Laminate Forming with Separate Isocyanate-Reactive Adhesive Components
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Solution Overview
Problem
Existing laminate production processes using solvent-based adhesives require a drying step, which increases equipment and processing costs, and pre-mixed solvent-less adhesives with sufficient adhesion exhibit a short pot life and slow curing properties.
Innovation Solution
A process involving the uniform application of an isocyanate component and an isocyanate-reactive component to separate substrates, followed by mixing and curing to form a solvent-less adhesive layer, with a stoichiometric ratio of 1.0 to 5.0, to create a laminate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based adhesives are used to form laminates, then adhesion between substrates is achieved, but an additional drying step is required which increases equipment and processing costs
Solution Approach 1:
The invention extracts and eliminates the solvent component from the adhesive system, transitioning from solvent-based to solvent-less adhesives. This removal of the solvent eliminates the need for drying equipment and processing steps, directly resolving the contradiction between adhesion effectiveness and equipment complexity
Solution Approach 2:
The invention changes the chemical composition parameters of the adhesive by using solvent-less formulations with specific isocyanate-to-reactive component ratios (1:4 to 4:1). This parameter change enables the adhesive to cure without solvent evaporation, eliminating the drying step and associated equipment while maintaining bonding performance
2Device complexity
If pre-mixed solvent-less adhesives are used to eliminate drying steps, then equipment costs are reduced, but the adhesive exhibits short pot life and slow curing properties
Solution Approach 1:
The invention segments the adhesive into two separate components: an isocyanate component and a reactive component. These components are applied separately to substrates and only mix upon contact between substrates, preventing premature reaction and extending pot life while enabling fast curing once mixed, thus resolving the contradiction between equipment simplicity and bonding productivity
Solution Approach 2:
The invention performs preliminary action by pre-applying each adhesive component to substrates before they are laminated together. This allows the components to be ready for immediate reaction upon substrate contact, enabling fast bonding without requiring pre-mixing that would limit pot life, thereby resolving the contradiction between equipment simplicity and bonding speed
3Strength
If pre-mixed solvent-less adhesives are used to provide sufficient adhesion, then bonding strength is achieved, but pot life is short and curing is slow
Solution Approach 1:
The invention divides the adhesive system into two stable, non-reactive components that can be stored and handled separately with extended pot life. When applied to substrates and brought into contact, these segments rapidly react to form strong bonds, thus resolving the contradiction between adhesion strength and pot life duration
Solution Approach 2:
The invention creates a dynamic system where the adhesive components remain stable and non-reactive during storage and application (long pot life), but rapidly react when substrates are laminated together (fast curing). This dynamic behavior resolves the contradiction between maintaining adhesion capability and extending usable time
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
This method allows for faster bonding and curing of laminates without the need for additional drying steps, reducing equipment costs and improving pot life.
Implementation Method 1
bringing the first substrate and the second substrate together, thereby mixing and reacting the isocyanate component and the isocyanate-reactive component to form an adhesive composition between the first substrate and the second substrate
Implementation Method 2
curing the adhesive composition to bond the first substrate and the second substrate
Data Source
AI summary
The present disclosure provides a process for forming a laminate. The process includes (A) uniformly applying an isocyanate component to a first substrate, the isocyanate component containing an isocyanate compound; (B) uniformly applying an isocyanate-reactive component to a second substrate, the isocyanate-reactive component containing an amine-terminated compound; (C) bringing the first substrate and the second substrate together, thereby mixing and reacting the isocyanate component and the isocyanate-reactive component to form an adhesive composition between the first substrate and the second substrate; (D) curing the adhesive composition to bond the first substrate and the second substrate; and (E) forming the laminate.