Tack-Free Hot Melt Adhesive Block via Granule Moulding
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Solution Overview
Problem
Hot melt adhesives (HMAs) and hot melt pressure sensitive adhesives (HMPSAs) face handling difficulties and contamination risks due to their tacky nature, and existing packaging methods are inefficient, leading to carbonization, clogging, and environmental issues.
Innovation Solution
A process involving moulding cold HMA granules into a truncated cone-shaped block and applying a tack-free coating to the surfaces, allowing for easy handling and elimination of film-based packaging, which reduces carbonization and clogging risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If HMA is cast in molten state in containers and cooled, then the material can be handled and packed, but the process requires long cooling time, additional cooling containers, and cannot be carried out as continuous in-line process
Solution Approach 1:
The HMA material is pre-cooled and solidified into granules before being fed into the extrusion process. This preliminary cooling action eliminates the need for post-extrusion cooling time, allowing continuous operation. The granules are stored in a hopper and fed continuously to the extruder, enabling uninterrupted production.
Solution Approach 2:
The process enables continuous in-line operation by pre-cooling the HMA material into granules before extrusion. The extruder continuously melts and forms the material, which is then immediately coated and solidified. This continuous flow eliminates idle cooling time between batches and allows uninterrupted production.
2Ease of operation
If HMA is cast in molten state in containers, then the material can be handled, but disposable containers are required creating waste and environmental problems
Solution Approach 1:
The process extracts the HMA material from the need for disposable containers by forming it into granules that can be continuously fed through an extrusion process. The material is processed in a controlled environment without requiring individual containers for each batch, eliminating container waste.
Solution Approach 2:
The process eliminates the need to discard disposable containers by using a continuous extrusion method. The HMA material is recovered and reused efficiently through continuous processing, and the only waste generated is the minimal coating material applied to the final product.
3Ease of manufacture
If HMA is cast in molten state, then the material can be formed into blocks, but hot liquid handling creates high hazard potential
Solution Approach 1:
The HMA material is pre-cooled into solid granules before being fed to the extruder. This preliminary cooling action eliminates the need to handle large quantities of hot liquid during the forming process, significantly reducing safety hazards while still enabling block formation through extrusion.
Solution Approach 2:
The process replaces the mechanical handling of hot liquid with a thermal processing sequence where material is pre-cooled mechanically into granules, then melted and formed through controlled extrusion. This substitution reduces the need for direct hot liquid handling and associated safety risks.
4Ease of operation
If HMA is extruded through die orifice and sprayed with molten coating, then tack-free surface is achieved, but heat treatment is required to provide continuous film
Solution Approach 1:
The extrusion and coating operations are merged into a single continuous process. The HMA material is extruded through a die and immediately coated with solidifying agent in the same operational sequence, eliminating the need for separate heat treatment equipment while achieving continuous film formation.
Solution Approach 2:
The extrusion and coating steps are performed continuously in sequence without interruption. The material flows continuously from the die, receives continuous coating application, and solidifies immediately, eliminating idle heat treatment steps and reducing equipment complexity.
5Ease of operation
If plastic packaging film is used to envelop HMA portions, then handling is improved, but film carbonizes and blocks filters in melt pot
Solution Approach 1:
The process extracts the HMA material from the need for plastic packaging film by forming it into granules and processing it through continuous extrusion. The material is handled in a controlled processing environment without requiring protective film envelopment, eliminating the source of carbonization and clogging problems.
Solution Approach 2:
Instead of using disposable plastic film that causes environmental and operational problems, the process uses a minimal amount of coating material that solidifies immediately and does not carbonize. This replacement eliminates the harmful effects while maintaining handling efficiency.
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 process enables efficient handling and packaging of HMAs with a tack-free coating that maintains non-stick properties up to 50°C, reducing waste and environmental impact while allowing the coated material to melt faster and more efficiently.
Implementation Method 1
a coating material is applied at least partially to the top, bottom and lateral surfaces of the block of agglomerated HMA granules
Implementation Method 2
The HMA granules are compressed under mechanical pressure into the block of agglomerated HMA granules
Implementation Method 3
the coating and the HMA mass melt simultaneously, so that the coating properly mixes with the HMA material
Data Source
AI summary
The present invention relates to a process for producing a hot melt adhesive (HMA) material, preferably hot melt pressure sensitive adhesive (HMPSA) material, having a substantially tack-free coating comprising a novel moulding and spraying step, wherein said HMA material, preferably HMPSA material, can be easily handled, packed and transported for further use. In addition, the present invention relates to a corresponding device for producing a hot melt adhesive (HMA) material, preferably hot melt pressure sensitive adhesive (HMPSA) material, having a substantially tack-free coating.