Starch Adhesive with Expandable Microspheres for Thermal Insulation

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Solution Overview

Problem

Conventional adhesives used in insulating paper products do not provide insulation themselves, leading to the need for multiple layers of paper and increased material usage, which is costly and environmentally unsustainable.

Innovation Solution

A starch-based adhesive composition incorporating expandable microspheres that expands to create a foam-like material, providing insulation while maintaining sufficient adhesion, made from natural components and optimized for gelatinization and curing temperatures to balance insulation and adhesion properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional adhesives are used in insulating paper products, then adhesion between layers is achieved, but the adhesive does not provide insulation itself, requiring multiple layers of paper and increasing material usage

Engineering Contradiction:

Improveamount of paper requiredVSAvoidinsulation efficiency

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The adhesive composition is formulated to perform multiple functions simultaneously: it provides adhesion between paper layers while also providing thermal insulation through the expandable microspheres that create air pockets. This multi-functionality eliminates the need for separate insulation layers, reducing the total quantity of paper required while maintaining insulation efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The adhesive is a composite material combining starch-based adhesive agents with expandable microspheres. This composite structure allows the adhesive to exhibit both adhesive properties (from the starch component) and insulating properties (from the expanded microsphere foam structure), resolving the contradiction between adhesion and insulation functionality.

Inventive Principle:

Principle #40Composite materials

2Reliability

If multiple layers of paper are used to achieve proper insulation, then insulation performance is improved, but the amount of paper used increases, adding cost and environmental impact

Engineering Contradiction:

Improveinsulation performanceVSAvoidamount of paper used

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

By making the adhesive itself insulating through the inclusion of expandable microspheres, the system reduces the need for additional insulation layers. The adhesive layer serves dual purposes: bonding and insulating, thereby decreasing the total paper quantity while maintaining insulation performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The expandable microspheres create a porous, foam-like structure within the adhesive that traps air pockets. This porous structure provides thermal insulation comparable to or better than solid paper layers, allowing reduction in paper quantity while maintaining insulation performance.

Inventive Principle:

Principle #31Porous materials

3Quantity of substance

If the adhesive provides insulation through expanded microspheres, then material usage is reduced, but the gelatinization and curing temperatures must be balanced with expansion temperatures

Engineering Contradiction:

Improvematerial usageVSAvoidtemperature process control

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The starch-based adhesive is specifically selected and formulated to have gelatinization and curing temperatures that are coordinated with the expansion temperature of the microspheres. By adjusting and matching these thermal parameters, the process achieves microsphere expansion and adhesive curing in a coordinated manner, reducing material usage while managing process complexity through parameter optimization.

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

The adhesive composition reduces the amount of paper required for insulation, enabling thinner or single-layered products with improved insulation efficiency and environmental sustainability.

Implementation Method 1

an adhesive composition including a starch component, an alkaline component, sodium tetraborate, water, and a plurality of expandable microspheres, where the starch component is selected to permit full gelatinization of the starch component at a temperature at or greater than the temperature at which the expandable microspheres expand

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

the starch component is selected to permit full gelatinization of the starch component at a temperature at or greater than the temperature at which the expandable microspheres expand

Methodology Applied

Scientific EffectGelatinization: Phase Change

Implementation Method 3

Adhesive having insulative properties

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11649589B2Adhesive having insulative properties

Publication Date: 2023.05.16 HENKEL KGAA

AI summary

An improved adhesive composition having increased insulative properties is provided. The adhesive composition having improved insulative properties includes a starch component; an alkaline component; sodium tetraborate; water; and a plurality of expandable microspheres. Products having improved insulation capabilities and methods of making the products having improved insulation capabilities are also provided. The present adhesive and products including the adhesive is environmentally friendly.