Epoxy adhesive compositions comprising an adhesion promoter

Abstract

Curable adhesive compositions comprising i. a curable epoxy resin ii. an amine curing agent, iii. a polymeric toughening agent, iv. a filler and v. a phosphoric acid ester according to the formula as an adhesion promoter, wherein R represents an aliphatic or aromatic residue that contains one or more carboxylic acid ester units and/or one or more urethane units and that further contains at least one ether group and n represents an integer of 1 or 2, methods of making them, bonded articles and methods for bonding.

1 . A construction comprising a curable epoxy adhesive composition comprising
 vi. a curable epoxy resin   vii. an amine curing agent,   viii a polymeric toughening agent,   ix. a filler material and   x. a phosphoric acid ester according to the formula   
       
         
           
           
               
               
           
         
       
       wherein R represents an aliphatic or aromatic residue that contains one or more carboxylic acid ester units and/or one or more urethane units and that further contains at least one ether group and n represents an integer of 1 or 2; and
 first and second substrates, wherein the first and second substrates are selected independently from each other from aluminium, steel and a resin-based composite material; 
 wherein the curable epoxy adhesive composition is between and in contact with both the first and second substrate. 
 
     
     
         2 . The construction according to  claim 1  wherein the group R of the phosphoric acid ester has a molecular weight between 200 and 10,000. 
     
     
         3 . The construction according to  claim 1  wherein the curable epoxy resin comprises one or more aromatic glycidyl ether units. 
     
     
         4 . The construction according to  claim 1  wherein the epoxy resin has a molecular weight of from 150 to 4,000 g/mole. 
     
     
         5 . The construction according to  claim 1  wherein the epoxy resin has a functionality of from 1 to 3.8 
     
     
         6 . The construction according to  claim 1  wherein the filler material comprises glass particles. 
     
     
         7 . The construction according to  claim 1  wherein the amine curing agent comprises a polyamido amine. 
     
     
         8 . The construction according to  claim 1  wherein the polymer toughening agent comprises a core shell polymer. 
     
     
         9 . The construction according to  claim 1  wherein the composition comprises a liquid polymer comprising repeating units derived from butadiene. 
     
     
         10 . The construction according to  claim 1  further comprising a fire-retardant system that includes a mixture of:
 (a) at least one compound selected from the group comprising alkaline earth metal hydroxides and aluminium group hydroxides, and 
 (b) at least one phosphorous-containing material. 
 
     
     
         11 . An article comprising a first substrate, a second substrate and a composition between the first and second substrate bonding the first substrate to the second substrate, said composition comprising the reaction product of a curing reaction of a curable epoxy adhesive composition comprising
 vi. a curable epoxy resin   vii. an amine curing agent,   viii a polymeric toughening agent,   ix. a filler material and   x. a phosphoric acid ester according to the formula   
       
         
           
           
               
               
           
         
       
       wherein R represents an aliphatic or aromatic residue that contains one or more carboxylic acid ester units and/or one or more urethane units and that further contains at least one ether group and n represents an integer of 1 or 2; and wherein the first and second substrates are selected independently from each other from aluminium, steel and a resin-based composite material. 
     
     
         12 . A method for bonding a first substrate to a second substrate comprising
 (i) adding to at least a part of the first substrate a curable epoxy adhesive composition comprising   vi. a curable epoxy resin   vii. an amine curing agent,   viii a polymeric toughening agent,   ix. a filler material and   x. a phosphoric acid ester according to the formula   
       
         
           
           
               
               
           
         
       
       wherein R represents an aliphatic or aromatic residue that contains one or more carboxylic acid ester units and/or one or more urethane units and that further contains at least one ether group and n represents an integer of 1 or 2;
 (ii) applying the second substrate to the first substrate at a position where the first substrate contains the curable composition 
 (iv) subjecting the curable epoxy adhesive composition to curing, wherein the first and second substrate are selected independently from each other from aluminium, steel and a resin-based composite material. 
 
     
     
         13 . The method according to  claim 12  wherein the curable epoxy adhesive composition is applied directly to the surface or the first or the second surface or is directly applied to the first and the second surface. 
     
     
         14 . The method according to  claim 12  wherein the curing is carried out at room temperature. 
     
     
         15 . (canceled) 
     
     
         16 . The article according to  claim 11  wherein the group R of the phosphoric acid ester has a molecular weight between 200 and 10,000. 
     
     
         17 . The article according to  claim 11  wherein the curable epoxy resin comprises one or more aromatic glycidyl ether units. 
     
     
         18 . The article according to  claim 11  wherein the filler material comprises glass particles. 
     
     
         19 . The article according to  claim 11  wherein the amine curing agent comprises a polyamido amine. 
     
     
         20 . The article according to  claim 11  wherein the polymer toughening agent comprises a core shell polymer. 
     
     
         21 . The article according to  claim 11  wherein the composition comprises a liquid polymer comprising repeating units derived from butadiene.