WO2003040151A1

WO2003040151A1 - Internally blocked organoborate initiators and adhesive therefrom

Info

Publication number: WO2003040151A1
Application number: PCT/US2002/035185
Authority: WO
Inventors: Jonathan L. Kendall; Kirk J. Abbey; Robin F. Righettini
Original assignee: Lord Corporation
Priority date: 2001-11-06
Filing date: 2002-11-01
Publication date: 2003-05-15
Also published as: US6630555B2; US20040048070A1; US6646076B1; US20030199651A1; US20030138651A1; US6841635B2

Abstract

The internally blocked borate according to the present invention have the general structure (I): Wherein R1 and R2 are substituted or unsubstituted alkyl groups, X is 0, S pr CH2; G has the general structure -(CR3R4)n wherein R3 and R4 are each independently from one another are hydrogen, alkyl, aryl, a fused aromatic ring, a substituted akyl group, or a substituted aryl group; n is from 3 to 5 and Mis any positively charged species with m being greater than O. The organoborates have utility in the initiation of addition polymerisable monomers. The invention pertains also to adpation for adhesives, with particular reference to polymerisable acrylic adhesive systems.

Description

Internally Blocked Organoborate Initiators and Adhesives Therefrom

Field Of The Invention

[0001] The invention is directed to novel internally blocked organoborates having utility in the initiation of addition polymerizable monomers. The invention pertains also to adaptations for adhesives, with particular reference to polymerizable acrylic adhesive systems.

Background Of the Invention

[0002] Typical conventional reactive acrylic adhesives utilize well known non-borate free radical initiators. U.S. Patent No. 4,348,503 discloses acrylic adhesives initiated by a dibasic acid perester and a metal ion. U.S. Patent No. 4,081 ,308 discloses an acrylic adhesive initiated with a saccarin salt and α- hydroxysulfone. U.S. Pat. No 4,331 ,795 discloses an acrylic adhesive cured with hydroperoxide, thiourea and a metal salt. The non-borate initiated reactions for the above adhesives are inhibited by oxygen.

[0003] Organoborane free-radical initiation has been reported in the literature. See, for example, Baen, C. E. H., Margerison, D. and Richardson, N.M., Proc. Chem. Soc, 1959, 397-398; Furukawa, J., Tsuruta.T., J. Po.ym. Sci., 1958, 28, 727-729; Dotty, P.M., Fouss, R.M., Mark, H., Overberger, CG. and Smets, G. J. Polym. Sci. 1958, 33, 502-504. Two mechanisms of the oxygen- organoborane reaction have been postulated. Miruiss, S. B., J. Am. Chem. Soc. 1961 , 83, 3051-3056; Davies, A.G., Roerts, B.P., J. Chem. Soc. B, 1969, 311- 317; Allies, P.G., Brindly, P.B., J. Chem. Soc. B. 1969, 1126-1131. One mechanism involves the homolytic cleavage of the oxygen-oxygen bond to generate an alkoxy radical and a dialkyl boratoxy radical. The other major pathway is believed to involve homolytic cleavage of the alkyl-oxygen bond to form an alkyl radical and a dialkyl boraperoxy radical. The alkyl radical may react with more oxygen to produce a alkylperoxy radical which may then react with organoborane to regenerate the alkyl radical and the borane peroxide. Thus one of the advantages in the use of organoborane initiated reactions is that atmospheric oxygen can be used as the source for the co-initiator in the formation of radicals.

[0004] Approaches to control the reactivity of organoboranes are known. E. Frankland, reported the synthesis of triethyl borane and its air-stable complex with a Lewis base, e.g., ammonia. Phil. Trans. Royal Soc. Vol. 152, pp. 167-183 (1863). The air-stable amine complex is believed to slow down the oxidation of organoboranes by blocking the borane open site for oxygen binding which is the first step in the reaction of organoboranes with oxygen. The initiator can thus be stored in the blocked state and then de-blocked with an appropriate de-blocking or de-complexing agent, such as a stronger Lewis acid.

[0005] British Patent Specification No. 1,113,722 entitled "Aerobically Polymerisable Compositions," published May 15, 1968 discloses a polymerizable composition adapted as a structural adhesive and containing acrylic monomer(s) and an peroxide-activated triaryl, e.g., triphenylborane, complex with hydroxide, ammonia, benzene, or an amine. The polymerization is activated by heating or the addition of an acid. The resulting compositions are reportedly useful as adhesives.

[0006] Japanese Patent App. 69-100477 discloses a simple adhesive containing methyl methacrylate, tributylborane, and PMMA for use in the bonding of polyolefins or vinyl polymer articles. Excellent tensile shear strengths of over 1800 p.s.i. are reported. Acrylic adhesives polymerized with tributylborane and other trialkylboranes were reported during the 1970's. (See, U.S. Pat. No. 3,527,737 to Masuhara, et al. and GDR Pat. No. 2,321 ,215 to Masuhara, et al.)

[0007] Two-part adhesives utilizing in one part trialkyl, triphenyl, or alkylphenyl borane blocked with a primary or secondary amine and in the other part an organic acid or aldehyde are reported in U.S. Patent 5,106, 928, Can. Patent 2,061 ,021, U.S. Patent 5,143,884, U.S. Patent 5 310 835, and U.S. Patent 5,376,746.

[0008] U. S. Patent Nos. 5, 539, 070, 5,690,780 and 5,691 ,065 disclose polyoxyalkylenepolyamine-blocked organoborane initiator, with a nitrogen to boron ratio of 1 :1 to 1.5:1 useful for adhesives to bond low surface energy materials such as polyolefins and polytetrafluoroethylene.

[0009] Organoborane alkoxide complexes are known but there is little reported literature. See, Ludman, C. J.; Waddington, T. C. J. Chem. Soc. A 1966, 1816-1819 and Angew. Chem. Int. Ed. Engl. 1972, 11, 48-49. A combination of potassium methoxide with triethyl borane resulted in the isolation of the hygroscopic white solid potassium triethylmethoxy borate(lll). Similarly, the synthesis of tetraalkylborates, such as sodium tetraethyl borate(lll) are known. Honeycutt, Jr,. J.B., Riddle, J.M., J. Am. Chem. Soc. 1961 , 83, 369-373. The present inventors have shown that these tetraalkylborates are effective as initiators for acrylic adhesives with or without a dblocking agent. The particular advantage of these initiators over amine-blocked boranes is their tendency to remain colorless after cure. In contrast, amine-blocked borane initiated acrylic adhesives yellow with time.

[0010] Hydroxyl and/or alkoxy complexing agents for organoborane initiators are described in WO 01/32716, published May 10, 2001. The complexed initiator has the following structure:

wherein the R groups are alkyl or phenyl and Cx is an alkoxide, or hydroxide. Mixtures of hydroxide complexes with alkoxide complexes are suggested. One alkoxide blocking group is illustrated as

( ^("O - R ⁴ )_n M ^{(m + )}

where R⁴ is independently selected from hydrogen or an organic group, e.g. alkyl or alkylene, M^(m+) is a group I A, 11 A, or ammonium countercation, n is an integer > 0, and m is an integer > 0. An organoborane complex having the following structure follows from this:

[0011] It has been observed cured polymerizable adhesives initiated with amine-blocked boranes begin to turn yellow due to the presence of the amine group. In contrast, the decomposition products of alkoxy-blocked organoborates (alcohols) and alkyl-blocked organoborates (alkanes) do not undergo the unfortunate yellowing with time. The avoidance of discoloration of the cured bondline is important where a bondline must appear on a visually accessible surface of a bonded article for acceptable aesthetics.

