CA2195790C - Multi-layer compositions having a fluoropolymer layer - Google Patents
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- CA2195790C CA2195790C CA002195790A CA2195790A CA2195790C CA 2195790 C CA2195790 C CA 2195790C CA 002195790 A CA002195790 A CA 002195790A CA 2195790 A CA2195790 A CA 2195790A CA 2195790 C CA2195790 C CA 2195790C
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Abstract
A method for increasing the adhesion of a first layer comprising fluoropolym er to a second layer comprising a melt-processable, substantially non-fluorinated polymer is disclosed. The method comprises mixing, preferably in a melt an aliphatic di- or polyamine of less than 1,000 molecular weight with the melt-processable, substantially no n- fluorinated polymer. The resulting multi-layer compositions and articles comprising the composition are also disclosed.
Description
s~r~'°~ 2i9~790 Multi-Layer Compositions Having a Fluoropolymer Layer FIELD OF THE INVENTION
The invention relates to multi-layer compositions comprising a fluoropolymer layer, in particular, a fluoropolymer comprising interpolymerized units derived from vinylidene fluoride. In another aspect, this invention relates to methods of improving the adhesion between the fluoropolymer layer and other dissimilar materials, such as polyamides, polyurethanes, and polyolefins.
BACKGROUND OF THE INVENTION
Fluorine-containing polymers, or fluoropolymers, are an important class of polymers and include for example, fluoroelastomers and fluoroplastics. Within this class are polymers of high thermal stability and usefulness at high temperatures, and extreme toughness and flexibility at very low temperatures. Many of these polymers are almost totally insoluble in a wide variety of organic solvents.
See, for exampIeF.W. Billmeyer, Textbook ofPolvmer Science_3rd ed., pp. 398-403, John Wiley & Sons, New York (1984).
Fluoroelastomers, particularly the copolymers of vinylidene fluoride with other ethylenically unsaturated halogenated monomers, such as hexafluoropropene, have particular utility in high temperature applications, such as seal gaskets and linings. See, for example, Brullo, R.A., "Fluoroelastomer Rubber for Automotive Applications," Automotive Elastomer & l~esien. June 1985, "Fluoroelastomers Seal Up Automotive Future," Materials En ineering, October 1988, and "Fluorinated Elastomers," Kirk-Othmer, Enc~pedia of Chelni al Technoloev 3rd ed., Vol. 8, pp. 500-515, John Wiley & Sons, New York (1979).
Fluoroplastics, particularly polychlorotrifluoroethylene, polytetrafluoroethylene, copolymers of tetrafluoroethylene and hexafluoropropylene, and poly(vinylidene fluoride), have numerous electrical, R'0 96/05965 ' ' ' C r~ 11.: ; ~ ~' ~ ~ 7 9 0 PCT/US95110516 mechanical, and chemical applications. Fluoroplastics are useful, for example, in wire, electrical components, seals, solid and lined pipes, and pyroelectric detectors.
See, for example, "Organic Fluorine Compounds," Kirk-Othmer, Encyclopedia of Chemical Technoloev. Vol. I 1, pp. 20, 21, 32, 33, 40, 41, 48, 50, 52; 62, 70, and 71, John Wiley & Sons, New York (1980).
Increased concerns with evaporative fuel standards have led to a need for fiael system components that have increased barrier properties to minimize the permeation of fuel vapors through automotive components such as fuel filler lines, fuel supply lines, fizel tanks, and other components of the emission control system of the engine. Various types of tubing have been proposed to address these concerns. In general, the most successful of these have been co-extruded multi-layer tubing.
Multi-layer compositions comprising a fluorinated polymer layer and a polyamide or polyolefin layer are known. See, for example, U.S. Pat. No.
4,933,090 (Krevor) which discloses laminate tubular articles which can comprise layers offluorocarbon elastomers, and PCT Publication WO 93/1493 (LaCourt) which discloses a laminar film structure comprising a polyimide and a fluoropolymer. The use of fluorinated polymers in retroreflective sheeting is also known. See for example U.S. Pat. Nos. 3,551,025 and 4,348,312 for products including glass microspheres, and PCT WO 95111466 and WO 95/11464 for products containing retroreflective cube corner arrays.
A variety of methods have been used to increase the adhesion between a fluorinated polymer layer and a polyamide or polyolefin layer. For example, an adhesive layer can be added between the two polymer layers. U.S. 5,047,287 discloses a diaphragm, suitable for use in automotive applications, which comprises a base fabric having bonded to at least one surface a fluororubber layer by an adhesive which includes an acrylonitrile-butadiene or acrylonitrile-isoprene rubber having an amino group. See also, for example, European Patent Application 05595445 (Nishino et al.), UK Patent 2,204,932 (Washizu). See also U.S.
5,242,976 (Strassel et a1.) which discloses coextruding vinylidene polyfluoride with an alkyl polymethacrylate and vinylidene polyfluoride composition.
The invention relates to multi-layer compositions comprising a fluoropolymer layer, in particular, a fluoropolymer comprising interpolymerized units derived from vinylidene fluoride. In another aspect, this invention relates to methods of improving the adhesion between the fluoropolymer layer and other dissimilar materials, such as polyamides, polyurethanes, and polyolefins.
BACKGROUND OF THE INVENTION
Fluorine-containing polymers, or fluoropolymers, are an important class of polymers and include for example, fluoroelastomers and fluoroplastics. Within this class are polymers of high thermal stability and usefulness at high temperatures, and extreme toughness and flexibility at very low temperatures. Many of these polymers are almost totally insoluble in a wide variety of organic solvents.
See, for exampIeF.W. Billmeyer, Textbook ofPolvmer Science_3rd ed., pp. 398-403, John Wiley & Sons, New York (1984).
Fluoroelastomers, particularly the copolymers of vinylidene fluoride with other ethylenically unsaturated halogenated monomers, such as hexafluoropropene, have particular utility in high temperature applications, such as seal gaskets and linings. See, for example, Brullo, R.A., "Fluoroelastomer Rubber for Automotive Applications," Automotive Elastomer & l~esien. June 1985, "Fluoroelastomers Seal Up Automotive Future," Materials En ineering, October 1988, and "Fluorinated Elastomers," Kirk-Othmer, Enc~pedia of Chelni al Technoloev 3rd ed., Vol. 8, pp. 500-515, John Wiley & Sons, New York (1979).
Fluoroplastics, particularly polychlorotrifluoroethylene, polytetrafluoroethylene, copolymers of tetrafluoroethylene and hexafluoropropylene, and poly(vinylidene fluoride), have numerous electrical, R'0 96/05965 ' ' ' C r~ 11.: ; ~ ~' ~ ~ 7 9 0 PCT/US95110516 mechanical, and chemical applications. Fluoroplastics are useful, for example, in wire, electrical components, seals, solid and lined pipes, and pyroelectric detectors.
See, for example, "Organic Fluorine Compounds," Kirk-Othmer, Encyclopedia of Chemical Technoloev. Vol. I 1, pp. 20, 21, 32, 33, 40, 41, 48, 50, 52; 62, 70, and 71, John Wiley & Sons, New York (1980).
Increased concerns with evaporative fuel standards have led to a need for fiael system components that have increased barrier properties to minimize the permeation of fuel vapors through automotive components such as fuel filler lines, fuel supply lines, fizel tanks, and other components of the emission control system of the engine. Various types of tubing have been proposed to address these concerns. In general, the most successful of these have been co-extruded multi-layer tubing.
Multi-layer compositions comprising a fluorinated polymer layer and a polyamide or polyolefin layer are known. See, for example, U.S. Pat. No.
4,933,090 (Krevor) which discloses laminate tubular articles which can comprise layers offluorocarbon elastomers, and PCT Publication WO 93/1493 (LaCourt) which discloses a laminar film structure comprising a polyimide and a fluoropolymer. The use of fluorinated polymers in retroreflective sheeting is also known. See for example U.S. Pat. Nos. 3,551,025 and 4,348,312 for products including glass microspheres, and PCT WO 95111466 and WO 95/11464 for products containing retroreflective cube corner arrays.
A variety of methods have been used to increase the adhesion between a fluorinated polymer layer and a polyamide or polyolefin layer. For example, an adhesive layer can be added between the two polymer layers. U.S. 5,047,287 discloses a diaphragm, suitable for use in automotive applications, which comprises a base fabric having bonded to at least one surface a fluororubber layer by an adhesive which includes an acrylonitrile-butadiene or acrylonitrile-isoprene rubber having an amino group. See also, for example, European Patent Application 05595445 (Nishino et al.), UK Patent 2,204,932 (Washizu). See also U.S.
5,242,976 (Strassel et a1.) which discloses coextruding vinylidene polyfluoride with an alkyl polymethacrylate and vinylidene polyfluoride composition.
-2-,.
W096105965 '. '~ r~' ~ ~5.~ ~ /7 U PC1'/US95/IOSI6 Sometimes surface treatment of one or both of the layers is used to help increase bonding. For example, fluoropolymer layers have been treated with charged gaseous atmosphere followed by applying a layer of a second material, for example thermoplastic polyamide. See, for example, European Patent Applications 0185590 (Ueno et al.) and 0551094 (Krause et al.) and U.S. Pat. Nos. 4,933,060 (Prohaska et al.) and 5,170,011 (Martucci).
Blends of the two layers are sometimes used as an intermediate layer to help bond the two layers together. European Patent Application 0523644 (Kawashima et al.) discloses a plastic laminate having a polyamide resin surface layer and a fluororesin surface Layer. The application states that it is diffcult to make laminates having a polyamide layer and a ffuororesin layer due to the incompatibility of the two materials. The laminate is prepared by the use of an intermediate layer of a blend of an aliphatic polyamide resin with a fluorine-containing graft copolymer.
SUMMARY OF THE INVENTION
Briefly, in one aspect, the present invention provides a method for increasing the adhesion of a first layer comprising fluoropolymer to a second layer comprising melt-processable, preferably thermoplastic, substantially non-fluorinated polymer, comprising the steps of (A) mixing a melt-processable aliphatic di- or polyamine of less than 1,000 molecular weight with a melt-processable composition comprising said substantially non-fluorinated polymer; and (B) forming a multi-layer composition comprising a layer comprising the mixture resulting from step A and a layer comprising said fluoropolymer; wherein said two layers are in substantial contact, said fluoropolymer comprises interpolymerized units derived from vinylidene fluoride, said melt-processable, substantially non-fluorinated polymer is a polyamide, polyimide, polyurethane, or carboxyl, anhydride, or imide functional polyolefin, and said di- or.polyamine is present in an amount sufficient to increase the adhesion between the two layers compared to compositions without said di- or polyamine. Preferably said first layer is predominantly fluoropolymers and said second layer is predominantly melt-processable, non-fluorinated polymers.
W096105965 '. '~ r~' ~ ~5.~ ~ /7 U PC1'/US95/IOSI6 Sometimes surface treatment of one or both of the layers is used to help increase bonding. For example, fluoropolymer layers have been treated with charged gaseous atmosphere followed by applying a layer of a second material, for example thermoplastic polyamide. See, for example, European Patent Applications 0185590 (Ueno et al.) and 0551094 (Krause et al.) and U.S. Pat. Nos. 4,933,060 (Prohaska et al.) and 5,170,011 (Martucci).
Blends of the two layers are sometimes used as an intermediate layer to help bond the two layers together. European Patent Application 0523644 (Kawashima et al.) discloses a plastic laminate having a polyamide resin surface layer and a fluororesin surface Layer. The application states that it is diffcult to make laminates having a polyamide layer and a ffuororesin layer due to the incompatibility of the two materials. The laminate is prepared by the use of an intermediate layer of a blend of an aliphatic polyamide resin with a fluorine-containing graft copolymer.
SUMMARY OF THE INVENTION
Briefly, in one aspect, the present invention provides a method for increasing the adhesion of a first layer comprising fluoropolymer to a second layer comprising melt-processable, preferably thermoplastic, substantially non-fluorinated polymer, comprising the steps of (A) mixing a melt-processable aliphatic di- or polyamine of less than 1,000 molecular weight with a melt-processable composition comprising said substantially non-fluorinated polymer; and (B) forming a multi-layer composition comprising a layer comprising the mixture resulting from step A and a layer comprising said fluoropolymer; wherein said two layers are in substantial contact, said fluoropolymer comprises interpolymerized units derived from vinylidene fluoride, said melt-processable, substantially non-fluorinated polymer is a polyamide, polyimide, polyurethane, or carboxyl, anhydride, or imide functional polyolefin, and said di- or.polyamine is present in an amount sufficient to increase the adhesion between the two layers compared to compositions without said di- or polyamine. Preferably said first layer is predominantly fluoropolymers and said second layer is predominantly melt-processable, non-fluorinated polymers.
-3-Sometimes, in order to obtain sufficient adhesion, it may be desirable or necessary to further treat the resulting multi-layer composition, for example by additional heat or pressure.
According to another aspect of the present invention, there is provided a method for increasing the adhesion of a first layer comprising fluoropolymer to a second layer comprising a melt-processable, substantially non-fluorinated polymer, comprising the steps of (A) mixing an aliphatic di- or polyamine of less than 1,000 molecular weight with a tackifier and a melt-processable composition comprising said substantially non-fluorinated polymer; (B) forming a multi-layer composition comprising a layer comprising the mixture resulting from step A and a layer comprising said fluoropolymer; wherein said two layers are in substantial contact, said fluoropolymer comprises interpolymerized units derived from vinylidene fluoride, said substantially non-fluorinated polymer is a polyamide, polyimide, polyurethane, or a carboxyl, anhydride, or imide functional polyolefin, and said di- or polyamine is present in an amount sufficient to increase the adhesion between the two layers compared to compositions without said di- or polyamine.
