Rosin Dispersion Continuous Process Tack and Shear
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Solution Overview
Problem
Existing rosin dispersions for pressure-sensitive adhesives lack improved loop tack and shear resistance performance, and current methods for producing rosin dispersions are batch-based rather than continuous.
Innovation Solution
A rosin dispersion is created using a continuous process that involves merging streams of molten rosin resin and water with added olefin (meth)acrylic acid copolymers as dispersants, processed through methods like modification, hydrogenation, or polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batch process with specially selected dispersants is used, then rosin dispersion can be produced, but loop tack and shear resistance performance are insufficient
Solution Approach 1:
The patent changes the chemical structure parameters of the dispersant by selecting copolymers with specific functional groups (carboxyl, hydroxyl, amine) and molecular weights. This parameter optimization enables the dispersant to effectively compatibilize the rosin resin with the acrylic polymer emulsion, achieving improved loop tack and shear resistance while maintaining ease of manufacture.
Solution Approach 2:
The patent uses composite dispersant systems comprising copolymers of olefin with (meth)acrylic acid, combining different functional groups and molecular characteristics. This composite approach allows the dispersant to simultaneously provide steric stabilization and electrostatic repulsion, resolving the contradiction between manufacturability and adhesive performance.
2Productivity
If batch process is used for producing rosin dispersions, then production can be carried out, but productivity and efficiency are limited
Solution Approach 1:
The patent transitions from batch processing to continuous processing, where rosin resin, dispersant, and acrylic polymer emulsion are continuously fed and mixed in a reactor. This continuous operation eliminates idle time between batches, maintains steady-state conditions for optimal mixing, and enables uninterrupted production, thereby significantly improving productivity while managing device complexity through standardized continuous flow equipment.
3Reliability
If dispersant is added to improve dispersion quality, then loop tack improves, but formulation complexity increases
Solution Approach 1:
The patent optimizes the dispersant formulation by selecting copolymers with specific functional group compositions and molecular weights. The dispersant contains carboxyl, hydroxyl, and/or amine groups in controlled amounts, providing effective adhesion promotion without requiring complex multi-component systems. This parameter-optimized approach improves loop tack while keeping the formulation relatively simple.
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 resulting rosin dispersion exhibits enhanced loop tack and shear resistance, and the continuous process offers improved efficiency and scalability compared to traditional batch methods.
Implementation Method 1
The dispersant is selected olefin (meth)acrylic acid copolymers
Implementation Method 2
olefin (meth)acrylic acid copolymers as dispersants
Implementation Method 3
merging into a mechanical disperser a stream of a molten disperse phase with a stream of a molten continuous phase
Implementation Method 4
mechanical disperser
Implementation Method 5
a stream of a molten disperse phase with a stream of a molten continuous phase
Data Source
AI summary
A rosin dispersion is a reaction product of, by dry weight based on total dry weight of the rosin dispersion, from 80 % to 98 % a rosin resin, and from 2% to 20 % a dispersant. The rosin resin is processed by at least one method of a) modification, b) hydrogenation or disproportionation, and c) polymerization or esterification from raw material rosins. The dispersant is selected from C 18-C 32 aliphatic carboxylic acids, olefin (meth) acrylic acid copolymers, and other acid/anhydride modified polymers. A continuous process for preparing the rosin dispersion and an adhesive formulation comprising the rosin dispersion are also included.