[0012] The replacement of mechanically fastened articles with adhesive bonding is growing in importance. However a general requirement for ease of bonding relates to the open time provided by an adhesive. It has been observed that conventional alkoxyborates have relatively poor air stability. For example when sodium ethoxotriethylborate(lll) is exposed to air for 24 hours, the borate loses 46% of its mass and becomes inactive, unable to initiate the polymerization of methacrylate monomers. Air stability is important for meeting the practical problems in the commercial manufacturing and packaging of formulated borane- containing adhesive systems. [0013] The inventors have found a new class of blocked borate having surprisingly good air stability. In adhesive embodiments illustrated below the novel borates exhibit typically open-time in air up to seven days and still maintain its ability to cure methacrylate monomers. Moreover, the novel borate initiators of the present invention remain colorless after curing.

Summary of the Invention

[0014] In accordance with the invention, novel internally blocked borates with internal cyclic alkyl, cyclic alkoxy or cyclic thiolate blocking groups are disclosed. These borates exhibit unexpected stability in the blocked state, ready reaction with de-blocking agents, rapidly initiate polymerization in the unblocked state. Internal blocking refers to the presence of boron itself as part of the internal ring structure with two of the four available boron bonding valences on the boron atom forming part of the ring. The internally blocked borate according to the present invention have the general structure ( I ):

wherein Ri and R₂ are substituted or unsubstituted alkyl groups, substituted or unsubstituted aryl groups, X is O, S or CH₂ ; G has the general structure -(CR³R⁴)_n — wherein R³ and R⁴ are each independently from one another are hydrogen, alkyl, aryl, a fused aromatic ring, a substituted alkyl group, or a substituted aryl group; n is from 2 to 5 and M is any positively charged species with m being greater than 0, e.g. 1 , 2 3, etc.. The substituents of alkyl and aryl groups are readily selected and will not tend to de-complex the borate. Generally the substituents chosen will exclude acids, and acid halides. Exemplary useful substituents are halo, esters, alkoxy, hydroxy, alkoxycarbonyl, and phenyl groups. Preferred embodiments are provided below. [0015] In accordance with another aspect of the invention there is provided a two-part oxygen-promoted adhesive, where a first part comprises a polymerizable component and an optional deblocking agent, an optional accelerator which is either another more reactive borane initiator or a non-borane initiator; and the second part comprises the internally blocked borate (I) and a carrier. The adhesive preferably contains oligomer or polymer components in either or both of the first and/or second parts. The preferred optional accelerator is a non-borane containing, free radical initiator.

[0016] In accordance with another aspect of the invention there is provided a method for adhesively bonding two substrates together to form a bonded composite, the method to form the composite comprising the steps of:

(a) providing a first substrate and a second substrate which is the same material or a different material as substrate;

(b) applying to the first and/or second substrate the following materials in a mixture:

(i) at least one polymerizable component; (ii) an effective amount of an internally blocked organoborate (I); optionally (iii) an activating or deblocking agent, optional accelerator and/or optional non-borane free radical initiator; and

(c) mating the first and second substrates with the components of step (b) therebetween; and

(d) allowing the at least one polymerizable component to polymerize, at ambient conditions or with the optional application of heat, whereby the first and second substrates are adhesively bonded together.

[0017] In another aspect the invention relates to applying a primer prior to a method of bonding comprising applying a solution of the internally blocked organoborate (I) in an inert organic solvent followed by treatment of at least one substrate with the polymerizable composition. Brief Description of the Drawings

[0018] Fig. I is an illustration of the rise in adhesive lap shear bond strength for polypropylene as a function of cure time using (a), a commercial amine borane complex, (b) an internally blocked alkoxyborate of the present invention, and (c) an accelerated internally blocked alkoxyborate.

[0019] Fig. 2, is an illustration of the development of adhesive lap shear strength of polypropylene as a function of adhesive open time using (a) a commercial amine borane complex, (b) internally blocked borate, and (c) an accelerated internally blocked borate.

Detailed Description of the Preferred Embodiments

[0020] In accordance with structure (I)

R¹ and R² are, independently, alkyl groups having 1 to 10 carbon atoms, e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl and decyl as linear or branched C C-io alkyl groups, e.g., isopropyl, isobutyl, neopentyl, methylhexyl, etc.. R³ and R⁴ can be alkyl or phenyl groups. More preferably, R¹ and R² are alkyl groups having 1 to 5 carbon atoms such as methyl, ethyl, propyl, iso-propyl, n-butyl, isobutyl, and pentyl.

[0021] In general, shorter carbon chain lengths of from 1 to 5 carbon atoms are preferred for the R¹ and R² groups as this promotes reactivity in the deblocked state. By "independently selected" it is meant that R¹ and R² may be the same or that they may be different. Preferably R¹ and R² are identical substituents. [0022] Alkyl structures are represented by G are -CH₂-, -C(CH₃)-, - CH2CH2-, -CH₂ CH2CH2-, -CH2CH2CH2CH2-, - CH2CH2CH2CH2CH2-, - CH₂CH(CH3) - , -CH2CH₂C(CH₃)₂- , -C₆H₄CH2-, CH₂CH(CH₃)CH2CH(CH₃)CH₂- , and the like as can be seen in the following illustrated embodiments where M is a counter ion having positive charge m.

[0023] An exemplary reaction scheme in the synthesis of internally blocked alkoxy borate where (X=O) is:

Example 1 [0024] The internally blocked alkoxy borates are synthesized by reacting triethyl borane with a catalytic amount pivalic acid under nitrogen to form (4) .

Reaction of (4) with a bromoalcohol, followed by treatment with sodium in THF gives a internally blocked alkoxy dialkyl borate (I). The following internally blocked alkoxy examples are shown in table 1.

TABLE 1

Examples 1-7 are illustrated by:

Na ©^U(,C, H₃CH₂)₂__PθCH₂CH₂CH₂ (i)

Na^CH₃CH₂)₂_^OCH₂CH₂CH₂CH₂ (2)

Na^CH₃CH₂)₂_ θCH₂CH₂CH₂ (₃)

CH₃

Na®(CH₃CH₂)₂__PθCH₂CH₂CH₂CH₂CH₂ (4)

Na^CH₃CH₂)₂ B^" CH₂C(CH₃)CH₂C(CH₃)CH₂ (6)

NP(CH₃CH₂)₂_ CH₂CH₂CH₂CH₂ (7)

[0025] Internally blocked borates in which X is CH₂ can be made by more than one route. The reaction of diborane with 2,4-dimethyl-1 ,4-pentadiene, followed by reaction with ethylene, and then ethyl sodium results in Example 6 in Table 2. Alternatively, the reaction of triethylborane with borane dimethyl sulfide results in the formation of diethyl borane, which can be reacted with 4-bromo-1- butene and then sodium to produce the internally blocked structure of Example 7.

