Solvent-Less Laminate Bonding with Separated Isocyanate Components
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Solution Overview
Problem
Existing laminate production processes using solvent-based adhesives require an additional drying step, which increases equipment and processing costs, and solvent-less adhesives with isocyanate components suffer from short pot life and slow curing.
Innovation Solution
A process involving the uniform application of an isocyanate component and an isocyanate-reactive component to separate substrates, followed by their combination to form an adhesive composition, which is then cured to bond the substrates, using a two-component solvent-less adhesive composition with an Isocyanate:Isocyanate-Reactive Stoichiometric Ratio from 1.0 to 5.0.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based adhesives are used to form laminates, then adhesion between substrates is achieved, but an additional drying step is required which increases equipment and processing costs
Solution Approach 1:
The patent extracts and removes the solvent component from the adhesive system, transitioning from solvent-based adhesives to solvent-less adhesives. This elimination of the solvent phase removes the need for drying equipment and processing steps, directly resolving the contradiction between manufacturing simplicity and equipment complexity
Solution Approach 2:
The patent changes the fundamental parameter of solvent content in the adhesive from present (solvent-based) to absent (solvent-less). This parameter change fundamentally alters the processing requirements, eliminating the drying step and associated equipment while maintaining adhesion functionality
2Strength
If pre-mixed solvent-less adhesive containing isocyanate component and isocyanate-reactive component is used, then adhesion between substrates is achieved, but pot life is short
Solution Approach 1:
The patent segments the adhesive system into separate isocyanate component and isocyanate-reactive component containers, preventing premature mixing. This segmentation allows each component to remain stable and usable for extended periods individually, while only mixing occurs at the point of application, thereby extending pot life while maintaining bond strength
Solution Approach 2:
The patent performs preliminary preparation by separately formulating and storing the isocyanate component and isocyanate-reactive component before use. This preliminary action allows the components to be optimized for stability and storage, while the actual mixing and bonding reaction occurs only when needed, extending the usable duration
3Strength
If pre-mixed solvent-less adhesive is used to provide sufficient adhesion, then bonding between substrates is achieved, but curing speed is slow
Solution Approach 1:
The patent introduces dynamic control over the mixing and curing process by keeping components separate until application. The mixing ratio and timing can be dynamically adjusted based on specific application requirements, allowing optimization of both bond strength and curing speed for different substrate and processing conditions
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
This process eliminates the need for a drying step, provides longer pot life, faster bonding, and faster curing compared to existing methods, while maintaining strong adhesive bonds.
Implementation Method 1
mixing and reacting the isocyanate component and the isocyanate-reactive component to form an adhesive composition between the first substrate and the second substrate
Implementation Method 2
curing the adhesive composition to bond the first substrate and the second substrate
Data Source
AI summary
The present disclosure provides a process for forming a laminate. The process includes (A) uniformly applying an isocyanate component to a first substrate, the isocyanate component containing an isocyanate compound; (B) uniformly applying an isocyanate-reactive component to a second substrate, the isocyanate-reactive component containing an amine-terminated compound; (C) bringing the first substrate and the second substrate together, thereby mixing and reacting the isocyanate component and the isocyanate-reactive component to form an adhesive composition between the first substrate and the second substrate; (D) curing the adhesive composition to bond the first substrate and the second substrate; and (E) forming the laminate.