Aqueous Resin Dispersion Adhesion to Polyolefin at Low Temperature
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Solution Overview
Problem
Existing aqueous resin dispersions face challenges in achieving sufficient adhesiveness to polyolefin base materials, particularly polypropylene, often requiring high-temperature baking and have stability issues due to large particle sizes and lack of insoluble components.
Innovation Solution
An aqueous resin dispersion is developed with an olefin polymer bonded to a hydrophilic polymer and a polymer containing reactive functional groups, where the median diameter is 300 nm or less, and contains 1% or more insoluble components, allowing for low-temperature adhesiveness and improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an aqueous resin dispersion without insoluble component is used, then the dispersion is easy to prepare, but adhesiveness to polyolefin base material is insufficient
Solution Approach 1:
The invention uses a composite resin composition containing both soluble polymer components and insoluble polyolefin particles. The soluble polymers (modified polyolefin and polymer from radically polymerizable monomer) provide adhesion and bonding, while the insoluble polyolefin particles provide mechanical interlocking and reinforce the adhesive effect on polyolefin base materials, achieving both ease of preparation and excellent adhesiveness.
2Reliability
If high temperature baking is applied to improve adhesiveness, then adhesiveness to polyolefin base material is improved, but energy consumption increases
Solution Approach 1:
The invention changes the chemical composition parameters of the resin dispersion to include polymers with reactive functional groups that can form strong bonds at lower temperatures. The modified polyolefin with hydrophilic groups and the polymer from radically polymerizable monomers enable effective adhesion to polyolefin base materials at reduced baking temperatures, thereby maintaining high adhesiveness while reducing energy consumption.
3Ease of manufacture
If particle size of aqueous resin dispersion is large, then the dispersion is easy to prepare, but storage stability is poor
Solution Approach 1:
The invention segments the resin system into multiple components with different functional roles: modified polyolefin particles, polymers from radically polymerizable monomers, and insoluble polyolefin particles. This segmentation allows each component to contribute specific properties, including improved dispersion stability through the combined effect of soluble polymers providing steric stabilization and insoluble particles providing structural support, preventing aggregation and improving storage stability.
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 solution enables excellent adhesiveness to polyolefin base materials like polypropylene at low baking temperatures and enhances storage stability of the aqueous resin dispersion.
Implementation Method 1
a median diameter of the aqueous resin dispersion (C) measured by a dynamic light scattering method is 300 nm or less
Data Source
AI summary
An aqueous resin dispersion with which excellent adhesiveness to a polyolefin base material such as a polypropylene base material can be easily obtained, which can be baked at low temperature, and which is for producing an aqueous coating material; and an aqueous coating material and an adhesive which contain the aqueous resin dispersion, are provided. In an aqueous resin dispersion (C) of the present invention, an olefin polymer (A) and a polymer (B) containing a constitutional unit derived from a radically polymerizable monomer (b1) having a reactive functional group are dispersed in an aqueous medium, a median diameter of the aqueous resin dispersion (C) measured by a dynamic light scattering method is 300 nm or less, and a dry product of the aqueous resin dispersion (C) contains 1 mass% or more of an insoluble component (D) that is insoluble in tetrahydrofuran.