[0026] An internally blocked thioborate is formed by reacting triethylborane with borane dimethyl sulfide followed by reacting with 4-bromo-1- butene and thiourea, followed by sodium hydroxide which results in the internally blocked borate in which X is S, as in example 8. TABLE 2

Synthesis of Example 9 is illustrated as:

[0027] The counterion M can be any Group IA or Group IIA metal, ammonium, tetraalkyl ammonium, phosphonium, or metal complex with a charge of from 1 to 7, preferably 1 , 2 or 3. The preferred counterions are Na and Mg. The counterion can be ion exchanged after formation of the internally blocked organoborate.

[0028] An effective amount of the internally blocked organoborate is an amount that is enough to permit polymerization to readily occur to obtain adhesive bonding from the polymerizable component for the desired end use. If the amount of internally blocked organoborate is too high, then the polymerization may proceed too rapidly to allow for effective mixing and application of the composition to the substrate(s). The useful rate of polymerization will depend in part on the method of applying the composition to the substrate. Thus, the rate of polymerization for a high speed automated industrial applicator can be faster than if the composition is applied with a hand applicator or if the composition is mixed manually.

[0029] Generally an adhesive formulation will contain effective amounts of internally blocked organoborate (I), such as from about 1 mol % to about 20 mol % based on the moles of free radical polymerizable component(s). This range provides useful results. Good adhesive bond strength was obtained using acrylic polymerizable components with from 1.5 to 6 mol % of internally blocked organoborate initiator.

[0030] Suitable deblocking agents that liberate the active organoborane initiator include acids. Acids can be selected which also provide an accelerator function, however useful some accelerators useful in the present invention do not provide a de-blocking function and may be used in addition to a deblocking agent. Useful acids which de-block the organoborate include Lewis acids (e.g., SnCI₄, TiCI 4. and the like) and Brόnsted acids such as those monofunctional acids having the general formula R' -COOH, where R' is hydrogen, an alkyl group, or an alkenyl group of 1 to 12 and preferably 1 to 6 carbon atoms, or an aryl group of 6 to 10, preferably 6 to 8 carbon atoms. Carboxylates having more than one acidic moiety can be used. The alkyl and alkenyl groups on a monofunctional carboxylic acid used as a deblocking agent may comprise a straight chain or they may be branched. Such groups may be saturated or unsaturated. The aryl groups may contain substituents such as alkyl, alkoxy or halogen moieties. Specific examples as illustrative acids of this type include acrylic acid, methacrylic acid, acetic acid, benzoic acid, and p-methoxybenzoic acid. Other useful Brόnsted acids include HCI, H₂S0₄, H₃ P0₄ and the like. SnCI₄ , acrylic acid and methacrylic acid are preferred acid deblocking agents.

[0031] The deblocking agent should be used in an amount effective to promote polymerization. If too little agent is employed, the rate of polymerization may be too slow and the monomers that are being polymerized may not adequately increase in molecular weight. However, a reduced amount of acid may be helpful in slowing the rate of polymerization. If too much acid is used, then the polymerization tends to proceed too quickly and, in the case of adhesives, the resulting materials may demonstrate inadequate adhesion to low energy surfaces. On the other hand, an excess of deblocking agent is useful for attaining good adhesion to relatively more polar surfaces. Within these parameters, the acid should, preferably, be provided in an amount of about 30 to 540 mole % based on the number of equivalents of internally blocked initiator functionality, more preferably about 100 to 350 mol %, and most preferably about 150 to 250 mol % based on the equivalents of initiator functionality of the borate.

[0032] Adhesives can contain optionally a non-borane free radical initiator which are well known in the art. A non-borane free radical initiator can readily be contained in the polymerizable monomer part of a two-part polymerizable composition. Preferred non-borane free radical initiators are those which do not readily react with monomer under shelf-aging conditions, or can be inhibited suitably to provide desired shelf stability of up to several months, if needed. Illustrative examples of suitable non-borane free radical initiators optionally employed in combination with the polymerizable monomers described above include organic hydroperoxy initiators, particularly those organic hydroperoxides having the formula R" OOH wherein R" is a hydrocarbon radical containing up to about 18 carbon atoms, preferably an alkyl, aryl, or aryl alkyl radical containing from one to 12 carbon atoms. Specific examples of such hydroperoxides are cumene hydroperoxide, tertiary butyl hydroperoxide, methyl ethyl ketone peroxide, and hydroperoxides formed by the oxygenation of various hydrocarbons, such as methylbutene, cetane, and cyclohexene, and various ketones and ethers. Other examples of useful initiators include hydroperoxides such as p-menthane hydroperoxide, 2,5-dimethylhexane, 2,5-dihydroperoxide and the like. Additionally, moree than one non-borane free radical initiator may be employed, such as a mixture of hydroperoxides with peresters, such as t-butyl perbenzoate or t-butyl-peroxymaleate, can be advantageously used. For reasons of economics, availability, and stability, cumene hydroperoxide is especially preferred.

[0033] The invention is adapted to a variety of addition polymerizable compositions which are also referred to as curable compositions, such as described in U.S. Pat. Nos. 2,981 ,650; 3,321 ,351; 4,223,115; 4,293,665; 4,467,071 ; 4,452,944; and 4,769,419, the entire disclosure of each of which is hereby incorporated by reference. The addition polymerizable compositions of the invention polymerize in the presence of internally blocked organoborate ( I ) when the blocking group is de-coupled from boron by the de-blocking agent. Addition polymerizable compounds include free radical polymerizable compounds such as olefinic monomers which are characterized by the presence of a >C=C< group. Exemplary preferred olefinically unsaturated monomers include substituted and unsubstituted acrylic acid, and their amides, esters, salts and corresponding nitriles, as well as substituted and unsubstituted styrene, and the like. Representative free radical-polymerizable monomers include, but are not limited to, styrene, vinyl styrene, vinyl acetate, chlorostyrene, vinylidene chloride, 2,3-dichloro-1 ,3-butadiene, 2-chloro-1 ,3-butadiene, methylstyrene, p- tert-butyl styrene, esters of fumaric and maleic acid which are capable of free radical polymerization, and mixtures thereof. The compositions of the invention typically include at least one free radical polymerizable compound in an amount from about 10 to about 90, preferably about 20 to about 75 weight percent based on the total weight of the polymerizable composition.

[0034] The preferred free radical polymerizable compounds are α, β- unsaturated esters, such as acrylic and substituted acrylic moieties or chemical groups; that is, groups which have the general structure 2:

R O

I II H₂C=C-C-0-R' ( 2)

wherein R is H or an organic radical, and R and R' are substituted and unsubstituted organic radicals that may be the same or different.

[0035] The polymerizable components can be monofunctional and/or polyfunctional including combination of monofunctional and polyfunctional monomers, oligomers and polymers, including mixtures thereof. There are widely available monofunctional acrylate and methacrylate esters, and the substituted versions such as hydroxy, amide, cyano, chloro, and silane substituted derivatives. Specific examples include, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl methacrylate, butyl acrylate, cyclohexyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, isobomyl methacrylate, hydroxyethyl methacrylate, hydroxypropyl acrylate, hydroxypropyl methacrylate, butyl acrylate, n-octyl acrylate, cyclohexyl methacrylate, hexyl methacrylate, 2-ethylhexyl methacrylate, decyl methacrylate, dodecyl methacrylate, lauryl acrylate, tert-butyl methacrylate, acrylamide, N-methyl acrylamide, diacetone acrylamide, N-tert-butyl acrylamide, N-tert-octyl acrylamide, N-butoxyacrylamide, gamma-methacryloxypropyl trimethoxysilane, dicyclopentadienyloxyethyl methacrylate, 2-cyanoethyl acrylate, 3-cyanopropyl acrylate, tetrahydrofurfuryl methacrylate, glycidyl acrylate, acrylic acid, methacrylic acid, itaconic acid, glycidyl methacrylate, dimethylaminoethyl acrylate, and dimethylamino methacrylate may be used.

