Thermosetting adhesive films including a fibrous carrier

Patent metadata

Field	Value
Publication number	US-2016160092-A1
Application number	US-201414907160-A
Country	US
Kind code	A1
Filing date	Jul 25, 2014
Priority date	Jul 26, 2013
Publication date	Jun 9, 2016
Grant date	—

Abstract

Flexible films comprise an adhesive layer and a fibrous supporting layer and the thermosetting adhesive materials which are non-tacky to the touch are storage stable at room temperature and can be cured at elevated temperature with a short cure time and can be cured to produce a tough flexible adhesive layer including bonding to oily surfaces, the materials are particularly useful in bonding together dissimilar substrates where they can reduce the formation of galvanic corrosion.

First claim

1 . A curable epoxy resin based thermosetting adhesive film which is:
a. non-tacky to the touch at room temperature; b. flexible prior to cure; and c. storage stable at room temperature; comprising an adhesive layer and a fibrous supporting layer.

2 . An adhesive film according to claim 1 , that can be cured in no more than 45 minutes at a temperature no higher than 190° C.

3 . An adhesive film according to claim 2 , which forms an adhesive bond with oily surfaces.

4 . An adhesive film according to claim 2 , which can be cured at a temperature in the range 130° C. to 190° C.

5 . An adhesive film according to claim 2 , in which the adhesive layer is foamable.

6 . An adhesive film according to claim 1 , wherein the adhesive layer has an uncured thickness between 0.2 and 3.0 mm.

7 . An adhesive film according to claim 1 , wherein the adhesive layer has a density of from 1.1 to 1.5 g/ml.

8 . An adhesive film according to claim 1 , wherein the adhesive layer is derived from a mixture of:
i) a phenoxy resin; ii) an elastomer/epoxy resin adduct; iii) a core shell material; and iv) a curing agent.

9 . An adhesive film according to claim 8 , wherein the mixture contains an epoxy resin.

10 . An adhesive film according to claim 9 , wherein the mixture contains at least 15 wt % of a phenoxy resin, preferably from 15 to 40 wt % of a phenoxy resin, from 5 to 40 wt % of an elastomer epoxy resin adduct, from 5 to 25 wt % of a core shell polymer.

11 . An adhesive film according to claim 10 , wherein the fibrous support layer or fleece is selected from a woven or knit mat, a random mat and is derived from glass, polyester, polyimide, carbon or aramid fibres.

12 . An adhesive film according to claim 11 , wherein the fibrous layer has a thickness of from 10 to 500 μm.

13 . An adhesive film according to claim 11 , wherein the fibrous layer has an area weight of from 10-200 grams/square metre.

14 . An adhesive film according to claim 1 , wherein the fibrous layer has a porosity of from 1-1000 μm.

15 . An adhesive film according to claim 1 , wherein the film is uncured and the uncured film is on one or both sides of the fibrous carrier.

16 . An adhesive film according to claim 10 , wherein the film is uncured and the uncured film is on one or both sides of the fibrous carrier.

17 . The use of an adhesive film according to claim 1 for bonding together substrates having different coefficients of thermal expansion.

18 . The use of an adhesive film according to claim 1 for the bonding of metals to fibre reinforced resin composites.

19 . The use according to claim 18 , wherein the fibre reinforced composite is a glass, carbon or aramid fibre reinforced epoxy or polyester based resin.

20 . A cured adhesive film derived from a thermosetting adhesive film according to any of claim 1 .

21 - 32 . (canceled)

Assignees

• Zephyros Inc

Inventors

• Awkal Michel
• Chene Morgan

Classifications

• C09J2461/00

  Presence of condensation polymers of aldehydes or ketones · CPC title

• C09J7/21

  Paper; Textile fabrics · CPC title

• C09J5/06

  involving heating of the applied adhesive · CPC title

• C09J7/35

  Heat-activated · CPC title

• C09J2400/263

  in the substrate · CPC title