According to another aspect of the present invention, there is provided a method for increasing the adhesion of a first layer comprising fluoropolymer to a second layer comprising a melt-processable, substantially non-fluorinated polymer, comprising the steps of (A) mixing an aliphatic di- or polyamine of less than 1,000 molecular weight with a tackifier and a melt-processable composition comprising said substantially non-fluorinated polymer; (B) forming a multi-layer composition comprising a layer comprising the mixture resulting from step A and a layer comprising said fluoropolymer; wherein said two layers are in substantial contact, said fluoropolymer comprises interpolymerized units derived from vinylidene fluoride, said substantially non-fluorinated polymer is a polyamide, polyimide, polyurethane, or a carboxyl, anhydride, or imide functional polyolefin, and said di- or polyamine is present in an amount sufficient to increase the adhesion between the two layers compared to compositions without said di- or polyamine.
-4-In another aspect, the present invention provides a multi-layer composition comprising a first layer comprising fluoropolymer, a second layer comprising melt-processable, substantially non-fluorinated polymer, and a melt-processable aliphatic di- or polyamine of less than 1,000 molecular weight, wherein said fluoropolymer comprises interpolymerized units derived from vinylidene fluoride, said substantially non-fluorinated polymer is a polyamide, polyimide, polyurethane, or carboxyl, anhydride, or imide functional polyolefin, substantially all of said amine is located in said second layer, and said amine is present in an amount sufficient to increase the adhesion between said layers compared to compositions without said di- or polyamine. The invention also provides articles comprising the compositions of this invention. Preferably said first layer is predominantly fluoropolymers and said second layer is predominantly melt-processable, non-fluorinated polymers.
The invention also provides multi-layer compositions and articles with improved inter-layer adhesion. The methods and compositions of this invention are particularly useful for making articles, such as tubing and hoses suitable for use in motor vehicles, for example as fuel-line hoses, and flexible retroreflective sheetings.
DETAILED DESCRIPTION OF THE INVENTION
Fluoropolymer materials suitable for use in this invention are those comprising interpolymerized units derived from vinylidene fluoride ("VFZ" or "VDF"). Preferably such polymers comprise at least 3% by weight of interpolymerized units derived from VF2. Such polymers may be homopolymers of VF2 or copolymers of VFZ and other ethylenically unsaturated monomers.
Such VF2 polymers and copolymers can be made by well-known conventional means, for example by free-radical polymerization of VF2 with or without other ethylenically-unsaturated monomers. For example, the preparation of colloidal, aqueous dispersions of such polymers and copolymers is described, for -4a-r _ 2195790 W O 96105965 ~ ' ;~ S" ' ~ ' ~ PCTIUS95/10516 example, in U.S. Pat. No 4,335,238. It follows the customary process for ,.
copolymerizing fluorinated olefins in aqueous, colloidal dispersions, which is carried out in,the presence of water-soluble initiators which produce free radicals, such as, for example, ammonium or alkali metal persulfates or alkali metal permanganates, and in the presence of emulsifiers, such as, in particular, the ammonium or alkali metal salts of perfluorooctanoic acid. Useful fluorine-containing monomers include hexafluoropropene (HF'P), tetrafluoroethylene (TFE), chlorotrifluoroethylene (CTFE), 2-chloropentafluoro-propene, perfluoroalkyl vinyl ethers, e.g.
CF30CF=CF2 or CF3CF20CF=CF2, I-hydropentafluoropropene, 2-hydro-pentafluoropropene, dichlorodifluoroethylene, trifluoroethylene, 1,1-dichlorofluoroethylene, vinyl fluoride, and perfluoro-1,3-dioxoles such as those described in U.S. Pat. No. 4,558,142 (Squire). Certain fluorine-containing di-oleflns are also useful, such as perfluorodiallylether and perfluoro-1,3-butadiene.
Said fluorine-containing monomer may also be copolymerized with fluorine-free terminally unsaturated monoolefin comonomers, e.g., ethylene or propylene.
Preferably at least 50% by weight of all monomers in a polymerizable mixture are fluorine-containing. Said fluorine-containing monomer may also be copolymerized with iodine- or bromine-containing cure-site monomers in order to prepare peroxide curable polymer. Suitable cure-site monomers include terminally unsaturated monoolefins oft to 4 carbon atoms such as bromodifluoroethylene, bromotrifluoroethylene, iodotrifluoroethylene, and 4-bromo-3,3,4,4-tetrafluoro-butene-1.
Useful fluoropolymer materials include commercially available ffuoropolymers, for example, TF3V 500 fluoropoIymer (available from 3M), KynarTM 740 fluoropolymer (available from Elf Atochem North America, Inc.), and Fluorel~ FC-2178 fluoropolymer (available from 3M).
The di- or polyamines usefial in this invention are aliphatic amines of molecular weight less than 1,000. By "aliphatic" is meant that the nitrogen atoms of at least two amines in the compound are bonded directly to only hydrogen atoms or to aliphatic carbon atoms rather than being bonded directly to aromatic moieties or functional groups (e.g., carboxyl). For example, as "aliphatic amine" is used in this
The invention also provides multi-layer compositions and articles with improved inter-layer adhesion. The methods and compositions of this invention are particularly useful for making articles, such as tubing and hoses suitable for use in motor vehicles, for example as fuel-line hoses, and flexible retroreflective sheetings.
DETAILED DESCRIPTION OF THE INVENTION
Fluoropolymer materials suitable for use in this invention are those comprising interpolymerized units derived from vinylidene fluoride ("VFZ" or "VDF"). Preferably such polymers comprise at least 3% by weight of interpolymerized units derived from VF2. Such polymers may be homopolymers of VF2 or copolymers of VFZ and other ethylenically unsaturated monomers.
Such VF2 polymers and copolymers can be made by well-known conventional means, for example by free-radical polymerization of VF2 with or without other ethylenically-unsaturated monomers. For example, the preparation of colloidal, aqueous dispersions of such polymers and copolymers is described, for -4a-r _ 2195790 W O 96105965 ~ ' ;~ S" ' ~ ' ~ PCTIUS95/10516 example, in U.S. Pat. No 4,335,238. It follows the customary process for ,.
copolymerizing fluorinated olefins in aqueous, colloidal dispersions, which is carried out in,the presence of water-soluble initiators which produce free radicals, such as, for example, ammonium or alkali metal persulfates or alkali metal permanganates, and in the presence of emulsifiers, such as, in particular, the ammonium or alkali metal salts of perfluorooctanoic acid. Useful fluorine-containing monomers include hexafluoropropene (HF'P), tetrafluoroethylene (TFE), chlorotrifluoroethylene (CTFE), 2-chloropentafluoro-propene, perfluoroalkyl vinyl ethers, e.g.
CF30CF=CF2 or CF3CF20CF=CF2, I-hydropentafluoropropene, 2-hydro-pentafluoropropene, dichlorodifluoroethylene, trifluoroethylene, 1,1-dichlorofluoroethylene, vinyl fluoride, and perfluoro-1,3-dioxoles such as those described in U.S. Pat. No. 4,558,142 (Squire). Certain fluorine-containing di-oleflns are also useful, such as perfluorodiallylether and perfluoro-1,3-butadiene.
Said fluorine-containing monomer may also be copolymerized with fluorine-free terminally unsaturated monoolefin comonomers, e.g., ethylene or propylene.
Preferably at least 50% by weight of all monomers in a polymerizable mixture are fluorine-containing. Said fluorine-containing monomer may also be copolymerized with iodine- or bromine-containing cure-site monomers in order to prepare peroxide curable polymer. Suitable cure-site monomers include terminally unsaturated monoolefins oft to 4 carbon atoms such as bromodifluoroethylene, bromotrifluoroethylene, iodotrifluoroethylene, and 4-bromo-3,3,4,4-tetrafluoro-butene-1.
Useful fluoropolymer materials include commercially available ffuoropolymers, for example, TF3V 500 fluoropoIymer (available from 3M), KynarTM 740 fluoropolymer (available from Elf Atochem North America, Inc.), and Fluorel~ FC-2178 fluoropolymer (available from 3M).
The di- or polyamines usefial in this invention are aliphatic amines of molecular weight less than 1,000. By "aliphatic" is meant that the nitrogen atoms of at least two amines in the compound are bonded directly to only hydrogen atoms or to aliphatic carbon atoms rather than being bonded directly to aromatic moieties or functional groups (e.g., carboxyl). For example, as "aliphatic amine" is used in this
-5-t~ ~r ~'~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ pC1'/US9511051b WO 96!05965 specification and claims, aniline and urea are not aliphatic amines. Secondary amines are more preferred than tertiary amines and primary amines are most preferred. Most preferred are alkylene polyamines or diamines that comprise at least two primary amines, such as hexamethylene diamine, dodecyl diamine, and 2,4,8,10-tetraoxaspiro[5,5]undecane-3,9-dipropanamine.
Polyamides usefixl as the substantially non-fluorinated polymer are generally commercially available. For example, polyamides such as any of the well-known Nylons are available from a number of sources. Particularly preferred polyamides are nylon 6, nylon 6,6, nylon 11, or nylon 12. It should be noted that the selection of a particular polyamide material should be based upon the physical requirements of the particular application for the resulting article. For example, nylon 6 and nylon 6,6 offer higher heat resistant properties than nylon 11 or nylon 12, whereas nylon 11 and nylon 12 offer better chemical resistant properties. In addition to those polyamide materials, other nylon material such as nylon 6,12, nylon 6,9, nylon 4, nylon 4,2, nylon 4,6, nylon 7, and nylon 8 may also be used. Ring containing polyamides, e.g., nylon 6,T and nylon 6,I, may also be used. Polyether containing polyamides, such as PebaxT'" polyamines, may also be used.
Useful polyurethane polymers include aliphatic, cycloaliphatic, aromatic, and polycyclic polyurethanes. These polyurethanes are typically produced by reaction of a polyfunctional isocyanate with a polyol according to well known reaction mechanisms. Useful diiisocyanates for employment in the production of a polyurethane include dicyclohexy!methane-4,4'-diisocyanate, isophorone dusocyanate, 1,6-hexamethylene diisocyanate, cyclohexyl diisocyanate, diphenylmethane diisocyanate. Combinations of one or more polyfunctional isocyanates may also be used. Useful polyols include polypentyleneadipate glycol, polytetramethylene ether glycol, polyethylene glycol, polycaprolactone diol, poly-1,2-butylene oxide glycol, and combinations thereof Chain extenders, such as butanediol or hexanediol, may also optionally be used in the reaction.
Commercially available urethane polymers useful in the present invention include:
PN-04 or 3429 from Morton International, Inc., Seabrook, New Hampshire, and X-4107 from B.F. Go-odrich Company, Cleveland, Ohio.
Polyamides usefixl as the substantially non-fluorinated polymer are generally commercially available. For example, polyamides such as any of the well-known Nylons are available from a number of sources. Particularly preferred polyamides are nylon 6, nylon 6,6, nylon 11, or nylon 12. It should be noted that the selection of a particular polyamide material should be based upon the physical requirements of the particular application for the resulting article. For example, nylon 6 and nylon 6,6 offer higher heat resistant properties than nylon 11 or nylon 12, whereas nylon 11 and nylon 12 offer better chemical resistant properties. In addition to those polyamide materials, other nylon material such as nylon 6,12, nylon 6,9, nylon 4, nylon 4,2, nylon 4,6, nylon 7, and nylon 8 may also be used. Ring containing polyamides, e.g., nylon 6,T and nylon 6,I, may also be used. Polyether containing polyamides, such as PebaxT'" polyamines, may also be used.
Useful polyurethane polymers include aliphatic, cycloaliphatic, aromatic, and polycyclic polyurethanes. These polyurethanes are typically produced by reaction of a polyfunctional isocyanate with a polyol according to well known reaction mechanisms. Useful diiisocyanates for employment in the production of a polyurethane include dicyclohexy!methane-4,4'-diisocyanate, isophorone dusocyanate, 1,6-hexamethylene diisocyanate, cyclohexyl diisocyanate, diphenylmethane diisocyanate. Combinations of one or more polyfunctional isocyanates may also be used. Useful polyols include polypentyleneadipate glycol, polytetramethylene ether glycol, polyethylene glycol, polycaprolactone diol, poly-1,2-butylene oxide glycol, and combinations thereof Chain extenders, such as butanediol or hexanediol, may also optionally be used in the reaction.
Commercially available urethane polymers useful in the present invention include:
PN-04 or 3429 from Morton International, Inc., Seabrook, New Hampshire, and X-4107 from B.F. Go-odrich Company, Cleveland, Ohio.
-6-WO 96105965 ~. ; ~'; ~ '~~ .~ ~~ ~ ~ ~ 9 ~5 j 9 Q p~~S95II0516 The polyolefin polymers useful as the substantially non-fluorinated polymer are generally homopolymers or copolymers of ethylene, propylene, acrylic monomers, or other ethylenically unsaturated monomers, for example, vinyl acetate.
Such polymers and copolymers can be prepared by conventional free-radical polymerization of such ethylenically unsaturated monomers. The degree of crystalIinity of the hydrocarbon polymer or copolymer is not critical. The polymer may, for example, be a semi-crystalline high density polyethylene or may be an elastomeric copolymer of ethylene and propylene. Although not necessary to the performance of the hydrocarbon polymer within the present invention, carboxyl, anhydride, or imide functionalities may be incorporated into the polymer or copolymer by polymerizing or copolymerizing functional monomers, for example, acrylic acid or malefic anhydride, or by modifying a polymer after polymerization, for example by oxidation. The carboxyl, anhydride, or imide functional polymers useful as the hydrocarbon polymer are generally commercially available. For example, acid modified ethylene vinyl acetates, acid modified ethylene acrylates, anhydride modified ethylene acrylates, anhydride modified ethylene vinyl acetates, anhydride modified polyethylenes, and anhydride modified polypropylenes are available from DuPont as Bynel'"" coextrudable adhesive resins.
