JP7350080B2 - 多層系および多層系を製造する方法 - Google Patents
多層系および多層系を製造する方法 Download PDFInfo
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- JP7350080B2 JP7350080B2 JP2021546793A JP2021546793A JP7350080B2 JP 7350080 B2 JP7350080 B2 JP 7350080B2 JP 2021546793 A JP2021546793 A JP 2021546793A JP 2021546793 A JP2021546793 A JP 2021546793A JP 7350080 B2 JP7350080 B2 JP 7350080B2
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- BIKXLKXABVUSMH-UHFFFAOYSA-N trizinc;diborate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]B([O-])[O-].[O-]B([O-])[O-] BIKXLKXABVUSMH-UHFFFAOYSA-N 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
- B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/536—Hardness
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
- B32B2307/7242—Non-permeable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/726—Permeability to liquids, absorption
- B32B2307/7265—Non-permeable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2581/00—Seals; Sealing equipment; Gaskets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/08—Cars
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/18—Aircraft
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Sealing Material Composition (AREA)
- Laminated Bodies (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Description
本発明は、例えば、以下の項目を提供する
(項目1)
2つまたは2つより多くの層を含み、前記層のうちの1つまたは1つより多くがシーラント層を含む多層系を製造する方法であって、
(a)第1の成分および第2の成分を混合して、共反応性シーラント組成物を形成するステップであって、
前記共反応性シーラント組成物が第1の反応性化合物および第2の反応性化合物を含み、
前記第1の反応性化合物が前記第2の反応性化合物に反応性である、ステップと、
(b)前記共反応性シーラント組成物を押出成形して、押出物を形成するステップと、
(c)前記押出物を堆積させて、前記シーラント層を形成するステップと、を含む、方法。
(項目2)
堆積が3次元印刷を含む、項目1に記載の方法。
(項目3)
堆積が、前記多層系の下層の上に前記押出物を堆積させることを含む、項目1または2に記載の方法。
(項目4)
前記堆積されたシーラント層の下にある第1の共反応性組成物を堆積させて、下層を形成するステップ、および/または
前記シーラント層の上にある第2の共反応性組成物を堆積させて、上層を形成するステップ
