CN105358631B - 注塑用底漆组合物 - Google Patents

注塑用底漆组合物 Download PDF

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Publication number
CN105358631B
CN105358631B CN201480030978.0A CN201480030978A CN105358631B CN 105358631 B CN105358631 B CN 105358631B CN 201480030978 A CN201480030978 A CN 201480030978A CN 105358631 B CN105358631 B CN 105358631B
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Prior art keywords
component
composition
methyl
article
acrylate
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CN105358631A (zh
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M·M·科纳尔斯基
N·彭罗斯
D·诺兰
B·迪根
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Henkel AG and Co KGaA
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Henkel IP and Holding GmbH
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    • C09D4/00—Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16
    • C09D4/06—Organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond in combination with a macromolecular compound other than an unsaturated polymer of groups C09D159/00 - C09D187/00
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
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Abstract

提供可固化组合物，该组合物例如可通过暴露于电磁谱中的辐射的方法固化，所述组合物可作为注塑应用中的底漆组合物。

Description

注塑用底漆组合物
技术领域
提供可固化组合物，例如通过暴露于电磁谱中的辐射的方法固化，所述组合物可作为注塑应用中的底漆组合物。
背景技术
目前，在许多市场中具有生产过程流线化的趋势，尤其是对于手持式消费电子设备。为此，需要排除被称为重叠注塑(overmolding)工艺中的由于使用传统粘合剂连接塑料部件至金属框架和玻璃显示器的过程中通常比较缓慢并且有时成本高的问题。
通过使用水性、使用溶剂的和/或双组分粘合剂，进行了其他尝试以提供用于这些重叠注塑组装工艺的连接层涂层。这些方法均具有缺陷。
例如，水性和使用溶剂的粘合剂，由于其暴露于空气中几乎很短暂的时间也会形成膜的趋势，常常有损于多种应用性能。另外，需要使用过长的干燥过程(将是复杂和/或昂贵的)以除去水或溶剂载体。双组分粘合剂需要在使用前混合并且通常经历一个过长的固化过程，其还经常包括高成本的加热步骤。
