Hot-Melt Adhesives Using Depolymerized Polyolefin Waxes
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Solution Overview
Problem
Current hot-melt adhesive formulations using polypropylene waxes, styrenic polymers, and styrenic oligomers face issues with thermal stability and compatibility, leading to phase separation and poor adhesion, requiring complex and costly processes with hazardous materials.
Innovation Solution
A method involving the depolymerization of polymeric materials like polypropylene and polyethylene to create depolymerized waxes, which are then added to hot-melt formulations, employing a catalyst and processing steps such as extrusion and filtering to enhance compatibility and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polypropylene waxes, styrenic polymers, and styrenic oligomers are used in hot-melt adhesive formulations, then bond strength and integrity at high temperatures are improved, but thermal stability deteriorates leading to phase separation and poor adhesion
Solution Approach 1:
The patent applies parameter changes by controlling the molecular weight distribution and composition of the polyolefin wax through controlled depolymerization. By adjusting the average molecular weight and molecular weight distribution of the polyolefin components, the formulation achieves both high bond strength and thermal stability, resolving the contradiction between strength and reliability.
2Strength
If polypropylene waxes are used to achieve better adhesion to polypropylene and lower surface energy materials, then adhesion is improved, but compatibility with polymer scaffold materials deteriorates leading to phase separation
Solution Approach 1:
The patent applies local quality by creating distinct functional components within the formulation: a polyolefin wax component for adhesion to polypropylene surfaces, and a polymer scaffold component for compatibility and phase stability. The controlled molecular weight distribution ensures that each component performs its specific function optimally without causing phase separation.
3Reliability
If styrenic polymers and styrenic oligomers are added to improve thermal stability, then thermal stability is improved, but compatibility with polymer scaffold materials deteriorates causing poor adhesion
Solution Approach 1:
The patent applies composite materials by formulating a multi-component system consisting of polymer scaffold, polyolefin wax, tackifier, and stabilizer. The controlled molecular weight distribution and composition ratios ensure compatibility between components while achieving the desired thermal stability and adhesion properties.
4Reliability
If complex processes with hazardous materials are used to achieve thermal stability and compatibility, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies self-service by using controlled depolymerization of polyolefin to generate the required polyolefin wax with specific molecular weight distribution. This in-house generation of key formulation components eliminates the need for complex external processing and hazardous materials, achieving thermal stability through a simpler, safer process.
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 method produces thermally stable and cost-effective hot-melt formulations with improved adhesion and compatibility, reducing phase separation and allowing for higher percentages of polypropylene and polyethylene waxes in formulations, thus modifying open and set times and thermal stability.
Implementation Method 1
employing a catalyst and processing steps such as extrusion and filtering to enhance compatibility and stability
Implementation Method 2
processing steps such as extrusion and filtering to enhance compatibility and stability
Implementation Method 3
processing steps such as extrusion and filtering to enhance compatibility and stability
Data Source
AI summary
A hot-melt formulation can utilize a depolymerized polymeric material such as a wax, styrenic polymer, and/or styrenic oligomer, wherein the wax, styrenic polymer, and/or styrenic oligomer is created via depolymerization of a polymer. In some embodiments, the polymer is polypropylene. In some embodiments, the polymer is polyethylene. In some embodiments, the polymer is polystyrene. In some embodiments, the hot-melt formulation can include, among other things, ethylene-vinyl acetate copolymers, olefinic block copolymer, amorphous polyolefins, styrene block copolymers, amorphous poly-alpha-olefins, thermoplastic polyolefins, tackifiers, stabilizers, paraffin waxes and/or Fisher Tropsch waxes.