In addition to the melt-processable aliphatic di- or polyamine, the compositions of the present invention having a first layer comprising a fluoropolymer and a second layer comprising a hydrocarbon polymer may contain one or more tackifiers to improve inter-layer adhesion. Although suitable tackifiers vary greatly in chemical structure, the most useful tackifier compounds generally will have a softening point between approximately 90 °C and I50 °C. Preferably, tackifiers used in accordance with this invention are combined along with a suitable di- or polyamine and incorporated into the hydrocarbon polymer-containing layer to comprise between I and 50 weight percent of the hydrocarbon layer.
Tackifiers useful for this purpose include any of the tackifier compounds known to improve adhesion performance characteristics of elastomer-based adhesives. Such compounds include, for example, the following: rosins, including gum rosins, tall oil rosins, wood rosins; polymerized rosins, hydrogenated rosins, _7-WO 96105965 x "~ y'''~ 4'rt s ~ ~ ~ 9 5 7 9 0 PCT/US95110516 and disproportionated rosins; rosin esters, including pentaerythritol-wood rosins, pentaerythritol-stabilized rosins, and glycerine-hydrogenated wood rosins;
hydrocarbon resins, including aliphatic and cycloaliphatic resins, aromatic resins, petroleum resins, and dicyclopentadiene; terpenes, including alpha-pinene, beta-pinene, d fimonene, and polyterpenes; and pure monomer resins, including styrene resins, styrene/AMS resins, and AMS/vinyl toluene resins.
Commercially available tackifiers useful in this invention include ArkonTM P-125 tackifier, a hydrogenated C9 aromatic hydrocarbon, and Super EsterTM W-125 modified rosin ester tacltifier, both available from Arakawa Chemical USA., Inc.;
and PiccolyteTM S I 15 terpene resin tackifier, available from Hercules, Inc.
The mixing of the di- or polyamine may be by conventional means. For example, the di or polyamine can be melt-processed with the second layer material, for example nylon. In some cases the di or polyamine may react with the second layer material such that the second layer material becomes modified. For example, a diamine such as 1,12 dodecyl diamine (DDDA) may be blended into a polyamide such as nylon 12, resulting in a modified nylon. The modified nylon and a vinylidene fluoride monomer unit-containing fluoropolymer could then be coextruded to form a multi-layer article, such as a film or a tube.
The heat and pressure of the method by which the layers are brought together, for example normal coextrusion processes, may be adequate to provide sufficient adhesion. However, it may be desirable to further treat the resulting multi-layer composition, for example, with additional heat or pressure or both. One way of supplying extra heat when the multi-layer composition is prepared by extrusion is by delaying the cooling of the composition because the composite is hot as a result of the coextrusion process. Where additional heating or pressure is desired, it may be accomplished by performing the steps of applying or coextruding at a temperature higher than necessary for merely processing the several components. Alternatively, the finished article may be held at an elevated temperature for an extended period of time, or the finished article may be placed in a separate means for elevating the temperature of the article, such as an oven or heated liquid bath. A combination of these methods may also be used.
_g_ ~ ~t~H ~.~ ~'~9~790 R'O 9b105965 - - pCT/17g95/10516 The methods of this invention provide multi-layer compositions with improved inter-layer adhesion v The methods and compositions of this invention are particularly useful for making articles, such as tubing and hoses, suitable for use in motor vehicles, for example as fuel-line hoses, and for films and blow-molded articles such as bottles where chemical resistance or barrier properties are important. The two-layer compositions of this invention are also useful in preparing compositions having three or more layers. For example, a three layer composition of fluoropolymer to anhydride modified polyolefin to unmodified polyolefin could be prepared and might be useful in a fuel-tank construction.
Transparent embodiments of multi-layer compositions of the present invention may find particular utility in the construction of retroreflective sheeting articles generally, and particularly when resistance to chemical agents, solvents, soils, reduced moisture vapor transmission or good interlayer adhesion in flexible sheetings subject to severe bending and flexing is required.
The compositions ofthis invention may be rendered retroreflective by forming retroreflective elements on one side of the composition, or alternatively, by attaching a retroreflective base sheet by means of a transparent adhesive or by direct lamination. The retroreflective base sheet may comprise a member with cube corner retroreflective elements or may comprise a microsphere-based retroreflective structure, e.g. comprising a monolayer oftransparent microspheres and reflective means disposed on the opposite side ofthe monolayer from the multi-layer composition. It is preferred that the base layer is disposed on the non-ffuoropolymer layer of the multi-layer composition. An embodiment of this invention includes the encapsulated retroreflective sheeting article as is disclosed in U.S. Patent No. 3,190,178, in which the cover layer is provided by a multi-layer composition according to the present invention.
Retroreflective articles of the invention may be made in rigid or flexible form. Multi-layer compositions of the present invention may be used as barrier layers. An embodiment of the present invention includes articles in accordance with U.S. Pat. No. 5,069,964, in which the plasticiser resistant barrier layer comprises a multi-layer composition in accordance with the present invention. The multi-layer _9_ ry~:k :,;~;.;.~: 2195790 compositions of the present invention may find particular utility in the construction of flexible retroreflective sheeting articles. A preferred embodiment of the present invention includes a retroreflective article in accordance with PCT WO
95/11464 or PCT/WO 95/11943, wherein the flexible overlay film described in PCT WO
95/11464 or the flexible body layer of PCT/WO 95/11943 is constituted by a multi-layer composition in accordance with this invention. Suitable fluoropolymers comprising interpolymerized units of vinylidene fluoride of the type specified for use with flexible sheeting in accordance with these two patent applications may be poly(vinylidene fluoride-co-hexafluoropropylene), for example, Kynar FIexTM-available from Elf Atochem North America, Inc., Philadelphia, Pennsylvania, or poly(tetrafluoroethylene - co -hexafluoropropylene - vinylidene fluoride), for example, THV 200 or 500 available from 3M, St. Paul, Minnesota. The non-fluoropolymer layer of the present invention in such constructions may be any of the non-fluoropolymers specified in the above patent applications, for example, 1 S ionomeric ethylene copolymers, low density polyethylenes, polyethylene copolymers, or aliphatic or aromatic polyurethanes or similar compounds. For highly flexible products, a multi-layer composition of this invention that include a THV layer and a polyurethane layer is particularly preferred. The microstructure elements including either solidly connected or segregated cube corners may be microreplicated, preferably onto the non-fluoropolymer layer. Alternatively, the multi-layer compositions may be adhered to microstructure elements. As will be understood, any conventional form of retroreflective microstructure elements may be used including, for example, arrays of canted, tiled, specially shaped, colored, or colorless cube corner elements.
Similarly, multi-layer compositions according to the present invention may be used with retroreflective sheeting products including microspheres in a base Layer. Specific embodiments ofthe invention include retroreflective articles according to U.S. Pat Nos. 4,896,943, U.S. Pat No. 4,025,159 or U.S. Pat No.
5,066,098, all of which are included herein by reference, in which the cover film of U.S. Pat Nos. 4,896,943 or 4,025,159 or the cover sheet of U.S. Pat No.
5,066,098 is constituted by a multi-layer composition in accordance with this invention.
2'9579 Further, the,multi-layer compositions of the present invention may themselves include retroreflective micro-elements, such as transparent microspheres, incorporated into the fluoropolymer or the non-fluoropolymer layer, for example in a further embodiment of the present invention, the fluoropolymer layer of a multi-layer composition according to the present invention may constitute the continuous overlaying transparent topcoat of U.S. Pat. No. 3,551,025 and the non-fluoropolymer layer may constitute the binder of the same.
EXAMPLES
In the following Examples and Comparative Examples various multi-layer compositions were prepared and the adhesion between the layers was evaluated.
All concentrations and percentages are by weight unless otherwise indicated.
F~cample I -In Example 1, a 4 inch by 4 inch (10 cm by 10 cm) diamine-containing nylon sheet was prepared by melting 46 g of VestamidT"'i L2140 nylon 12, available from Huls Aktiengesellschaft, using a Rheomix~ 600 internal bowl mixer equipped with roller blades, available from Haake Buchler Instruments Inc., set at a temperature of 200°C and a mixer rotor setting of 10 rpm. After mixing the melted nylon for 1 minute, 0.23 g (0.5% by wt.) of 1,12-dodecyl diamine (DDDA), available from Aldrich Chemical Co., Inc., was added to and mixed into the melted nylon.
During the next 2 minutes, the temperature was gradually cooled down to 180°C
and the speed on the mixer rotor was increased to 50 rpm. The temperature and the rotor speed were then held for 3 minutes. The internal bowl-mixed, diamine-containing nylon was then removed from the mixer and molded at 177°C into a sheet about 20 mils (508 micro meters) thick using a 20 mil shim stock and a Wabash Hydraulic Press Co. heated platen press. After cooling to room temperature, the sheet was cut into a square 4 in. by 4 in. (10 cm by 10 cm). A composite was made with the sheet ofinternal bowl-mixed, diamine-containing nylon and 3 layers of 10 mil (254 micro meters) thick sheets of a terpolymer of tetrafluoroethylene (TFE), ~~~;i E~~;~ 239190 R'096105965 - p~n7S95I10516 hexafluoropropylene (F~?P) and vinylidene fluoride (VDF), made from resin available from 3M Co. as THV 500. An 18 mil (457 micro meters) thick sheet of unmodified Vestamid"~' L2140 nylon 12 was applied to the other side of the internal bowl-mixed, diamine-containing nylon sheet giving a final structure of a layer of .
unmodified nylon 12, the middle layer of a internal bowl-mixed, diamine-containing nylon sheet and a third layer of the three 10 mil (254 micro meters) sheets of THV
500.
The adhesion between the layers was tested using ASTM D-1876, commonly known as a "T-peel" test. To facilitate testing via the T-peel test, a sheet of 3 mil (76.2 micro meters) polyester (PET) film coated with a silicone release agent was placed between the internal bowl-mixed, diamine-containing nylon 12 layer and the THV layer and a second sheet was placed between the internal bowl-mixed, diamine-containing nylon 12 layer and the nylon 12 layer. The release-coated PET films were both inserted about 2.5 cm only along the same edge of the 4 inch by 4 inch (10 cm by 10 cm) sample. The sheet ofpolyester did not adhere to any of the layers and was used only to create a THV "tab" and a nylon 12 "tab"
to insert into the jaws of a test device. A "middle" tab of internal bowl-mixed, diamine-containing nylon was also present, but not used during the test.
The resulting composite was heated under pressure using a Wabash Hydraulic Press Co. heated platen press at 177°C and 3.5 psi (24 kPa) for 3 minutes. The sample was removed from the press and allowed to cool to room temperature. The resulting sample was cut into three 1-inch (2.54 cm) wide strips.
Peel strength or adhesion was measured on the three strips in accordance with ASTM D 1876 (T-Peel Test). An Instron~ Model 1125 tester, available from Instron Corp., set at a 100 rrun/min crosshead speed was used as the test device. If there were many peaks recorded on the graph from the T-peel test, the peel strength was calculated in accordance with ISO 6133=81. The value reported was the average of testing three samples. The average peel strength on the strips from Example I is reported in Table 1.
Colt parative Examples C1 and C2 __ w0 96105965 In Comparative Examples C1 and C2, samples were prepared and tested as in Example 1 except a nylon 12 sheet was applied directly to the THV 500 sheets without a middle layer of internal bowl-mixed, diamine-containing nylon. The time in the press and the test results are summarized in Table I .
Exam le nd 3 In Examples 2 and 3, samples were prepared and tested as described in Example 1 except the amount of DDDA additive was varied as shown in Table 1.
The time in the press and the test results are summarized in Table I .
In Example 4, a sample was prepared and tested as in Example 1 except 1.0% Jeff'amine~ EDR-148 polyoxyalkylene polyamine, available from Texaco Inc., was used instead of the DDDA. The time in the press and the test results are summarized in Table 1.
In Comparative Example C3, a sample was prepared and tested as in Example 1 except 0.23 g of octadecyl amine (ODA), available from Aldrich Chemical, was added to the nylon instead of DDDA. The time in the press and the test results are summarized in Table I.
In Example 5, a sample was prepared and tested as in Example 1 except the internal bowl-mixed, diamine-containing nylon layer was replaced by a nylon layer which had been prepared by soaking an 18 mil (457 micro meters) sheet of the unmodified nylon 12 used in Example I, in a 5% HIVmA methanol solution for 18 hours and drying the soaked sheet at 80°C for 2 hours. The time in the press and the test results are summarized in Table 1.
Comparative Exam 1~-wo vsiosvss i'~ '.~ ~: ~ ~' 1. S 219 5 7 9 0 PCT/U595l10516 In Comparative Example C4, a sample was prepared and tested as in Example 1, except the amount ofDDDA added to the nylon was only 0.1%. The time in the press and the test results are summarized in Table 1.
Table 1 Example Nylon Modifier Time Peel ' (Min.) (kg/2.54 cm) 1 0.5% DDDA 3 16.8 2 0.3% DDDA 3 13.0 3 I .0% DDDA 3 22.8 4 1.0% JeffamineTM EDR-483 22.5 C3 0.5% ODA 3 1.2 5 0.5% HMDA soak 3 7.6 Cl ____ 3 0 2 C2 _____ 6 0.2 C4 0.1% DDDA 3 0.1 The data in Table 1 show that substantially improved adhesion between the layers may be obtained if a sufficient amount of a diamine component is added to a nylon layer. Substantial improvements are achieved over the samples without any or only low levels of diamine modifier. The mono-amine of Comparative Example C3 showed only a minor improvement over the control without amine.
Example 6 -In Example 6, a sample was prepared and tested as in Example 1 except the diamine and nylon were melt blended using a Rheomex'M TW 100 conical twin screw extruder with high intensity screws, available from Haake Buchler Instruments Inc., instead of the Haake RheomixT"' 600 internal bowl mixer.
Prior to adding the materials to the extruder, 2000 g of Vestamid~ L2140 nylon 12 pellets, and 11.06 g of DDDA (0.55% by wt.) ground to a fine powder by using a \.