[0036] Particularly preferred polymerizable components are mixtures of CrC₄ alkyl acrylates (e.g., methyl, ethyl, propyl, and butyl acrylate) and C-|C - alkyl methacrylates (e.g., methyl methacrylate, ethylmethacrylate, and the like). The polymerizable component of the compositions according to the invention may broadly comprise, based on the total weight of the composition, about 10 to 60 wt. % (more preferably about 30 to 40 wt. %) of the alkyl methacrylate, and about 10 to 50 wt. % (more preferably about 25 to 35 wt. %) of the alkyl acrylate.

[0037] Another useful class of polymerizable monomers corresponds to the general formula:

wherein R⁷ may be selected from the group consisting of hydrogen, methyl, ethyl, -CH₂OH, and

R₈ O I II H₂C=C-C-0-CH₂ —

R⁸ may be selected form the group consisting of chlorine, methyl and ethyl. R⁹ may be selected from the group consisting of hydrogen, hydroxy, and

R₈ O

I II

H₂C=C-C-0—

The value of "a" in (3) is an integer greater than or equal to 1 , preferably a represents 1 to 8 CH₂ groups. The integral value of "b" is greater than or equal to 1 , preferably 1 to 20, and c is 0 or 1.

[0038] Di-functional monomers useful in the polymerizable component of the present invention include ethylene glycol dimethacrylate, ethylene glycol diacrylate, polyethylene glycol diacrylate, tetraethylene glycol dimethacrylate, diglycerol diacrylate, diethylene glycol dimethacrylate, pentaerythritol triacrylate, trimethylolpropane trimethacrylate, and other polyether diacrylates and dimethacrylates. The polyether (e.g., exhoxylated and/or propoxylated) dimethacrylates include dimethacrylate of bis(ethylene g!ycol)adipate, dimethacrylate of bis(ethylene glycol)maleate, dimethacrylate of bis(ethylene glycol)phthalate, dimethacrylate of bis(tetraethylene glycol)phthaIate, dimethacrylate of bis(tetraethylene glycol)sebacate, dimethacrylates of bis(tetraethylene glycol)maleate, and the diacrylates and chloroacrylates corresponding to the dimethacrylates, and the like.

[0039] Also useful are monomers that are the known and widely available isocyanate-hydroxyacrylate or isocyanate-aminoacrylate reaction products. These may be characterized as acrylate terminated polyurethanes (also referred to as acrylourethane) and polyureides or polyureas. Such monomers have the following general formula:

where X is selected from the group consisting of --O-- and >N-R¹³, where R¹³ is selected from the group consisting of hydrogen and lower alkyl groups (i.e., 1 to 7 carbon atoms). T is the organic residue of an active hydrogen-containing acrylic ester the active hydrogen having been removed and the ester being hydroxy or amino substituted on the alkyl portion thereof (including the methyl, ethyl and chlorine homologues). The integral value of "f" is from 1 to 6. L is a mono- or polyvalent organic radical selected from the group consisting of alkyl, alkylene, alkenyl, cycloalkyl, cycloalkylene, aryl, aralkyl, alkaryl, poly(oxyalkylene), poly(carboalkoxyalkylene), and heterocyclic radicals, both substituted and unsubstituted. Typical monomers of this class include the reaction product of mono- or polyisocyanates, for example, toluene diisocyanate, with an acrylate ester containing a hydroxy or an amino group in the non-acrylate portion thereof, for example, hydroxyethyl methacrylate.

[0040] Another class of monomers useful herein are the mono- and polyacrylate and methacrylate esters of bisphenol- type compounds many of which are widely available. Representative monomers of the bisphenol type include dimethacrylate and diacrylate esters of 4,4'-bis-hydroxyethoxy-bisphenol A, dimethacrylate and diacrylate esters of bisphenol A, etc.

[0041] Epoxy compounds can be included in the adhesive compositions of the invention in amounts from 0 to about 40, preferably 0 to about 20, weight based on the total weight of the composition. The addition of an epoxy compound can impart heat resistance to the compositions. Epoxy compounds which are suitable for use in the invention are described in U.S. Pat. No. 4,467,071 , referenced above, and can be any monomeric or polymeric compound or mixture of compounds having an average of greater than one 1 ,2- epoxy groups per molecule. The polymeric epoxide compounds can have a number average molecular weight from about 300 to about 10,000. Epoxy compounds are well-known, and disclosed in U.S. Pat. Nos. 2,467,171 ; 2,615,007; 2,716,123; 3,030,336 and 3,053,855. Useful epoxy compounds include the polyglycidyl ethers of polyhydric alcohols, such as ethylene glycol, triethylene glycol, 1 ,2-propylene glycol, 1 ,5-pentanediol, 1 ,2,6-hexanetriol, glycerol and 2,2-bis(4-hydroxy-cyclohexyl)propane; the polyglycidyl esters of aliphatic or aromatic polycarboxylic acids, such as oxalic acid, succinic acid, glutaric acid, terephthalic acid, 2,6-naphthalene dicarboxylic acid and dimerized linolenic acid; and the polyglycidyl ethers of polyphenols, such as Bisphenol A, 1 ,1-bis(4-hydroxyphenyl)ethane, 1 ,1-bis(hydroxyphenyl)isobutane, 2,2-bis (4- hydroxy-t-butylphenyl)propane, 1 ,5-dihydroxynaphthalene and novolak resins.

[0042] The compositions of the invention advantageously also include at least one polymeric material which can provide toughness, impact and shatter resistance to the resultant adhesive and to decrease the brittleness thereof. The polymeric material may or may not include an olefinically unsaturated structure that is capable of being polymerized per se or copolymerized with at least one of the free radical polymerizable monomers described above. The polymeric material can be, for example, polychloroprene as described in U.S. Pat. No. 2,981 ,650, referenced above; a polymer-in-monomer syrup as described in U.S. Pat. Nos. 2,981 ,650; 3,321 ,351 ; and 4,223,115; various solid and liquid elastomeric polymeric materials like ATBM, and CTBN, and in particular liquid olefinic-terminated elastomers (e.g., olefin terminated polyalkadiene, butadiene- based elastomers and urethane-modified butadiene-based elastomers as described in U.S. Pat. Nos. 4,223,115; 4,452,944; and 4,769,419, and 5,641 ,834; chlorosulfonated polyethylene rubbers, as described, for example, in U.S. Pat. No. 4,223,115; olefinic urethane reaction products of an isocyanate-f unction al prepolymer and a hydroxy-functional monomer, as described in U.S. Pat. Nos. 4,223,115; 4,452,944; 4,467,071 ; and 4,769,419, referenced above; and triblock copolymers of the general configuration A-B-A, wherein A is an alkenyl aromatic hydrocarbon polymer block and B is a conjugated diene hydrocarbon polymer block. Alkenyl aromatic hydrocarbons are useful as the A blocks and the B portion can be any four to ten carbon conjugated diene. Specific examples of A- B-A block copolymers include polystyrene-polyisoprene-polystyrene, poly(α- methylstyrene)-polyisoprene-poly(α-methylstyrene) and polystyrene- polybutadiene-polystyrene.

