Thermoset adhesive films

Abstract

This invention is a film adhesive prepared from an adhesive composition comprising a polymer system, a film forming rubber compound, and curing agents for the polymeric system. The polymer system comprises a base polymer and electron donor and electron acceptor functionality.

What is claimed:  
     
         1 . A film adhesive prepared from materials comprising (i) a polymer containing no electron donor or acceptor functionality having a molecular weight in the range of 2,000 to 1,000,000, (ii) an independent electron donor compound and (iii) an independent electron acceptor compound.  
     
     
         2 . The film adhesive according to  claim 1  in which the polymer (i) is prepared from acrylic, vinyl, or conjugated diene monomers.  
     
     
         3 . The film adhesive according to  claim 2  in which the polymer (i) is an acrylic polymer, a styrene-acrylic copolymer, or a acrylonitrile-butadiene copolymer.  
     
     
         4 . The film adhesive according to  claim 1  in which the independent electron donor compound is selected from the group consisting of vinyl ethers, vinyl silanes, and compounds containing a carbon to carbon double bond attached to an aromatic ring and conjugated with the unsaturation in the ring.  
     
     
         5 . The film adhesive according to  claim 4  in which the vinyl ethers are selected from the group consisting of bis[4-(vinyloxy)butyl]terephthalate, bis[4-(vinyloxy)butyl](4-methyl-1,3-phenylene)biscarbamate, bis[4-(vinyloxy) butyl]1,6-hexanediylbiscarbamate, 4-(vinyloxy)butyl stearate, and bis[4-(vinyloxy) butyl](methylenedi-4,1-phenylene)biscarbamate.  
     
     
         6 . The film adhesive according to  claim 4  in which the compounds containing a carbon to carbon double bond attached to an aromatic ring and conjugated with the unsaturation in the ring are selected from the group consisting of:  
       
         
           
           
               
               
           
         
         
           
           
               
               
           
         
       
     
     
         7 . The film adhesive according to  claim 1  in which the independent electron acceptor compound is selected from the group consisting of fumarates, maleates, acrylates, and maleimides.  
     
     
         8 . The film adhesive according to  claim 7  in which the independent electron acceptor compound is a bismaleimide selected from the group consisting of N,N′-ethylene-bis-maleimide, N,N′-butylene-bis-maleimide, N,N′-phenylene-bis-maleimide, N,N′-hexamethylene-bis-maleimide, N,N′-4,4′-diphenyl methane-bis-maleimide, N,N′-4,4′-diphenyl ether-bis-maleimide, N,N′-4,4′-diphenyl sulfone-bis-maleimide, N,N′-4,4′-dicyclohexyl methane-bis-maleimide, N,N′-xylylene-bis-maleimide, and N,N′-diphenyl cyclohexane-bis-maleimide.  
     
     
         9 . A film adhesive prepared from (i) a polymer substituted with pendant electron acceptor functionality having a molecular weight in the range of 2,000 to 1,000,000, (ii) an independent electron donor compound, and optionally (iii) an independent electron acceptor compound.  
     
     
         10 . The film adhesive according to  claim 9  in which the polymer (i) is prepared from acrylic, vinyl, or conjugated diene monomers and has pendant electron acceptor functionality.  
     
     
         11 . The film adhesive according to  claim 10  in which the polymer (i) is an acrylic, styrene-acrylic copolymer, or a acrylonitrile-butadiene copolymer and has pendant electron acceptor functionality.  
     
     
         12 . The film adhesive according to  claim 9  in which the independent electron donor compound is selected from the group consisting of vinyl ethers, vinyl silanes, and compounds containing a carbon to carbon double bond attached to an aromatic ring and conjugated with the unsaturation in the ring.  
     
     
         13 . The film adhesive according to  claim 12  in which the vinyl ethers are selected from the group consisting of bis[4-(vinyloxy)butyl]terephthalate, bis[4-(vinyloxy)butyl](4-methyl-1,3-phenylene)biscarbamate, bis[4-(vinyloxy) butyl]1,6-hexanediylbiscarbamate, 4-(vinyloxy)butyl stearate, and bis[4-(vinyloxy) butyl](methylenedi-4,1-phenylene)biscarbamate.  
     
     
         14 . The film adhesive according to  claim 12  in which the compounds containing a carbon to carbon double bond attached to an aromatic ring and conjugated with the unsaturation in the ring are selected from the group  
       
         
           
           
               
               
           
         
         
           
           
               
               
           
         
       
     
     
         15 . The film adhesive according to  claim 9  in which the independent electron acceptor compound is selected from the group consisting of fumarates, maleates, acrylates, and maleimides.  
     
     
         16 . The film adhesive according to  claim 15  in which the independent electron acceptor compound is a bismaleimide selected from the group consisting of N,N′-ethylene-bis-maleimide, N,N′-butylene-bis-maleimide, N,N′-phenylene-bis-maleimide, N,N′-hexamethylene-bis-maleimide, N,N′-4,4′-diphenyl methane-bis-maleimide, N,N′-4,4′-diphenyl ether-bis-maleimide, N,N′-4,4′-diphenyl sulfone-bis-maleimide, N,N′-4,4′-dicyclohexyl methane-bis-maleimide, N,N′-xylylene-bis-maleimide, and N,N′-diphenyl cyclohexane-bis-maleimide.  
     
     
         17 . A film adhesive prepared from (i) a polymer having pendant electron donor functionality having a molecular weight in the range of 2,000 to 1,000,000, (ii) an independent electron acceptor compound and optionally (iii) an independent electron donor compound;  
     
     
         18 . The film adhesive according to  claim 17  in which the polymer (i) is prepared from acrylic, vinyl, or conjugated diene monomers and has pendant electron donor functionality.  
     
