Coated Substrate Adhesive Layer Composition
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Solution Overview
Problem
Existing coated fabrics face challenges in combining weatherability, environmental friendliness, ease of application, and adhesion, particularly with polyolefin elastomers being difficult to laminate to fabric substrates, while traditional materials like PVC are not environmentally benign and styrene block copolymers have poor weatherability.
Innovation Solution
A coated substrate comprising a fabric substrate layer, an adhesive layer formed from a composition including a thermoplastic elastomer such as maleic anhydride functionalized olefin-based polymer or SEBS block copolymer, an anhydride functionalized, chlorinated olefin-based polymer, and a non-aromatic solvent, and a non-polar olefin-based layer, which enhances adhesion and weatherability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If polyolefin elastomers are used as adhesive, then environmental friendliness is improved, but adhesion to fabric substrate deteriorates
Solution Approach 1:
The patent uses a composite adhesive system combining polyolefin elastomer with maleic anhydride functionalized polyolefin and chlorinated polyolefin. This composite approach maintains the environmental benefits of polyolefin while improving adhesion through synergistic interactions between the different polymer components, where the functionalized polymers enhance bonding to the fabric substrate.
Solution Approach 2:
The patent modifies the chemical parameters of the polyolefin elastomer by incorporating functionalized polymers (maleic anhydride groups) and chlorinated polymers. These parameter changes alter the surface properties and chemical reactivity of the adhesive, enabling better adhesion to fabric substrates while maintaining the base polyolefin's environmental compatibility.
2Ease of manufacture
If styrene block copolymers are used as adhesive, then ease of lamination is improved, but weatherability deteriorates
Solution Approach 1:
The patent creates a composite adhesive system that replaces styrene block copolymers with a combination of polyolefin elastomer, maleic anhydride functionalized polyolefin, and chlorinated polyolefin. This composite maintains processability similar to styrene copolymers while providing superior weatherability through the inherent UV resistance of polyolefin-based materials.
Solution Approach 2:
The patent selects polyolefin-based materials that offer comparable ease of use to styrene copolymers but with extended service life and weatherability. The functionalized and chlorinated modifiers ensure the adhesive maintains its bonding capabilities over time despite environmental exposure.
3Strength
If PVC is used as adhesive, then adhesion is improved, but environmental friendliness deteriorates
Solution Approach 1:
The patent replaces PVC with polyolefin elastomer-based adhesives that provide comparable adhesion performance but without the environmental harm associated with PVC. The functionalized and chlorinated polyolefin components replicate PVC's adhesive properties while maintaining biodegradability and environmental compatibility.
Solution Approach 2:
The patent extracts the harmful chlorine from PVC's molecular structure while retaining the beneficial adhesion properties through the use of chlorinated polyolefin with controlled chlorine content (5-40 wt%). This selective extraction removes the environmental toxicity while preserving the adhesive strength.
4Object-generated harmful factors
If polyolefin elastomer is used as adhesive, then environmental friendliness is improved, but ease of lamination deteriorates
Solution Approach 1:
The patent formulates a composite adhesive where polyolefin elastomer is combined with maleic anhydride functionalized polyolefin and chlorinated polyolefin. This composite maintains the environmental benefits of polyolefin while the functionalized components improve processability and lamination ease through enhanced flow characteristics and bonding kinetics.
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 provides improved peel strength and balanced hand feel, achieving enhanced adhesion and weatherability while being environmentally friendly, addressing the limitations of traditional materials.
Implementation Method 1
an adhesive layer which is formed from a first composition comprising (i) a thermoplastic elastomer selected from the group consisting of maleic anhydride functionalized olefin-based polymer and a styrene ethylene butene styrene (SEBS) block copolymer with a styrene content of equal to or less than 35 wt%, (ii) an anhydride functionalized, chlorinated olefin-based polymer that has a chlorine content from 10 to 35 wt%, based on the total weight of the anhydride functionalized, chlorinated olefin-based polymer and the thermoplastic elastomer; and (iii) a non-aromatic and nonchlorinated solvent selected from the group consisting of the following: methyl cyclohexane, ethyl cyclohexane, methyl ethyl ketone, ethyl acetate, butyl acetate, and combinations thereof, the first composition having a Brookfield viscosity (solution) at 26 °C from 10 cP to 100 cP
Data Source
Figure 1~2
Figure 3
AI summary
A coated substrate which includes a) a fabric substrate layer; b) an adhesive layer which is formed from a first composition comprising a thermoplastic elastomer and an anhydride and/or carboxylic acid functionalized, chlorinated olefin-based polymer that has a chlorine content from 1 to 20wt%, based on the total weight of the anhydride and/or carboxylic acid functionalized, chlorinated olefin-based polymer and the thermoplastic elastomer; and c) a non-polar olefin-based layer formed from a second composition comprising at least one non-polar olefin-based polymer is provided. Also provided are an adhesive composition and articles comprising the coated substrate. A coated substrate comprising the following: a) a fabric substrate layer; b) an adhesive layer which is formed from a first composition comprising a thermoplastic elastomer and an anhydride and/or carboxylic acid functionalized, chlorinated olefin-based polymer that has a chlorine content from 10 to 35 wt%, based on the total weight of the anhydride and/or carboxylic acid functionalized, chlorinated olefin-based polymer; and c) a non-polar olefin-based layer formed from a second composition comprising at least one non-polar olefin-based polymer.