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Electron beam curing in a composite having a flow resistant adhesive layerRelated Patent Categories: Stock Material Or Miscellaneous Articles, Composite (nonstructural Laminate)Electron beam curing in a composite having a flow resistant adhesive layer description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070092731, Electron beam curing in a composite having a flow resistant adhesive layer. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS REFERENCE TO RELATED APPLICATION [0001] This application is a divisional of U.S. patent application Ser. No. 10/881,677 filed on Jun. 30, 2004, the disclosure of which is incorporated herein by reference. INTRODUCTION [0002] This invention relates to composites and to articles formed of composites. In particular, the present invention relates to composites having a polymeric adhesive layer that is bonded to adjacent layers of the composite with use of radiation treatment. [0003] Composites are important materials in enabling many of the benefits of modern life. Composites provide multilayered structures having individual layers made of metal, polymer, or ceramic. Each layer contributes to the overall performance of the composite as viewed from the intended application. This is especially true of the outside layers of a composite. [0004] The adhesive layer of a composite, while important in holding various layers together, is also frequently the basis for the weak point respective to the overall integrity of the composite. The adhesive layer of a composite, is also frequently the most difficult to handle in assembling the composite. What is needed is a way for the adhesive layer to provide the properties needed to enable assembly of the composite, but then to further provide properties equal to (or even superior to) similar properties in the other layers so that the adhesive layer is not the source of concern respective to composite integrity. This and other needs are achieved with the invention. SUMMARY [0005] The invention provides a composite of: [0006] (a) a first layer of structural material selected from the group consisting of metal, polymer, and ceramic; [0007] (b) a second layer of structural material selected from the group consisting of metal, polymer, and ceramic; and [0008] (c) an adhesive layer comprising a polymer, positioned between the first layer and the second layer; [0009] where the adhesive layer is inter-bonded to the structural material of at least one of the first layer and the second layer with at least one inter-bonding molecule corresponding to the formula AD where A is a polymeric carbon chain moiety derived from the polymer of the adhesive layer, D is a metallic element derived from said metal of said inter-bonded structural material layer when said inter-bonded structural material layer comprises metal, D is a ceramic moiety derived from said ceramic of said inter-bonded structural material layer when said inter-bonded structural material layer comprises ceramic, and D is a polymeric moiety derived from said polymer of said inter-bonded structural material layer when said inter-bonded structural material layer comprises polymer; and [0010] where the polymer of the adhesive layer has a first value respective to a measurement of a characteristic performance property (any of tensile strength, elongation, modulus, or chemical resistance), with the first value being in excess of a second value respective to a measurement of the same characteristic performance property in the structural material of the inter-bonded structural material layer. Preferably, D is a metallic element derived from the metal of the inter-bonded structural material layer when the inter-bonded structural material layer comprises metal, D is a ceramic moiety from a free radical ceramic derivative of the ceramic of the inter-bonded structural material layer when the inter-bonded structural material layer comprises ceramic, and D is from a free radical polymeric derivative of the polymer of the inter-bonded structural material layer when the inter-bonded structural material layer comprises polymer. [0011] In another aspect, the invention provides a composite having [0012] (a) a first layer of structural material selected from the group consisting of metal, polymer, and ceramic; [0013] (b) a second layer of structural material selected from the group consisting of metal, polymer, and ceramic; and [0014] (c) an adhesive layer positioned between the first layer and the second layer, the adhesive layer of polymer; [0015] where the adhesive layer is bonded to the structural material of the first layer with at least one first inter-bonding molecule corresponding to the formula AD where A is a polymeric carbon chain moiety derived from the polymer of the adhesive layer, D is a metallic element derived from the metal of the first layer when the first