Thereafter, the polypropylene plate was coated uniformly with the paint and then allowed to stand at room temperature for 7 days. The thus obtained painted product was subjected to a cross-cut peel test and an environmental exposure test to observe whether blisters, cracks and peeling were caused in the paint coat, thereby evaluating the performance thereof. The results are as shown in Table 13.

Claims: Process for bonding non-polar or highly crystalline resin substrates to each other or to another material, characterized in that a primer comprising at least one organophosphorus compound and an alpha-cyanoacrylate as the adhesive is used. Process according to Claim 1, wherein the organophosphorus compound is a compound selected from the group consisting of trioleyl phosphate, tridecyl phosphate, dibutyl phosphite, trisisodecyl phosphite, di-2-ethylhexyl phosphite, tridecyl phosphite. Process according to claim 1 or 2, wherein the α-cyanoacrylate is a compound represented by the formula wherein R is an alkyl, alkenyl, aryl, alkoxyalkyl, aralkyl or haloalkyl. Process according to any of the preceding claims, wherein the non-polar or highly crystalline resin substrate is a polyolefin, polyfluoroolefin, polyethylene terephthalate, polyacetal, nylon or plasticizer-rich soft polyvinyl chloride substrate. Process according to one of the preceding claims, wherein the solution of a organophosphorus compound is a 0.001 - 10 wt.% solution thereof. Process according to one of the preceding claims, wherein the resulting poly-α-cyanoacrylate film has a thickness of 0.1 - 100 µ. Process according to claim 6, wherein the poly-α-cyanoacrylate film has a thickness of 10 - 50 µ. Process according to any preceding claim, wherein the amount of primer is 0.001 - 1 g/m². Process according to claim 8, wherein the amount of primer is 0.01 - 0.1 g/m².

Inventors: ITO KENJI C O TOAGOSEI CHEMICA, KIMURA KAORU C O RESEARCH INST, ITO, KENJI, C/O TOAGOSEI CHEMICAL, KIMURA, KAORU C/O RESEARCH INSTITUTE TOAGOSEI CHEM
Applicants: TOAGOSEI CO LTD, TOAGOSEI CO., LTD.
Application year: 1984
Main classification: C08J5
IPC codes: C08J7, C08J5