Dry adhesive

Abstract

This composite uses the bonding of PVC to a variety of materials, from cloth to concrete, by the simple laying of the PVC surface to the other surface without the use of conventional wet, tacky, intermediate layer or layers of conventional adhesives. A simple preapplication of a chemical intermediate to the second surface in latex form and dried to a nontacky state is done. This is followed in any length of time thereafter with the simple contact of both surfaces, one to the other. A mild to aggressive tack bond, or a hard permanent joining of both surfaces is achieved. This bond is formed by the polar attraction of certain acrylics to the plasticizers in the PVC.

We claim:  
     
         1 . A composite comprising in order: 
 a substrate;    a dry acrylic adhesive adhered to the substrate; and    a plasticized, polyvinyl chloride layer adhered to the dry acrylic adhesive.    
     
     
         2 . A composite according to  claim 1 , wherein the dry acrylic adhesive is at least one polymer or copolymer of methyl methacrylate, ethyl acrylate, acrylic acid or acrylic esters.  
     
     
         3 . A composite according to  claim 1 , wherein the dry acrylic adhesive is at least one polymer, copolymer or terepolymer of ethyl acrylate, butyl acrylate, stryrenated acrylics or acrylonitrile.  
     
     
         4 . A composite according to  claim 1 , wherein the dry adhesive is an acrylic acid-acrylic ester copolymer having  
       
         
           
           
               
               
           
         
       
       wherein: 
 R 1  is H or CH 3    
 R 2  is CH 3 , CH 2 CH3, (CH 2 )3CH 3 , n-octyl or 2-ethylhexyl  
 R 3  is H, CH3 or COOH  
 o is equal to 4 to 12, and  
 P is equal to 1.  
 
     
     
         5 . A composite according to  claim 1 , wherein the substrate is carpet backing, cloth, concrete, wood or flooring.  
     
     
         6 . A composite according to  claim 1 , wherein the polyvinyl layer is a floor covering layer.  
     
     
         7 . A composite according to  claim 1 , wherein the dry acrylic adhesive is an acrylic latex.  
     
     
         8 . A composite according to  claim 1 , wherein the polyvinyl chloride is represented by the formula (—H 2 CCHCl—) n  wherein n is an integer ranging from about 1000 to about 2500.  
     
     
         9 . A composite according to  claim 1 , wherein the plasticized, polyvinyl chloride layer includes at least one phthalic diester plasticizer.  
     
     
         10 . A composite according to  claim 1 , wherein the plasticized, polyvinyl chloride layer includes at least one adipate plasticizer.  
     
     
         11 . A composite according to  claim 1 , wherein the plasticized., polyvinyl chloride layer is a blend of PVC homopolymers and PVC copolymers.  
     
     
         12 . A composite comprising in order: 
 a substrate;    a dry acrylic adhesive adhered to the substrate;    a plasticized, polyvinyl chloride layer adhered to the dry acrylic adhesive;    a second layer of dry acrylic adhesive adhered to the PVC layer; and    a ceramic tile adhered to the second layer of dry acrylic adhesive.    
     
     
         13 . A composite according to  claim 12  wherein the PVC layer is a PVC foam.  
     
     
         14 . A process for bonding a plasticized, polyvinyl chloride layer to a substrate comprising the steps of: 
 applying an acrylic adhesive to a substrate;    drying the adhesive;    laying the polyvinyl chloride layer over the dried adhesive; and    allowing the resulting composite to stand for a period of time.    
     
     
         15 . A process according to  claim 14  wherein the adhesive is dried for a period of time ranging up to 2 hours before laying the polyvinyl chloride layer thereon.  
     
     
         16 . A process according to  claim 14  including the additional steps of: 
 applying a second layer of acrylic adhesive to a ceramic tile;  
 drying the second layer of acrylic adhesive on the ceramic tile; and  
 layering the dried second layer of acrylic adhesive on the PVC layer.  
 
     
     
         17 . A process according to  claim 16  wherein the PVC layer is a PVC foam.