をさらに含み、前記第1の共反応性組成物および前記第2の共反応性組成物が、前記シーラント層とは異なる組成物を含む、項目1~3のいずれか1項に記載の方法。
(項目5)
前記第1の共反応性組成物が前記第2の共反応性組成物とは異なる、項目4に記載の方法。
(項目6)
前記共反応性シーラント組成物のうちのいずれかが熱硬化性組成物を含む、項目1~5のいずれか1項に記載の方法。
(項目7)
前記多層系の前記層がそれぞれ熱硬化性物質を含む、項目1~6のいずれか1項に記載の方法。
(項目8)
前記押出物の断面プロファイルが前記断面プロファイルにわたって均一な組成を有する、項目1~7のいずれか1項に記載の方法。
(項目9)
前記押出物の断面プロファイルが前記断面プロファイルにわたって不均一な組成を有する、項目1~7のいずれか1項に記載の方法。
(項目10)
前記多層系の前記2つまたは2つより多くの層のうちの最外層がシーラント層を含む、項目1~9のいずれか1項に記載の方法。
(項目11)
前記多層系の前記層がそれぞれ、独立して、シーラント層または非シーラント層を含む、項目1~10のいずれか1項に記載の方法。
(項目12)
前記共反応性シーラント組成物が、耐薬品性の骨格を含むプレポリマーを含む、項目1~11のいずれか1項に記載の方法。
(項目13)
前記共反応性シーラント組成物が、10重量%超の硫黄含有量を含み、重量%が、前記共反応性シーラント組成物の有機構成要素の総重量に基づく、項目1~12のいずれか1項に記載の方法。
(項目14)
前記共反応性シーラント組成物が硫黄含有プレポリマーを含む、項目1~13のいずれか1項に記載の方法。
(項目15)
前記硫黄含有プレポリマーが、ポリチオエーテル、ポリスルフィド、硫黄含有ポリホルマール、モノスルフィド、または前述のもののうちのいずれかの組み合わせを含む、項目14に記載の方法。
(項目16)
前記硫黄含有プレポリマーが、10重量%超の硫黄含有量を含み、重量%が、前記硫黄含有プレポリマーの総重量に基づく、項目14または15に記載の方法。
(項目17)
前記第1の反応性化合物が、50℃未満の温度で前記第2の反応性化合物に反応性である、項目1~16のいずれか1項に記載の方法。
(項目18)
前記第1の反応性化合物が、触媒および/または重合開始剤の存在下で前記第2の反応性化合物に反応性であり、
前記触媒および/または重合開始剤が、前記第1の反応性化合物と前記第2の反応性化合物との間の反応を触媒および/または開始することができる、項目1~17のいずれか1項に記載の方法。
(項目19)
前記押出物を堆積させる前、堆積させる間、および/または堆積させた後に前記重合開始剤を活性化させるステップをさらに含む、項目18に記載の方法。
(項目20)
前記第1の成分が前記第1の反応性化合物および前記第2の反応性化合物を含み、
前記第2の成分が、前記第1の反応性化合物と前記第2の反応性化合物との間の前記反応のための触媒、硬化活性剤、および/または重合開始剤を含む、項目1~19のいずれか1項に記載の方法。
(項目21)
前記第1の成分が前記第1の反応性化合物を含み、前記第2の成分が前記第2の反応性化合物を含む、項目1~19のいずれか1項に記載の方法。
(項目22)
前記第1の反応性化合物がポリアミンおよび/もしくはポリオールを含み、前記第2の反応性化合物がポリイソシアネートを含むか、
前記第1の反応性化合物がポリアミンを含み、前記第2の反応性化合物がポリエポキシドを含むか、
前記第1の反応性化合物がマイケル受容体を含み、前記第2の反応性化合物がマイケル供与体を含むか、または
前記第1の反応性化合物がポリチオールを含み、前記第2の反応性化合物が、ポリチオール、ポリイソシアネート、ポリアルケニル、ポリアルキニル、ポリエポキシド、マイケル受容体、もしくは前述のもののうちのいずれかの組み合わせを含む、項目1~21のいずれか1項に記載の方法。
(項目23)
第1のポンプを使用して前記第1の成分をミキサーに圧送するステップと、
第2のポンプを使用して前記第2の成分を前記ミキサーに圧送するステップと、をさらに含む、項目1~22のいずれか1項に記載の方法。
(項目24)
前記押出物を堆積させた後に、前記堆積された押出物を硬化させるステップをさらに含む、項目1~23のいずれか1項に記載の方法。