使用这些类型粘合剂技术的另一个缺点是重叠注塑前在部件上的操作时间短，因此不适宜用于独立于主要的重叠注塑组装工艺的离线过程。换言之，在用于重叠注塑组装工艺前，使用这些传统的粘合剂在注塑部件上进行B阶(B-stage)工艺变得不切实际。
因此，需要一种用于重叠注塑组装工艺的底漆组合物，以满足商业上的需求，该底漆组合物不含有载体，不要求长和/或昂贵的工艺时间，并且在部件上具有改进的操作时间。
发明内容
上述需求在本公开中得到了满足。
本发明一方面提供了一种光固化底漆组合物，包含：
(甲基)丙烯酸酯单体组分；
光引发剂组分；和
橡胶组分，包含(a)(i)分子量小于约120,000Mw的聚乙烯醇缩丁醛组分或(a)(ii)丙烯腈-丁二烯-苯乙烯共聚物，和(b)任选存在的，平均直径在约100nm至约300nm范围内的核壳橡胶。
另一方面提供一种组合物，包含：
(甲基)丙烯酸酯单体组分；
光引发剂组分；
橡胶组分，包含(a)(i)分子量小于约120,000Mw的聚乙烯醇缩丁醛组分或(a)(ii)丙烯腈-丁二烯-苯乙烯共聚物，和(b)任选存在的，平均直径在约100nm至约300nm范围内的核壳橡胶；和
氰酸酯组分。
另一方面提供一种组合物，包含：
(甲基)丙烯酸酯单体组分；
光引发剂组分；
橡胶组分，包含(a)(i)分子量小于约120,000Mw的聚乙烯醇缩丁醛组分或(a)(ii)丙烯腈-丁二烯-苯乙烯共聚物，和(b)任选存在的，平均直径在约100nm至约300nm范围内的核壳橡胶；和
芳香胺组分，例如氨基化二苯砜组分。
另一方面提供一种组合物，包含：
(甲基)丙烯酸酯单体组分；
光引发剂组分；
橡胶组分，包含(a)(i)分子量小于约120,000Mw的聚乙烯醇缩丁醛组分或(a)(ii)丙烯腈-丁二烯-苯乙烯共聚物，和(b)任选存在的，平均直径在约100nm至约300nm范围内的核壳橡胶；
氰酸酯组分；和
胺组分，例如芳香胺组分，例如氨基化二苯砜组分，或环脂族二胺组分，例如二氨基二环己基甲烷。
另一方面提供一种组合，包含：
前述任一方面的组合物；和
热塑性树脂。
另一方面提供一种组合，包含：
在其至少一个表面上作为涂层涂覆有前述任一方面的组合物的B-阶形式的物品；和
与所述组合物的B-阶形式相接触的热塑性树脂。
另一方面提供一种在物品周围形成注塑体的方法，包含步骤：
向注塑腔中放置物品，热塑性材料将被在该物品周围注塑成一定形状；并且
在一定温度和压力下向放置有所述物品的注塑腔中注射热塑性材料以使所述热塑性材料在模具中所述物品的周围和附近流动，保持模具在合适温度和压力下以使所述热塑性材料固化，在放置物品前，用前述任一方面的组合物对所述物品涂覆底漆，并且暴露于适于固化所述组合物的电磁谱辐射下。
附图说明
图1描述了一种手持式消费电子显示器设备的不同组分层的分解图，其中重叠注塑体可以作为它们之间的界面使用。
具体实施方式
如上所述，本发明提供几个方面。更具体地，它们是：
一方面是一种可光固化底漆组合物，包含：
(a)(甲基)丙烯酸酯单体组分；
(b)光引发剂组分；和
(c)橡胶组分，包含(a)(i)分子量小于约120,000Mw的聚乙烯醇缩丁醛组分或(a)(ii)丙烯腈-丁二烯-苯乙烯共聚物，和(b)任选存在的，平均直径在约100nm至约300nm范围内的核壳橡胶。
另一方面是提供一种组合物，包含：
(a)(甲基)丙烯酸酯单体组分；
(b)光引发剂组分；
(c)橡胶组分，包含(a)(i)分子量小于约120,000Mw的聚乙烯醇缩丁醛组分或(a)(ii)丙烯腈-丁二烯-苯乙烯共聚物，和(b)任选存在的，平均直径在约100nm至约300nm范围内的核壳橡胶；和
(d)氰酸酯组分。
另一方面是提供一种组合物，包含：
(a)(甲基)丙烯酸酯单体组分；
(b)光引发剂组分；
(c)橡胶组分，包含(a)(i)分子量小于约120,000Mw的聚乙烯醇缩丁醛组分或(a)(ii)丙烯腈-丁二烯-苯乙烯共聚物，和(b)任选存在的，平均直径在约100nm至约300nm范围内的核壳橡胶；和