VVO 96105965 ~ . ~ ~ r~ ~ } ~ ~ 1 ~ 5 7 9 0 P~,~S95/10516 mortar, were pre-mixed in a plastic bottle by hand shaking. The pre-mixed blend was fed to the twin-screw extruder by a AccuRate'~' solids feeder and extruded as a strand at 230°C and 150 rpm giving a through-put rate of 39 g/min. The extrudate was quenched in a water bath and pelletized. The resulting extruder-mixed, diamine-modified nylon pellets were then molded as in Example I at 177°C into a ' 20 mil (508 micro meters) thick sheet. The sample was prepared and tested in the same manner as described in Example 1 except the extruder-mixed, diamine-containing nylon sheet was used instead of the internal bowl-mixed, diamine-containing sheet. Test results and process conditions are summarized in Table 2.
Example 7 In Example 7, a sample was prepared and tested as in Example 6 except Grilamid~ L25W40X nylon 12, available from EMS-Chemie AG, was used in the extruder-mixed, modified-nylon layer and the unmodified nylon layer instead of Vestamid~ L2140 nylon 12. Test results and process conditions are summarized in Table 2.
Example 8-10 In Examples 8-10, samples were prepared to simulate a process, such as coextrusion. These samples were prepared using the three materials described in Example 6, but preheating the three components for 3 minutes at 177°C, then pressing the three components together with the extruder-mixed, diamine-modified, nylon 12 sheet between the THV 500 fluoropolymer and the nylon 12 sheets, but at a lower pressure of 0.75 psi (S kl?a) and the other process conditions as shown in Table 2. The samples were then tested in same way as described in Example 1.
Test results and process conditions are summarized in Table 2.
is v.e.~'a~ ~1957~0 W096/05965 ~ PCT~S95/10516 Comparative Exam~,lhe CS
In Comparative Example C5, a sample was prepared and tested as in Example 9 except the time in the press was shortened as shown in Table 2. Test results and process conditions are summarized in Table 2.
Table 2 ' Example Time Temp. Pressure Peel # (Min.) C (kPa) (kg/ 2.54 cm.) 6 3 177 24 24.1
Such polymers and copolymers can be prepared by conventional free-radical polymerization of such ethylenically unsaturated monomers. The degree of crystalIinity of the hydrocarbon polymer or copolymer is not critical. The polymer may, for example, be a semi-crystalline high density polyethylene or may be an elastomeric copolymer of ethylene and propylene. Although not necessary to the performance of the hydrocarbon polymer within the present invention, carboxyl, anhydride, or imide functionalities may be incorporated into the polymer or copolymer by polymerizing or copolymerizing functional monomers, for example, acrylic acid or malefic anhydride, or by modifying a polymer after polymerization, for example by oxidation. The carboxyl, anhydride, or imide functional polymers useful as the hydrocarbon polymer are generally commercially available. For example, acid modified ethylene vinyl acetates, acid modified ethylene acrylates, anhydride modified ethylene acrylates, anhydride modified ethylene vinyl acetates, anhydride modified polyethylenes, and anhydride modified polypropylenes are available from DuPont as Bynel'"" coextrudable adhesive resins.
In addition to the melt-processable aliphatic di- or polyamine, the compositions of the present invention having a first layer comprising a fluoropolymer and a second layer comprising a hydrocarbon polymer may contain one or more tackifiers to improve inter-layer adhesion. Although suitable tackifiers vary greatly in chemical structure, the most useful tackifier compounds generally will have a softening point between approximately 90 °C and I50 °C. Preferably, tackifiers used in accordance with this invention are combined along with a suitable di- or polyamine and incorporated into the hydrocarbon polymer-containing layer to comprise between I and 50 weight percent of the hydrocarbon layer.
Tackifiers useful for this purpose include any of the tackifier compounds known to improve adhesion performance characteristics of elastomer-based adhesives. Such compounds include, for example, the following: rosins, including gum rosins, tall oil rosins, wood rosins; polymerized rosins, hydrogenated rosins, _7-WO 96105965 x "~ y'''~ 4'rt s ~ ~ ~ 9 5 7 9 0 PCT/US95110516 and disproportionated rosins; rosin esters, including pentaerythritol-wood rosins, pentaerythritol-stabilized rosins, and glycerine-hydrogenated wood rosins;
hydrocarbon resins, including aliphatic and cycloaliphatic resins, aromatic resins, petroleum resins, and dicyclopentadiene; terpenes, including alpha-pinene, beta-pinene, d fimonene, and polyterpenes; and pure monomer resins, including styrene resins, styrene/AMS resins, and AMS/vinyl toluene resins.
Commercially available tackifiers useful in this invention include ArkonTM P-125 tackifier, a hydrogenated C9 aromatic hydrocarbon, and Super EsterTM W-125 modified rosin ester tacltifier, both available from Arakawa Chemical USA., Inc.;
and PiccolyteTM S I 15 terpene resin tackifier, available from Hercules, Inc.
The mixing of the di- or polyamine may be by conventional means. For example, the di or polyamine can be melt-processed with the second layer material, for example nylon. In some cases the di or polyamine may react with the second layer material such that the second layer material becomes modified. For example, a diamine such as 1,12 dodecyl diamine (DDDA) may be blended into a polyamide such as nylon 12, resulting in a modified nylon. The modified nylon and a vinylidene fluoride monomer unit-containing fluoropolymer could then be coextruded to form a multi-layer article, such as a film or a tube.
The heat and pressure of the method by which the layers are brought together, for example normal coextrusion processes, may be adequate to provide sufficient adhesion. However, it may be desirable to further treat the resulting multi-layer composition, for example, with additional heat or pressure or both. One way of supplying extra heat when the multi-layer composition is prepared by extrusion is by delaying the cooling of the composition because the composite is hot as a result of the coextrusion process. Where additional heating or pressure is desired, it may be accomplished by performing the steps of applying or coextruding at a temperature higher than necessary for merely processing the several components. Alternatively, the finished article may be held at an elevated temperature for an extended period of time, or the finished article may be placed in a separate means for elevating the temperature of the article, such as an oven or heated liquid bath. A combination of these methods may also be used.
_g_ ~ ~t~H ~.~ ~'~9~790 R'O 9b105965 - - pCT/17g95/10516 The methods of this invention provide multi-layer compositions with improved inter-layer adhesion v The methods and compositions of this invention are particularly useful for making articles, such as tubing and hoses, suitable for use in motor vehicles, for example as fuel-line hoses, and for films and blow-molded articles such as bottles where chemical resistance or barrier properties are important. The two-layer compositions of this invention are also useful in preparing compositions having three or more layers. For example, a three layer composition of fluoropolymer to anhydride modified polyolefin to unmodified polyolefin could be prepared and might be useful in a fuel-tank construction.
Transparent embodiments of multi-layer compositions of the present invention may find particular utility in the construction of retroreflective sheeting articles generally, and particularly when resistance to chemical agents, solvents, soils, reduced moisture vapor transmission or good interlayer adhesion in flexible sheetings subject to severe bending and flexing is required.
The compositions ofthis invention may be rendered retroreflective by forming retroreflective elements on one side of the composition, or alternatively, by attaching a retroreflective base sheet by means of a transparent adhesive or by direct lamination. The retroreflective base sheet may comprise a member with cube corner retroreflective elements or may comprise a microsphere-based retroreflective structure, e.g. comprising a monolayer oftransparent microspheres and reflective means disposed on the opposite side ofthe monolayer from the multi-layer composition. It is preferred that the base layer is disposed on the non-ffuoropolymer layer of the multi-layer composition. An embodiment of this invention includes the encapsulated retroreflective sheeting article as is disclosed in U.S. Patent No. 3,190,178, in which the cover layer is provided by a multi-layer composition according to the present invention.
Retroreflective articles of the invention may be made in rigid or flexible form. Multi-layer compositions of the present invention may be used as barrier layers. An embodiment of the present invention includes articles in accordance with U.S. Pat. No. 5,069,964, in which the plasticiser resistant barrier layer comprises a multi-layer composition in accordance with the present invention. The multi-layer _9_ ry~:k :,;~;.;.~: 2195790 compositions of the present invention may find particular utility in the construction of flexible retroreflective sheeting articles. A preferred embodiment of the present invention includes a retroreflective article in accordance with PCT WO
95/11464 or PCT/WO 95/11943, wherein the flexible overlay film described in PCT WO
95/11464 or the flexible body layer of PCT/WO 95/11943 is constituted by a multi-layer composition in accordance with this invention. Suitable fluoropolymers comprising interpolymerized units of vinylidene fluoride of the type specified for use with flexible sheeting in accordance with these two patent applications may be poly(vinylidene fluoride-co-hexafluoropropylene), for example, Kynar FIexTM-available from Elf Atochem North America, Inc., Philadelphia, Pennsylvania, or poly(tetrafluoroethylene - co -hexafluoropropylene - vinylidene fluoride), for example, THV 200 or 500 available from 3M, St. Paul, Minnesota. The non-fluoropolymer layer of the present invention in such constructions may be any of the non-fluoropolymers specified in the above patent applications, for example, 1 S ionomeric ethylene copolymers, low density polyethylenes, polyethylene copolymers, or aliphatic or aromatic polyurethanes or similar compounds. For highly flexible products, a multi-layer composition of this invention that include a THV layer and a polyurethane layer is particularly preferred. The microstructure elements including either solidly connected or segregated cube corners may be microreplicated, preferably onto the non-fluoropolymer layer. Alternatively, the multi-layer compositions may be adhered to microstructure elements. As will be understood, any conventional form of retroreflective microstructure elements may be used including, for example, arrays of canted, tiled, specially shaped, colored, or colorless cube corner elements.
Similarly, multi-layer compositions according to the present invention may be used with retroreflective sheeting products including microspheres in a base Layer. Specific embodiments ofthe invention include retroreflective articles according to U.S. Pat Nos. 4,896,943, U.S. Pat No. 4,025,159 or U.S. Pat No.
5,066,098, all of which are included herein by reference, in which the cover film of U.S. Pat Nos. 4,896,943 or 4,025,159 or the cover sheet of U.S. Pat No.
5,066,098 is constituted by a multi-layer composition in accordance with this invention.
2'9579 Further, the,multi-layer compositions of the present invention may themselves include retroreflective micro-elements, such as transparent microspheres, incorporated into the fluoropolymer or the non-fluoropolymer layer, for example in a further embodiment of the present invention, the fluoropolymer layer of a multi-layer composition according to the present invention may constitute the continuous overlaying transparent topcoat of U.S. Pat. No. 3,551,025 and the non-fluoropolymer layer may constitute the binder of the same.
EXAMPLES
In the following Examples and Comparative Examples various multi-layer compositions were prepared and the adhesion between the layers was evaluated.
All concentrations and percentages are by weight unless otherwise indicated.
F~cample I -In Example 1, a 4 inch by 4 inch (10 cm by 10 cm) diamine-containing nylon sheet was prepared by melting 46 g of VestamidT"'i L2140 nylon 12, available from Huls Aktiengesellschaft, using a Rheomix~ 600 internal bowl mixer equipped with roller blades, available from Haake Buchler Instruments Inc., set at a temperature of 200°C and a mixer rotor setting of 10 rpm. After mixing the melted nylon for 1 minute, 0.23 g (0.5% by wt.) of 1,12-dodecyl diamine (DDDA), available from Aldrich Chemical Co., Inc., was added to and mixed into the melted nylon.
During the next 2 minutes, the temperature was gradually cooled down to 180°C
and the speed on the mixer rotor was increased to 50 rpm. The temperature and the rotor speed were then held for 3 minutes. The internal bowl-mixed, diamine-containing nylon was then removed from the mixer and molded at 177°C into a sheet about 20 mils (508 micro meters) thick using a 20 mil shim stock and a Wabash Hydraulic Press Co. heated platen press. After cooling to room temperature, the sheet was cut into a square 4 in. by 4 in. (10 cm by 10 cm). A composite was made with the sheet ofinternal bowl-mixed, diamine-containing nylon and 3 layers of 10 mil (254 micro meters) thick sheets of a terpolymer of tetrafluoroethylene (TFE), ~~~;i E~~;~ 239190 R'096105965 - p~n7S95I10516 hexafluoropropylene (F~?P) and vinylidene fluoride (VDF), made from resin available from 3M Co. as THV 500. An 18 mil (457 micro meters) thick sheet of unmodified Vestamid"~' L2140 nylon 12 was applied to the other side of the internal bowl-mixed, diamine-containing nylon sheet giving a final structure of a layer of .
unmodified nylon 12, the middle layer of a internal bowl-mixed, diamine-containing nylon sheet and a third layer of the three 10 mil (254 micro meters) sheets of THV
500.
The adhesion between the layers was tested using ASTM D-1876, commonly known as a "T-peel" test. To facilitate testing via the T-peel test, a sheet of 3 mil (76.2 micro meters) polyester (PET) film coated with a silicone release agent was placed between the internal bowl-mixed, diamine-containing nylon 12 layer and the THV layer and a second sheet was placed between the internal bowl-mixed, diamine-containing nylon 12 layer and the nylon 12 layer. The release-coated PET films were both inserted about 2.5 cm only along the same edge of the 4 inch by 4 inch (10 cm by 10 cm) sample. The sheet ofpolyester did not adhere to any of the layers and was used only to create a THV "tab" and a nylon 12 "tab"
to insert into the jaws of a test device. A "middle" tab of internal bowl-mixed, diamine-containing nylon was also present, but not used during the test.
The resulting composite was heated under pressure using a Wabash Hydraulic Press Co. heated platen press at 177°C and 3.5 psi (24 kPa) for 3 minutes. The sample was removed from the press and allowed to cool to room temperature. The resulting sample was cut into three 1-inch (2.54 cm) wide strips.
