Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
2001-02-16
2003-09-02
Wu, David W. (Department: 1713)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C053S415000, C106S443000, C106S436000, C106S447000, C106S281100, C106S264000, C106S003000
Reexamination Certificate
active
06613832
ABSTRACT:
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
This invention relates to sets of binder premixes methods of preparing adhesives and caulks from the sets of premixes, and to methods of preparing ranges of adhesives and caulks from sets of the premixes.
In co-pending U.S. patent applications Ser. Nos. 60/183,655; 60/183,656; and 60/247,639; we describe prepaints and method of making paints from these prepaints employing delayed product differentiation. The use of sets of premixed ingredients or raw materials as described in these applications may be extended to the preparation of adhesives.
Adhesive formulating involves selecting and admixing appropriate adhesive ingredients in the correct proportions to provide an adhesive with specific processing and handling properties, as well as the desired final dry adhesive film properties. The major ingredients of many adhesives are the binder, optional tackifier, and a fluid medium if the formulation is not presented neat, the fluid medium is, water if the adhesive is a water-borne adhesive, or solvent if the adhesive is a solvent-borne adhesive. Common optional ingredients include defoamers, coalescents, plasticizers, thickeners, rheology modifiers, solvents, driers, anti-skinning agents, surfactants, mildewcides, biocides, crosslinkers, white opacifying pigments, extender pigments, colorants, and dispersants. After the fluid adhesive is formulated and applied to a surface, the adhesive dries by evaporation of the water and/or the solvent, with or without the application of heat or radiation, and the binder forms a film containing therein the pigment and the extender particles, if any.
Formulating adhesives is complex—it is not simply a matter of mixing a few ingredients in different ratios. Rather, it involves the selection and mixing of different ingredients in different ratios depending on the type of adhesive desired. This requires manufacturers to store many different ingredients and change ingredients during manufacture depending on the specific adhesive type being prepared.
Furthermore, it requires those involved in the supply chain, and in particular, adhesive retailers, to carry a large inventory of adhesives in order to offer a range of adhesives, such as various peel levels, viscosity levels, adhesion levels, removability levels and repositionability levels.
From the perspective of number of ingredients required, formulating an adhesive is less complex than formulating an architectural paint. However, the processing and end-use applications of an adhesive may involve a broader range of conditions than are typically experienced during the application of an architectural paint. For example, an adhesive may be applied at varying shear rates depending on the processing equipment used (for example, extrusion, gravure and mayer rod type applicators, roller and die coating, and the like) and used over a broad range of temperatures (for example, from less than 0° C. in low-temperature or all-temperature applications to greater than 40° C. in some packaging applications).
Therefore, it would be desirable to make adhesives, either at a relatively large-scale industrial plant or at a relatively smaller-scale, point-of-application, point-of-sale, or point-of-use location using a limited number of ingredients, to prepare all of these different adhesives, thus, minimizing the number and type of ingredients required to make a range of adhesives. Thus, it would be useful to have a system that would permit the manufacturer, seller, or user to adjust the adhesive at the point of manufacture, sale, or application, to suit the processing and end-use conditions.
SUMMARY OF THE INVENTION
The present invention provides sets of fluid premixes binder, one or more adhesive lines, and a range of adhesives. A “fluid,” as used herein, means any material that flows, including liquids, flowable powders, and viscous, amorphous solids. As used herein, premixes are “mutually compatible” if the adhesives formed by admixing the premixes do not evidence signs of colloidal instability such as flocculation. Preferably, the adhesives formed from the premixes exhibit less than 5 grams of residue, such as gel and grit, per liter of adhesive when the adhesive is passed through a 325 mesh screen, more preferably less than 1 gram of residue per liter. Preferably, the premixes exhibit less than 5 grams of residue, such as gel and grit, per liter of premix when passed through a 325 mesh screen, more preferably less than 1 gram of residue per liter of premix. If the premixes and optional additives included to enhance specific adhesive properties are fully compatible, i.e., they can be blended at any ratio without inducing colloidal instability, then they can be blended in any combination falling within the formulation space needed to achieve the desired property profile in the final adhesive. It is sufficient, however, if the premixes and optional additives can be blended at desired ratios without inducing colloidal instability to achieve the desired property profile in the range of adhesives. As used herein, “adhesive” is used in a broad sense to include all types of adhesives including neat, water-borne, and solvent-borne adhesives, including pressure sensitive adhesive and non-pressure sensitive adhesives. Pressure sensitive adhesives (“PSAs”) that may be made by the method of the invention include any conventional PSAs including, without limitation, hot melt adhesives, solvent-based rubber adhesives, styrene-butadiene rubber emulsion adhesives, and acrylic adhesives. Such PSAs are employed in a number of applications, for example in tape and label applications. This definition of “adhesives” is intended to include products conventionally known as sealants, joint cements, plasters, pastes, ceramic tile adhesives, caulks, and like building adhesives.
An “adhesive line”, as used herein, includes at least two different adhesives which offer properties which differ materially from each other in at least one observable property, such as adhesion to certain substrates, viscosity, removability, and repositionability. Adhesive manufacturers and retailers typically offer a range of adhesives, the range including at least two adhesive lines. By “the range including at least two adhesive lines,” as used herein, is meant that the discrete elected levels of the observable property defining a first adhesive line are combined with the discrete elected levels of the observable property defining a second adhesive line, etc. to define the adhesives in the range of adhesives. For example, preparing a range of adhesives including five adhesive lines may require preparing adhesives encompassing two peel levels, two viscosity levels, two adhesion levels, two removability levels, two repositionability levels, and preferably all combinations thereof. Thus, 32 different adhesive formulations (2×2×2×2×2) may be needed. Also encompassed, however, is a range of adhesives in which a certain number of adhesive lines or premixes, including up to as high as 10-60% of the total number, are omitted, for example, for commercial reasons or for stability reasons.
A set of different, but mutually compatible, fluid adhesive binder premixes, sufficient to formulate at least one adhesive line, comprises (a) at least one premix comprising at least one polymeric binder having a peel of less than about 20 ounces/inch, a tack of less than about 300 grams, and a shear of greater than about 50 hours; (b) at least one premix comprising at least one polymeric binder having a peel of about 20 to about 50 ounces/inch, a tack of about 300 to about 500 grams, and a shear of about 5 to about 50 hours, and (c) at least one premix comprising at least one polymeric binder having a peel of greater than about 50 ounces/inch, a tack of greater than about 500 grams, and a shear of less than about 10 hours. Preferably, the number of premixes is from 3 to 15.
The present invention also provides an adhesive composition which comprises the set of premixes as set forth above, and optionally at least one a
Costanzo James Alexander
Friel John Michael
Hook, III John William
Lorah Dennis Paul
Washel Jerry William
Bakule Ronald D.
Hu Henry S
Rohm and Haas Company
Wu David W.
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