(d)胺组分，例如芳香胺组分，例如氨基化二苯砜组分，或环脂族二胺组分，例如二氨基二环己基甲烷。
另一方面是提供一种组合物，包含：
(a)(甲基)丙烯酸酯单体组分；
(b)光引发剂组分；
(c)橡胶组分，包含(a)(i)分子量小于约120,000Mw的聚乙烯醇缩丁醛组分或(a)(ii)丙烯腈-丁二烯-苯乙烯共聚物，和(b)任选存在的，平均直径在约100nm至约300nm范围内的核壳橡胶；
(d)氰酸酯组分；和
(e)胺组分，例如芳香胺组分，例如氨基化二苯砜组分，或环脂族二胺组分，例如二氨基二环己基甲烷。
另一方面是提供一种组合，包含：
前述的任意一种组合物；以及
热塑性树脂，例如聚碳酸酯、聚碳酸酯/丙烯腈-丁二烯-苯乙烯，或聚酰胺，含有或不含有玻璃纤维。
另一方面是提供一种组合，包含：
(a)在其至少一个表面上作为涂层涂覆有前述任一方面的组合物的B-阶形式的物品；和
(b)与所述组合物的B-阶形式接触的热塑性树脂。
另一方面提供一种用于在物品周围形成注塑体的方法，包含步骤：
向注塑腔中放置物品，在物品周围热塑性材料将被注塑成一定形状；并且
在一定温度和压力下向放置有所述物品的注塑腔中注射热塑性材料以使该热塑性材料在模具中所述物品的周围和附近流动，保持模具在合适温度和压力下以使所述热塑性材料固化，
在放置所述物品前，用前述任一方面的组合物对所述物品涂覆底漆，并且暴露于适当的电磁谱辐射下固化所述组合物。
所有这些方面的共同部分是(甲基)丙烯酸酯组分。(甲基)丙烯酸酯可选自一种或多种宽范围的不同的材料，例如那些以H2C＝CGCO2R1代表的材料，其中G可以是氢或具有1至约4个碳原子的烷基基团，并且R1可以选自具有1至约16个碳原子的烷基、环烷基、烯基、环烯基、烷芳基、芳烷基或芳基，其中任意一个均可以任选地被例如硅烷、硅、氧、卤素、羰基、羟基、酯、羧酸、脲、氨基甲酸酯、碳酸盐(酯)、胺、酰胺、硫、磺酸盐(酯)、砜等取代或中断。例子包括N，N-二甲基丙烯酰胺、(甲基)丙烯酸苯氧基乙酯、四氢呋喃(甲基)丙烯酸酯、(甲基)丙烯酸环己基酯、(甲基)丙烯酸异冰片基酯、(甲基)丙烯酸丁酯、(甲基)丙烯酸羟乙酯和(甲基)丙烯酸羟丙酯。
在这里其他适用的(甲基)丙烯酸酯单体包括多官能(甲基)丙烯酸酯单体，例如但不限于二或三官能(甲基)丙烯酸酯，例如聚乙二醇二(甲基)丙烯酸酯、四氢呋喃(甲基)丙烯酸酯和二(甲基)丙烯酸酯、(甲基)丙烯酸羟丙酯(“HPMA”)、己二醇二(甲基)丙烯酸酯、三羟甲基丙烷三(甲基)丙烯酸酯(“TMPTMA”)、二乙二醇二甲基丙烯酸酯、三乙二醇二甲基丙烯酸酯(“TRIEGMA”)、四乙二醇二甲基丙烯酸酯、二丙二醇二甲基丙烯酸酯、二(戊二醇)二甲基丙烯酸酯、四甘醇二丙烯酸酯(tetraethylene diglycol diacrylate)、双甘油四甲基丙烯酸酯、二甲基丙烯酸四亚甲基酯、二甲基丙烯酸亚乙基酯、新戊二醇二丙烯酸酯、三羟甲基丙烷三丙烯酸酯和双酚A单和二(甲基)丙烯酸酯、例如乙氧基双酚A(甲基)丙烯酸酯(“EBIPMA”)，和双酚F单和二(甲基)丙烯酸酯，例如乙氧基双酚F(甲基)丙烯酸酯。
还可以使用其他的(甲基)丙烯酸酯单体，包括硅氧烷(甲基)丙烯酸酯部分(“SiMA”)，例如那些在美国专利No.5605999(Chu)中教导和要求保护的，其公开的内容在此明确地援引加入。
当然，也可以使用这些(甲基)丙烯酸酯单体的组合。尽管期望地，所述(甲基)丙烯酸酯单体组分选自N，N-二甲基丙烯酰胺、(甲基)丙烯酸苯氧基乙酯、四氢呋喃(甲基)丙烯酸酯、(甲基)丙烯酸环己基酯、(甲基)丙烯酸异冰片基酯、(甲基)丙烯酸丁酯、(甲基)丙烯酸羟乙酯以及(甲基)丙烯酸羟丙酯中的一种或多种。
基于总质量，所述(甲基)丙烯酸酯组分应占约10至约90重量％，例如约40至约80重量％。
光引发剂可选自在电磁谱的紫外光区域、可见光区域或者两个区域中通过辐射激发的引发剂中的一种或多种。
