Thermoplastic Elastomer Adhesion to Hard Resins
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Solution Overview
Problem
Conventional thermoplastic elastomer compositions fail to achieve a balance between flexibility, heat adhesiveness, and moldability when laminated with hard resins like polycarbonate or ABS, often requiring adhesives and resulting in inferior adhesion and increased complexity, while existing solutions do not adequately address hydrolysis and tensile strength issues.
Innovation Solution
A thermoplastic elastomer composition comprising a hydrogenated styrene-block copolymer, an acrylic block copolymer with distinct polymer blocks, and a block copolymer containing a hydrophilic group, which are combined to create a composite resin that adheres to hard thermoplastic resins without adhesives, enhancing flexibility, rubber elasticity, water resistance, and moldability, and improving tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If styrene-based elastomer or olefin-based elastomer is laminated on hard resin molded article, then flexibility is improved, but heat adhesiveness to hard resins like polycarbonate or ABS deteriorates
Solution Approach 1:
The patent uses a composite elastomer system combining styrene-based block copolymer (provides flexibility) with polar thermoplastic elastomer (provides heat adhesiveness to hard resins). This composite approach allows simultaneous achievement of flexibility and heat adhesiveness without requiring adhesives or complex surface treatments.
Solution Approach 2:
The patent modifies the chemical composition parameters of the elastomer by incorporating polar groups (carboxyl, hydroxyl, or amine groups) into the block copolymer structure. This parameter change enables direct heat adhesion to hard resins like polycarbonate and ABS while maintaining the flexibility characteristics of styrene-based elastomers.
2Strength
If polar thermoplastic elastomer such as polyamide-based, polyurethane-based, or polyester-based elastomer is laminated on hard resin molded article, then heat adhesiveness is improved, but balance of flexibility and moldability deteriorates
Solution Approach 1:
The patent creates a composite system where polar thermoplastic elastomer (providing heat adhesiveness) is combined with styrene-based block copolymer (providing flexibility and moldability). The specific composition ratio and structural design enable all three properties—heat adhesiveness, flexibility, and moldability—to be well-balanced, overcoming the limitations of using polar elastomers alone.
3Strength
If polyamide-based elastomer, polyurethane-based elastomer, or polyester-based elastomer is added to styrene-based elastomer, then heat adhesiveness is improved, but hydrolysis resistance deteriorates
Solution Approach 1:
The patent changes the chemical structure parameters by using hydrogenated block copolymers with polar groups instead of conventional polyamide, polyurethane, or polyester elastomers. This structural modification provides heat adhesiveness to hard resins while improving hydrolysis resistance through the hydrogenated saturated structure that is less susceptible to hydrolytic degradation.
4Ease of manufacture
If conventional elastomer composition is used, then manufacturing process is simple, but adhesion to hard resin requires adhesive agents or mechanical joining, increasing device complexity
Solution Approach 1:
The patent enables the elastomer to self-adhere to hard resin surfaces through its inherent polar functional groups (carboxyl, hydroxyl, or amine groups) that form strong interactions with the hard resin. This self-adhesion capability eliminates the need for separate adhesive agents, primers, or mechanical joining methods, thereby maintaining manufacturing simplicity while reducing structural complexity.
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 composition provides excellent adhesion to hard thermoplastic resins, superior water resistance, and balanced mechanical properties, including high tensile strength, without the need for adhesives, making it suitable for various applications.
Implementation Method 1
a styrene-based block copolymer having a number average molecular weight of 70000 or more which is formed by a hydrogenation of a block copolymer having at least two terminal polymer blocks (A1) comprising vinyl aromatic compound units, and at least one intermediate polymer block (A2) comprising a conjugated diene compound unit
Data Source
AI summary
[PROBLEMS] To provide a thermoplastic elastomer composition which can tightly adhere to a resin having a polar group without the need of using any adhesive and is excellent in water resistance, rubber properties and moldability, or to provide a composite molded article manufactured from the composition. [MEANS FOR SOLVING PROBLEMS] A thermoplastic elastomer composition comprising: (a) 100 parts by mass of a styrene block copolymer constituted by a [vinyl aromatic polymer block (A1)]-[hydrogenated conjugated diene polymer block (A2)]-[vinyl aromatic polymer block (A1)]; (b) 2 to 1000 parts by mass of an acrylic block copolymer having a methacrylic acid ester polymer block (B3) and an acrylic acid ester polymer block (B1) ; and (c) 2 to 200 parts by mass of a block copolymer containing a hydrophilic group; and a composite resin molded article manufactured by compositing the thermoplastic elastomer composition with a thermoplastic resin.