(項目25)
硬化が、前記堆積された押出物を30℃未満の温度で硬化させることを含む、項目24に記載の方法。
(項目26)
1つまたは1つより多くの追加の共反応性組成物を前記共反応性シーラント組成物と融合させるステップをさらに含み、
押出成形が、前記共反応性シーラント組成物および前記1つまたは1つより多くの追加の共反応性組成物を共押出成形して、共押出物を形成するステップを含み、
堆積が、前記共押出物を堆積させて、1つまたは1つより多くのシーラント層を含む多層系を形成するステップを含む、項目1~25のいずれか1項に記載の方法。
(項目27)
前記1つまたは1つより多くの追加の共反応性組成物がそれぞれ、独立して、追加の共反応性シーラント組成物または共反応性非シーラント組成物を含む、項目26に記載の方法。
(項目28)
前記共反応性シーラント組成物および隣接する追加の共反応性組成物が同じ硬化化学反応を含む、項目26または27に記載の方法。
(項目29)
前記共反応性シーラント組成物および隣接する追加の共反応性組成物が異なる硬化化学反応を含む、項目26~28のいずれか1項に記載の方法。
(項目30)
前記共反応性シーラント組成物が、隣接する追加の共反応性組成物に反応性である、項目26~29のいずれか1項に記載の方法。
(項目31)
添加剤含有組成物を追加の共反応性組成物の一部と組み合わせて、添加剤修飾された追加の共反応性組成物を形成するステップであって、前記添加剤含有組成物が添加剤を含む、ステップをさらに含み、
押出成形が、前記共反応性シーラント組成物および前記添加剤修飾された追加の共反応性組成物を共押出成形して、共押出物を形成するステップを含む、項目26~30のいずれか1項に記載の方法。
(項目32)
前記共押出物の断面プロファイルが、不均一な添加剤濃度を有する、項目31に記載の方法。
(項目33)
前記押出物が、前記共押出物の長手方向の寸法において前記添加剤の濃度が不均一であることを特徴とする、項目31または32に記載の方法。
(項目34)
第3の成分を第4の成分と混合して、前記1つまたは1つより多くの追加の共反応性組成物を形成するステップをさらに含む、項目26~33のいずれか1項に記載の方法。
(項目35)
添加剤含有組成物を前記共反応性シーラント組成物の一部と組み合わせて、添加剤修飾された共反応性シーラント組成物を形成するステップであって、前記添加剤含有組成物が添加剤を含む、ステップと、
前記添加剤修飾された共反応性シーラント組成物を押出成形して、押出物を形成するステップと、をさらに含む、項目1~34のいずれか1項に記載の方法。
(項目36)
前記押出物の断面プロファイルが、不均一な添加剤濃度を有する、項目35に記載の方法。
(項目37)
前記押出物が、前記押出物の長手方向の寸法において前記添加剤の濃度が不均一であることを特徴とする、項目35または36に記載の方法。
(項目38)
接着促進組成物を前記共反応性シーラント組成物と融合させるステップをさらに含み、
押出成形が前記第1の共反応性組成物および前記接着促進組成物を共押出成形するステップを含む、項目1~37のいずれか1項に記載の方法。
(項目39)
前記押出物を堆積させる前に接着促進層を前記押出物に塗布するステップをさらに含む、項目1~38のいずれか1項に記載の方法。
(項目40)
項目1~39のいずれか1項に記載の方法によって製造されたシーラント層を含む、多層系。
(項目41)
隣接する層が化学的および/または物理的に結合されている、項目40に記載の多層系。
(項目42)
完全に硬化した多層シーラントの破壊エネルギーが個々の層の破壊エネルギーと実質的に同じであり、前記破壊エネルギーがASTM D7313に従って決定される、項目40または41に記載の多層系。
(項目43)
前記層がそれぞれ熱硬化性材料を含む、項目40~42のいずれか1項に記載の多層系。
(項目44)
前記層がそれぞれ異なる熱硬化性材料を含む、項目40~43のいずれか1項に記載の多層系。
(項目45)
前記多層系が、AMS3277に記載されている航空宇宙用シーラントについての要件を満たすか、またはこれを上回る、項目40~44のいずれか1項に記載の多層系。