[0043] Polymer-in-monomer syrups, compositionally as well as their preparation are well known in the art. Representative syrups including precursor liquid monomer compounds containing at least one olefinically unsaturated group and their preparation are disclosed in U.S. Pat. Nos. 3,333,025; 3,725,504; and 3,873,640, the entire disclosure of each of which is hereby incorporated by reference.

[0044] Representative liquid olefinic-terminated elastomers include homopolymers of butadiene; copolymers of butadiene and at least one monomer copolymerizable therewith, for example, styrene, acrylonitrile, methacrylonitrile (e.g., poly(butadiene-(meth)acrylonitrile) or poly (butadiene-(meth)acrylonitrile- styrene) and mixtures thereof; as well as modified elastomeric polymeric materials, such as butadiene homopolymers and copolymers as noted above modified by copolymerization therewith of trace amounts of up to about 5 percent by weight of the elastomeric material of at least one functional monomer (such as acrylic acid, methacrylic acid, maleic anhydride, fumaric acid, styrene, and methyl methacrylate, to give, for example, methacrylate-terminated polybutadiene homopolymers and/or copolymers of butadiene).

[0045] As described in U.S. Pat. No. 4,769,419, referenced above, the second hydroxyl group of liquid butadiene-based elastomers can be reacted with a isocyanate to form a liquid urethane-modified butadiene elastomer. Representative urethane-modified butadiene-based elastomeric polymeric compounds and processing for preparing the same are described in U.S. Pat. No. 4,769,419.

[0046] Such liquid olefinic-terminated elastomers can be present in the compositions of the invention in amounts from about 10 to about 80, preferably about 20 to about 50, weight percent based on the total weight of the composition.

[0047] Exemplary chlorosulfonated polyethylene rubbers are described in U.S. Pat. No. 4,223,115 and include chlorosulfonated polyethylene and a mixture of sulfonyl chloride with chlorinated polyethylene. These compositions can have a chlorine content in the range of about 25 to about 67 weight percent and from 3 to about 160 mmols sulfonyl chloride moiety per 100 grams of polymer. Further, the polyethylene from which the chlorosulfonated polyethylene is made preferably has a melt index in the range from about 4 to about 500.

[0048] Representative olefinic urethane reaction products of isocyanate- functional prepolymers and hydroxy-functional monomers having at least one unit of polymerizable unsaturation characterized by the presence of at least two units of unsaturation and the substantial absence of free isocyanate groups are also well-known. Typically, such prepolymers are adducts or condensation products of polyisocyanate compounds having at least two free isocyanate groups and monomeric or polymeric polyols having at least two hydroxy groups, including mixtures of such polyols. The reaction between the polyisocyanate and the polyols is effected employing an excess amount of polyisocyanate to ensure that the reaction product will contain at least two free, unreacted isocyanate groups. Such olefinic urethane reaction products can be present in the compositions of the invention in amounts from 0 to about 40, preferably about 1 to about 25, weight percent based on the total weight of the composition.

[0049] Advantageously, the adhesive compositions of the present invention optionally include a phosphorus-containing compound having one or more olefinic groups and no less than one P--OH group. Phosphorus-containing compounds, which have been found to enhance metal adhesion, are selected from the group consisting of derivatives of phosphinic acid, phosphonic acid and phosphoric acid having at least one P--OH group and at least one organic moiety characterized by the presence of an olefinic group, which is preferably terminally located. A listing of such phosphorus-containing compounds is found in U.S. Pat. No. 4,223,115, referenced above. Such phosphorus-containing compounds can utilized in amounts of from about 0.1 to about 20, preferably about 2 to about 10, percent by weight, based on the total weight of the composition.

[0050] A preferred phosphorus-containing compound has a structure that may be represented by the formula

wherein R¹² is selected from the group consisting of hydrogen, an alkyl group having from one to 8, preferably one to 4, carbon atoms, and CH₂ = CH--; R¹¹ is selected from the group consisting of hydrogen, an alkyl group having from one to 8, preferably one to 4 carbon atoms; A is selected from the group consisting of -R²² O- and (R²³ 0)_n , wherein R²² is an aliphatic or cycloaliphatic alkylene group containing from one to 9, preferably 2 to 6, carbon atoms; R²³ is an alkylene group having from one to 7, preferably 2 to 4, carbon atoms; n is an integer from 2 to 10, and m is 1 or 2, and preferably m = 1.

[0051] Phosphorous-containing compounds having vinyl unsaturation are preferred. Monoesters of phosphinic, phosphonic and phosphoric acids having one unit of vinyl or allylic, especially vinyl unsaturation are preferred. Representative phosphorus-containing compounds include, without limitation, phosphoric acid; 2-methacryloyloxyethyl phosphate; bis-(2- methacryloxyloxyethyl) phosphate; 2-acryloyloxyethyl phosphate; bis-(2- acryloyloxyethyl) phosphate; methyl-(2-methacryloyloxyethyl) phosphate; ethyl methacryloyloxyethyl phosphate; methyl acryloyloxyethyl phosphate; ethyl acryloyloxyethyl phosphate; compounds of the above formula wherein R.sup.8 is hydrogen or methyl and R.sup.9 is propyl, isobutyl, ethylhexyl, halopropyl, haloisobutyl or haloethylhexyl; vinyl phosphonic acid; cyclohexene-3-phosphonic acid; alphahydroxybutene-2 phosphonic acid; 1-hydroxy-1-phenylmethane-1 ,1- diphosphonic acid; 1-hydroxy-1-methyl-1-disphosphonic acid: 1-amino-1 phenyl- 1 ,1-diphosphonic acid; 3-amino-1-hydroxypropane-1 ,1-disphosphonic acid; amino-tris (methylenephosphonic acid); gamma-amino-propylphosphonic acid; gamma-glycidoxypropylphosphonic acid; phosphoric acid-mono-2-aminoethyl ester; allyl phosphonic acid; allyl phosphinic acid; .beta.-methacryloyloxyethyl phosphinic acid; diallylphosphinic acid; .beta.-methacryloyloxyethyl) phosphinic acid and allyl methacryloyloxyethyl phosphinic acid.

[0052] The compositions of the invention can optionally contain up to about 5 percent by weight based on the total weight of the composition of an unsaturated dicarboxylic acid ester which is not polymerizable by free radical reaction mechanisms, in addition to any of the unsaturated dicarboxylic acid ester free radical polymerizable monomers listed above. Unsaturated dicarboxylic acid esters suitable for use in this regard are preferably alkyl esters with the alkyl moiety having from 1 to 18, preferably 1 to 8, carbon atoms, with fumaric and maleic being especially preferred.

[0053] The compositions of the invention can also optionally contain from zero to about 10 percent by weight based on the total weight of the composition of at least one unsaturated polyester resin. Unsaturated polyester resins suitable for use in the adhesive systems described herein are well known in the art. Such resin esters are derived from polycarboxylic acids and polyhydric alcohols, preferably dicarboxylic acids and dihydric alcohols, at least one of the acid and alcohol components being unsaturated. Preferably, the unsaturated polyester resin component will contain a relatively large number of double bonds and be derived from short chain aliphatic polyhydric polyols, such as ethylene glycol and 1 ,3-propylene glycol, and short chain unsaturated polybasic acids, such as fumaric acid and maleic acid. Such resins can contain quantities of longer chain polyols such as 1 ,6-hexanediol, as well as higher polybasic acids, such as adipic acid and phthalic acid.