Peel strength or adhesion was measured on the three strips in accordance with ASTM D 1876 (T-Peel Test). An Instron~ Model 1125 tester, available from Instron Corp., set at a 100 rrun/min crosshead speed was used as the test device. If there were many peaks recorded on the graph from the T-peel test, the peel strength was calculated in accordance with ISO 6133=81. The value reported was the average of testing three samples. The average peel strength on the strips from Example I is reported in Table 1.
Colt parative Examples C1 and C2 __ w0 96105965 In Comparative Examples C1 and C2, samples were prepared and tested as in Example 1 except a nylon 12 sheet was applied directly to the THV 500 sheets without a middle layer of internal bowl-mixed, diamine-containing nylon. The time in the press and the test results are summarized in Table I .
Exam le nd 3 In Examples 2 and 3, samples were prepared and tested as described in Example 1 except the amount of DDDA additive was varied as shown in Table 1.
The time in the press and the test results are summarized in Table I .
In Example 4, a sample was prepared and tested as in Example 1 except 1.0% Jeff'amine~ EDR-148 polyoxyalkylene polyamine, available from Texaco Inc., was used instead of the DDDA. The time in the press and the test results are summarized in Table 1.
In Comparative Example C3, a sample was prepared and tested as in Example 1 except 0.23 g of octadecyl amine (ODA), available from Aldrich Chemical, was added to the nylon instead of DDDA. The time in the press and the test results are summarized in Table I.
In Example 5, a sample was prepared and tested as in Example 1 except the internal bowl-mixed, diamine-containing nylon layer was replaced by a nylon layer which had been prepared by soaking an 18 mil (457 micro meters) sheet of the unmodified nylon 12 used in Example I, in a 5% HIVmA methanol solution for 18 hours and drying the soaked sheet at 80°C for 2 hours. The time in the press and the test results are summarized in Table 1.
Comparative Exam 1~-wo vsiosvss i'~ '.~ ~: ~ ~' 1. S 219 5 7 9 0 PCT/U595l10516 In Comparative Example C4, a sample was prepared and tested as in Example 1, except the amount ofDDDA added to the nylon was only 0.1%. The time in the press and the test results are summarized in Table 1.
Table 1 Example Nylon Modifier Time Peel ' (Min.) (kg/2.54 cm) 1 0.5% DDDA 3 16.8 2 0.3% DDDA 3 13.0 3 I .0% DDDA 3 22.8 4 1.0% JeffamineTM EDR-483 22.5 C3 0.5% ODA 3 1.2 5 0.5% HMDA soak 3 7.6 Cl ____ 3 0 2 C2 _____ 6 0.2 C4 0.1% DDDA 3 0.1 The data in Table 1 show that substantially improved adhesion between the layers may be obtained if a sufficient amount of a diamine component is added to a nylon layer. Substantial improvements are achieved over the samples without any or only low levels of diamine modifier. The mono-amine of Comparative Example C3 showed only a minor improvement over the control without amine.
Example 6 -In Example 6, a sample was prepared and tested as in Example 1 except the diamine and nylon were melt blended using a Rheomex'M TW 100 conical twin screw extruder with high intensity screws, available from Haake Buchler Instruments Inc., instead of the Haake RheomixT"' 600 internal bowl mixer.
Prior to adding the materials to the extruder, 2000 g of Vestamid~ L2140 nylon 12 pellets, and 11.06 g of DDDA (0.55% by wt.) ground to a fine powder by using a \.
VVO 96105965 ~ . ~ ~ r~ ~ } ~ ~ 1 ~ 5 7 9 0 P~,~S95/10516 mortar, were pre-mixed in a plastic bottle by hand shaking. The pre-mixed blend was fed to the twin-screw extruder by a AccuRate'~' solids feeder and extruded as a strand at 230°C and 150 rpm giving a through-put rate of 39 g/min. The extrudate was quenched in a water bath and pelletized. The resulting extruder-mixed, diamine-modified nylon pellets were then molded as in Example I at 177°C into a ' 20 mil (508 micro meters) thick sheet. The sample was prepared and tested in the same manner as described in Example 1 except the extruder-mixed, diamine-containing nylon sheet was used instead of the internal bowl-mixed, diamine-containing sheet. Test results and process conditions are summarized in Table 2.
Example 7 In Example 7, a sample was prepared and tested as in Example 6 except Grilamid~ L25W40X nylon 12, available from EMS-Chemie AG, was used in the extruder-mixed, modified-nylon layer and the unmodified nylon layer instead of Vestamid~ L2140 nylon 12. Test results and process conditions are summarized in Table 2.
Example 8-10 In Examples 8-10, samples were prepared to simulate a process, such as coextrusion. These samples were prepared using the three materials described in Example 6, but preheating the three components for 3 minutes at 177°C, then pressing the three components together with the extruder-mixed, diamine-modified, nylon 12 sheet between the THV 500 fluoropolymer and the nylon 12 sheets, but at a lower pressure of 0.75 psi (S kl?a) and the other process conditions as shown in Table 2. The samples were then tested in same way as described in Example 1.
Test results and process conditions are summarized in Table 2.
is v.e.~'a~ ~1957~0 W096/05965 ~ PCT~S95/10516 Comparative Exam~,lhe CS
In Comparative Example C5, a sample was prepared and tested as in Example 9 except the time in the press was shortened as shown in Table 2. Test results and process conditions are summarized in Table 2.
Table 2 ' Example Time Temp. Pressure Peel # (Min.) C (kPa) (kg/ 2.54 cm.) 6 3 177 24 24.1
7 3 177 24 21.5
8 1 177 5 1.0
9 I 204 5 4.0 3 204 5 24.5 CS I 0.5 I 204 I 5 I 0.1 The data in Table 2 show substantial adhesion improvements are possible
10 under properly selected process conditions.
Examples 11 -In Example 11, a polyurethane polymer was evaluated for bonding to a fluoropolymer. Samples were prepared in an identical manner as for Example 1 except that 0.23 g (0.5% by wt.) of 1,12-dodecyldiamine (DDDA), available from Aldrich Chemical Co., Inc., was blended with 46 grams of PE-192 polyurethane, available from Morton International, Inc. A three-layer composite sheet was prepared for testing as in Example 1 comprising a sheet of THV 500, a sheet of the above prepared composition, and a sheet PE-192 polyurethane. The average peel strength of the strips is reported in Table 3.
F' s".~" ~ f~ t 4.
W O 96!05965 . - . .,~ ~ ~ 9 5 7 9 0 pCT~7S95110516 Example 12 In Example 12, samples of the invention were prepared and tested as in Example 11, except that the three-layer sheet comprised THV 200, a sheet of the - prepared composition ofExample 11, and a sheet ofMorton PN03-214 urethane.
The average initial peel strengths of the strips are reported in Table 3.
Tests carried out one week later demonstrated that the composite strip had become inseparable due possibly to the continuation of the bonding reaction at room temperature.
In Comparative Example C6, samples were prepared as in Example 1 I, except that a sheet of PE-192 polyurethane was applied directly to the THV 500 sheet without a middle layer of internal bowl-mixed, diamine-containing polyurethane. The average peel strength of the strips is reported in Table 3.
Table 3 Example DDDA (%) Time Peel Min. k /2.54 cm
Examples 11 -In Example 11, a polyurethane polymer was evaluated for bonding to a fluoropolymer. Samples were prepared in an identical manner as for Example 1 except that 0.23 g (0.5% by wt.) of 1,12-dodecyldiamine (DDDA), available from Aldrich Chemical Co., Inc., was blended with 46 grams of PE-192 polyurethane, available from Morton International, Inc. A three-layer composite sheet was prepared for testing as in Example 1 comprising a sheet of THV 500, a sheet of the above prepared composition, and a sheet PE-192 polyurethane. The average peel strength of the strips is reported in Table 3.
F' s".~" ~ f~ t 4.
W O 96!05965 . - . .,~ ~ ~ 9 5 7 9 0 pCT~7S95110516 Example 12 In Example 12, samples of the invention were prepared and tested as in Example 11, except that the three-layer sheet comprised THV 200, a sheet of the - prepared composition ofExample 11, and a sheet ofMorton PN03-214 urethane.
The average initial peel strengths of the strips are reported in Table 3.
Tests carried out one week later demonstrated that the composite strip had become inseparable due possibly to the continuation of the bonding reaction at room temperature.
In Comparative Example C6, samples were prepared as in Example 1 I, except that a sheet of PE-192 polyurethane was applied directly to the THV 500 sheet without a middle layer of internal bowl-mixed, diamine-containing polyurethane. The average peel strength of the strips is reported in Table 3.
Table 3 Example DDDA (%) Time Peel Min. k /2.54 cm
11 0.5 3 1.5
12 0.5 3 2.0 C6 _--__ 3 0.1 Examples 13 and 14 In Examples 13 and 14, carboxyl-containing hydrocarbon elastomers were evaluated for bonding to THV 500. Samples were prepared as in Example 1 except a diamine was added to a hydrocarbon elastomer which was used instead of the sheet of nylon 12 used in Example I. The ingredients used in each sheet of elastomer were compounded on a two-roll mill using conventional methods. The DIAKTM #1 and DIAKT~s #3 contained the diamine functionalities in a blocked form. The compositions of the compounded elastomer sheets are summarized in Table 4. All amounts referred to therein are in parts per 100 parts by weight rubber abbreviated "phr". Table 5 lists the sources for the ingredients shown in Table 4. A
sheet about 2 mm thick was formed from each elastomer composition by using the f ' ~ ~~ PCTlUS95/10516 two-roll mill. Samples of the invention were then prepared as in Example I
except using the above prepared elastomer sheets instead of the nylon 12 sheet. The samples were then held in the press at 177°C for 6 minutes instead of 3 minutes.
Test results are summarized in Table 6.
Table 4: Preparation of Elastomers Vamac HytempT"'' 4051EP 100 Vamac~ HGB-124 124 N-774 Carbon Black 35 N-550 Carbon Black 65 Stearic Acid 1 2 Armeen 18D 0.5 DiakT"~ #1 1.25 DiakTM #3 3 AgeRite Stalite S 1 Diphenylguanidine 4 Table 5 rh,~ ource Hytemp'"~4051EP
(acrylic ester copolymer) Zeon Chemical Vamac~HGB-124 (ethylene/acrylic rubber) DuPont Stearic acid EM Science Armeen'~"~ 18D (octadecyl amine) Armak Co.
Diak~ #1 (hexamethylene diamine carbamate)DuPont Diak~ #3 (N,N'dicinnamilidene-1,6-hexandiamine)DuPont AgeRite Stalite~ S (anti-oxidant) - R.T.Vanderbilt DPG (diphenyl guanidine) American Cyanamid , Example 15 In Example 15, a 508 micrometer thick molded sheet of an amine-modified olefin was made by mixing 0.23 g of DDDA with 46 g BynelTM 4003 adhesive resin, R'O 96/05965 ~.-' ~~' ~ ~ '' ~~ ~~ . 2 ~ 9 ~ 7 9 0 an anhydride-modified HDPE (AM-HDPE), available from DuPont, in the internal mixer as in Example 1. A sample of the invention was made using the sheet of the amine-containing ByneITM 4003 AM-HDPE bonded to the THV 500 sheet.
A sheet of unmodified LS901046 HDPE, available from Quantum, was placed on the other surface of the amine-containing BynelTM 4003 AM-HDPE sheet. The resulting three layer sample was pressed and tested as in Example I . Test results are summarized in Table 6.
F~amole 16 In Example 16, a sample was prepared and tested as in Example 15, except DDDA was mixed into oxidized polyethylene with an acid number of 15 mg KOH
per g, available from Aldrich Chemical, at 100°C and the resulting amine-containing oxidized polyethylene was used for the middle layer. Test results are summarized in Table 6.
I S All Examples shown in Table 6 were run at a pressure of 3.5 psi (24 kPa).
Table 6 Example Substrate Time Peel (Min.) (kg/2.54 cm)
sheet about 2 mm thick was formed from each elastomer composition by using the f ' ~ ~~ PCTlUS95/10516 two-roll mill. Samples of the invention were then prepared as in Example I
except using the above prepared elastomer sheets instead of the nylon 12 sheet. The samples were then held in the press at 177°C for 6 minutes instead of 3 minutes.
Test results are summarized in Table 6.
Table 4: Preparation of Elastomers Vamac HytempT"'' 4051EP 100 Vamac~ HGB-124 124 N-774 Carbon Black 35 N-550 Carbon Black 65 Stearic Acid 1 2 Armeen 18D 0.5 DiakT"~ #1 1.25 DiakTM #3 3 AgeRite Stalite S 1 Diphenylguanidine 4 Table 5 rh,~ ource Hytemp'"~4051EP
(acrylic ester copolymer) Zeon Chemical Vamac~HGB-124 (ethylene/acrylic rubber) DuPont Stearic acid EM Science Armeen'~"~ 18D (octadecyl amine) Armak Co.
Diak~ #1 (hexamethylene diamine carbamate)DuPont Diak~ #3 (N,N'dicinnamilidene-1,6-hexandiamine)DuPont AgeRite Stalite~ S (anti-oxidant) - R.T.Vanderbilt DPG (diphenyl guanidine) American Cyanamid , Example 15 In Example 15, a 508 micrometer thick molded sheet of an amine-modified olefin was made by mixing 0.23 g of DDDA with 46 g BynelTM 4003 adhesive resin, R'O 96/05965 ~.-' ~~' ~ ~ '' ~~ ~~ . 2 ~ 9 ~ 7 9 0 an anhydride-modified HDPE (AM-HDPE), available from DuPont, in the internal mixer as in Example 1. A sample of the invention was made using the sheet of the amine-containing ByneITM 4003 AM-HDPE bonded to the THV 500 sheet.
A sheet of unmodified LS901046 HDPE, available from Quantum, was placed on the other surface of the amine-containing BynelTM 4003 AM-HDPE sheet. The resulting three layer sample was pressed and tested as in Example I . Test results are summarized in Table 6.