光引发剂可以是二苯酮或取代二苯酮，例如α-羟基酮。一种特别合适的α-羟基酮是1-羟基-环己基-苯基酮(作为IRGACURE 184可从Ciba Specialty Chemicals，Inc.商购)。其他合适的α-羟基酮和它们的混合物包括：2-羟基-2-甲基-1-苯基-丙-1-酮(DAROCUR1173)；2-羟基-1-[4-(2-羟乙氧基)苯基]-2-甲基-1-丙酮(IRGACURE 2959)；以及例如IRGACURE 1000和IRGACURE 500(均可从Ciba Specialty Chemicals，Inc.商购)的混合物。其他合适的UV光引发剂包括：苯乙酮和取代苯乙酮；安息香和它的烷基酯；氧杂蒽酮和取代的氧杂蒽酮；二乙氧基苯乙酮；安息香甲醚；安息香乙醚；安息香异丙醚；二乙氧基氧杂蒽酮；氯噻吨酮；N-甲基二乙醇胺二苯酮；1-苯甲酰环己醇；2-苄基-2-(二甲基氨基)-1-[4-(4-吗啉基)苯基]-1-丁酮；氨基酮，例如IRGACURE 907、IRGACURE369和IRGACURE 1300(可从Ciba Specialty Chemicals，Inc.商购)；苯偶酰二甲基酮缩醇，例如IRGAGURE 651(可从Ciba Specialty Chemicals，Inc.商购)；BAPO(双酰基氧化膦)和它们的混合物，例如IRGACURE 819、IRGACURE 1700、IRGACURE 1800，IRGACURE 1850和DAROCUR 4265(均可从Ciba Specialty Chemicals，Inc.商购)；2，4，6三甲基苯甲酰基二氧化膦，含有或不含有1-羟基-环己基苯基酮；茂金属，例如IRGACURE 784和IRGACURE 261(均可从Ciba SpecialtyChemicals，Inc.商购)；二苯酮，例如DAROCUR BP(可从Ciba Specialty Chemicals，Inc.商购)；和它们的混合物。
美国专利No.5399770公开并要求保护一系列具有光引发剂功能的化合物。因此，该’770专利的公开内容在此明确地全文援引加入。’770专利包括的一种特别理想的光引发剂，可以商品名IRGACURE 819从Ciba Specialty Chemicals，Inc.商购。IRGACURE 819是双(2，4，6三甲基苯甲酰基)苯基氧化膦。
还可以使用樟脑醌过氧化酯引发剂；9-芴羧酸过氧化酯；dl-樟脑醌；IRGACURE784DC(基于取代的二茂钛的光引发剂)；包含染料和给电子体的双组分引发剂；包含染料、给电子体和氧化剂的三组分引发剂；和它们的混合物。这些可见光引发剂可以与双酰基氧化膦光引发剂配合使用以达到期望的效果。
关于双组分引发剂，合适的染料包括但不限于：樟脑醌、5，7-二碘-3-丁氧基-6-荧光酮、孟加拉玫瑰红、核黄素、曙红Y、苯偶酰、荧光酮染料、苯偶酰衍生物、香豆素酮、吖啶染料、苯并黄素和它们的混合物，以及合适的给电子体包括但不限于甲基二乙醇胺、二甲基对甲苯胺、N，N-二甲基氨乙基甲基丙烯酸酯、乙基4-二甲基氨基苯甲酸酯和它们的混合物。
并且关于三组分引发剂，除了上面提到的双组分之外，作为第三组分，合适的氧化剂包括但不限于：双(三氯甲基)三嗪、鎓盐和它们的混合物。鎓盐的例子包括硫盐和碘盐。
其他合适的可见光引发剂体系包括在下面专利或出版物中公开的那些，在此均以援引加入的方式全文引入。在此通过援引加入而引入的美国专利No.4505793公开了包含3-酮取代香豆素化合物和活性卤素化合物的组合的光聚合引发剂。大量的示例性化合物被公开。这些光聚合物引发剂通过暴露于波长范围在约180nm和600nm之间的光而固化。美国专利No.4258123，在此援引加入，公开了包含引发剂组分的光敏树脂组合物，所述引发剂组分在光化光(actinic light)的辐射下产生自由基。这些组分包括不同的三嗪化合物，其中作了更全面的描述。
