Extrudable Adhesive Formulations Using Olefin Block Copolymers

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Solution Overview

Problem

Conventional flexible packaging technologies, such as protective wraps and resealable films, rely on costly solvent-based methods and complex processes, necessitating the development of new adhesive compositions that can be extruded onto substrates without solvents, with good adhesion and rheological properties for extrusion processing.

Innovation Solution

A composition comprising an ethylene/α-olefin block copolymer and a tackifier, with specific melt index and 110/12 ratio ranges, and optionally including an oil, to provide excellent adhesion and processability, eliminating the need for solvents and enabling cost-effective, simple manufacturing of flexible packaging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solvent-based technologies are used for protective wraps, then adhesion performance is improved, but manufacturing cost increases and environmental waste increases

Engineering Contradiction:

Improveadhesion performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts and eliminates the solvent component from conventional adhesive formulations, developing a 100% solid adhesive composition that achieves effective adhesion without requiring solvent carriers. This extraction of the harmful solvent element resolves the contradiction by maintaining adhesion performance while eliminating the associated costs and environmental waste of solvent-based systems

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the physical state parameters of the adhesive from a solvent-based liquid system to a 100% solid composition with specific melt index (1-50 g/10 min) and 110/12 ratio (7.5 to 13) characteristics. This parameter transformation enables the adhesive to be processed via extrusion while achieving effective adhesion without solvents, thereby reducing manufacturing cost and environmental impact

Inventive Principle:

Principle #35Parameter changes

2Reliability

If solvent-based technologies are used for protective wraps, then adhesion performance is improved, but environmental waste increases

Engineering Contradiction:

Improveadhesion performanceVSAvoidenvironmental waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the potential disadvantage of being a 100% solid adhesive (which might be expected to have poor processability and adhesion) into a benefit by demonstrating that the specific composition with controlled melt index and 110/12 ratio achieves effective adhesion while eliminating solvent-related environmental harm

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If complex multi-step processes are used for cohesive fasteners and resealable films, then adhesion performance is improved, but device complexity increases

Engineering Contradiction:

Improveadhesion performanceVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the adhesive formulation and extrusion processing into a single integrated system. The 100% solid adhesive composition is designed with specific rheological properties (melt index 1-50 g/10 min, 110/12 ratio 7.5 to 13) that enable direct extrusion onto substrates, eliminating the need for separate solvent application, drying, and curing steps required by conventional processes

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent enables continuous extrusion processing of the adhesive composition without interruption for solvent evaporation or additional processing steps. The controlled rheology of the 100% solid composition allows it to be extruded continuously and achieve effective adhesion in a single continuous operation, thereby simplifying the process while maintaining performance

Inventive Principle:

Principle #20Continuity of useful action

4Ease of operation

If conventional adhesive compositions are used for extrusion, then ease of extrusion is improved, but adhesion performance worsens

Engineering Contradiction:

Improveextrusion processabilityVSAvoidadhesion performance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP2986672B1Extrudable adhesive formulations containing olefin block copolymers

Publication Date: 2023.01.04 ROHM & HAAS CO

AI summary

The invention provides a composition comprising the following components: A) an ethylene/alpha-olefin block copolymer; B) a tackifier; and wherein the composition has a melt index (I2) from 1 to 50 g/10 min and an I10/I2 ratio from 7.5 to 13.