F~amole 16 In Example 16, a sample was prepared and tested as in Example 15, except DDDA was mixed into oxidized polyethylene with an acid number of 15 mg KOH
per g, available from Aldrich Chemical, at 100°C and the resulting amine-containing oxidized polyethylene was used for the middle layer. Test results are summarized in Table 6.
I S All Examples shown in Table 6 were run at a pressure of 3.5 psi (24 kPa).
Table 6 Example Substrate Time Peel (Min.) (kg/2.54 cm)
13 ACM 6 14.6
14 Vamac 6 4.5 0.5% DDDA in HDPE - 3 21.1 16 5.0% DDDA in oxidized 3 0.8 PE
The data in Table 6 show that the methods of this invention are usefixl for increasing the bonding to carboxyl-containing and anhydride-containing polyolefins.
Exam lp a 17 In Example 17, a 508 micro meter thick molded sheet amine-containing polyolefin was made by mixing 0.5 % of DDDA with BynelTM 1123 adhesive resin, said to be an acid-modified ethylene vinyl acetate (AC-EVA), available from 2 l 9 5 7 9 0 PCTIUS95110516 DuPont, in the internal mixer as in Example 1. A sample of the invention was made using the sheet of the amine-containing BynelTM 1123 AC-EVA bonded to the THV
500 sheet. A sheet ofKal-Glass polyvinylchloride, available from Ellay, Inc., was placed on the other surface of the amine-containing BynelTM 1123 AC-EVA sheet.
The resulting three layer sample was pressed and tested as in Example 1. Test results are summarized in Table 7.
Exam lp a 18 In Example 18, a sample of the invention was made as in Example 17, except the fluoropolymer was a terpolymer of tetrafluoroethylene (TFE), hexafluoropropylene (HFP) and vinylidene fluoride (VDF), made from resin available from 3M Co. as THV 200, instead ofTHV 500. The process conditions were changed as summarized in Table 7. Test results are summarized in Table 7.
Exam Ip a 19 In Example 19, a sample of the invention was made as in Example 17, except 46 g of an anhydride-modified polypropylene, BynelTM E302 adhesive resin, available from DuPont, was used instead of the ByneITM 1123 acid modified EVA. Also, a sheet of Santoprene~" thermoplastic elastomer, available from Advanced Elastomers Systems, was used as the outer layer instead of the PVC layer. The three layers were pressed using the conditions in Table 6 and tested as in Example 1. Test results are summarized in Table 7.
All Examples shown in Table 7 were run at a pressure of 3.5 psi (24 kPa).
Table 7 Example Temperature Time Peel C (Min.) (kg/2.54 cm) 17 177 6 5.8 18 162 3 0.8 19 177 10 I 8.5 ~;l?c;-~y~'~ 27 95790 Example 19 illustrates the usefillness of the method of this invention in preparing compositions with three or more layers.
l~le 20 ' In Example 20, a sample was prepared and tested as in Example 1, except the nylon 12 layer was replaced by a nylon layer which had, been prepared by first soaking nylon 12 pellets in a 5% HMDA methanol solution for 18 hours and drying at 80°C for 2 hours, and then pressing the resulting dried pellets into an 18 mil (457 micro meters) sheet as in Example 1. The nylon modifier and the test results are summarized in Table 8.
Table 8 Example Nylon Modifier Time Pressure Peel (Min.) (Psi) (kg/in.) I 0.5% HMDA soak 3 3.5 7.6 In Example 21, a molded sheet of a 508 micrometers thick amine-modified polymer was made by mixing 0.23 g of DDDA with 46 g of AdmerTM SF600 poIyolefin based resin, available form Mitsui Petrochemicals America Co., having a density of 0.88 g/cm3 and a melt flow rate measured in accordance with ASTM D
1238 at 190 °C under 2.16 kg of 3.3 g/10 min and believed to be a blend of AM-HDPE and a ethylene/propylene copolymer with a tackifier, in an internal mixer as was done for Example 1. A sample of the invention was then prepared by bonding the sheet of the amine-containing AdmerTM SF600 resin to a sheet of THV 500 fluoroplastic. A sheet of unmodified LS901046 high density polyethylene (HDPE), available form Quantum Corp., was placed on the opposing side of the amine-containing AdmarTM SF600 resin sheet. The resulting three layer sample was pressed and tested as in Example 1. Table 9 summarizes the test results.
j',~y.iF'.~ f S, 219~~90 Example 22-25 _ _ . _ _ _ __ _ ._. _ __ In Examples 22-25, samples were prepared and tested as in Example 21, except that, respectively, AdmerT"' SF700A, SF710A, SE800, and SE810 polyolefin resins, available form Mitsui Petrochemicals America Co., having densities of 0.88, 0.90, 0.90, and 0.89 g/cm~ respectively, melt flow rates measured in accordance with ASTM D 1238 at 190 °C under 2.16 kg of 1.0, 3.4, 4.4, and 7.2 g/10 min respectively, and all believed to be blends of AM-HDPE and a ethylene/propylene copolymer with a tackifler, were used in place of AdmerTM
SF600. Test results and process conditions are summarized in Table 9.
Comparative Exam 1R a C7 -In comparative Example C7, a sample was prepared and evaluated as in Example 21, except that DDDA was not added to the AdmerTM SF600: Test 1 S results and process conditions for this comparative sample are summarized in Table 9.
Table 9 Example DDDA (%) Time (Min.) Peel (kg/2.45 cm) 21 0.5 1 10.8 22 0.5 1 6.7 23 0.5 I 1.5 24 0.5 1 4.0 25 0.5 1 6.5 C7 ____ 1 0.1 The data ofTable 9 demonstrate that the samples ofthe present invention that contain a diamine exhibit much improved layer adhesion.
Examples 26-27. . ...__ . .. _ _..__.... _ ~ _. .. . .
In Examples 26 and 27, samples were prepared in a manner designed to simulate co-extrusion. These samples were prepared using the three layers wo 9s~o59s5 ~;.' ~' ~''" ~;' 'r ~ 2 ~ 9 5 7 9 0 described in Example 21, preheating the three components for 3 minutes at 260 °C
and pressing the three layers together with the extruder-mixed, diamine-modified polymer sheet between the THV 500 fiuoroplastic and the HDPE sheets at a pressure of 5 IcPa under the process conditions shown in Table 10. The samples were tested in the same manner as described for Example 21.
Table 10 Example Time (sec.) Temp (C) Pressure Peel (kPa) k 2.45 cm 26 10 260 5 10.0 27 20 260 5 10.5 The data of Table 10 show substantial adhesion improvements under properly selected process conditions for those samples containing a diamine over those samples not containing a di- or polyamine.
In examples 28 and 29, samples were prepared and tested as in Example 21 IS except that, respectively, VestamidT"~ 1.2140 nylon 12, available form Huls Aktiengesellschaft, and SantopreneTM 201-73 thermoplastic elastomer, having a Shore A hardness of 73 and a specific gravity of 0.98, available form Advanced Elastomer Systems, Inc., were used in place of the HDPE substrate sheet. Test results and process conditions are summarized by Table 11.
Table 11 Example Substrate Time (min.) Peel (kg/2.45 cm) 28 nylon 12 1 3.4 29 Santoprene 1 4.5 WO 96105965 ~~ ~ ~ r ~- ~' 't ~ ! ~',~ ~ ~ ~ PCT/U595/10516 ~xam~e 30 _ -In Example 30, a 508 micrometer thick molded sheet of an amine-modified polymer composite was made by mixing 0.23 g of DDDA with 32.2 g of PolysarTM
EPM 306 ethylene propylene rubber, available form Bayer, Inc., and 2.3 g of BynelTM 4003 adhesive resin, an anhydride-modified HDPE available form E.I. du Pont de Nemours and Company, and 11.5 g of ArkonTM P-125 tackifler, a ' hydrogenated C9 aromatic hydrocarbon resin tackifler (softening point 125 °C) availabie form Arakawa Chemical USA Inc., in an internal mixer as in Example 1.
A sample of the invention was then prepared by bonding the sheet of the amine-containing PolysarTM EPM 306 rubber to a sheet of THV 500 fluoroplastic according to the method described in Example I. A sheet of unmodified LS901046 HDPE, available form Quantum Corp., was placed on the opposing surface of the amine-containing polymer composite sheet. The resulting three layer sample was pressed and tested as in Example I . The time in the press and test results are summarized by Table 12.
Exam 1pe31 In Example 31, a sample was prepared and tested as in Example 30 except that PiccolyteT"' S115 terpene resin tackifier (softening point I 15 °C), available form Hercules, Inc., was used in place of the ArkonTM P-125 tackifier. Test results and process conditions for this sample are summarized by Table 12.
Exam I,~ a 32 In Example 32, a sample was prepared and tested as in Example 30 except that Super EsterTM W-125 modified rosin ester tackifier (softening point 125 °C), available form Arkawa Chemical USA, Inc., was used in place ofthe ArkonTM P-125 tackifier. Test results and process conditions for this sample are summarized by Table 12.
~~nct~-P
W O 96105965 -- ~ .- 219 5 7 9 0 pCT/I7S95/I0516 W a rat ve Fxamnle .8 r-For Comparative Example C8, a sample was prepared and evaluated as in Example 30 except that DDDA was not added to the polymer composite. Test results and corresponding process conditions for this comparative sample are 3 summarized by Table 12.
Table 12 E:ample Tackifier DDDA (%) Time (min.) Peel k /2.45 cm 30 hydrocarbon 0.5 I 6.5 resin 31 terpene resin0.5 1 8.1 32 rosin ester 0.5 1 1.5 C8 hydrocarbon ----- I 0.1 resin i The data of Table 12 demonstrate substantially improved adhesion speed between layers may be obtained by addition of both a tackifier and a diamine to the polymer composite.
Examples 33-34 In Examples 33 and 34, a 508 micrometer thick molded sheet of an amine-IS modified polymer composite was made by mixing 0.23 g ofDDDA with 46.0 g of Polysar''M EPM 306 ethylene propylene rubber, available form Bayer, Inc., in an internal mixer as in Example 1. A sample of the invention was then prepared by bonding the sheet of the amine-containing PolysarT"~ EPM 306 rubber to a sheet of THV 500 fluoroplastic according to the method described in Example 1. A sheet of unmodified LS901046 HDPE, available form Quantum Corp., was placed on the opposing surface of the amine-containing polymer composite sheet. The resulting three layer sample was pressed and tested as in Example 1. The time in the press and test results for each example are summarized by Table 13.
WO 96105965 ' ' ~ ~'~ ~ ~ ~' ~ ~ ~ 2 ~ 9 5 7 9 0 PC'fIUS95110516 Comparative Example C9 For Comparative Example C9, a sample was prepared and evaluated as for Examples 33-34 except that DDDA was not added to the polymer composite. Test results and corresponding process conditions for this comparative sample are summarized by Table 13.
Table 13 Example DDDA (%) Time (min.) Peel k /2.45 cm 33 0.5 1 1.7 34 0.5 3 2.4 C9 _____ 1 * The layers of this sample did not-sufficiently adhere to one another to perform the test.
The data of Table 13 demonstrate that samples of the invention that contain a diamine and wherein the hydrocarbon polymer component comprises an elastomeric copolymer of ethylene and propylene exhibit much improved layer adhesion.
Example 35 In Example 35, a sample of the invention was prepared in the same manner as for Examples 33 and 34 except that 11.5 g of ArkonT~~ P-125 tackifter, a hydrogenated C9 aromatic hydrocarbon resin tackifier (softening point 125 °C) available form Arakawa Chemical USA Inc., was added to the ethylene propylene rubber along with the diamine, and that only 34.5 g of the ethylene propylene rubber was used. The resulting three layer sample was pressed and tested as in Example 1, and the time in the press and test results are summarized by Table 14.
Exam lp a 36 In Example 36, a sample was prepared and tested as in Example 35, except 10 mil (0.25 mm) thickness sheet ofKynarTM 740 polyvinylidene fluoride (PVDF), ~~'~~'~' V
WO 96105965 21 g 5 7 9 0 PCT/US95/I0516 available from Atochem, was used in place of the THV 500 fluoropolymer. The time in the press and test results are summarized in Table 14.
Comparative Exam le 10 For Comparative Example C10, a sample was prepared and evaluated as for Example 35 except that DDDA was not added to the polymer composite. Test results and corresponding process conditions for this comparative sample are summarized by Table 14.
Table 14 Example Substrate DDDA (%) Time (min.) Peel k /2.45 cm 35 THV 500 0.5 1 6.5 36 PVDF 0.5 1 5.5 me payers or ims sample a~a not sufficiently adhere to one another to perform the test.
The data of Table 14 again demonstrate the improved inter-layer adhesion according to this invention using both a diamine and a tackifier.
Examples 37-38 In Examples 37 and 38, a 508 micrometer thick molded sheet of an amine-modified polymer composite was made by mixing 0.23 g ofDDDA with 34.5 g of BynelTM 4003 adhesive resin, an anhydride-modified HDPE available form E.I. du Pont de Nemours and Company, and 1 I .5 g of ArkonTM P-125 tackifier, a hydrogenated C9 aromatic hydrocarbon resin tackifier (softening point 125 °C) available form Arakawa Chemical USA Inc., in an internal mixer as in Example 1.
A sample of the invention was then prepared by bonding the sheet of the amine-containing Bynel'''~' 4003 resin to a sheet of THV 500 fluoroplastic according to the method described in Example 1. A sheet of unmodified LS901046 HDPE, available form Quantum Corp., was placed on the opposing surface of the amine-containing _27_ wo .9sros9ss i L' ~'~'~~..~ '~=' ~ ~ 9 5 ~ ~ ~
rcTrUS95!aosi6 polymer composite sheet. The resulting three layer sample was pressed and tested as in Example 1. The time in the press and test results are summarized by Table 15.