(項目46)
前記多層シーラントの前記層のうちの1つまたは1つより多くが、不均一な組成物断面プロファイルを有する、項目40~45のいずれか1項に記載の多層系。
(項目47)
前記多層シーラントの前記層のうちの1つまたは1つより多くが、前記長手方向の寸法において不均一な組成を有する、項目40~46のいずれか1項に記載の多層系。
(項目48)
項目40~47のいずれか1項に記載の多層系を含む、部品。
(項目49)
前記部品が自動車車両部品または航空宇宙ビークル部品を含む、項目48に記載の部品。
(項目50)
項目40~47のいずれか1項に記載の多層系を含む、ビークル。
(項目51)
前記ビークルが航空宇宙ビークルまたは自動車車両を含む、項目50に記載のビークル。
B(-V)z
式中、Bは多官能化剤のコアであり、各Vは、チオール基、アルケニル基、エポキシ基、イソシアネート基、またはマイケル受容体基のような反応性官能基で末端化された部分であり、zは、3~6、例えば、3、4、5、または6の整数である。多官能化剤において、各-Vは、例えば、-R-SHまたは-R-CH=CH2の構造を有し得て、式中、Rは、例えば、C2~10アルカンジイル、C2~10ヘテロアルカンジイル、置換C2~10アルカンジイル、または置換C2~10ヘテロアルカンジイルであり得る。部分Vを別の化合物と反応させると、部分-V1-が得られ、これは他の化合物との反応に由来すると言われる。例えば、Vが-R-CH=CH2であり、これを例えばチオール基と反応させる場合、部分V1は、-R-CH2-CH2-であり、この反応に由来する。
-S-R1-[S-A-S-R1-]n-S- (1)
HS-R1-[S-A-S-R1-]n-SH (1a)
R3-S-R1-[S-A-S-R1-]n-S-R3 (1b)
式中、
nは、1~60の整数であり得て、
各R1は、独立して、C2~10アルカンジイル、C6~8シクロアルカンジイル、C6~14アルカンシクロアルカンジイル、C5~8ヘテロシクロアルカンジイル、および-[(CHR)p-X-]q(CHR)r-から選択され得て、式中、
pは、2~6の整数であり得て、
qは、1~5の整数であり得て、
rは、2~10の整数であり得て、
各Rは、独立して、水素およびメチルから選択され得て、
各Xは、独立して、O、S、およびS-Sから選択され得て、
各Aは、独立して、式(2)のポリビニルエーテルまたは式(3)のポリアルケニル多官能化剤に由来する部分であり得て:
CH2=CH-O-(R2-O)m-CH=CH2 (2)
B(-R4-CH=CH2)z (3)
式中、
mは、0~50の整数であり得て、
各R2は、独立して、C1~10アルカンジイル、C6~8シクロアルカンジイル、C6~14アルカンシクロアルカンジイル、および-[(CHR)p-X-]q(CHR)r-から選択され得て、式中、p、q、r、R、およびXは、R1に関して定義される通りであり、
Bは、z価のポリアルケニル多官能化剤B(-R4-CH=CH2)zのコアを表し、
zは、3~6の整数であり得て、
各R4は、独立して、C1~10アルカンジイル、C1~10ヘテロアルカンジイル、置換C1~10アルカンジイル、および置換C1~10ヘテロアルカンジイルから選択され得て、
各R3は、独立して、末端反応性基を含む部分であり得る。
-(CH2)2-O-(R2-O)m-(CH2)2- (2a)
B{-R4-(CH2)2-}2{-R4-(CH2)2-S-[-R1-S-A-S-R1-]n-SH}z-2 (3a)
式中、m、R1、R2、R4、A、B、m、n、およびzは、式(1)、式(2)、および式(3)に定義される通りである。
HS-(-R5-S-S-)n-R5-SH (4)
HS-(-R5-S-S-)a-CH2-CH{-CH2-(-S-S-R5-)b-SH}{-(-S-S-R5-)c-SH} (5)
式中、各R5は-(CH2)2-O-CH2-O-(CH2)2-であり、n=a+b+cであり、nの値は、ポリスルフィドプレポリマーの合成中に使用される三官能性架橋剤(1,2,3-トリクロロプロパン;TCP)の量に応じて7~38であり得る。Thioplast(登録商標)Gポリスルフィドは、1,000Da未満~6,500Daの数平均分子量、1重量%~5.5重量%超の-SH含有量、および0重量%~2.0重量%の架橋密度を有し得る。
