1K Isocyanate Prepolymer Adhesive for Packaging Lamination
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Solution Overview
Problem
Current multilayer packaging constructions require mixing of 2K polyurethane adhesive components prior to application, which complicates the lamination process and reduces efficiency.
Innovation Solution
A 1K isocyanate prepolymer adhesive layer with a hyperbranched polyester binder, eliminating the need for mixing additional components and enhancing lamination efficiency by forming strong adhesion between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If 2K polyurethane adhesive components are used, then adhesion strength is achieved, but process complexity and mixing requirements increase
Solution Approach 1:
The patent segments the adhesive system into two distinct functional components: a 1K isocyanate prepolymer that provides the adhesive base and a hyperbranched polyester binder that contains reactive functional groups. This segmentation allows each component to be optimized independently while eliminating the need for complex mixing procedures required by traditional 2K systems.
Solution Approach 2:
The hyperbranched polyester binder is pre-formulated with the necessary functional groups (—OH, —COOH, or —COOR) that will react with the isocyanate prepolymer. This preliminary preparation of reactive groups eliminates the need for on-site mixing and curing agent addition, simplifying the application process while maintaining strong adhesion.
2Strength
If 2K polyurethane adhesive components are used, then adhesion strength is achieved, but lamination efficiency decreases due to mixing requirements
Solution Approach 1:
The adhesive system is divided into a 1K isocyanate prepolymer component and a hyperbranched polyester binder component with pre-incorporated functional groups. This segmentation eliminates the need for mixing operations, allowing for faster application and improved lamination efficiency while maintaining strong bond strength.
Solution Approach 2:
The hyperbranched polyester binder contains all necessary reactive functional groups (—OH, —COOH, or —COOR) within its molecular structure, enabling it to self-react with the isocyanate prepolymer without requiring external mixing or additional curing agents. This self-service capability streamlines the lamination process and improves productivity.
3Productivity
If 1K isocyanate prepolymer adhesive is used, then lamination process efficiency is improved, but adhesion performance must be maintained
Solution Approach 1:
The patent creates a composite adhesive system combining a 1K isocyanate prepolymer with a hyperbranched polyester binder that contains multiple reactive functional groups (—OH, —COOH, or —COOR). This composite material approach maintains the simplicity and efficiency of 1K systems while achieving adhesion performance comparable to or exceeding traditional 2K polyurethane adhesives through the reactive functionality of the hyperbranched structure.
Solution Approach 2:
The invention changes the chemical parameters of the adhesive system by incorporating hyperbranched polyester with specific functional groups (—OH, —COOH, or —COOR) that have different reactivity characteristics toward isocyanates. This parameter change enables the 1K system to achieve strong adhesion performance while maintaining process efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The 1K isocyanate prepolymer adhesive system simplifies the packaging lamination process and achieves superior adhesion between layers, improving overall efficiency and reducing the complexity of the lamination process.
Implementation Method 1
a 1K isocyanate prepolymer adhesive layer between the print layer and one of the films, where the print layer contains a hyperbranched polyester binder containing functional groups selected from the group consisting of —OH, —COOH and —COOR
Data Source
AI summary
A multilayer composition for packaging comprising a first polymer film, a second film, at least one print layer between the films and a 1 K isocyanate prepolymer adhesive layer between the at least one print layer and one of the films, where the print layer contains a hyperbranched polyester binder containing functional groups selected from the group consisting of —OH, —COOH and —COOR, where R is methyl, ethyl, vinyl, isopropyl, n-propyl, n-butyl, isobutyl, sec-butyl or tert-butyl provides packaging laminates with excellent adhesion. The hyperbranched polyester is for example a polymer of trimethyolpropane and hexahydrophthalic anhydride and optionally a cycloaliphatic diol.