Table is Example DDDA (%) Time (min.) Peel k 12.45 cm 37 0.5 1 0.5 38 I 0.5 I 3 I 0.5 s The data of Table 15 demonstrate, that although not a preferred embodiment of the this invention, the addition of a tackifier and a diamine to anhydride-modified HDPE exhibits some improved adhesion characteristics over those samples that do not contain a di- or polyamine, for example as shown by Comparative Example C8. Preferred embodiments incorporate an amorphous hydrocarbon polymer along with the HDPE to enhance the performance of the tackifier, if one is employed.
Example 39 THV 200 was extruded onto a 61 micrometer thick, low shrinkage polyethylene terephthalate film to form a 12.7to 25.4 micrometer thick layer.
In a second pass a 50.8 to 76.2 micrometer thick layer of urethane (Morton L424.167) and a 12.7 micrometer thick tie layer comprising a blend of urethane (Morton L424.167) and 0.5% dodecyl diamine (Aldrich Chemical) were co-extruded onto the THV layer with the tie layer adjacent to the THV layer.
The resulting multi-layer composition was provided with a base layer by micro-replicating with retroreflective cube corners in accordance with the method described in PCT WO 95111464, in particular with figure 4 of the document and the associated description. A mixed acryiate solution (19.8% bisphenol A
diacrylate, 29.7% ietrahydrofuran acrylate and 49.5% trimethylol propane triacrylate with DaracureTM D4265 as the photoinitiator) was coated onto the urethane layer followed by micro-replicating by the method indicated above. The acrylate cube corners were first cured with visible light and then annealed with ultraviolet light.
_28_ ,;~~'~~ ~~~' 2195790 R'O 96105965 PCTIUS95110516 The retro-reflective properties of the multi-layer composition were measured to be in the range 700 to 1200 candle power at an observation angle of 0.33°
and an entrance angle of-4°.
The exposed cube corner layer was ultrasonically sealed with a 114.4 micrometer thick white urethane layer. A 127 micrometer layer of plasticiser ' resistant acrylate pressure sensitive adhesive was applied to the exposed surface of the white urethane layer and the complete multi-layer composition laminated to a 585 micrometer thick layer of blue canvas (DuraskinTM manufactured by Verseidag, Germany) comprising a polyester scrim impregnated with polyvinyl chloride.
The resultant material was subjected to a test simulating the folding and vibration of a retroreflective product applied to the flapping canvas covering of a truck being driven at low temperatures. The laminated sample was cut into squares of 34.9 mm x 34.9 mm. These squares were clamped individually between the steel jaws of a flexing tester (Dauerknickpruefer MP 49, manufactured by Karl Schroeder, Germany) with the jaws set initially at a distance of25.4 mm. The flexing tester was housed in a refrigerator (So-Low Environmental, Cincinnati) and the temperature reduced to -20 °C (-4 °F) and maintained at this temperature for the remainder of the test. The flexing tester was operated so that the distance between the jaws reciprocated between 25.4 mm and 4.75 mm at 2 cycles per second, the sample being tightly folded between the jaws at the minimum position with the THV layer forming the outermost layer of the fold. The samples withstood 2000-cycles without visible cracking or delamination of the layers.
~xamDle 40 THV 200, a blend of urethane (Morton L424.167) and dodecyl diamine (Aldrich Chemical) and urethane (Morton L424.167) were triple co-extruded to form a multi-IayeT composition comprising a 12.7 to 25.4 micrometer thick THV
layer, a 12.7 micrometer thick tie layer and a 50.8 to 76.2 micrometer thick urethane layer. The resulting composite layer was tested in a PermatranTM W6 instrument (Modem Controls, Inc., Minneapolis, Minn.) for moisture vapor transmission rate with the THV layer facing the source of moisture. The instrument f~ ti.',! ~-','~ '-'~-I : ; .. .
w:vlep.,, temperature was set at 38 °C with 100% humidity from deionized water.
Before each measurement, the instrument was calibrated with a polyester film sample supplied by the manufacturer. The moisture vapor transmission values for a composition in accordance with Example 39 are given in Table 16.
Example 41 A THV/tie layer/urethane layer was manufactured and tested as in Example 40 above except THV 200 was used for the THV layer. The moisture vapor transmission values for this composition are given in Table 16.
Comparative sample C 11 A film was manufactured from extruded polyurethane (Morton L424.167) and an application of ADSD 6912 two-part crosslinking polyurethane clear coat available from 3M, having a total thickness of 152.4 micrometer.
Table 16 Example Average Thickness Average Moisture Transmission Rate (micrometer) mm2/da 40 122 3 8.1 41 135 38.0 .
Cll 150 115.0 Various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope of this invention and this invention should not be restricted to that set forth herein for illustrative purposes.
The data in Table 6 show that the methods of this invention are usefixl for increasing the bonding to carboxyl-containing and anhydride-containing polyolefins.
Exam lp a 17 In Example 17, a 508 micro meter thick molded sheet amine-containing polyolefin was made by mixing 0.5 % of DDDA with BynelTM 1123 adhesive resin, said to be an acid-modified ethylene vinyl acetate (AC-EVA), available from 2 l 9 5 7 9 0 PCTIUS95110516 DuPont, in the internal mixer as in Example 1. A sample of the invention was made using the sheet of the amine-containing BynelTM 1123 AC-EVA bonded to the THV
500 sheet. A sheet ofKal-Glass polyvinylchloride, available from Ellay, Inc., was placed on the other surface of the amine-containing BynelTM 1123 AC-EVA sheet.
The resulting three layer sample was pressed and tested as in Example 1. Test results are summarized in Table 7.
Exam lp a 18 In Example 18, a sample of the invention was made as in Example 17, except the fluoropolymer was a terpolymer of tetrafluoroethylene (TFE), hexafluoropropylene (HFP) and vinylidene fluoride (VDF), made from resin available from 3M Co. as THV 200, instead ofTHV 500. The process conditions were changed as summarized in Table 7. Test results are summarized in Table 7.
Exam Ip a 19 In Example 19, a sample of the invention was made as in Example 17, except 46 g of an anhydride-modified polypropylene, BynelTM E302 adhesive resin, available from DuPont, was used instead of the ByneITM 1123 acid modified EVA. Also, a sheet of Santoprene~" thermoplastic elastomer, available from Advanced Elastomers Systems, was used as the outer layer instead of the PVC layer. The three layers were pressed using the conditions in Table 6 and tested as in Example 1. Test results are summarized in Table 7.
All Examples shown in Table 7 were run at a pressure of 3.5 psi (24 kPa).
Table 7 Example Temperature Time Peel C (Min.) (kg/2.54 cm) 17 177 6 5.8 18 162 3 0.8 19 177 10 I 8.5 ~;l?c;-~y~'~ 27 95790 Example 19 illustrates the usefillness of the method of this invention in preparing compositions with three or more layers.
l~le 20 ' In Example 20, a sample was prepared and tested as in Example 1, except the nylon 12 layer was replaced by a nylon layer which had, been prepared by first soaking nylon 12 pellets in a 5% HMDA methanol solution for 18 hours and drying at 80°C for 2 hours, and then pressing the resulting dried pellets into an 18 mil (457 micro meters) sheet as in Example 1. The nylon modifier and the test results are summarized in Table 8.
Table 8 Example Nylon Modifier Time Pressure Peel (Min.) (Psi) (kg/in.) I 0.5% HMDA soak 3 3.5 7.6 In Example 21, a molded sheet of a 508 micrometers thick amine-modified polymer was made by mixing 0.23 g of DDDA with 46 g of AdmerTM SF600 poIyolefin based resin, available form Mitsui Petrochemicals America Co., having a density of 0.88 g/cm3 and a melt flow rate measured in accordance with ASTM D
1238 at 190 °C under 2.16 kg of 3.3 g/10 min and believed to be a blend of AM-HDPE and a ethylene/propylene copolymer with a tackifier, in an internal mixer as was done for Example 1. A sample of the invention was then prepared by bonding the sheet of the amine-containing AdmerTM SF600 resin to a sheet of THV 500 fluoroplastic. A sheet of unmodified LS901046 high density polyethylene (HDPE), available form Quantum Corp., was placed on the opposing side of the amine-containing AdmarTM SF600 resin sheet. The resulting three layer sample was pressed and tested as in Example 1. Table 9 summarizes the test results.
j',~y.iF'.~ f S, 219~~90 Example 22-25 _ _ . _ _ _ __ _ ._. _ __ In Examples 22-25, samples were prepared and tested as in Example 21, except that, respectively, AdmerT"' SF700A, SF710A, SE800, and SE810 polyolefin resins, available form Mitsui Petrochemicals America Co., having densities of 0.88, 0.90, 0.90, and 0.89 g/cm~ respectively, melt flow rates measured in accordance with ASTM D 1238 at 190 °C under 2.16 kg of 1.0, 3.4, 4.4, and 7.2 g/10 min respectively, and all believed to be blends of AM-HDPE and a ethylene/propylene copolymer with a tackifler, were used in place of AdmerTM
SF600. Test results and process conditions are summarized in Table 9.
Comparative Exam 1R a C7 -In comparative Example C7, a sample was prepared and evaluated as in Example 21, except that DDDA was not added to the AdmerTM SF600: Test 1 S results and process conditions for this comparative sample are summarized in Table 9.
Table 9 Example DDDA (%) Time (Min.) Peel (kg/2.45 cm) 21 0.5 1 10.8 22 0.5 1 6.7 23 0.5 I 1.5 24 0.5 1 4.0 25 0.5 1 6.5 C7 ____ 1 0.1 The data ofTable 9 demonstrate that the samples ofthe present invention that contain a diamine exhibit much improved layer adhesion.
Examples 26-27. . ...__ . .. _ _..__.... _ ~ _. .. . .
In Examples 26 and 27, samples were prepared in a manner designed to simulate co-extrusion. These samples were prepared using the three layers wo 9s~o59s5 ~;.' ~' ~''" ~;' 'r ~ 2 ~ 9 5 7 9 0 described in Example 21, preheating the three components for 3 minutes at 260 °C
and pressing the three layers together with the extruder-mixed, diamine-modified polymer sheet between the THV 500 fiuoroplastic and the HDPE sheets at a pressure of 5 IcPa under the process conditions shown in Table 10. The samples were tested in the same manner as described for Example 21.
Table 10 Example Time (sec.) Temp (C) Pressure Peel (kPa) k 2.45 cm 26 10 260 5 10.0 27 20 260 5 10.5 The data of Table 10 show substantial adhesion improvements under properly selected process conditions for those samples containing a diamine over those samples not containing a di- or polyamine.
In examples 28 and 29, samples were prepared and tested as in Example 21 IS except that, respectively, VestamidT"~ 1.2140 nylon 12, available form Huls Aktiengesellschaft, and SantopreneTM 201-73 thermoplastic elastomer, having a Shore A hardness of 73 and a specific gravity of 0.98, available form Advanced Elastomer Systems, Inc., were used in place of the HDPE substrate sheet. Test results and process conditions are summarized by Table 11.
Table 11 Example Substrate Time (min.) Peel (kg/2.45 cm) 28 nylon 12 1 3.4 29 Santoprene 1 4.5 WO 96105965 ~~ ~ ~ r ~- ~' 't ~ ! ~',~ ~ ~ ~ PCT/U595/10516 ~xam~e 30 _ -In Example 30, a 508 micrometer thick molded sheet of an amine-modified polymer composite was made by mixing 0.23 g of DDDA with 32.2 g of PolysarTM
EPM 306 ethylene propylene rubber, available form Bayer, Inc., and 2.3 g of BynelTM 4003 adhesive resin, an anhydride-modified HDPE available form E.I. du Pont de Nemours and Company, and 11.5 g of ArkonTM P-125 tackifler, a ' hydrogenated C9 aromatic hydrocarbon resin tackifler (softening point 125 °C) availabie form Arakawa Chemical USA Inc., in an internal mixer as in Example 1.
A sample of the invention was then prepared by bonding the sheet of the amine-containing PolysarTM EPM 306 rubber to a sheet of THV 500 fluoroplastic according to the method described in Example I. A sheet of unmodified LS901046 HDPE, available form Quantum Corp., was placed on the opposing surface of the amine-containing polymer composite sheet. The resulting three layer sample was pressed and tested as in Example I . The time in the press and test results are summarized by Table 12.
Exam 1pe31 In Example 31, a sample was prepared and tested as in Example 30 except that PiccolyteT"' S115 terpene resin tackifier (softening point I 15 °C), available form Hercules, Inc., was used in place of the ArkonTM P-125 tackifier. Test results and process conditions for this sample are summarized by Table 12.
Exam I,~ a 32 In Example 32, a sample was prepared and tested as in Example 30 except that Super EsterTM W-125 modified rosin ester tackifier (softening point 125 °C), available form Arkawa Chemical USA, Inc., was used in place ofthe ArkonTM P-125 tackifier. Test results and process conditions for this sample are summarized by Table 12.
~~nct~-P
W O 96105965 -- ~ .- 219 5 7 9 0 pCT/I7S95/I0516 W a rat ve Fxamnle .8 r-For Comparative Example C8, a sample was prepared and evaluated as in Example 30 except that DDDA was not added to the polymer composite. Test results and corresponding process conditions for this comparative sample are 3 summarized by Table 12.
Table 12 E:ample Tackifier DDDA (%) Time (min.) Peel k /2.45 cm 30 hydrocarbon 0.5 I 6.5 resin 31 terpene resin0.5 1 8.1 32 rosin ester 0.5 1 1.5 C8 hydrocarbon ----- I 0.1 resin i The data of Table 12 demonstrate substantially improved adhesion speed between layers may be obtained by addition of both a tackifier and a diamine to the polymer composite.