R3-S-(-R5-S-S-)n-R5-S-R3 (4a)
R3-S-(-R5-S-S-)a-CH2-CH{-CH2-(-S-S-R5-)b-S-}{-(-S-S-R5-)c-S-R3} (5a)
式中、n、a、b、c、およびR5は、式(4)および式(5)について定義される通りであり、R3は、末端反応性基を含む部分である。
HS-[(CH2)2-O-CH2-O-(CH2)2-S-S-]n-(CH2)2-O-CH2-O-(CH2)2-SH (6)
R3-S-[(CH2)2-O-CH2-O-(CH2)2-S-S-]n-(CH2)2-O-CH2-O-(CH2)2-S-R3 (6a)
式中、nは、1,000Da~7,500Daの数平均分子量であるようなもの、例えば、8~80の整数であり得て、各R3は、末端反応性官能基を含む部分である。
-R6-(Sy-R6)t- (7)
HS-R6-(Sy-R6)t-SH (7a)
R3-S-R6-(Sy-R6)t-S-R3 (7b)
式中、
tは、1~60の整数であり得て、
各R6は、独立して、分岐状アルカンジイル、分岐状アレーンジイル、および-(CH2)p-O-(CH2)q-O-(CH2)r-の構造を有する部分から選択され得て、
qは、1~8の整数であり得て、
pは、1~10の整数であり得て、
rは、1~10の整数であり得て、
yは、1.0~1.5の範囲の平均値を有し得て、
各R3は、末端反応性官能基を含む部分である。
-(R7-O-CH2-O-R7-Sm-)n-1-R7-O-CH2-O-R7- (8)
HS-(R7-O-CH2-O-R7-Sm-)n-1-R7-O-CH2-O-R7-SH (8a)
R3-S-(R7-O-CH2-O-R7-Sm-)n-1-R7-O-CH2-O-R7-S-R3 (8b)
式中、R7はC2~4アルカンジイルであり、mは2~8の整数であり、nは2~370の整数であり、各R3は、独立して、末端反応性官能基を含む部分である。
-R8-(S)p-R8-[O-C(R9)2-O-R8-(S)p-R8-]n- (9)
R10-R8-(S)p-R8-[O-C(R9)2-O-R8-(S)p-R8-]n-R10 (9a)
R3-R8-(S)p-R8-[O-C(R9)2-O-R8-(S)p-R8-]n-R3 (9b)
{R10-R8-(S)p-R8-[O-C(R9)2-O-R8-(S)p-R8-]n-O-C(R9)2-O-}mZ (9c)
{R3-R8-(S)p-R8-[O-C(R9)2-O-R8-(S)p-R8-]n-O-C(R9)2-O-}mZ (9d)
式中、nは1~50の整数であり得て、各pは、独立して、1および2から選択され得て、各R8は、C2~6アルカンジイルであり得て、各R9は、独立して、水素、C1~6アルキル、C7~12フェニルアルキル、置換C7~12フェニルアルキル、C6~12シクロアルキルアルキル、置換C6~12シクロアルキルアルキル、C3~12シクロアルキル、置換C3~12シクロアルキル、C6~12アリール、および置換C6~12アリールから選択され得て、各R10は、末端チオール基を含む部分であり、各R3は、独立して、チオール基以外の末端反応性官能基を含む部分であり、Zは、m価の親ポリオールZ(OH)mのコアに由来し得る。
-S-R13-[-S-(R11-X)p-(R12-X)q-R13-]n-S- (10)
HS-R13-[-S-(R11-X)p-(R12-X)q-R13-]n-SH (10a)
{HS-R13-[-S-(R11-X)p-(R12-X)q-R13-]n-S-V’-}zB (10b)
R3-S-R13-[-S-(R11-X)p-(R12-X)q-R13-]n-S-R3 (10c)
{R3-S-R13-[-S-(R11-X)p-(R12-X)q-R13-]n-S-V’-}zB (10d)
式中、
