Low Misting Laminating Adhesives for High-Speed Application
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional solventless laminating adhesives used in high-speed applications tend to form adhesive mist, leading to inefficiencies, increased costs, and safety concerns due to the formation of aerosol droplets that can collect on machinery and pose health risks.
Innovation Solution
A two-component laminating adhesive system comprising an isocyanate-functionalized compound (Component A) and a mixture of high functionality polyols with lower functionality polymeric polyols (Component B) is used, which reduces the tendency to form mist during high-speed application, allowing for efficient application at speeds exceeding 1000 feet per minute.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional solventless laminating adhesives are used for high-speed application, then productivity is improved, but adhesive misting increases causing harmful effects
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesive system by incorporating specific polyether polyols with controlled molecular weights and hydroxyl values, along with isocyanate prepolymers formulated at specific NCO percentages. This parameter optimization reduces adhesive misting while maintaining high-speed application capability of 1000 feet per minute or greater
Solution Approach 2:
The invention creates a composite adhesive system combining multiple components: isocyanate prepolymer, polyether polyol, and optional modifiers. This composite formulation achieves both high productivity through solventless application and reduced harmful misting by leveraging the synergistic effects of the composite material composition
2Productivity
If high line speeds are used for adhesive application, then productivity increases, but adhesive droplets are released into the air causing loss of substance
Solution Approach 1:
By optimizing the viscosity parameters and molecular weight characteristics of the polyether polyol and isocyanate prepolymer components, the adhesive maintains stable transfer characteristics at high line speeds of 1000 feet per minute or greater, minimizing droplet formation and adhesive loss during the metering and application process
3Productivity
If conventional adhesives are applied at high speed, then productivity is improved, but adhesive collects on machinery requiring cleaning
Solution Approach 1:
The patent optimizes the chemical composition parameters including polyol molecular weight, hydroxyl value, and isocyanate index to reduce adhesive misting and droplet formation during high-speed application. This parameter control minimizes adhesive accumulation on machinery surfaces, reducing the frequency of cleaning and maintenance operations
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 adhesive system significantly minimizes misting, enhancing operational efficiency and safety by maintaining adhesive integrity at high line speeds, thereby reducing costs and health risks associated with aerosol droplets.
Implementation Method 1
Component A comprises an isocyanate-functionalized compound and Component B comprises at least one high functionality polyol containing at least four hydroxyl groups per molecule
Data Source
AI summary
The tendency of a two component laminating adhesive based on polyurethane chemistry to form a mist of fine droplets when applied at a high line speed may be reduced by including both a high functionality polyol and a lower functionality polymeric polyol in Component B which is combined and reacted with an isocyanate-functionalized polyurethane prepolymer in Component A.