欧洲专利公开No.EP0369645A1公开了一种三组分光引发剂体系，其包含三卤甲基取代的均三嗪、可吸收范围在约300-1000nm辐射的增感化合物以及给电子体。公开了示例性增感化合物，包括：酮；香豆素染料；占吨染料；3H-占吨-3-酮染料；吖啶染料；噻唑染料；噻嗪染料；噁嗪染料；吖嗪染料；氨基酮染料；甲烷和甲川染料；卟啉；芳香聚环烃；对位取代氨基苯乙烯基酮化合物；氨基三芳基甲烷；部花青；方酸菁染料；以及吡啶染料。还公开了示例性给电子体，包括：胺；酰胺；醚；脲；二茂铁；亚硫酸和它们的盐；氰亚铁酸盐；抗坏血酸和它的盐；二硫代氨基甲酸和它的盐；黄酸盐；乙二胺四乙酸盐；以及四苯基硼酸盐。这些引发剂对紫外和可见光都是敏感的。
欧洲专利公开No.EP0563925A1公开了光聚合引发剂，其包含可吸收范围在约250-1000nm辐射的增感化合物以及2-芳基-4，6-双(三氯甲基)-1，3，5-三嗪。公开的示例性增感化合物包括染料，例如青色素、部花青、香豆素、香豆素酮、(噻)吨、吖啶、噻唑、噻嗪、噁嗪、吖嗪、氨基酮、方酸菁(squarylium)、吡啶、(噻)吡喃、卟啉、三芳基甲烷、(聚)甲烷、氨基苯乙烯基化合物和芳香聚环烃。这些光聚合引发剂对紫外和可见光是敏感的。
在此明确地援引加入的美国专利No.5395862公开了对可见光敏感的荧光酮光引发剂。这样的荧光酮引发剂体系还包括可接受来自激发的荧光酮物质的电子的共引发剂。公开了示例性共引发剂，包括：鎓盐、硝基卤代甲烷和重氮砜。在此明确地援引加入的美国专利No.5451343公开了作为引发剂的吸收波长大于350nm的光的荧光酮和派洛宁Y衍生物。在此援引加入的美国专利No.5545676公开了在紫外或可见光下固化的三组分光引发剂体系。该三组分体系包含芳基碘鎓盐、增感化合物和给电子体。示例性的碘鎓盐包括二苯基碘鎓盐。
2，4，6三甲基苯甲酰基双氧化膦和1-羟基环己基-苯基酮是在本发明的组合物中使用的两种特别理想的光引发剂。
光引发剂组分应以约1至约5重量％的量存在。
橡胶组分包含平均直径范围在100至约300nm的核壳橡胶和分子质量小于约120000Mw，例如在约40000至约70000Mw范围内的的聚乙烯醇缩丁醛组分的组合。
橡胶组分应以约15至约35重量％，例如约20至约30重量％的量存在。
核壳橡胶理想地具有丁苯橡胶构成的核和聚丙烯酸酯构成的壳。核壳橡胶存在许多商业来源，虽然其中拥有这项技术的主要的是Kaneka North America LLC，Houston，TX，其提供商品名为KaneAce例如Kane Ace MX的这种橡胶。在提供的KaneAce品牌产品中特别期望的是可以分散在(甲基)丙烯酸酯载体中的那些。一个这样的例子是KaneAce MX 920，如生产商所报告的，其使用丙烯酸苯氧基乙酯作为载体并且该核壳橡胶以约15重量％的量存在于分散体中。
当使用时，橡胶组分的核壳橡胶部分应该以至多约50重量％的量存在，相对于聚乙烯醇缩丁醛或丙烯腈-丁二烯-苯乙烯组分。
在某些方面，氰酸酯组分也存在于组合物中。氰酸酯组分的代表性例子包括一种或多种双酚A二氰酸酯(以及它们的氟化类似物)、酚醛清漆聚氰酸酯、双酚E二氰酸酯、双酚F二氰酸酯、二环戊二烯二醇二氰酸酯、1，3-二氰酰苯、1，4-二氰酰苯、1，3，5-三氰酰苯、1，3-、1，4-、1，6-、1，8-、2，6-或2，7-二氰酰萘、1，3，6-三氰酰萘、4，4’-二氰酰联苯、双(4-氰酰苯基)甲烷和3，3′，5，5′-四甲基，双(4-氰酰苯基)甲烷、2，2-双(3，5-二氯-4-氰酰苯基)丙烷、2，2-双(3，5-二溴-4-二氰酰苯基)丙烷、双(4-氰酰苯基)醚、双(4-氰酰苯基)硫化物、2，2-双(4-氰酰苯基)丙烷、三(4-氰酰苯基)亚磷酸盐、三(4-氰酰苯基)磷酸盐、双(3-氯-4-氰酰苯基)甲烷、氰化酚醛、1，3-双[4-氰酰苯基1-(甲基亚乙基)]苯和氰化、双酚封端的聚碳酸酯或其他热塑性低聚体。