各R11は、独立して、C2~10アルカンジイル、例えば、C2~6アルカンジイル;C2~10分岐状アルカンジイル、例えば、C3~6分枝アルカンジイル、または例えばメチル基もしくはエチル基のようなアルキル基であり得る1つまたは1つより多くのペンダント基を有するC3~6分岐状アルカンジイル;C6~8シクロアルカンジイル;C6~14アルキルシクロアルカンジイル、例えば、C6~10アルキルシクロアルカンジイル;およびC8~10アルキルアレーンジイルから選択され得て、
各R12は、独立して、C1~10n-アルカンジイル、例えば、C1~6n-アルカンジイル、C2~10分岐状アルカンジイル、例えば、メチルもしくはエチル基のようなアルキル基であり得る1つまたは1つより多くのペンダント基を有するC3~6分岐状アルカンジイル;C6~8シクロアルカンジイル;C6~14アルキルシクロアルカンジイル、例えば、C6~10アルキルシクロアルカンジイル;およびC8~10アルキルアレーンジイルから選択され得て、
各R13は、独立して、C1~10n-アルカンジイル、例えば、C1~6n-アルカンジイル、C2~10分岐状アルカンジイル、例えば、メチルもしくはエチル基のようなアルキル基であり得る1つまたは1つより多くのペンダント基を有するC3~6分岐状アルカンジイル;C6~8シクロアルカンジイル基;C6~14アルキルシクロアルカンジイル、例えば、C6~10アルキルシクロアルカンジイル;およびC8~10アルキルアレーンジイルから選択され得て、
各Xは、独立して、OおよびSから選択され得て、
pは、1~5の整数であり得て、
qは、0~5の整数であり得て、
nは、1~60、例えば、2~60、3~60、または25~35の整数であり得て、
各R3は、独立して、反応性官能基から選択され、
Bは、z価の多官能化剤B(-V)zのコアを表し、式中、
zは、3~6の整数であり得て、
各Vは、チオール基に反応性の末端基を含む部分であり得て、
各-V’-は、-Vとチオールとの反応に由来し得る。
-[-S-(R14-X)p-C(R15)2-(X-R14)q-]n-S- (11)
H-[-S-(R14-X)p-C(R15)2-(X-R14)q-]n-SH (11a)
R3-[-S-(R14-X)p-C(R15)2-(X-R14)q-]n-S-R3 (11b)
{H-[-S-(R14-X)p-C(R15)2-(X-R14)q-]n-S-V’-}zB (11c)
{R3-[-S-(R14-X)p-C(R15)2-(X-R14)q-]n-S-V’-}zB (11d)
式中、
各R14は、独立して、C2~10アルカンジイル、例えば、C2~6アルカンジイル;C3~10分岐状アルカンジイル、例えば、C3~6分枝アルカンジイル、または例えばメチル基もしくはエチル基のようなアルキル基であり得る1つまたは1つより多くのペンダント基を有するC3~6分岐状アルカンジイル;C6~8シクロアルカンジイル;C6~14アルキルシクロアルカンジイル、例えば、C6~10アルキルシクロアルカンジイル;およびC8~10アルキルアレーンジイルから選択され得て、
各R15は、独立して、水素、C1~10n-アルカンジイル、例えば、C1~6n-アルカンジイル、C3~10分岐状アルカンジイル、例えば、例えばメチルもしくはエチル基のようなアルキル基であり得る1つまたは1つより多くのペンダント基を有するC3~6分岐状アルカンジイル;C6~8シクロアルカンジイル基;C6~14アルキルシクロアルカンジイル、例えば、C6~10アルキルシクロアルカンジイル;およびC8~10アルキルアレーンジイルから選択され得て、
各Xは、独立して、OおよびSから選択され得て、
pは、1~5の整数であり得て、
qは、1~5の整数であり得て、
nは、1~60、例えば、2~60、3~60、または25~35の整数であり得て、
各R3は、末端官能基を含む部分であり、
Bは、z価の多官能化剤B(-V)zのコアを表し、式中、
zは、3~6の整数であり得て、
各Vは、チオール基に反応性の末端基を含む部分であり得て、
各-V’-は、-Vとチオールとの反応に由来し得る。
σc=σf(φ-φc)t EQN.1
式中、φは充填材の体積分率であり、φcは浸透閾値であり、σfは充填材の導電率であり、φは複合導電率であり、tはスケーリング成分である。充填材は、電流の流れのために直接接触している必要はなく、伝導は、電気伝導性充填材粒子を取り囲む結合剤の薄層間のトンネリングを介して生じ得て、このトンネリング抵抗は、電気伝導性層の伝導性の制限因子であり得る。
