Modified Starch Adhesive for Corrugated Board Bonding

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Solution Overview

Problem

Conventional starch-based corrugating adhesives often require high levels of chemical additives, such as boron-containing compounds and ketone-aldehyde resins, to achieve desired tack and wet bond strength, which are regulated in discharge water, necessitating the development of adhesives with fewer or no additives while maintaining performance.

Innovation Solution

The use of starch-based adhesives with modified starches, such as oxidized or crosslinked pea starch, which have high amylose content and are formulated to provide strong adhesive bonds with reduced chemical additives, utilizing a combination of granular and gelatinized starch components and caustic agents to achieve the necessary viscosity and bonding properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional starch-based corrugating adhesives use high levels of chemical additives (boron-containing compounds and ketone-aldehyde resins) to achieve desired tack and wet bond strength, then adhesive performance is improved, but discharge water regulation compliance deteriorates

Engineering Contradiction:

Improvetack and wet bond strengthVSAvoiddischarge water regulation compliance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the adhesive by using modified starches (oxidized or crosslinked) with high amylose content (30-40%) instead of conventional starches requiring high levels of boron and ketone-aldehyde additives. This parameter substitution maintains adhesive performance while reducing harmful chemical discharge

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite adhesive system combining modified high-amylose starch with specific additives (borax at 0.1-5% and wet strength resin at 0.1-5%) to achieve the desired performance profile with reduced overall chemical content compared to conventional formulations

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If starch-based adhesives are formulated with modified starches and reduced chemical additives, then environmental compliance is improved, but adhesive tack and bonding performance may deteriorate

Engineering Contradiction:

Improvechemical additive reductionVSAvoidtack and wet bond strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent optimizes the amylose content parameter to 30-40% (higher than conventional starches) and applies modification treatments (oxidation or crosslinking) to enhance the intrinsic adhesive properties of the starch, allowing reduced chemical additive levels while maintaining performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention applies specific modifications (oxidation or crosslinking) to the starch molecules to enhance their adhesive properties locally at the molecular level, creating stronger bonding capability with fewer additives

Inventive Principle:

Principle #3Local quality

3Productivity

If corrugating adhesives use high solids content, then productivity is improved through faster production rates, but flowability and application performance may deteriorate

Engineering Contradiction:

Improveproduction rateVSAvoidflowability

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent optimizes the solids content parameter to 20-40% (higher than conventional adhesives) while adjusting the rheological properties through modified starch usage and additive selection to maintain adequate flowability for application

Inventive Principle:

Principle #35Parameter changes

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

These adhesives demonstrate improved wet and dry bond strength with reduced chemical usage, allowing for faster production rates and enhanced water resistance, achieving equivalent or superior performance to traditional adhesives without the need for additional wet strength resins.

Implementation Method 1

starch-based adhesives with modified starches, such as oxidized or crosslinked pea starch, which have high amylose content and are formulated to provide strong adhesive bonds

Methodology Applied

Scientific EffectGelatinization:

Implementation Method 2

gel rapidly to form a strong adhesive bond between substrates

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

utilizing a combination of granular and gelatinized starch components and caustic agents to achieve the necessary viscosity and bonding properties

Methodology Applied

Scientific EffectViscosity modification:

Data Source

PatentUS20220135854A1Improved corrugating adhesives

Publication Date: 2022.05.05 CORN PRODUCTS DEVELOPMENT INC

AI summary

Disclosed herein is a starch based corrugating adhesive comprising modified starch, and methods for making such corrugating adhesive. In some embodiments, the corrugating adhesive may contain a carrier component comprising a gelatinized modified starch, and a suspended component comprising a granular modified starch. In some embodiments, the granular and gelatinized modified starch may be from the same base starch. In some embodiments, the modified starch is obtained from a starch having an amylose content between about 30% and less than 40%. Also disclosed herein are corrugated materials made using the corrugating adhesives described herein.