此处适用的氰酸酯可从大量的来源商购获得。例如双酚E氰酸酯树脂(或1，1′-双(4-氰酰苯基)乙烷)可以商品名AroCy L-10从Huntsman获得。双酚A氰酸酯树脂、六氟双酚A氰酸酯树脂和四甲基双酚F氰酸酯树脂[或双(4氰酰-3，5-二甲基苯基)甲烷]也可分别以商品名AroCy B-10、AroCy F-10和AroCy M-10从Huntsman获得。双酚C氰酸酯树脂、双酚M氰酸酯树脂、酚醛清漆氰酸酯树脂和双环戊二烯-双酚氰酸酯树脂(或氰化酚-双环戊二烯加成物)可以商品名AroCy RD98-228、AroCy XU-366、AroCy XU-371和XU-71787.02L从Huntsman获得。
当使用时，氰酸酯组分应以约1至约20重量％的量存在。
在一些方面，胺组分也存在于组合物中。胺化合物可以是芳香胺或环脂肪族二胺组分。芳香胺组分的例子是氨化二苯砜，例如3，3′二氨基二苯砜、4，4′二氨基二苯砜、3，3′二氨基二苯醚、4，4′二氨基二苯醚、二氨基二苯基甲烷、苯二胺、二氨基二苯硫醚和二氨基二苯氧化物。
可以使用环脂肪族二胺组分作为芳香胺组分的替代物或附加物。这样的组分的一个例子是二氨基二环己基甲烷。
当使用时，胺组分应以约0.25至约5重量％的量存在。
在一个特别理想的方面，组合物包括：以约20至约80重量％的量存在的(甲基)丙烯酸酯单体组分(例如N，N-二甲基丙烯酰胺、丙烯酸苯氧基乙酯和四氢呋喃丙烯酸酯中的一种或多种)；以约1至约5重量％的量存在的光引发剂组分(例如2，4，6三甲基苯甲酰基二氧化膦和1-羟基环己基-苯基酮中的一种或多种)；以及以15至约35重量％的量存在的橡胶组分(例如橡胶组分包含(a)(i)分子量小于约120000Mw的聚乙烯醇缩丁醛组分或(a)(ii)丙烯腈丁二烯苯乙烯共聚物，和(b)任选存在的平均直径在约100至约300nm的核壳橡胶)。
当使用时，氰酸酯组分(例如AroCy XU 366，可从Huntsman Advanced Materials商购)以约1至约20重量％的量存在，以及氨基化二苯砜组分(例如3，3′二氨基二苯砜)以约0.25至约5重量％的量存在。
本发明组合物可以作为用于物品的底漆使用，该物品将经历重叠注塑过程，在该过程中将会在该物品的周围形成注塑体。所述物品可由多种基材构成，但是玻璃和铝是优选的，阳极化铝是尤其优选的。其他金属，例如镁和氧化镁，也可以是用于构成基材的金属的选择。
本发明的组合物可以用于将要进行重叠注塑的物品上，并且随后暴露于电磁谱的辐射中以在所述物品表面的至少一部分上固定所述组合物。
所述组合物可以多种方式中的任意一种施涂于物品上，例如喷涂、丝网印刷、转印等等。施涂后，组合物通过暴露于电磁谱例如UV或UV/可见辐射的能量中而固化(或B阶化)形成干燥可触(或不粘)表面。
所述B阶使得涂覆了底漆的物品可以被储存用于后面的重叠注塑过程。
随后在重叠注塑过程中，所述涂覆了底漆的物品放置于注塑腔中并且腔体封闭以在升高的温度和/或压力条件下接收将要注射入其中的热塑性树脂。
所述热塑性树脂通常选自诸如玻璃填充的聚碳酸酯和PC/ABS合金的工程热塑性塑料。
所述热塑性树脂通常选自诸如聚碳酸酯、玻璃填充聚碳酸酯、聚芳基酰胺例如IXEF和PC/ABS合金的工程热塑性塑料。所述热塑性树脂应在升高的温度和压力下被注入注塑腔中，宜在0.5-5秒内完成最终组件的模塑。至少在初始阶段，注塑温度本身通常在50至120℃的范围内。温度、时间和压力将取决于具体的热塑性塑料以及注塑腔的尺寸、结构和路径长度。注塑的热固性树脂的温度通常在180℃至325℃的范围内，例如260℃。例如，PBT应为240至260℃，PC-ABS应为250至270℃，以及PC和PA应为290至310℃。所使用的压力将受许多因素的影响，例如树脂化学性质、填料负载、树脂温度、注塑温度、部件厚度和流动长度。然而通常，在注射和成型过程中压力应为50至5000psi，例如500psi。流速须适于在热塑性塑料达到非流动状态时填充整个注塑腔。
