DE29824879U1 - Bonding air-permeable track-shaped material - Google Patents

Abstract

Bonding two air-permeable track-shaped materials comprises applying a hot-melt adhesive between the materials and contacting, preferably under pressure, where the adhesive is applied without contact between the application device and the material as a sealed film.

Description

MAIWALD PATENT LAWYERS GMBH

Munich ■ Hamburg ■ Dusseldorf New York

Patent attorneys

Dr. Walter Maiwald (Munich) Dr. Volker Hamm (Hamburg) Dr. Stefan Michalski (Düsseldorf) Dr. Regina Neuefeind (Munich) Dipl.-Ing. Udo Preuss (Munich) Dipl.-Ing. Korbinian Kopf, M.A. (Munich) Dr. Norbert Hansen (Munich) Dipl.-Ing. Lutz Kietzmann LL.M. (Düsseldorf) Dr, Martin Huenges (Munich) Dr, Holger Glas (Munich)

Lawyer

Stephan N, Schneller (Munich)

In co-operation with:
Maiwald Inc.,

European IP Services, New York Dipl.-Ing. Korbinian Kopf, M.A. U.S. Patent Agent

Reference number Our reference

Utility model application F 8245 / WM

H.B. FULLER LICENSING & FINANCING, INC.

Munich,

8 November 2002

H.B. FULLER LICENSING & FINANCING, INC.

Willow Lake Boulevard
St. Paul, Minnesota 55110-5132, V.St.A.

Film/film laminations with hot melt adhesives

The present invention relates to laminations (laminates) produced by a non-contact slot die coating process (slot die application process).
The present invention particularly relates to laminations
produced by a process for the continuous coating of a film
enclosing substrate with a molten hot melt adhesive (adhesive) excluding hot melt pressure sensitive adhesives, where
Hot melt adhesives are hot melt adhesives with permanent surface tack that enable bonding with contact pressure, which reduces the adhesion caused by particles.

Reduces streaking and enables film-to-film laminations with non-reactive hot melt adhesives. It also enables low application weights.

It is not a problem to apply hot melt adhesives at low application weights, provided that the coating does not need to be completely closed, i.e. non-porous. In the context of this description, the term "continuous" is used to describe a completely closed, i.e. non-porous film or coating. However, if a completely closed, i.e. non-porous coating is to be produced, this can only be done using conventional coating methods if the application weight of the hot melt adhesive is significantly higher. Such high application weights are expensive.

In conventional contact application processes, the slot nozzle touches the substrate to be coated and simultaneously spreads the applied composition. Uniform and continuous coatings with low-viscosity coating compositions are produced, the slot nozzle is kept in as close contact with the substrate as possible. These processes are therefore not film-forming processes, whereby in this context, film-forming means that a freely hanging film is formed by the nozzle (short liquid curtain), which is then applied to the substrate (see also Stephan F Kistler and Peter M. Schweizer "Liquid Film Coating, Scientific principles and their technological implications" 1997 Chapman & Hall, pages 401 to 403). DE 195 46 272 Cl describes such a contact application process for hot melt adhesives.

A disadvantage of such processes is that thermoplastic compositions often contain unmelted particles in the form of impurities such as dirt and char, or in the form of a particulate ingredient such as fillers and additives. If these particles are of a corresponding size and/or the slot nozzle has a relatively small opening, the particles tend to accumulate in the application device and interfere with the deposition of the coating. The particles block the exit of the thermoplastic material and cause corresponding streaking or lines on the substrate to be coated (see

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(see also Edgar B. Gutoff and Edward D. Cohen "Coating and Drying Defects, Troubleshooting Operating Problems" John Wiley & Sons 1995, pages 134 and 135). Streaking is particularly problematic with very thin coatings, especially when optical quality is important.

In addition, direct application with a slot nozzle leads to considerable mechanical and thermal stress on the coated substrates, especially if the slot nozzle is heated during coating.

