Chlorinated Propylene Copolymer Adhesion

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Solution Overview

Problem

Conventional chlorinated polyolefin resins face challenges in achieving sufficient adhesion strength to substrates like polyvinyl chloride, polycarbonate, PET, ABS, and nylon, especially at low temperature baking conditions, and exhibit poor gasohol resistance and solubility in solvents, making them unsuitable for modern applications.

Innovation Solution

A chlorinated propylene-based random copolymer is produced by copolymerizing propylene with another α-olefin using a metallocene catalyst, with a melting point below 115°C, and then chlorinated, which is further modified with α,β-unsaturated carboxylic acid or anhydride to enhance adhesion and solubility, resulting in a resin with improved adhesion strength and gasohol resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional chlorinated polyolefin resins are used, then adhesion strength to polypropylene substrates is improved, but adhesion strength to other substrates (polyvinyl chloride, polycarbonate, PET, ABS, nylon) is insufficient

Engineering Contradiction:

Improveadhesion strength to polypropylene substratesVSAvoidadhesion strength to multiple substrate types

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent introduces specific functional groups (carboxyl, hydroxyl, amine) at localized positions on the polymer chain through copolymerization with maleic acid, itaconic acid, or glycidyl methacrylate. This creates regions of enhanced polarity and chemical reactivity that specifically improve adhesion to diverse substrates while maintaining the base polymer's properties

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention creates a composite polymer structure combining chlorinated polyolefin backbone with grafted functional groups from copolymerization. This composite structure integrates the adhesion benefits of polar groups with the mechanical properties of the polyolefin matrix, achieving broad substrate compatibility

Inventive Principle:

Principle #40Composite materials

2Temperature

If chlorinated polyolefin resins are used for low temperature baking, then processing temperature is reduced, but adhesion strength becomes insufficient

Engineering Contradiction:

Improvebaking temperatureVSAvoidadhesion strength

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent modifies the chemical composition parameters of the resin by incorporating polar functional groups through copolymerization. This changes the fundamental adhesion mechanism from purely physical to include chemical interactions, enabling strong adhesion at lower baking temperatures where conventional resins fail

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conventional chlorinated polyolefin resins are used, then gasohol resistance is poor, but solubility in solvents is also insufficient

Engineering Contradiction:

Improvegasohol resistanceVSAvoidsolubility in solvents

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent introduces polar functional groups at specific locations on the polymer chain through controlled copolymerization. These localized polar regions enhance solvent compatibility and adhesion properties while the bulk polyolefin structure maintains gasohol resistance

Inventive Principle:

Principle #3Local quality

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 resulting copolymer exhibits excellent adhesion strength and gasohol resistance on a wide range of substrates, including polyolefin-based materials, even at low temperature baking, and maintains stability as a waterborne dispersion, making it suitable for various industrial applications such as primers, paints, and adhesives.

Implementation Method 1

copolymerizing propylene with another α-olefin using a metallocene catalyst

Methodology Applied

Scientific EffectCopolymerization: Chemical Bonding

Implementation Method 2

using a metallocene catalyst as a polymerization catalyst

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

then chlorinating the copolymer

Methodology Applied

Scientific EffectChlorination: Chemical Bonding

Implementation Method 4

modified with α,β-unsaturated carboxylic acid or anhydride to enhance adhesion and solubility

Methodology Applied

Scientific EffectGraft copolymerization: Chemical Bonding

Data Source

PatentUS7635520B2Chlorinated propylene random copolymer and compositions containing the same

Publication Date: 2009.12.22 NIPPON PAPER CHEM

AI summary

A novel binder resin which attains good adhesion to various substrates such as polyolefin resins, vinyl chloride resins, polycarbonate resins, polyethylene terephthalate resins, acrylonitrile/butadiene/styrene resins, and nylon resins even by low-temperature baking and has excellent solubility in solvent. Namely, a chlorinated propylene random copolymer produced by subjecting a propylene random copolymer which is obtained by copolymerizing propylene with other alpha-olefins by using a metallocene catalyst as the polymerization catalyst and which has a melting point (Tm) of less than 115° C. as determined with a differential scanning calorimeter (DSC) to thermally kneaded preferably at a temperature ranging from the melting point of the copolymer to 350° C. and chlorination successively.