可通过所述的重叠注塑过程形成的一个或多个物品的例子可参见图1。其中在手持式消费电子设备组装中使用的一些物品在图中显示出来，其受益于上文所公开的重叠注塑技术。更具体地，使用所公开的重叠注塑技术制备了四个物品：1.触控面板窗11和盖12；2.扬声器21和摄影机镜头22；3.盖31、金属边饰32和底架33；以及4.触控面板41、塑料窗口(bezel)42和金属边饰43。
实施例
所述组合物可以通过混合下表中所列组分直至溶解而获得。
表1
11-羟基环己基苯酮，IRGACURE 184
22，4，6三甲基苯甲酰双氧化膦
3N，N-二甲基乙酰胺
4BUTVAR B-98
5KANEKA MX920
6PRIMASET BADCy
表2
表3
*四氢呋喃丙烯酸酯
#丙烯腈-丁二烯-苯乙烯，MAGNUMABS树脂，Styron LLC，Gales Ferry，CT
表4
表5
表6
使用拉棒将组合物施涂于阳极化铝基材(MIL-A-8625，Type II，厚度在1.8至2.5微米之间)以产生经由光谱反射显示为厚度约25-50微米的基本均一的层。组合物涂覆的基材随后暴露于强度为100mW/cm2的UV辐射中大约5秒钟以在物品上形成固化的不粘表面。
上述底漆涂覆的物品可随后经重叠注塑而生成在注塑塑料和被涂覆的物品之间具有优异强度的集成件。更具体地，所述底漆涂覆的物品放置于合适的注塑腔中。在大约260℃下在注塑设备中加热PC/ABS塑料直至状态从固态变为熔融态，并且随后在约50-100psi注射压力下注射至模具中。塑料在注射数秒内硬化，取决于模具体积和结构，从而生成易从模具中移除的集成件。
从样品A-C涂覆的阳极化铝分别钉住拉伸，所获得的拉脱强度的性能如下：6.1Mpa，7.7Mpa和8.4Mpa。
从样品D-F涂覆的阳极化铝分别钉住拉伸，所获得的拉脱强度的性能如下：-Mpa，-Mpa和-Mpa。
对于样品G-L，使用ABS代替聚乙烯醇缩丁醛。ABS应具有1.03至1.07g/cm3的密度，例如1.04至1.05g/cm3，33-50Mpa的拉伸屈服应力，例如35至40Mpa，1500至2500Mpa的拉伸模量，例如1900至2100Mpa，以及2.0至28.0g/10min的在220℃/10kg下的熔体质量流速，例如4.0至8.5g/10min。
从样品G-I涂覆的阳极化铝分别钉住拉伸，所获得的拉脱强度的性能如下：0Mpa，0.7Mpa和2.1Mpa。
从样品J-L涂覆的阳极化铝分别钉住拉伸，所获得的拉脱强度的性能如下：7.1Mpa，7.9Mpa和8.9Mpa。
从样品M-O涂覆的阳极化铝分别钉住拉伸，所获得的拉脱强度的性能如下：8.6Mpa，8.5Mpa和8.6Mpa。
从样品P-R涂覆的阳极化铝分别钉住拉伸，所获得的拉脱强度的性能如下：8.5Mpa，9.2Mpa和4.3Mpa。

Claims (28)

1.一种光固化底漆组合物，包含：
(甲基)丙烯酸酯单体组分；
光引发剂组分；和
橡胶组分，包含(a)(i)分子量小于120,000Mw的聚乙烯醇缩丁醛组分，和(b)平均直径在100nm至300nm范围内的核壳橡胶。
2.权利要求1的组合物，其中所述(甲基)丙烯酸酯单体组分选自N,N-二甲基丙烯酰胺、(甲基)丙烯酸苯氧基乙酯、四氢呋喃(甲基)丙烯酸酯、(甲基)丙烯酸环己基酯、(甲基)丙烯酸异冰片基酯、(甲基)丙烯酸丁酯、(甲基)丙烯酸羟乙酯以及(甲基)丙烯酸羟丙酯中的一种或多种。
3.权利要求1的组合物，其中所述(甲基)丙烯酸酯单体组分以40至80重量％的量存在。
