Simple and Rapid Adhesion of Commodity Polymer Substrates under Ambient Conditions Using Complexed Alkylboranes

Abstract

Adhesives are ubiquitous in manufacturing spanning nearly all sectors from healthcare and photovoltaics to aerospace and electronics. Yet many commercial polymers remain challenging to adhere, necessitating either pretreatment, mechanical fastening, or adhesive processes that involve specialized equipment, high temperature/vacuum, and long cure times. Thus, rapid-cure adhesives for polymers that can set under ambient conditions using simple procedures are desirous because they offer cost savings, faster production, and greater design freedom to producers. Herein, we report a powerful adhesive platform that bonds a wide scope of commodity polymers via (hydrogen) atom transfer and free-radical (graft) polymerization initiated with a trialkylborane-ligand complex and isocyanate decomplexing agent. The developed adhesive formulation is air-stable, bulk, and operates in air at room temperature using a high-glass-transition temperature polyacrylate, i.e., poly(isobornyl acrylate). The alkylborane-initiated bonding process is rapid (∼30 min), requires minimal surface preparation (cleaning and mild roughening), and successfully bonds seven diverse substrates including polytetrafluoroethylene, polyethylene, polypropylene, polycarbonate, nylon, polymethylmethacrylate, and polyvinylchloride. This contribution uniquely investigates the process-property relationships for the adhesive formulation, lap-shear performance, mechanism of failure, and a reactive additive for enhancing the adhesive's glass-transition temperature to ∼120 °C (polyhedral oligomeric silsesquioxane or POSS) to widen its operation temperature. We envision that the reported alkylborane-initiated adhesion platform could hold promise in the automotive, aerospace, and marine sectors as means for rapid manufacturing and structural adhesion.