CH2=CH-O-(CH2)w-OH (12)
式中、wは、2~10の整数である。式(12)のヒドロキシル官能性ビニルエーテルにおいて、wは、2、3、4、5であり得るか、またはwは、6であり得る。好適なヒドロキシル官能性ビニルエーテルの例としては、1-メチル-3-ヒドロキシプロピルビニルエーテル、4-ヒドロキシブチルビニルエーテル、およびそれらの組み合わせが挙げられる。ヒドロキシル官能性ビニルエーテルは、反応性希釈剤としての4-ヒドロキシブチルビニルエーテルであり得る。
CH2=CH-O-(CH2)t-NH2 (13)
式中、tは、2~10の整数である。式(13)のアミノ官能性ビニルエーテルにおいて、tは、2、3、4、5であり得るか、またはtは、6であり得る。好適なアミノ官能性ビニルエーテルの例としては、1-メチル-3-アミノプロピルビニルエーテル、4-アミノブチルビニルエーテル、および前述のもののうちのいずれかの組み合わせが挙げられる。アミノ官能性ビニルエーテルは、4-アミノブチルビニルエーテルであり得る。
CH2=CH-O-(CH2)w-R (14)
式中、wは、2~10の整数であり、Rは、エポキシ基である。式(14)のエポキシ官能性ビニルエーテルにおいて、wは、2、3、4、5、またはwは、6であり得る。エポキシ官能性ビニルエーテルは、2-(4(ビニルオキシ)ブチル)オキシランであり得る。
本発明は、以下の態様のうちの1つまたは1つより多くによってさらに定義され得る。
チオール末端ポリエポキシ伸長コポリマーの合成
チオール末端ポリチオエーテルポリマーPermapol(登録商標)P3.1E(384.32g、PPG Aerospaceから市販、メルカプタン当量1650)およびポリエポキシドDEN(登録商標)431(8.45g、Dow Chemicalから入手可能)をプラスチックカップ内で組み合わせた。これらの成分を、ミキサー(Hauschild Speed Mixer、2,300rpm、45秒)を使用して組み合わせた。アミンDabco(登録商標)33-LV(5.38g、Air Products&Chemicalsから入手可能)を混合物に添加し、高速ミキサー(Hauschild SpeedMixer(登録商標)、2,300rpmで30秒および800rpmで5分)を使用して組み合わせた。次いで、得られたチオール末端ポリエポキシ伸長ポリチオエーテルプレポリマーを23℃で24時間にわたって静置してから、他の構成要素と組み合わせて、共反応性シーラント組成物を調製した。チオール末端ポリエポキシ伸長ポリチオエーテルプレポリマーは、4,716Daの数平均分子量および2,069Daのチオール当量を有していた。
Skydrol(登録商標)耐性ポリチオエーテルシーラントの調製
実施例1のチオール末端ポリエポキシ伸長ポリチオエーテルプレポリマーを含むベース共反応性成分(B成分)を調製した。表1に示される構成要素を組み合わせ、混合して、ベース成分(B成分)を形成した。
1Honeywell,Morris Plains,NJから市販されている。
2Sakai Trading,New York,NYから市販されている。
3Solvayから市販されている。
4Cabot Corpから市販されている。
5PPG Aerospace,Sylmar,CAから市販されている。
6Momentiveから市販されている。
7Durez Corpから市販されている。
1Dow Chemicalから市販されている。
2ポリウレタンポリエポキシド、エポキシ等価重量245;Adeka Corporation,Tokyo,Japanから市販されている。
3二官能性エポキシ末端ポリチオエーテル;エポキシ等価重量584;PPG Aerospace,Sylmar,CAから市販されている。
4Dow Chemicalから市販されている。
5Solvayから市販されている。
6Sun Chemical Corp.から市販されている。
多層系
