# US 10,307,983 B2 · Foam adhesion promotion

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- Number: US 10,307,983 B2
- Document ID: US10307983B2
- Status: Granted
- Kind: B2
- Application number: 15/590,727
- Filed: 2017-05-09
- Published: 2017-11-09
- Granted: 2019-06-04
- Earliest claimed: 2016-05-09
- Assignees: Kraton Polymers U.S. LLC; International Automotive Components Group North America, Inc.
- Applicants: Kraton Polymers U.S. LLC; International Automotive Components Group North America, Inc.
- Inventors: Rose A. Ryntz; William J. Tansey; Matt Starling; Giachiano Bedogne; Freddy Vervoort
- Web page: https://patentgrep.com/patent/US10307983B2

## CPC

- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 27/065: {of foam}
- B32B 27/18: characterised by the use of special additives
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/36: comprising polyesters
- B32B 27/40: comprising polyurethanes
- C08G 18/42: Polycondensates having carboxylic or carbonic ester groups in the main chain
- C08G 18/48: Polyethers
- C08J 5/124: {using adhesives based on a macromolecular component}
- C09J 5/02: involving pretreatment of the surfaces to be joined
- C09J 175/04: Polyurethanes
- B32B 2250/02: 2 layers
- B32B 2266/0278: Polyurethane
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2274/00: Thermoplastic elastomer material
- B32B 2451/00: Decorative or ornamental articles
- B32B 2605/003: Interior finishings
- C08G 2101/00: Manufacture of cellular products
- C08G 2110/0066: ≥ 150kg/m3
- C08G 2140/00: Compositions for moulding powders
- C09J 2400/243: in the substrate
- C09J 2421/006: in the substrate
- C09J 2421/008: in the pretreated surface to be joined
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C09J: ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES (preparation of glue or gelatine C09H)

## Abstract

Methods for forming a TPE-skinned composite include forming a skin layer having at least one surface and having a thermoplastic elastomer and an adhesive promoting agent; providing a foam layer; and forming the foam layer onto the said surface of the skin layer to form the TPE-skinned composite. Optional additives such as an organo-silane compound may be added to further improve the adhesion between the skin layer and the foam. The present disclosure also provides a TPE-skinned composite including a skin layer having a thermoplastic elastomer present in an amount of greater than 90 wt. %; and an adhesive promoting agent present in an amount of from 0.5 wt. % to 10 wt. % based upon the total weight of the skin layer.

## Claims

### Claim 1

A method for forming a thermoplastic elastomer (TPE)-skinned composite comprising the steps of:
a) forming a skin layer having at least one surface comprising:
(i) a thermoplastic elastomer; and
(ii) an adhesive promoting agent;
b) providing a foam layer forming mixture on the at least one surface of the skin layer; and
c) forming a foam layer on the at least one surface of the skin layer to form the TPE-skinned composite.

### Claim 2 (depends on 1)

The method of claim 1, wherein the skin layer comprises the adhesive promoting agent in an amount of 0.5 wt. % to 10 wt. % based upon the total weight of the skin layer.

### Claim 3 (depends on 1)

The method of claim 1, wherein the skin layer comprises the thermoplastic elastomer in an amount of equal to or greater than 90 wt. % based upon the total weight of the skin layer.

### Claim 4 (depends on 1)

The method of claim 1 wherein the adhesive promoting agent is a diethanol amine amide (DEAA) having the following structure:
wherein R is a hydrocarbon chain, saturated or unsaturated, containing 6-18 carbon atoms.

### Claim 5 (depends on 1)

The method of claim 1, wherein the skin layer has a thickness of 0.5 mm to 2.5 mm.

### Claim 6 (depends on 4)

The method of claim 4, wherein the adhesive promoting agent further comprises an organo-silane compound.

### Claim 7 (depends on 4)

The method of claim 4, wherein the DEAA is present in the range of 0.5 wt. % to 5.0 wt. % based upon the total weight of the skin layer.

### Claim 8 (depends on 6)

The method of claim 6, wherein the organo-silane compound is present in the range of from 0.05 wt. % to 5.0 wt. % based upon the total weight of the skin layer.

### Claim 9 (depends on 6)

The method of claim 6, wherein the organo-silane compound contains one or more carbon-silicon bonds and wherein the organo-silane compound has a molecular weight of less than or equal to 1000 g/mol.

### Claim 10 (depends on 6)

The method of claim 6, wherein the organo-silane compound has the following structure:

### Claim 11 (depends on 1)

The method of claim 1, wherein the thermoplastic elastomer has at least one glass transition temperature below 25° C., has an elongation of at least 50% as measured according to ISO 37, and has a tensile strength of at least 4 MPa as measured according to ASTM D412.

### Claim 12 (depends on 1)

The method of claim 1, further including at least one of the following:
the thermoplastic elastomer and the adhesive promoting agent are mixed and extruded to form pellets prior to forming the skin layer; or
the thermoplastic elastomer is extruded and formed into pellets and then combined with the adhesive promoting agent prior to forming the skin layer.

### Claim 13 (depends on 12)

The method of claim 12, wherein the pellets are cryo-ground to form a cryo-ground powder having a particle size distribution average of 200 μm to 1600 μm.

### Claim 14 (depends on 13)

The method of claim 13, wherein the cryo-ground powder is combined with an organo-silane compound to form a silane-coated powder.

### Claim 15 (depends on 12)

The method of claim 12, wherein the pellets have a diameter of 2.0 to 3.0 mm and a bulk density of 20.0 lbs/ft3 to 30.0 lbs/ft3.

### Claim 16 (depends on 1)

The method of claim 1, wherein the thermoplastic elastomer is selected from a group consisting of a thermoplastic polyolefin formulation (TPE-O), a styrenic block copolymer formulation (TPE-S), a polyester or copolyester formulation (TPE-E), a thermoplastic vulcanizate (TPE-V), or a polyurethane formulation (TPE-U) or a mixture of one or more thermoplastic elastomer formulations.

### Claim 17 (depends on 1)

The method of claim 1, wherein the foam layer has a thickness in the range of 3.0 mm to 8.0 mm.

### Claim 18 (depends on 1)

The method of claim 1, wherein step a) further comprises treating the skin layer by flaming the at least one surface to produce a flame treated skin layer.

### Claim 19 (depends on 1)

The method of claim 1, wherein the skin layer and the foam layer form a foam-skin bond wherein the foam-skin bond demonstrates a cohesive failure of at least 50% and wherein the pull force for the cohesive failure is in the range of 175 Newtons/meter to 250 Newtons/meter measured according to ASTM D 6862.

### Claim 20

A method for forming a thermoplastic elastomer (TPE)-skinned composite comprising the steps of:
a) forming a skin layer having at least one surface comprising:
(i) a thermoplastic elastomer wherein the thermoplastic elastomer has at least one glass transition temperature below 25° C., has an elongation of at least 50% as measured according to ISO 37, and has a tensile strength of at least 4 MPa as measured according to ASTM D412; and
(ii) an adhesive promoting agent wherein said adhesive promoting agent comprises diethanol amine amide (DEAA) having the following structure:
wherein R is a hydrocarbon chain, saturated or unsaturated, containing 6-18 carbon atoms wherein DEAA is present at a level of 0.5 wt. % to 5.0 wt. % based upon the total weight of the skin layer;
b) providing a foam layer forming mixture on the at least one surface of the skin layer;
c) forming a foam layer on the at least one surface of the skin layer to form the TPE-skinned composite.