Formulating (Meth)Acrylic Structural Adhesives for Modern Vehicle Assembly Al DeCato

1. Formulating (Meth)Acrylic Structural Adhesives for Modern Vehicle Assembly Al DeCato Technical Manager TT-Automotive Product Development Henkel Corp. 1001 Trout Brook Crossing Rocky Hill, CT 06067 860-571-2565 al.decato@us.henkel.com Presented at a meeting of the Thermoset Resin Formulators Association at the Hyatt Regency Montreal in Montreal, Quebec, Canada, September 11 through 12, 2006.

2. Presentation Outline • History of formulations • Goals of formulating • Components of formulations • desired properties • Acknowledgements

3. History of formulations • From rubber cement beginnings • Significant developments • monomer:polymer ratio • redox curing system

4. Goals of formulating • Cure activity versus stability • Fixture time versus open time • Strength versus toughness

5. Formulation components Monomer • (Meth)acrylic esters • Methyl methacrylate, ethyl methacrylate, 2-ethylhexyl methacrylate, cyclohexyl methacrylate, ethyl acrylate • Effects  • Solvency, stiffness, odor, cure speed

6. Formulation components Polymeric elastomer/liquid rubber •  Polychloroprene,polybutadiene, chlorosulfonated polyethylene, copolymers of butadiene or isoprene with styrene, acrylonitrile, copolymers of ethylene and acrylate esters, homopolymers of epichlorohydrin, copolymers of epichlorohydrin and ethylene oxide, nitrile • Effects • Toughening, low temperature flexibility, vibration damping

7. Formulation components Graft co-polymer/core shell •  methyl methacrylate/1,3-butadiene/styrene (MBS) • acrylonitrile/butadiene/styrene (ABS) •  styrene/butadiene/styrene (SBS) • Effects • Impact modifier, thixotropy

8. Formulation components Inhibitors • 2,6-di-t-butyl-4-methylphenol (BHT), hydroquinone (HQ), methylhydroquinone (MHQ) • Effects • stability, cure speed, heat of exotherm

9. Formulation components Carboxylic acid •  acrylic acid, methacrylic acid • Effects • Fast cure, adhesion

10. Formulation components Initiators • Organic peroxides, organic hydroperoxide, peresters, peracids, and azo compounds • Effects • Cure speed, heat of exotherm, open time, and stability

11. Formulation components Activators • N,N-dimethylaniline, diethyl aniline, N,N-dimethyl-p-toluidine, aldehyde-amine reaction products, dihydropyridine • Effects • cure speed, open time, heat of exotherm, and stability

12. Formulation components Catalysts • oxidizable heavy metal salts, such as the naphthenates, octoates, acetylacetonates, and hexoates of transition metals such as copper, cobalt, nickel, and iron • Effects • cure speed, heat of exotherm, open time, and stability

13. Formulation components Additives • Adhesion promoters • Carboxylic acid, phosphorus compounds • Wax • Effects • adhesion, cure speed • reduce odor, extend open time

14. Acknowledgements To Henkel Corp. for the opportunity, encouragement, and support to develop this chemistry To my family which has supported me, always To Paul Rachielles who has always had the faith that I could succeed