Therefore, very sensitive substrates, such as plastic films, cannot always be coated with a hot composition from a slot die in the conventional manner without damaging the substrate.

In contrast to slot die contact application processes, extrusion coating processes are also carried out without contact with the substrate. Here, a molten film is extruded and then applied to the substrate. In contrast to the conventional slot die application process, only highly viscous coating materials such as simple unmixed polymer melts can be coated here (see also Edgar B. Gutoff and Edward D. Cohen "Coating and Drying Defects, Troubleshooting Operating Problems" John Wiley & Sons 1995, pages 100). Commonly used polymers are polyethylene, polypropylene, EVA's, acidic copolymers, ionomers, polyesters, polyamides and fluoropolymers. A stable bridge between the substrate and the nozzle can only be made possible by suitable rheological properties of the coating composition (relatively high melt viscosity correlating with a low "MeIt Index", usually up to 10g/10 min). EP 0259694 discloses an extrusion lamination process of unmixed polymer melts using a "T-die". Stable films cannot be formed thereafter at melt viscosities below 1000 poise.

The nozzles commonly used for the extrusion of high-viscosity coating compositions (such as the "T-die") are, as already mentioned, not readily suitable for low-viscosity compositions. These nozzles are designed for high-viscosity coating materials and correspondingly high pressures (see also

Edgar B. Gutoff and Edward D. Cohen "Coating and Drying Defects, Troubleshooting Operating Problems" John Wiley & Sons 1995, page 148). Low viscosity coating materials such as most hot melt adhesives do not form a stable thin film when using such nozzles. This problem is addressed in US 4708629. There a special nozzle for hot melt adhesives for use in contact coating processes is disclosed.

A disadvantage of coating or laminating processes using simple unmixed, high-viscosity polymer melts is the high processing temperature, which is usually in the range of 300 ^° C and higher, and the low adhesion force of the films formed to the substrates to be coated or laminated. Surface treatments of the substrates or the extruded polymer film are necessary in most cases, especially for films and foils. Examples of this are corona treatments, flame treatments and chemical priming of the substrate or oxidation of the extruded polymer film before it is brought into contact with the substrate (see F. Shepherd in "Modern coating technology systems, for paper, film and foil" Emap Maclaren Ltd. 1995, pages 34 and 35). This makes additional process steps necessary. US 4370187 discloses the extrusion coating and laminating of paper, films and foils with polymer melts, such as polypropylene, at temperatures around 240 ⁰ C - 300 ⁰ C. The film surface of the extruded polymer melt is oxidized with ozone to promote adhesion. US 5676791 describes an extrusion coating process in which polymer melts are extruded and the film surface of the extruded melt is corona-treated with the aid of a spray electrode and a counter electrode to increase adhesion. US 3862869 discloses a lamination process for the production of polyolefin film/paper laminations in which a polyolefin melt is extruded as an adhesive between the two substrates. In order to ensure sufficient adhesion for the lamination, the paper and the polyolefin film are pretreated and the polyolefin acting as an adhesive is extruded between the two substrates at high temperatures, around 300 ⁰ C.

In contrast to extrusion coating, curtain coating is a contactless coating process for low-viscosity

Coating compositions. This is a method for coating various materials, including substrates such as non-porous materials, e.g. paper, foils and films, and porous materials such as textiles and fabrics. Typically, the substrate is passed horizontally under a free-flowing liquid curtain of a low-viscosity coating composition, which follows the force of gravity downwards and is formed from a curtain dispenser from a significant height. Excess material which flows past the substrate to be coated is collected in a collecting vessel below the substrate and fed back to the curtain dispenser. The coating material is thus fed in a large circuit. The coating weight can vary depending on the ratio of the speed at which the substrate is fed and the flow rate of the curtain. The fluid dynamics of the coating composition in the various zones, such as the film-forming zone, the curtain flow zone and the impact zone, are of great importance for uniform coating. The viscosity, the flow rate and the substrate speed are critical parameters (see also Edgar B. Gutoff and Edward D. Cohen "Coating and Drying Defects, Troubleshooting Operating Problems" John Wiley & Sons 1995, Chapter lic).