[0054] Still further, the compositions of the invention can optionally contain from zero to about 50 percent by weight based on the total weight of the adhesive composition of at least one polyvinyl alkyl ether. Polyvinyl alkyl ethers are well-known in the art. Such ethers will preferably contain 1-8, more preferably 1-4, carbon atoms in the alkyl moiety of the ether. Likewise, styrene-acrylonitrile polymers which are suitable for use in the invention are also well known.

[0055] The compositions of the invention can also include up to about 60, preferably not more than about 30, percent by weight based on the total weight of the composition of a polymeric component in addition to the polymeric materials listed above having an intrinsic viscosity of 0.1 to 1.3 that can be obtained by the polymerization of at least one acrylic, styrene, substituted acrylic and non-acrylic olefinic monomers. Exemplary polymeric materials include poly(methyl methacrylate/n-butylacrylate/ethyl acrylate) (90/5/5); poly (n-butyl methacrylate/isobutyl methacrylate) (50/50); poly(n-butyl methacrylate), poly(ethyl methacrylate), and poly(tetrahydrofurfurylmethacrylate).

[0056] The compositions may further comprise a variety of optional additives. One particularly useful additive is a thickener such as a low (i.e., less than or equal to about 100,000) molecular weight polymethyl methacrylate which may be incorporated in an amount of about 20 to 40 wt. % (weight percent), based on the weight of the composition. Thickeners may be employed to increase the viscosity of the composition to a more easily applied viscous syruplike consistency.

[0057] The optional multifunctional monomers provide crosslinking. A suggested amount of crosslinking monomer, if used, is 1 to 20 weight percent based on the weight of the composition, and can be predetermined pending on the physical properties of the cured material as is known and practiced in the art. Useful crosslinkers include ethylene glycol dimethacrylate, ethylene glycol diacrylate, triethyleneglycol dimethacrylate, diethylene glycol bismethacryloxy carbonate, polyethylene glycol diacrylate, tetraethylene glycol dimethacrylate, diglycerol diacrylate, diethlene glycol dimethacrylate, pentaerythritol triacrylate, trimethylopropane trimethacrylate, and other polyether diacrylates and dimethacrylates.

[0058] Various plasticizers and elastomeric materials (i.e., rubbery polymers based on polyisoprene, polybutadiene, polyolefins, polyurethanes and polyesters) may be added to improve flexibility and/or toughness. Other possible additives include non-reactive colorants, fillers (e.g., carbon black), etc. The optional additives are employed in an amount that does not significantly adversely affect the polymerization process or the desired properties of compositions made therewith.

[0059] The substrate which can be bonded together, or to other substrates in accordance with the present invention may be any substrate known to those of skill in the art. For example, the substrate may be, but is not limited to, woven or nonwoven fabrics, fibers, such as fiberglass, polyamides, polyester, aramids, e.g., Kevlar®, a trademark of E. I. du Pont de Nemours Co., (Inc.), of Wilmington, Del., glass, ceramics, metals, and especially thermoplastic and thermoset polymers, and the like. Metals and their alloys include, but are not limited to, steel, stainless steel, lead, aluminum, copper, brass, bronze, Monel metals, nickel, zinc, and the like, including treated metals such as phosphatized steel, galvanized steel, and the like.

[0060] The invention is particularly useful for adhesively bonding together low surface energy substrates or in crossbonding a low energy substrate with different substrates. A low surface energy substrate is defined as one having a surface energy of less than 45 mJ/m² , less than 40 mJ/m² or even less than 35 mJ/m². Included among the recognized low surface energy substrates are materials such as polyethylene, polypropylene, copolymers of α-olefins, acrylonitrile-butadiene-styrene, polyamide, and fluorinated polymers such as polytetrafluoroethylene. Other polymers of somewhat higher surface energy that can be structurally bonded with the adhesive compositions of the invention include polycarbonate and poly(methylmethacrylate). However, the invention is not so limited to bonding of low surface energy materials, but is a distinctive feature. The compositions may be used to bond any thermoplastic as well as wood, ceramics, glass concrete and non-primed and primed metals together or especially in bonding different, i.e., crossbonding with a different substrate.

[0061] The polymerizable compositions of the invention are effective as contained and dispensed from two-part dispensers. A one-part embodiment can be made but is not preferred. The components of the polymerizable composition are blended as would normally be done when working with such materials. An optional accelerator component of the polymerization initiator system can be included in this blend so as to separate it from the internally blocked organoborate, thus providing one part of the two-part composition. The internally blocked organoborate of the polymerization initiator system provides the second part of the composition in a carrier.

[0062] The internally blocked organoborate should be contained in one part as a mixture in a carrier. The carrier vehicles which are suitable for use in the bonding activators of the present invention can be a simple inert solvent or diluent such as methylene chloride, or butyl benzyl phthalate, including mixtures of such solvents or diluents. The carrier vehicle should contain a borane complex- reactive moiety, such as an acidic or basic group where appreciable reaction could occur at room temperature. The carrier vehicle can be a more complex mixture including at least one film-forming binder in addition to inert solvent or diluent. In this case, the film-forming binder is preferably substantially inert with respect to the oxidant which is present in the accelerator composition. A particularly preferred carrier vehicle comprising at least one film-forming binder is an admixture comprising from about 0.05 to about 50 percent by weight of (1) at least one saturated organic polymeric film-forming binder having a glass transition temperature in the range from about 0° C. to about 150° C. or (2) at least one polymer-in-monomer syrup as described below; and from about 40 to about 99 percent by weight of at least one organic solvent capable of maintaining the film-forming binder, phosphorus-containing compound when incorporated into the bonding activator composition, and oxidizing agent as a stable solution or dispersion. Among the polymeric film-forming binder materials which can be employed in the carrier vehicle are, without limitation, polyalkylacrylates and methacrylates and copolymers thereof, polystyrene and copolymers thereof, vinyl polymers and copolymers, polyesters, polyketones, polysulfones, phenolic resins, polyvinyl acetals and butyrals, and polycarbonates. The carrier vehicle can contain, in addition to solvent or solvent and film-forming binder, additives such as external plasticizers, flexibilizers, suspenders, and stabilizers, providing that any such additives do not unacceptably adversely affect the stability of the activator compositions. [0063] Specific examples of carriers are plasticizers such as aliphatic and aromatic esters of phthalic acid, aliphatic and aromatic esters of phosphoric acid, aliphatic trimellitate esters, aliphatic esters of adipic acid, as well as sterate, sebacate and oleate esters. Process oils commonly used in the elastomer industry such as aromatic process oil, paraffinic process oil, and napthenic process oil can be used. Liquid polymers such as low molecular weight polyester, low molecular weight polyisobutylene, or silicone oil are suitable.

[0064] In a two-part adhesive embodiment, the parts can be mixed as they are dispensed or shortly before it is desired to use the composition. The internally blocked organoborate compound may be added to the first part predissolved in an appropriate carrier. Once the two parts have been combined, the composition should be used quickly. The useful pot life may be on the order of a few to several minutes depending upon the specific internally blocked organoborate, amount thereof, the polymerizable components, the presence and amount of accelerator, and the temperature of the parts as applied.