     
         19 . The film adhesive according to  claim 18  in which the polymer (i) is an acrylic, a styrene-acrylic copolymer, or a acrylonitrile-butadiene copolymer and has pendant electron donor functionality.  
     
     
         20 . The film adhesive according to  claim 17  in which the independent electron acceptor compound is selected from the group consisting of fumarates, maleates, acrylates, and maleimides.  
     
     
         21 . The film adhesive according to  claim 20  in which the independent electron acceptor compound is a bismaleimide selected from the group consisting of N,N′-ethylene-bis-maleimide, N,N′-butylene-bis-maleimide, N,N′-phenylene-bis-maleimide, N,N′-hexamethylene-bis-maleimide, N,N′-4,4′-diphenyl methane-bis-maleimide, N,N′-4,4′-diphenyl ether-bis-maleimide, N,N′-4,4′-diphenyl sulfone-bis-maleimide, N,N′-4,4′-dicyclohexyl methane-bis-maleimide, N,N′-xylylene-bis-maleimide, and N,N′-diphenyl cyclohexane-bis-maleimide.  
     
     
         22 . The film adhesive according to  claim 17  in which the independent electron donor compound is selected from the group consisting of vinyl ethers, vinyl silanes, and compounds containing a carbon to carbon double bond attached to an aromatic ring and conjugated with the unsaturation in the ring.  
     
     
         23 . The film adhesive according to  claim 22  in which the vinyl ethers are selected from the group consisting of bis[4-(vinyloxy)butyl]terephthalate, bis[4-(vinyloxy)butyl](4-methyl-1,3-phenylene)biscarbamate, bis[4-(vinyloxy) butyl]1,6-hexanediylbiscarbamate, 4-(vinyloxy)butyl stearate, and bis[4-(vinyloxy) butyl](methylenedi-4,1-phenylene)biscarbamate.  
     
     
         24 . The film adhesive according to  claim 22  in which the compounds containing a carbon to carbon double bond attached to an aromatic ring and conjugated with the unsaturation in the ring are selected from the group consisting of:  
       
         
           
           
               
               
           
         
         
           
           
               
               
           
         
       
     
     
         25 . A film adhesive prepared from (i) a polymer having pendant electron donor and electron acceptor functionality and having a molecular weight in the range of 2,000 to 1,000,000, or a combination of a polymer having pendant electron donor functionality and having a molecular weight in the range of 2,000 to 1,000,000, and a polymer having pendant electron acceptor functionality and having a molecular weight in the range of 2,000 to 1,000,000; optionally (ii) an independent electron donor compound; and optionally (iii) an independent electron acceptor compound.  
     
     
         26 . The film adhesive according to  claim 25  in which the polymer (i) is prepared from acrylic, vinyl, or conjugated diene monomers and has pendant electron donor functionality and pendant electron acceptor functionality and the polymers in the combination of a polymer having pendant electron donor functionality and a polymer having pendant electron acceptor functionality polymers (i) are prepared from acrylic, vinyl, or conjugated diene monomers with, respectively, pendant electron donor functionality and pendant electron acceptor functionality.  
     
     
         27 . The film adhesive according to  claim 26  in which the polymer (i) is an acrylic, a styrene-acrylic copolymer, or a acrylonitrile-butadiene copolymer and has pendant electron donor functionality and pendant electron acceptor functionality, and the polymers in the combination of a polymer having pendant electron donor functionality and a polymer having pendant electron acceptor functionality polymers (i) is an acrylic, a styrene-acrylic copolymer, or a acrylonitrile-butadiene copolymer with, respectively, pendant electron donor functionality and pendant electron acceptor functionality.  
     
     
         28  The film adhesive according to  claim 25  in which the independent electron donor compound is selected from the group consisting of vinyl ethers, vinyl silanes, and compounds containing a carbon to carbon double bond attached to an aromatic ring and conjugated with the unsaturation in the ring.  
     
     
         29 . The film adhesive according to  claim 28  in which the vinyl ethers are selected from the group consisting of bis[4-(vinyloxy)butyl]terephthalate, bis[4-(vinyloxy)butyl](4-methyl-1,3-phenylene)biscarbamate, bis[4-(vinyloxy) butyl]1,6-hexanediylbiscarbamate, 4-(vinyloxy)butyl stearate, and bis[4-(vinyloxy) butyl](methylenedi-4,1-phenylene)biscarbamate.  
     
     
         30 . The film adhesive according to  claim 28  in which the compounds containing a carbon to carbon double bond attached to an aromatic ring and conjugated with the unsaturation in the ring are selected from the group consisting of:  
       
         
           
           
               
               
           
         
         
           
           
               
               
           
         
       
     
     
         31 . The film adhesive according to  claim 25  in which the independent electron acceptor compound is selected from the group consisting of fumarates, maleates, acrylates, and maleimides.  
     
     
         32 . The film adhesive according to  claim 31  in which the independent electron acceptor compound is a bismaleimide selected from the group consisting of N,N′-ethylene-bis-maleimide, N,N′-butylene-bis-maleimide, N,N′-phenylene-bis-maleimide, N,N′-hexamethylene-bis-maleimide, N,N′-4,4′-diphenyl methane-bis-maleimide, N,N′-4,4′-diphenyl ether-bis-maleimide, N,N′-4,4′-diphenyl sulfone-bis-maleimide, N,N′-4,4′-dicyclohexyl methane-bis-maleimide, N,N′-xylylene-bis-maleimide, and N,N′-diphenyl cyclohexane-bis-maleimide.