多層系を、まず、シーラントを含む第1の内層を調製し、次いで、第1の内層を覆って第2の外層を塗布することによって製造した。第1の内層を調製するために使用された材料は、Skydrol(登録商標)LD-4耐性ではなかった。
Claims (18)
- 2つまたは2つより多くの層を含み、前記層のうちの1つまたは1つより多くがシーラント層を含む多層シーラントを製造する方法であって、
(a)第1の成分および第2の成分を混合して、共反応性シーラント組成物を形成することであって、
前記共反応性シーラント組成物が第1の反応性化合物および第2の反応性化合物を含み、
前記第1の反応性化合物が前記第2の反応性化合物に反応性である、形成することと、
(b)1つまたは1つより多くの追加の共反応性組成物を前記共反応性シーラント組成物と融合させることと、
(c)前記融合した共反応性シーラント組成物および前記1つまたは1つより多くの追加の共反応性組成物を共押出成形して、共押出物を形成することと、
(d)三次元印刷を使用して前記共押出物を堆積させて、1つまたは1つより多くのシーラント層を含む多層シーラントを形成することと、
を含む、方法。 - 前記共反応性シーラント組成物が前記1つまたは1つより多くの追加の共反応性組成物とは異なる、請求項1に記載の方法。
- 前記共反応性シーラント組成物および前記1つまたは1つより多くの追加の共反応性組成物がそれぞれ熱硬化物を含む、請求項1~2のいずれか一項に記載の方法。
- 前記共押出物の断面プロファイルが前記断面プロファイルにわたって不均一な組成を有する、請求項1~3のいずれか一項に記載の方法。
- 前記多層シーラントの前記2つまたは2つより多くの層のうちの最外層がシーラント層を含む、請求項1~4のいずれか一項に記載の方法。
- 前記共反応性シーラント組成物が硫黄含有プレポリマーを含む、請求項1~5のいずれか一項に記載の方法。
- 前記第1の反応性化合物が、50℃未満の温度で前記第2の反応性化合物に反応性である、請求項1~6のいずれか一項に記載の方法。
- 前記共反応性組成物がそれぞれ、隣接する共反応性組成物に反応性である、請求項1に記載の方法。
- 添加剤含有組成物を前記共反応性シーラント組成物の一部と組み合わせて、添加剤修飾された共反応性シーラント組成物を形成することであって、前記添加剤含有組成物が添加剤を含む、形成することと、
前記添加剤修飾された共反応性シーラント組成物を押出成形して、前記共押出物を形成することと、をさらに含み、
前記共押出物の断面プロファイルが、不均一な濃度の前記添加剤を有し、かつ/または
前記共押出物が、前記共押出物の長手方向の寸法において不均一な濃度の前記添加剤を特徴とする、請求項1~8のいずれか一項に記載の方法。 - 接着促進組成物を前記共反応性シーラント組成物と融合させることと、
前記共反応性シーラント組成物および前記接着促進組成物を共押出成形することをさらに含む、請求項1~9のいずれか一項に記載の方法。 - 前記多層シーラントの隣接する層が化学的および/または物理的に結合される、請求項1~10のいずれか一項に記載の方法。
- 前記多層シーラントの層がそれぞれ熱硬化性材料を含む、請求項1~11のいずれか一項に記載の方法。
- 前記多層シーラントが、AMS 3277に記載されている航空宇宙用シーラントについての要件を満たすか、またはこれを上回る、請求項1~12のいずれか一項に記載の方法。
- 前記多層シーラントの1つまたは1つより多くの層が、不均一な組成物断面プロファイルを有する、請求項1~13のいずれか一項に記載の方法。
- 前記多層シーラントの1つまたは1つより多くの層が、長手方向の寸法において不均一な組成を有する、請求項1~14のいずれか一項に記載の方法。
- 請求項1~15のいずれか一項に記載の方法であって、前記多層シーラントが、部品に塗布するためのものである、方法。
- 前記部品が自動車車両部品または航空宇宙ビークル部品を含む、請求項16に記載の方法。
- 請求項1~15のいずれか一項に記載の方法であって、前記多層シーラントが、ビークルに塗布するためのものである、方法。
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