[0065] In an adhesive, the mixed initiator/polymerizable composition is applied to one or both substrates and then the substrates are joined together with pressure to force excess composition out of the bond line. In general, the bonds should be made shortly after the composition has been applied, preferably within about 10 minutes. The typical bond line thickness is about 0.1 to 0.3 mm. The bonding process can easily be carried out at room temperature and to improve the degree of polymerization it is desirable to keep the temperature at or above room temperature but preferably below about 40° C.

[0066] The bonds will cure to a reasonable green strength to permit handling of the bonded components within about 2 to 3 hours. Full strength will be reached in about 24 hours under ambient conditions; post-curing with heat may be used if desired. Examples

[0067] FIGURE 1 compares lap shear strength as a function of time obtained in bonding two polyoiefin coupons together using an adhesive initiated with the internally blocked alkoxy borate and accelerated embodiment (Example 4b below) against a commercially available borane-amine complex-initiated acrylic adhesive. The coupons used in this study were 1" x 4" x 1/8" (2.54 x 10.16 x 0.31 cm.) polypropylene (PP) coupons. The adhesive was dispensed onto one face of each substrate pair. Glass beads were used to maintain a uniform bond-line thickness. The two coupons were mated with a 1 in.² (6.45 cm.²) bond area and held with a 170 g weight for a cure time of 24 hr. Five to ten coupon pairs constituted each set of lap shear samples (except for unsanded polypropylene, where 30 samples were tested). The cured samples were pulled on a mechanical tensile tester at 0.5 in/minute.

[0068] An acrylic adhesive was prepared using the internally blocked organoborate of Example 1 . The components were mixed immediately prior to bonding the coupons and consisted of :

Component wt % amount

THF Methacrylate 75.9%

Styrene-isoprene-styrene copolymer 3%

Methacrylic acid 3%

Internally blocked borate from Example 1 4%

(equivalent of B(Et)₃ 1.4%)

Example 3 and 3a - Stability to air (oxygen inhibition) and package shelf stability

[0069] 3. To demonstrate the air stability of internally blocked organoborate structure 3, a sample was allowed to sit open to air for 7 days. Using this material, a test adhesive given in Example 2 was prepared. Polypropylene lap shear samples were joined after predetermined open time (minutes) and cured. The lap shear samples exhibited stock break and one t/c. (explain) The mean lap shear strength was 474 psi (3555 Kpa). As can be seen in FIG. 2, the lap shear strength of bonded PP using a commercially available borane-amine complex dropped to less than 50 psi (375 Kpa) when held open for 3 minutes, whereas the inventive examples exhibited bond strength above 500 psi (3750 KPa) after 5 minutes, and still exhibited useful bond strength above 300 psi 2250 Kpa) when bonding PP after 10 minutes open time.

[0070] 3a. The package shelf stability of the internally blocked borate initiated adhesives is shown by evaluating the adhesive's ability to provide good bonding long term storage in the typical container such as in 2-part cartridges employed commercially. The following formulation was prepared and packaged into a 2-part cartridge:

A-side Component wt % amount

THF Methacrylate 53.3%

2-ethylhexyl methacrylate 16.4 mono-2-(methacryloyloxy)ethyl succinate 6.0

Core-shell ABS copolymer 14.5

Glass microspheres 7.0

Silica 2.9

B-side Component wt % amount

Polypropylene glycol adipate carrier 75%

Internally blocked borate from Example 1 25%

Na⁺[B(CH2CH2CH2θ)(CH₂CH₃)2]^" which is sodium 3-diethylboranyl propan-1- olate

[0071] Two 2-part cartridges were prepared from the same lots of A-and B-sides. One cartridge was immediately used to bond PP lap shear samples, and the other was allowed to age at ambient lab conditions. After 3 months, the aged cartridge appeared unchanged, and lap shear strengths of bonded PP coupons using the aged cartridge were as good as the results obtained with the unaged cartridge.

Examples 4a and 4b

[0072] (4a) To demonstrate acceleration effect of peroxide coinitiator, 2- part cartridges containing accelerator were prepared. In example 4a, a 2- part cartridge containing the following components in the A- and B-side was prepared:

sodium 3-diethylboranyl propan-1 -olate [0073] (4b) A formulation was prepared in another 2-part cartridge and in addition to the above components, a mixed accelerator system reactive with monomer was used. In part A was added 0.19% N,N-dimethyl aniline, in part B 0.01 % of benzoyl peroxide was added.

[0074] FIG. 1 is a graphical illustration of the rate of bond strength obtained with PP lap shear coupons comparing the adhesive containing accelerators.

Example 5 Bonding to other low surface energy substrates

[0075] Six poly(tetrafluoroethylene) lap shear samples were prepared with an adhesive containing 3.76 g tetrahydrofurfuryl methacrylate, 0.94 g styrene- isoprene rubber, 0.18 g sodium 3-diethylboranyl propan-1-olate (Example 1) , and 0.22 g methacrylic acid as an adhesive.

[0076] McMaster-Carr (spell) coupons (4" x 1" x 1/8") (2.54 x 10.16 x 0.31 cm.) were bonded with a 1 in² (6.45 cm²) overlap. Glass beads having a diameter of 0.025 mm were used to maintain bond line control. The samples were held with a 170 g. weight and were allowed to cure for 22 h. The samples were pulled on a hydraulic tensile tester. The samples failed with a mean stress of 247 psi (1700 kPa) and a standard deviation of 8 psi (60 kPa). In all six cases the substrate yielded, but two samples broke with a mixture of adhesive and cohesive failure upon continued stress.

Open Time Study

[0077] Fig. 2, illustrates that the open time for acrylic adhesive initiated with internally blocked alkoxyborate adhesive is much better than for a commercial amine-blocked borane adhesive. The open time for the amine- blocked orgaonborane was less than three minutes. The lap shear strength falls from over 500 psi (3750 Kpa) to less than 50 psi (375 KPa) if the samples are held open for 3 minutes. In contrast, the internally blocked alkoxy borate had an open time of at least five minutes with little drop in lap shear strength, and still good lap shear strength after having delayed bonding for 10 minutes. The BPO/DMA-accelerated system had a shorter open time, but exhibits at least a five-minute open time.

[0078] It is understood that the foregoing description of preferred embodiments is illustrative, and that variations may be made in the present invention without departing from the spirit and scope of the invention. Although illustrated embodiments of the invention have been shown and described, a lattitude of modification, change and substitution is intended in the foregoing disclosure, and in certain instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims are to be construed in a manner consistent with the scope of the invention.

Claims

What is claimed is:

1. A method for adhesively bonding substrates, the method comprising the steps of:

(a) providing at least a first and a second substrate;

(b) applying to at least one of said first and said second substrates a mixture comprising:

(i) at least one addition polymerizable component;

(ii) an effective amount of a borate compound having the structure ( I );

wherein Ri and R are substituted or unsubstituted alkyl groups, substituted or unsubstituted aryl groups, X is O, S or CH₂ ; G is the divalent radical -(CR³R⁴)_n — , wherein R³ and R⁴ are each independently hydrogen, alkyl, aryl, a fused aromatic ring, a substituted alkyl group, or a substituted aryl group; n is from 2 to 5; M is a counter ion with charge m being greater than 0; and (iii) a deblocking agent;

(c) mating the first and second substrates with said materials of step (b) therebetween; and

(d) allowing the at least one addition polymerizable component to polymerize, optionally with application of heat, whereby the first and second substrates are adhesively bonding.