Examples 33-34 In Examples 33 and 34, a 508 micrometer thick molded sheet of an amine-IS modified polymer composite was made by mixing 0.23 g ofDDDA with 46.0 g of Polysar''M EPM 306 ethylene propylene rubber, available form Bayer, Inc., in an internal mixer as in Example 1. A sample of the invention was then prepared by bonding the sheet of the amine-containing PolysarT"~ EPM 306 rubber to a sheet of THV 500 fluoroplastic according to the method described in Example 1. A sheet of unmodified LS901046 HDPE, available form Quantum Corp., was placed on the opposing surface of the amine-containing polymer composite sheet. The resulting three layer sample was pressed and tested as in Example 1. The time in the press and test results for each example are summarized by Table 13.
WO 96105965 ' ' ~ ~'~ ~ ~ ~' ~ ~ ~ 2 ~ 9 5 7 9 0 PC'fIUS95110516 Comparative Example C9 For Comparative Example C9, a sample was prepared and evaluated as for Examples 33-34 except that DDDA was not added to the polymer composite. Test results and corresponding process conditions for this comparative sample are summarized by Table 13.
Table 13 Example DDDA (%) Time (min.) Peel k /2.45 cm 33 0.5 1 1.7 34 0.5 3 2.4 C9 _____ 1 * The layers of this sample did not-sufficiently adhere to one another to perform the test.
The data of Table 13 demonstrate that samples of the invention that contain a diamine and wherein the hydrocarbon polymer component comprises an elastomeric copolymer of ethylene and propylene exhibit much improved layer adhesion.
Example 35 In Example 35, a sample of the invention was prepared in the same manner as for Examples 33 and 34 except that 11.5 g of ArkonT~~ P-125 tackifter, a hydrogenated C9 aromatic hydrocarbon resin tackifier (softening point 125 °C) available form Arakawa Chemical USA Inc., was added to the ethylene propylene rubber along with the diamine, and that only 34.5 g of the ethylene propylene rubber was used. The resulting three layer sample was pressed and tested as in Example 1, and the time in the press and test results are summarized by Table 14.
Exam lp a 36 In Example 36, a sample was prepared and tested as in Example 35, except 10 mil (0.25 mm) thickness sheet ofKynarTM 740 polyvinylidene fluoride (PVDF), ~~'~~'~' V
WO 96105965 21 g 5 7 9 0 PCT/US95/I0516 available from Atochem, was used in place of the THV 500 fluoropolymer. The time in the press and test results are summarized in Table 14.
Comparative Exam le 10 For Comparative Example C10, a sample was prepared and evaluated as for Example 35 except that DDDA was not added to the polymer composite. Test results and corresponding process conditions for this comparative sample are summarized by Table 14.
Table 14 Example Substrate DDDA (%) Time (min.) Peel k /2.45 cm 35 THV 500 0.5 1 6.5 36 PVDF 0.5 1 5.5 me payers or ims sample a~a not sufficiently adhere to one another to perform the test.
The data of Table 14 again demonstrate the improved inter-layer adhesion according to this invention using both a diamine and a tackifier.
Examples 37-38 In Examples 37 and 38, a 508 micrometer thick molded sheet of an amine-modified polymer composite was made by mixing 0.23 g ofDDDA with 34.5 g of BynelTM 4003 adhesive resin, an anhydride-modified HDPE available form E.I. du Pont de Nemours and Company, and 1 I .5 g of ArkonTM P-125 tackifier, a hydrogenated C9 aromatic hydrocarbon resin tackifier (softening point 125 °C) available form Arakawa Chemical USA Inc., in an internal mixer as in Example 1.
A sample of the invention was then prepared by bonding the sheet of the amine-containing Bynel'''~' 4003 resin to a sheet of THV 500 fluoroplastic according to the method described in Example 1. A sheet of unmodified LS901046 HDPE, available form Quantum Corp., was placed on the opposing surface of the amine-containing _27_ wo .9sros9ss i L' ~'~'~~..~ '~=' ~ ~ 9 5 ~ ~ ~
rcTrUS95!aosi6 polymer composite sheet. The resulting three layer sample was pressed and tested as in Example 1. The time in the press and test results are summarized by Table 15.
Table is Example DDDA (%) Time (min.) Peel k 12.45 cm 37 0.5 1 0.5 38 I 0.5 I 3 I 0.5 s The data of Table 15 demonstrate, that although not a preferred embodiment of the this invention, the addition of a tackifier and a diamine to anhydride-modified HDPE exhibits some improved adhesion characteristics over those samples that do not contain a di- or polyamine, for example as shown by Comparative Example C8. Preferred embodiments incorporate an amorphous hydrocarbon polymer along with the HDPE to enhance the performance of the tackifier, if one is employed.
Example 39 THV 200 was extruded onto a 61 micrometer thick, low shrinkage polyethylene terephthalate film to form a 12.7to 25.4 micrometer thick layer.
In a second pass a 50.8 to 76.2 micrometer thick layer of urethane (Morton L424.167) and a 12.7 micrometer thick tie layer comprising a blend of urethane (Morton L424.167) and 0.5% dodecyl diamine (Aldrich Chemical) were co-extruded onto the THV layer with the tie layer adjacent to the THV layer.
The resulting multi-layer composition was provided with a base layer by micro-replicating with retroreflective cube corners in accordance with the method described in PCT WO 95111464, in particular with figure 4 of the document and the associated description. A mixed acryiate solution (19.8% bisphenol A
diacrylate, 29.7% ietrahydrofuran acrylate and 49.5% trimethylol propane triacrylate with DaracureTM D4265 as the photoinitiator) was coated onto the urethane layer followed by micro-replicating by the method indicated above. The acrylate cube corners were first cured with visible light and then annealed with ultraviolet light.
_28_ ,;~~'~~ ~~~' 2195790 R'O 96105965 PCTIUS95110516 The retro-reflective properties of the multi-layer composition were measured to be in the range 700 to 1200 candle power at an observation angle of 0.33°
and an entrance angle of-4°.
The exposed cube corner layer was ultrasonically sealed with a 114.4 micrometer thick white urethane layer. A 127 micrometer layer of plasticiser ' resistant acrylate pressure sensitive adhesive was applied to the exposed surface of the white urethane layer and the complete multi-layer composition laminated to a 585 micrometer thick layer of blue canvas (DuraskinTM manufactured by Verseidag, Germany) comprising a polyester scrim impregnated with polyvinyl chloride.
The resultant material was subjected to a test simulating the folding and vibration of a retroreflective product applied to the flapping canvas covering of a truck being driven at low temperatures. The laminated sample was cut into squares of 34.9 mm x 34.9 mm. These squares were clamped individually between the steel jaws of a flexing tester (Dauerknickpruefer MP 49, manufactured by Karl Schroeder, Germany) with the jaws set initially at a distance of25.4 mm. The flexing tester was housed in a refrigerator (So-Low Environmental, Cincinnati) and the temperature reduced to -20 °C (-4 °F) and maintained at this temperature for the remainder of the test. The flexing tester was operated so that the distance between the jaws reciprocated between 25.4 mm and 4.75 mm at 2 cycles per second, the sample being tightly folded between the jaws at the minimum position with the THV layer forming the outermost layer of the fold. The samples withstood 2000-cycles without visible cracking or delamination of the layers.
~xamDle 40 THV 200, a blend of urethane (Morton L424.167) and dodecyl diamine (Aldrich Chemical) and urethane (Morton L424.167) were triple co-extruded to form a multi-IayeT composition comprising a 12.7 to 25.4 micrometer thick THV
layer, a 12.7 micrometer thick tie layer and a 50.8 to 76.2 micrometer thick urethane layer. The resulting composite layer was tested in a PermatranTM W6 instrument (Modem Controls, Inc., Minneapolis, Minn.) for moisture vapor transmission rate with the THV layer facing the source of moisture. The instrument f~ ti.',! ~-','~ '-'~-I : ; .. .
w:vlep.,, temperature was set at 38 °C with 100% humidity from deionized water.
Before each measurement, the instrument was calibrated with a polyester film sample supplied by the manufacturer. The moisture vapor transmission values for a composition in accordance with Example 39 are given in Table 16.
Example 41 A THV/tie layer/urethane layer was manufactured and tested as in Example 40 above except THV 200 was used for the THV layer. The moisture vapor transmission values for this composition are given in Table 16.
Comparative sample C 11 A film was manufactured from extruded polyurethane (Morton L424.167) and an application of ADSD 6912 two-part crosslinking polyurethane clear coat available from 3M, having a total thickness of 152.4 micrometer.
Table 16 Example Average Thickness Average Moisture Transmission Rate (micrometer) mm2/da 40 122 3 8.1 41 135 38.0 .
Cll 150 115.0 Various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope of this invention and this invention should not be restricted to that set forth herein for illustrative purposes.
Claims (13)
1. A method for increasing the adhesion of a first layer comprising fluoropolymer to a second layer comprising a melt-processable, substantially non-fluorinated polymer, comprising the steps of (A) mixing an aliphatic di- or polyamine of less than 1,000 molecular weight with a melt-processable composition comprising said substantially non-fluorinated polymer;
(B) forming a multi-layer composition comprising a layer comprising the mixture resulting from step A and a layer comprising said fluoropolymer;
wherein said two layers are in substantial contact, said fluoropolymer comprises interpolymerized units derived from vinylidene fluoride, said substantially non-fluorinated polymer is a polyamide, polyimide, polyurethane or a carboxyl, anhydride, or imide functional polyolefin, and said di- or polyamine is present in an amount sufficient to increase the adhesion between the two layers compared to compositions without said di- or polyamine.
(B) forming a multi-layer composition comprising a layer comprising the mixture resulting from step A and a layer comprising said fluoropolymer;
wherein said two layers are in substantial contact, said fluoropolymer comprises interpolymerized units derived from vinylidene fluoride, said substantially non-fluorinated polymer is a polyamide, polyimide, polyurethane or a carboxyl, anhydride, or imide functional polyolefin, and said di- or polyamine is present in an amount sufficient to increase the adhesion between the two layers compared to compositions without said di- or polyamine.
2. A method for increasing the adhesion of a first layer comprising fluoropolymer to a second layer comprising a melt-processable, substantially non-fluorinated polymer, comprising the steps of (A) mixing an aliphatic di- or polyamine of less than 1,000 molecular weight with a tackifier and a melt-processable composition comprising said substantially non-fluorinated polymer;
(B) forming a multi-layer composition comprising a layer comprising the mixture resulting from step A and a layer comprising said fluoropolymer;
wherein said two layers are in substantial contact, said fluoropolymer comprises interpolymerized units derived from vinylidene fluoride, said substantially non-fluorinated polymer is a polyamide, polyimide, polyurethane, or a carboxyl, anhydride, or imide functional polyolefin, and said di- or polyamine is present in an amount sufficient to increase the adhesion between the two layers compared to compositions without said di- or polyamine.
(B) forming a multi-layer composition comprising a layer comprising the mixture resulting from step A and a layer comprising said fluoropolymer;
wherein said two layers are in substantial contact, said fluoropolymer comprises interpolymerized units derived from vinylidene fluoride, said substantially non-fluorinated polymer is a polyamide, polyimide, polyurethane, or a carboxyl, anhydride, or imide functional polyolefin, and said di- or polyamine is present in an amount sufficient to increase the adhesion between the two layers compared to compositions without said di- or polyamine.
3. The method of claim 1 or 2, further comprising the step of heating or applying pressure to said multi-layer composition.
4. The method of claim 1 or 2, wherein said amine comprises at least one primary amine.
5. The method of claim 1 or 2, wherein said fluoropolymer is a homopolymer, copolymer, or terpolymer derived from monomers selected from the group consisting of vinylidene fluoride, tetrafluoroethylene, and hexafluoropropene.
6. A multi-layer composition comprising a first layer comprising fluoropolymer, a second layer comprising a melt-processable, substantially non-fluorinated polymer, and an aliphatic di- or polyamine of less than 1,000 molecular weight, wherein said fluoropolymer comprises interpolymerized units derived from vinylidene fluoride, said substantially non-fluorinated polymer is a polyamide, polyimide, polyurethane, or a carboxyl, anhydride, or imide functional polyolefin, substantially all of said amine is located in said second layer, and said amine is present in an amount sufficient to increase the adhesion between said layers compared to compositions without said di- or polyamine.
7. The composition of claim 6, wherein said fluoropolymer is a homopolymer, copolymer, or terpolymer derived from monomers selected from the group consisting of vinylidene fluoride, tetrafluoroethylene, and hexafluoropropene.
8. The composition of claim 6 or 7, wherein said second layer further comprises a tackifier.~~
9. The composition of any one of claims 6 to 8, further comprising transparent microspheres.
10. A shaped article comprising the composition of any one of claims 6 to 8.
11. A shaped article comprising the composition of claim 9.
12. The article of claim 10 further comprising a retroreflective base sheet wherein said retroreflective base sheet comprises a monolayer of transparent microspheres and reflective means disposed on the side of said microspheres opposite said second layer.
13. The article according to claim 12, wherein retroreflective elements are formed on said second layer and wherein said retroreflective elements are cube-corner reflective elements.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US29322394A | 1994-08-19 | 1994-08-19 | |
| US08/293,223 | 1994-08-19 | ||
| PCT/US1995/010516 WO1996005965A1 (en) | 1994-08-19 | 1995-08-18 | Multi-layer compositions having a fluoropolymer layer |
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| Publication Number | Publication Date |
|---|---|
| CA2195790A1 CA2195790A1 (en) | 1996-02-29 |
| CA2195790C true CA2195790C (en) | 2006-03-14 |
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| Application Number | Title | Priority Date | Filing Date |
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| CA002195790A Expired - Fee Related CA2195790C (en) | 1994-08-19 | 1995-08-18 | Multi-layer compositions having a fluoropolymer layer |
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| CA (1) | CA2195790C (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| TWI537134B (en) | 2011-09-19 | 2016-06-11 | 財團法人工業技術研究院 | Multilayer composition containing fluoropolymer and method for fabricating the same, solar cell module |
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| CA2195790A1 (en) | 1996-02-29 |
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