Emulsifier Stabilized Copolymer Dispersion Nozzle Splashing
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Solution Overview
Problem
Aqueous emulsifier stabilized copolymer dispersions used in nozzle applications for adhesive bonding face issues with splashing and dirt formation, leading to contamination and machine downtime, as existing solutions either suffer from unacceptable splashing or dirt formation, limiting their use in high-speed applications.
Innovation Solution
An emulsifier stabilized formulated copolymer dispersion is prepared through emulsion polymerization, followed by a post-addition of a polyvinyl alcohol solution with specific molecular weight and degree of hydrolysis, which reduces splashing and dirt formation while maintaining adhesive properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If emulsifier stabilized dispersion-based adhesives are used in nozzle applications, then adhesive bonding is achieved, but splashing occurs on the substrate leading to imprecise application
Solution Approach 1:
The patent modifies the chemical composition parameters of the adhesive dispersion by incorporating specific surfactants and polymers in controlled concentrations. This changes the rheological properties and surface tension of the adhesive, preventing splashing while maintaining bonding reliability. The formulation includes specific ratios of emulsifiers, co-emulsifiers, and polymer stabilizers that optimize the balance between adhesion and application precision.
Solution Approach 2:
The adhesive system uses a composite formulation combining multiple components: copolymer dispersions, surfactants, co-emulsifiers, and polymer stabilizers. This composite approach creates a synergistic effect where each component contributes specific properties - the copolymer provides bonding, the surfactants control surface tension, and the stabilizers prevent splashing, achieving both reliability and precision simultaneously.
2Productivity
If high cycle frequency nozzle valves are used for high-speed application, then productivity increases, but dirt formation on the nozzle tip increases
Solution Approach 1:
The patent adjusts the viscosity, surface tension, and rheological parameters of the adhesive dispersion to optimize nozzle flow characteristics. By controlling these parameters, the adhesive maintains stable jet formation even under high shearing forces from high-frequency valve operation, reducing dirt accumulation while preserving high-speed application capability.
Solution Approach 2:
The formulation includes intermediary substances such as surfactants and co-emulsifiers that act as mediators between the adhesive polymer and the nozzle system. These intermediaries reduce surface tension and improve flow stability, preventing direct contact between the adhesive and nozzle surfaces that would cause dirt formation, while allowing high-frequency operation to maintain productivity.
3Manufacturing precision
If polyvinyl alcohol is added as post-addition to emulsifier stabilized copolymer dispersion, then splashing is reduced, but the formulation complexity increases
Solution Approach 1:
The patent incorporates polyvinyl alcohol and other stabilizing components during the polymerization process itself rather than adding them separately afterward. This preliminary action integrates the splashing-prevention functionality into the base formulation, reducing the need for separate post-addition steps and simplifying the overall manufacturing process while maintaining application precision.
Data Source
AI summary
The present invention relates an emulsifier stabilized formulated copolymer dispersion, processes for forming the emulsifier stabilized formulated copolymer dispersion, and to uses thereof. The emulsifier stabilized formulated copolymer dispersion may be formed by polymerizing at least one monomer in the presence of a stabilizer package, to form an emulsifier stabilizer copolymer dispersion, and introducing a post-addition comprising a polyvinyl alcohol solution to the emulsifier stabilized copolymer dispersion to form an emulsifier stabilized formulated copolymer dispersion. The polyvinyl alcohol, added as solution, may be added in an amount from 1 to 10 % by weight, solid polyvinyl alcohol based on solids content of the emulsifier stabilized copolymer dispersion. The polyvinyl alcohol may have a molecular weight expressed as viscosity from 3 mPa·s to 60 mPa·s based on a 4 % solution at 20° C. and a degree of hydrolysis from 70 mol.% to 85 mol.%, preferably from 78 mol.% to 82 mol.%, more preferably 80 mol.%.