2. The method according to claim 1 wherein one of said first and said second substrate comprises a material selected from the group consisting of a wood product, thermoplastic, a thermoset composition, and coated or uncoated metal.

3. The method according to claim 2 wherein one of said first and said second substrate comprise materials selected from the group consisting polyethylene, polypropylene, polyurethane, polyurea, fluoroplastic, polyvinylchloride, thermoset polymer, elastomer, aluminum, and steel.

4. The method according to claim 1 wherein said mixture further comprises (iv) an accelerator.

5. The method according to claim 1 wherein the at least one addition polymerizable component comprises monofunctional methacrylate ester selected from the group consisting of methyl methacrylate, ethyl methacrylate, methoxy ethyl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, cyclohexyl methacrylate, tetrahydrofurfuryl methacrylate, and blends thereof.

6. The method according to claim 5 wherein the methacrylate ester monomer is methyl methacrylate, and said addition polymerizable component further comprises an alkyl acrylate.

7. The method according to claim 1 wherein said mixture further comprises a thickening agent.

8. The method according to claim 1 wherein said mixture further comprises an elastomeric filler.

9. The method according to claim 1 wherein the internally blocked organoborate has the structure:

.wherein M is a counter ion with charge m being greater than 0.

10. The method according to claim 1 wherein the internally blocked organoborate has the structure :

wherein M is a counter ion with charge m being greater than 0.

11. The method according to claim 1 wherein the internally blocked organoborate has the structure:

wherein M is a counter ion with charge m being greater than 0.

12. The method according to claim 1 wherein the internally blocked organoborate has the structure:

wherein M is a counter ion with charge m being greater than 0.

13. The method according to claim 1 wherein the internally blocked organoborate has the structure:

wherein M is a counter ion with charge m being greater than 0.

14. The method according to claim 1 wherein the internally blocked organoborate has the structure:

wherein M is a counter ion with charge m being greater than 0.

15. The method according to claim 1 wherein the internally blocked organoborate has the structure:

wherein M is a counter ion with charge m being greater than 0.

16. The method according to claim 1 wherein the internally blocked organoborate has the structure:

wherein M is a counter ion with charge m being greater than 0.

17. The method according to claim 1 wherein the internally blocked organoborate has the structure:

wherein M is a counter ion with charge m being greater than 0.

18. A polymerizable composition comprising: a) at least one acrylic monomer; b) a compound having the structure ( I )

wherein Ri and R₂ are substituted or unsubstituted alkyl groups, substituted or unsubstituted aryl groups, X is O, S or CH₂ ; G is the divalent radical -(CR³R⁴)_n - wherein R³ and R⁴ are each independently hydrogen, alkyl, aryl, a fused aromatic ring, a substituted alkyl group, or a substituted aryl group; n is from 2 to 5 and M is a counter ion with charge m being greater than 0; and c) a compound that liberates an organoborane from ( I ).

19. A polymerizable composition according to claim 18 wherein the at least one acrylic monomer is selected from the group consisting of monofunctional substituted or unsubstituted acrylate ester, monofunctional substituted or unsubstituted methacrylate ester, and a mixture of said acrylate and said methacrylate ester.

20. A polymerizable composition according to claim 19 wherein the monofunctional methacrylate ester is selected from the group consisting of methyl methacrylate, ethyl methacrylate, methoxy ethyl methacrylate, hydroxyethyl methacrylate, hydroxypropyl methacrylate, cyclohexyl methacrylate, tetrahydrofurfuryl methacrylate, and mixtures thereof.

21. A polymerizable composition according to claim 19 wherein the at least one acrylic monomer comprises a mixture of methyl methacrylate and butyl acrylate.

22. A polymerizable composition according to claim 19 further comprising an elastomeric modifier.

23. A polymerizable composition according to claim 18 wherein the composition comprises about 1.5 to 6 mol% of ( I ).

24. A polymerizable composition according to claim 18 contained in a two- part dispenser, wherein ( i ) is contained in one part of said dispenser and (ii) is contained in the other part of said dispenser in a carrier liquid, said dispenser adapted to combine and mix the parts upon dispensing.

25. A polymerizable acrylic composition according to claim 24 wherein the two-part dispenser is adapted to combine the first part and the second part of the two-part adhesive composition in a whole number mix ratio of to 1 or less.

26. A polymerizable acrylic composition according to claim 18 wherein (I) two part dispenser is adapted to combine the first part and the second part of the two-part adhesive composition in a whole number mix ratio of :1 or less.

27. A compound which has the structure ( I ):

wherein Ri and R₂ are substituted or unsubstituted alkyl groups, substituted or unsubstituted aryl groups, X is O, S or CH₂ ; G is the divalent radical -(CR³R⁴)_n — wherein R³ and R⁴ are each independently hydrogen, alkyl, aryl, a fused aromatic ring, a substituted alkyl group, or a substituted aryl group; n is from 2 to 5 and M is a counter ion with charge m being greater than 0;

28. The compound of claim 25 having the structure:

wherein M is a counter ion with charge m being greater than 0.

29. The compound of claim 25 having the structure:

wherein M is a counter ion with charge m being greater than 0.

30. The compound of claim 25 having the structure:

wherein M is a counter ion with charge m being greater than 0.

31. The compound of claim 25 having the structure:

wherein M is a counter ion with charge m being greater than 0.

32. The compound of claim 25 having the structure:

wherein M is a counter ion with charge m being greater than 0.

33. The compound of claim 25 having the structure:

wherein M is a counter ion with charge m being greater than 0.

34. The compound of claim 25 having the structure:

wherein M is a counter ion with charge m being greater than 0.

35. The compound of claim 25 having the structure:

wherein M is a counter ion with charge m being greater than 0.

36. The compound of claim 25 having the structure:

wherein M is a counter ion with charge m being greater than 0.

37. A bonded composite comprising a first substrate, a second substrate, and a cured composition that adhesively bonds the first and second substrates together, wherein the composition results from the curing a composition comprising:

(a) at least one acrylic monomer;

(b) an internally blocked organoborate having the structure (I)

wherein Ri and R₂ are substituted or unsubstituted alkyl groups, substituted or unsubstituted aryl groups, X is O, S or CH₂ ; G is the divalent radical -(CR³R⁴)_n — , wherein R³ and R⁴ are each independently hydrogen, alkyl, aryl, a fused aromatic ring, a substituted alkyl group, or a substituted aryl group; n is from 2 to 5 and M is a counter ion with charge m being greater than 0.

38. A bonded composite according to claim 37 wherein the one of said substrates is formed from a material that has a surface energy of less than 45 mJ/m².

39. A bonded composite according to claim 37 wherein the first substrate comprises a material selected from the group consisting of polyethylene, a polypropylene, a polyvinylchloride and a fluoroplastic.

40. A bonded composite according to claim 38 wherein both the first and second substrates are formed from a material having a surface energy of less than 45 mJ/m².

41. A bonded composite according to claim 38 wherein both the first and second substrates comprise materials independently selected from the group consisting of a polyethylene, a polypropylene, a polyvinylchloride and a fluoroplastic.

42. A bonded composite according to claim 38 wherein Ri and R₂ are each independently selected from the group consisting of alkyl groups having 2 to 5 carbon atoms.