Surface treatment of polymers

Details Surface treatment of polymers Surface treatment of polymers

1996-07-18

1999-03-09

Ball, Michael W.

Coating processes

Direct application of electrical, magnetic, wave, or...

Polymerization of coating utilizing direct application of...

427536, 427539, 427544, 427553, 427560, 427601, 156 731, 1562726, B29C 7104

Patent

active

058797572

DESCRIPTION:

BRIEF SUMMARY
This application claims benefit of international application PCT/AU95/00025, filed Jan. 20, 1995.
This invention relates to new methods of treating the surface of polymers and/or polymer matrix composite materials to modify the surface chemistry thereof. For example, it is desirable to treat the surface of polymers or polymer matrix composite materials to improve their ability for bonding to other materials including, but not limited to, adhesives, sealants, paints, and any other reactive and/or non-reactive organic, inorganic or metallic materials, or mixtures thereof.
By the term "polymer", as used herein, we mean homo-polymers, co-polymers and/or their blends and alloys with other polymers and/or rubber, and polymer matrix composites.
In a preferred application of the invention, it is desirable to establish a strong and durable adhesive bond between a polymer substrate or a polymer matrix and another polymeric and/or non-polymeric material such as a thermoset,- or thermoplastic resin, paint or coating.
In order for the adhesive bond and/or composite material to perform satisfactorily, there must be good adhesion between the substrate (e.g. flat sheet, or fibre, complex shaped article, or powder) and the adhesive, paint, coating, thermoplastic, thermoset resin or non-polymeric material. However, it is well known that many polymeric substrates (e.g. polyolefins), are difficult to bond due to the absence of specific surface chemical functional groups capable of providing reactive sites for the establishment of strong interfacial interactions such as acid-base interactions and/or the formation of chemical bonding (e.g. covalent, ionic, etc.) between the untreated substrate and the adhesive, paint, matrix material or other adhering substance.
Various types of surface treatments are available for increasing the bonding properties of polymers. Typical surface treatments for enhanced adhesion include: mechanical abrasion; corona discharge; flame treatment; plasma treatment; UV radiation, chemical oxidation with the use of oxidising agents; and introduction of functional groups by surface chemical grafting.
Japanese Patent Document No. Sho 58-132029 discloses a method of treating the surface of polymers comprising corona discharge or plasma treatment followed by a chemical treatment. The chemical treatment described refers to the combination of two or more of the following processes: treating with an acid; treating with an alkali; treating with a coupling agent such as a silane or a titanium-based coupling agent. Whilst the combination of treatments is shown as being effective for increasing the adhesive properties of polymeric substrates the need for at least two chemical process steps substantially increases the cost associated with industrial application.
Japanese Patent Document No. Sho 64-80099 discloses a method of increasing the ability of polyimides to bond to adhesives by treating the surface of the polyimide with corona discharge, and then treating the surface with a silane based coupling agent. To achieve the result disclosed in this specification concentrations of silane based coupling agents must typically be such that the silane coverage rate is in the range of 25 to 50 mg/m.sup.2 when dry. This, although not specified in the invention, can be achieved upon application of a silane solution at the concentration estimated to be about 3.75% to 7.5%.
It has now been found, surprisingly, that the ability of polymers or polymer matrix composite materials to be durably bonded to thermoplastic or thermoset polymers and/or inorganic or metallic binders in the form of adhesives, paints, coatings, matrix materials or other substances may be improved by the use of very low concentrations, and/or otherwise ineffective concentrations of organofunctional coupling agents and/or chelating agents by suitable co-treatment steps.
In its broadest aspect the present invention provides a method of modifying at least part of the surface of a polymer or polymer matrix composite material including:
i) oxidising at least par

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