4.权利要求1的组合物，其中所述光引发剂组分选自2,4,6-三甲基苯甲酰双氧化膦、带或不带1-羟基-环己基苯酮的2,4,6-三甲基苯甲酰双氧化膦、2-羟基-2-甲基-1-苯基-丙-1-酮、2-羟基-1-[4-(2-羟乙氧基)苯基]-2-甲基-1-丙酮、苯乙酮和取代苯乙酮、安息香及其烷基酯、氧杂蒽酮和取代的氧杂蒽酮、安息香甲醚、安息香乙醚、安息香异丙醚、二乙氧基氧杂蒽酮、氯噻吨酮、1-苯甲酰环己醇、2-苄基-2-(二甲基氨基)-1-[4-(4-吗啉基)苯基]-1-丁酮、氨基酮、苯偶酰二甲基酮缩醇、双酰基氧化膦、茂金属和二苯酮类。
5.权利要求4的组合物，其中所述二苯酮为N-甲基二乙醇胺二苯酮。
6.权利要求4的组合物，其中所述取代苯乙酮为二乙氧基苯乙酮。
7.权利要求1的组合物，其中所述光引发剂以1至5重量％的量存在。
8.权利要求1的组合物，其中所述核壳橡胶具有苯乙烯丁二烯橡胶构成的核和聚丙烯酸酯构成的壳。
9.权利要求1的组合物，其中橡胶组分以15至35重量％的量存在。
10.一种组合物，包含：
(甲基)丙烯酸酯单体组分；
光引发剂组分；
橡胶组分，包含(a)(i)分子量小于120,000Mw的聚乙烯醇缩丁醛组分，和(b)平均直径在100nm至300nm范围内的核壳橡胶；和
氰酸酯组分。
11.权利要求10的组合物，其中所述氰酸酯组分选自双酚E二氰酸酯、双酚F二氰酸酯、二环戊烷二醇二氰酸酯、1,1’-双(4-氰酰苯基)乙烷、双酚A氰酸酯树脂、六氟双酚A氰酸酯树脂、四甲基双酚F氰酸酯树脂、双酚C氰酸酯树脂、双酚M氰酸酯树脂、酚醛清漆氰酸酯树脂和二环戊二烯双酚氰酸酯树脂中的一种或多种。
12.权利要求10的组合物，其中氰酸酯组分以1至20重量％的量存在。
13.一种组合物，包含：
(甲基)丙烯酸酯单体组分；
光引发剂组分；
橡胶组分，包含(a)(i)分子量小于120，000Mw的聚乙烯醇缩丁醛组分，和(b)平均直径在100nm至300nm范围内的核壳橡胶；和
胺组分。
14.权利要求13的组合物，其中所述胺组分为芳香胺组分或环脂族二胺组分。
15.权利要求13的组合物，其中所述胺组分以1至5重量％的量存在。
16.一种组合物，包含：
(甲基)丙烯酸酯单体组分；
光引发剂组分；
橡胶组分，包含(a)(i)分子量小于120，000Mw的聚乙烯醇缩丁醛组分，和(b)平均直径在100nm至300nm范围内的核壳橡胶；
氰酸酯组分；和
胺组分。
17.权利要求16的组合物，其中所述(甲基)丙烯酸酯单体组分以20至80重量％的量存在；光引发剂组分以1至5重量％的量存在；橡胶组分以15至35重量％的量存在；氰酸酯组分以1至10重量％的量存在；所述胺组分为氨基化二苯砜组分，并且所述氨基化二苯砜组分以0.25至5重量％的量存在。
18.一种组合，包含：
(a)权利要求1的组合物；和
(b)热塑性树脂。
19.权利要求18的组合，进一步包含氰酸酯组分和氨基化二苯砜中的一种或多种。
20.一种组合，包含：
(a)在其至少一个表面上作为涂层涂覆有权利要求1的组合物的B-阶形式的物品；和
(b)与所述组合物的B-阶形式接触的热塑性树脂。
21.权利要求20的组合，其中所述组合物进一步包含氰酸酯组分和氨基化二苯砜中的一种或多种。
22.权利要求20的组合，其中所述物品由铝构成。
23.权利要求20的组合，其中所述物品由阳极化铝构成。
24.一种用于在物品周围形成注塑体的方法，包含步骤：
(a)向注塑腔中放置物品，热塑性材料将被在该物品周围注塑成一定形状；并且
在一定温度和压力下向放置有所述物品的注塑腔中注射热塑性材料，所述温度和压力使得所述热塑性材料在模具中在所述物品周围和附近流动，保持模具在合适温度和压力下以使所述热塑性材料固化，其中
在放置所述物品前，用权利要求1的组合物对该物品涂覆底漆，并且暴露于适于固化所述组合物的电磁谱辐射下。
25.由权利要求24的方法形成的注塑成型产品。
26.权利要求24的方法，其中所述物品由玻璃构成。
27.权利要求24的方法，其中所述物品由铝构成。
28.权利要求24的方法，其中所述物品由阳极化铝构成。
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