layer comprises metal, D is a ceramic moiety from a free radical ceramic derivative of the ceramic of the first layer when the first layer comprises ceramic, and D is from a free radical polymeric derivative of the polymer of the first layer when the first layer comprises polymer; where the adhesive layer is bonded to the structural material of the second layer with at least one second inter-bonding molecule corresponding to the formula AE where A is a polymeric carbon chain moiety derived from the polymer of the adhesive layer, E is a metallic element derived from the metal of the second layer when the second layer comprises metal, E is a ceramic moiety from a free radical ceramic derivative of the ceramic of the second layer when the second layer comprises ceramic, and E is a polymeric carbon chain moiety from a free radical polymeric derivative of the polymer of the second layer when the second layer comprises polymer; and [0016] where the polymer of the adhesive layer has a first value respective to a measurement of a characteristic performance property (any of tensile strength, elongation, modulus, or chemical resistance), with the first value being in excess of a second and third values respective to a measurement of the same characteristic performance property in the structural materials of the respective inter-bonded structural material layers. [0017] In another aspect, the invention provides a method for making a composite of: [0018] (a) providing a first layer of structural material selected from the group consisting of metal, polymer, and ceramic; [0019] (b) positioning a solid adhesive layer onto the first layer, the adhesive layer of polymer; [0020] (c) positioning a second layer of structural material onto the adhesive layer, the structural material of the second layer selected from the group consisting of metal, polymer, and ceramic; and [0021] (d) irradiating the first layer, the second layer, and the adhesive layer with electron beam radiation sufficient to inter-bond the first layer to the adhesive layer and to inter-bond the second layer to the adhesive layer. [0022] In one form of the invention, the polymer of the adhesive layer is selected from the group consisting of fluoroelastomer, thermoplastic, thermoplastic elastomer, thermoplastic vulcanizate, thermoset plastic, polytetrafluoroethylene, and combinations of any of these materials. [0023] In another form of the invention, the polymer of the adhesive layer is selected from the group consisting of acrylic acid ester rubber/polyacrylate rubber thermoplastic vulcanizate acrylonitrile-butadiene-styrene, amorphous nylon, cellulosic plastic, ethylene chlorotrifluoroethylene, epoxy resin, ethylene tetrafluoroethylene, ethylene acrylic rubber, ethylene acrylic rubber thermoplastic vulcanizate, ethylene-propylene-diamine monomer rubber/polypropylene thermoplastic vulcanizate, tetrafluoroethylene/hexafluoropropylene, fluoroelastomer, fluoroelastomer thermoplastic vulcanizate, fluoroplastic, hydrogenated nitrile rubber, melamine-formaldehyde resin, tetrafluoroethylene/perfluoromethylvinyl ether, natural rubber, nitrile butyl rubber, nylon, nylon 6, nylon 610, nylon 612, nylon 63, nylon 64, nylon 66, perfluoroalkoxy (tetrafluoroethylene/perfluoromethylvinyl ether), phenolic resin, polyacetal, polyacrylate, polyamide, polyamide thermoset plastic, polyamide-imide, polybutene, polybutylene, polycarbonate, polyester, polyester thermoplastic, thermoplastic elastomer, polyesteretherketone, polyethylene, polyethylene terephthalate, polyimide, polymethylmethacrylate, polyolefin, polyphenylene sulfide, polypropylene, polystyrene, polysulfone, polytetrafluoroethylene, polyurethane, polyurethane elastomer, polyvinyl chloride, polyvinylidene fluoride, ethylene propylene dimethyl/polypropylene thermoplastic vulcanizate, silicone, silicone-thermoplastic vulcanizate, thermoplastic polyurethane, thermoplastic polyurethane elastomer, thermoplastic polyurethane vulcanizate, thermoplastic silicone vulcanizate, thermoplastic urethane, thermoplastic urethane elastomer, tetrafluoroethylene/hexafluoropropylene/vinylidene fluoride, polyamide-imide, and combinations of any of these materials. [0024] In one form of the invention, a curing agent is admixed into the polymer of the adhesive layer. [0025] In one form of the invention, the polymer of the inter-bonded layer is halogenated plastic and the adhesive layer corresponds to the formula [-TFE.sub.q-HFP.sub.r--VdF.sub.s--].sub.d where TFE is essentially a tetrafluoroethyl block, HFP is essentially a hexfluoropropyl block, and VdF is essentially a vinylidyl fluoride block, and products qd and rd and sd collectively provide proportions of TFE, HFP, and VdF whose values are within element 101 of FIG. 1. Continue reading about Electron beam curing in a composite having a flow resistant adhesive layer... 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