Composite and process for producing the same

Details Composite and process for producing the same Composite and process for producing the same

2002-09-16

2004-10-05

Robertson, Jeffrey B. (Department: 1712)

Stock material or miscellaneous articles

Composite

Of silicon containing

C428S451000, C427S387000, C525S474000, C525S479000

Reexamination Certificate

active

06800372

ABSTRACT:

TECHNICAL FIELD
The present invention relates to a composite (or a composite member) of a thermoplastic resin bonded to a silicone rubber integrally which is useful for a mechanical part or a machine element, an automobile part and so on, and relates to a process for producing the same.
BACKGROUND ART
An adhering method for adhering a resin molded article to a rubber molded article by an adhesive is known as a process of integrally joining a resin molded element to a rubber molded element. However, the process using the adhesives not only complicates the process to cause a troublesome process-control with resulting in costly but also does not necessarily give a sufficient adhesive strength.
Meanwhile, a composite of a resin directly bonded to a rubber has been proposed. For example, Japanese Patent Application Laid-Open No. 25682/1975 (JP-50-25682A) discloses a process for producing a rubber-plastic composite, which comprises rubbing a thermoplastic plastic component (e.g., a polyformaldehyde and an olefinic polymer) and a vulcanized rubber component compatible with the thermoplastic plastic component with contacting each other to melt or fuse the surface of the plastic, and solidifying the melted surface of the resin with contacting the thermoplastic resin component and the vulcanized rubber component.
Regarding to a process for producing a composite with utilizing a compatibility between a thermoplastic resin and a rubber, Japanese Patent Application Laid-Open No. 204260/1986 (JP-61-204260A) discloses a process for producing a composite, which comprises heating a polyphenylene ether-series resin and a synthetic rubber in the presence of a vulcanizing agent. Japanese Patent Application Laid-Open No. 124803/1997 (JP-9-124803A) discloses a process for producing a composite member, which comprises heating an acrylonitrile-containing thermoplastic resin and an acrylonitrile-containing rubber with closely contacting each other.
Referring to a process for producing a composite with utilizing a chemical reaction between a thermoplastic resin and a rubber, Japanese Patent Application Laid-Open No. 150439/1990 (JP-2-150439A), Japanese Patent Application Laid-Open No. 133631/1991 (JP-3-133631A) and Japanese Patent Application Laid-Open No. 138114/1991 (JP-3-138114A) disclose a process for producing a composite comprising a polyamide-series resin and a rubber component containing a carboxyl group- or an acid anhydride group-containing rubber, a peroxide, and a vulcanization-activating agent. Japanese Patent Application Laid-Open No. 156188/1996 (JP-8-156188A) discloses a process for producing a composite member, which comprises vulcanizing or crosslinking a carboxyl group- or an acid anhydride group-containing rubber member with contacting closely an epoxy group-containing resin member.
Further, as a process for producing a composite with the use of the specific additive, Japanese Patent Application Laid-Open No. 11013/1995 (JP-7-11013A) discloses a process for producing a composite, which comprises vulcanizing a rubber compound composed of a rubber, a peroxide vulcanizing agent and a silane compound, if necessary, a vulcanization-activating agent, in contact with a polyamide molded article. Furthermore, there are disclosed a process for producing a composite which comprises using a thermoplastic polyester as a hard component and a rubber component comprising a rubber, a peroxide vulcanizing agent, a bi- or poly-functional maleimide, if necessary, and a vulcanization-activating agent as a soft component [Japanese Patent Application Laid-Open No. 304880/1995 (JP-7-304880A)], and a process for producing a composite, which comprises using a rubber component containing a rubber, a peroxide vulcanizing agent, a silane compound, if necessary, and a vulcanization-activating agent [Japanese Patent Application Laid-Open No. 166043/1995 (JP-7-166043A)].
However, such processes are restricted in the species of a thermoplastic resin and a rubber. Especially, it is difficult to obtain a composite of a poor-reactive silicone rubber and the thermoplastic resin.
Japanese Patent Application Laid-Open No. 58605/1998 (JP-10-58605A) discloses a process for producing the composite film, which comprises laminating a substrate film (e.g., a polyester film) and a rubber film (e.g., silicone rubber, ethylene-propylene-series rubber) composed of a polyfunctional methacrylate as an adhesion-improving agent, and vulcanizing those, and the laminating step comprises laminating a rubber film layer having a large amount of an adhesion-improving agent on the substrate film, and laminating a rubber film layer having a small amount of an adhesion-improving agent on the laminated rubber film. In the literature, there is disclosed an example that a rubber solution having a large amount of an adhesion-improving agent and a rubber solution having a small amount thereof are coated in this order on an one-side surface of a substrate film which is treated with a corona discharge or adhesive treatment (easy adhesive treatment) in order to adhere with a rubber easily, and the external surface of the covering sheet is laminated on a rubber film, and the resultant laminated sheet is irradiated by an electron beam which has a high energy.
However, the process requires not only a treatment for the surface of the substrate but forming a double-layered rubber film on the surface of the substrate for achieving a high adhesion strength. Therefore, a configuration of a composite is restricted to a two-dimensional one, and thus a composite comprising a thermoplastic resin molded article and a rubber molded the process requires a preparation of the rubber solution, a production efficiency of the composite film can not be increased. Moreover, since the process utilizes coating technique to form a rubber layer, it is difficult that the process is applied to bonding between a rubber molded article and a resin molded article which has a thicker and/or three-dimensional configuration.
It is, therefore, an object of the present invention to provide a composite of a thermoplastic resin molded article bonded to a silicone rubber molded article directly and firmly without an adhesive treatment of the surface of the thermoplastic resin, and a process for producing the same.
It is another object of the present invention to provide a composite which is excellent in an adhesion strength between a thermoplastic resin molded article and a rubber molded article and has three dimensional configuration, and a process for producing the same.
DISCLOSURE OF INVENTION
The inventors of the present invention did intensive research, and finally found that a thermoplastic resin molded article can directly bond to a vulcanized silicone rubber molded article by contacting the thermoplastic resin molded article and a rubber composition composed of an unvulcanized silicone rubber and an organic peroxide, and heat-molding the molded article and the rubber composition; and further the thermoplastic resin molded article can surely and directly bond to the vulcanized silicone rubber molded article firmly by selecting a thermoplastic resin based on the specific criteria and selectively a species or formulation of the unvulcanized silicone rubber, and by coexisting an organic peroxide with a polyfunctional (meth)acrylic monomer.
That is, the composite of the present invention is a composite of a vulcanized silicone rubber member formed by a vulcanization of an unvulcanized silicone rubber, and a resin member comprising a thermoplastic resin and directly bonded to the rubber member, wherein the resin member bonds directly to the vulcanized silicone rubber member vulcanized or crosslinked with a radical-generating agent without an adhesive treatment of the resin member. The thermoplastic resin includes, for example, a polyamide-series resin, a polyester-series resin, a poly(thio)ether-series resin, a polycarbonate-series resin, a polyimide-series resin, a polysulfone-series resin, a polyolefinic resin, a halogen-containing vinyl-series resin, a polyurethane

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