Solvent-Free Lamination Adhesive for Printed Packaging Bonding
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Solution Overview
Problem
Existing two-component solvent-based adhesive compositions for laminating applications require separate storage, result in dosing errors, increase raw material costs, and pose handling and disposal challenges, while solvent-free one-component compositions are not suitable for printed laminates.
Innovation Solution
A solvent-free one-component adhesive composition comprising isocyanate moieties, specifically a reaction product of polyisocyanate with polyether polyol, is used for laminating applications, allowing for direct application without mixing and reducing waste, with a molar ratio of 2:1 or less, suitable for corona-treated substrates without grafting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If two-component solvent-based adhesive composition is used, then adhesion and bond strength are achieved, but separate storage facilities are required and dosing errors occur
Solution Approach 1:
The patent combines two separate adhesive components into a single-component system by incorporating the curing agent directly into the adhesive formulation. This eliminates the need for separate storage facilities and mixing equipment, reducing device complexity while maintaining bond strength through controlled curing via atmospheric moisture.
Solution Approach 2:
The patent segments the curing mechanism from the adhesive application process by designing a composition that cures upon exposure to atmospheric moisture rather than requiring immediate mixing of two components. This allows the adhesive to be stored and applied as a single stable component that activates only when needed.
2Strength
If two-component adhesive composition is used, then adhesion is achieved, but raw material costs and handling complexity increase
Solution Approach 1:
The patent merges the adhesive and curing agent into a single composition, eliminating the need for separate component storage, handling, and mixing operations. This simplifies the manufacturing process and reduces raw material costs by eliminating the overhead of managing two separate components while maintaining adhesion performance.
Solution Approach 2:
The adhesive composition is designed to self-cure upon exposure to atmospheric moisture, eliminating the need for external mixing or additional curing agents. This self-service capability simplifies manufacturing operations and reduces handling complexity while ensuring consistent adhesion performance.
3Ease of operation
If solvent-based adhesive is used, then application properties are achieved, but environmental impact and safety hazards increase
Solution Approach 1:
The patent changes the solvent parameter from organic solvents to water as the continuous phase, creating a water-based adhesive composition. This fundamental parameter change eliminates volatile organic compound emissions and associated environmental hazards while maintaining application properties through careful formulation of the water-based system.
Solution Approach 2:
The patent creates a safer, more environmentally friendly working environment by replacing flammable organic solvents with water, which is non-flammable and has no harmful vapors. This substitution maintains application properties while eliminating fire hazards and toxic emissions.
4Device complexity
If one-component adhesive composition is used, then storage and handling are simplified, but suitability for printed laminates is insufficient
Solution Approach 1:
The patent creates a composite water-based adhesive composition that combines the simplicity of one-component storage with the reliability needed for printed laminates. The formulation integrates multiple functional components (adhesive polymers, curing agents, and additives) into a single stable aqueous system that provides reliable adhesion to printed surfaces while maintaining ease of storage and handling.
Solution Approach 2:
The patent modifies the chemical composition parameters to create a water-based system that cures effectively on printed substrates. By adjusting the pH, molecular weight distribution, and functional group content of the adhesive polymers, the composition achieves both one-component storage simplicity and reliable adhesion to printed laminates.
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 solution provides higher bond strength, faster curing, and lower dry coating weight, reducing costs and environmental impact, while ensuring robust application properties and improved recyclability.
Implementation Method 1
The adhesive composition is applied in an uncured state onto a substrate and is then allowed to cure, for example by exposure to atmospheric moisture
Implementation Method 2
The substrate is corona-treated but not grafted with any polar component
Data Source
Figure 1
AI summary
The present invention is related to a laminate (1) for packaging applications, comprising a first substrate layer (2) and an adhesive layer (5) present on a surface of said first substrate layer (2), and a second substrate layer (2') on which at least one ink layer (4) is provided, characterized in that said adhesive layer (5) is made from a solvent-free one-component adhesive composition comprising isocyanate moieties as functional groups. The present invention is furthermore related to laminate comprising an adhesive layer (5) made from a one-component adhesive composition.