Coating with melts is rather unusual. "Cutain Coating of Web Stock with Hot Melts" Eugene R. Cox in Tappi Vo. 51, No. 7 1968 describes such a process. Here, stable films are formed with coating compositions that have a viscosity between 0.25 and 150 poise at the processing temperature. Doctor blades are used to obtain low coating weights. The coating material is fed in a large circuit. This process is not used for "inline" lamination purposes.

The disadvantage here is the limitation to a vertical guidance of the curtain and the "neck-in" problems that arise from the relatively large distance between the curtain dispenser and the substrate. Since no continuous film with sufficient cohesive force is formed between the dispenser and the substrate, the fine adjustment of the viscosity of the coating composition and the curtain flow rate required for a uniform thin coating is

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or substrate speed is critical, which allows only a small operating window (if any). In contrast to extrusion, no stable continuous film with cohesive force is formed between the dispenser and the substrate, but rather the substrate is covered with the coating composition. Furthermore, a large pumping system is required, which circulates the excess coating composition.

The present invention relates to a non-contact slot die application method, in contrast to conventional slot die application methods, extrusion coating and curtain coating, wherein a continuous film is formed by the slot die, which passes through the gap between the slot die and the substrate to be coated without support and is then applied to the substrate.

WO 96/25902 of H.B. Fuller Co. of St. Paul, MN, published August 29, 1996, teaches a coating process wherein certain thermoplastic compositions are rendered thermally flowable and dispensed from an applicator as a continuous coating without contact between the applicator and the substrate to be coated.

The present invention relates to laminations produced in specific variations of this novel coating process of non-porous materials, in particular film-film laminations.

The object of the invention is to provide laminations produced by a coating process which allows laminations to be carried out "inline" using thin films, metallized foils, heat-sensitive materials and other sensitive substrates with a reduced risk of obtaining defective or brittle products and enables low application weights.

Yet another important object of the invention is to provide film-on-film laminations which do not require the use of reactive adhesives.

These and other objects and advantages of the invention will become apparent from the following discussion.

The present invention encompasses laminations made by a process for coating a substrate with a hot melt adhesive using a non-contact coating process. The process results in a substantially continuous coating. The process is useful for a variety of adhesive and coating applications and particularly for those employing conventional slot application techniques, heat sensitive substrates, requiring low coating weights and/or using adhesives containing particles.

In one aspect, the present invention encompasses laminations made by a coating process wherein a particular hot melt adhesive that has been rendered thermally flowable is dispensed from an applicator onto a non-porous substrate without contact between the dispensing device and the substrate as a substantially continuous coating and subsequently applied to the surface of the substrate.

In another aspect, the present invention includes laminations produced by a coating process wherein a particular hot melt adhesive is dispensed from an applicator onto a substrate as a substantially continuous coating without contact between the applicator and the substrate and is subsequently applied to the surface of the substrate, the distance between the applicator and the substrate being greater than 20 mm.

In another aspect, the present invention encompasses laminations made by a coating process wherein a particular thermally flowable hot melt adhesive is provided in the form of a substantially continuous, non-porous film without contact of the film with a substrate, and the film is subsequently applied to a substrate either by means of a release coated roller in direct contact with the adhesive film, which roller presses the adhesive and the substrate together, or by means of a release coated second substrate,

which is applied to the surface of the adhesive and is not in contact with the first substrate, or is applied by means of a transfer coating process, wherein a thermally flowable hot melt adhesive is applied from an applicator, for example to a release coated roller, as a substantially continuous coating, i.e. as a non-porous film, without contact between the applicator and the roller and subsequently applied to the surface of the substrate.

In another aspect, the invention includes laminations made by a coating process wherein a particular hot melt adhesive is dispensed from an applicator without contact between the applicator and the substrate onto a first substrate as a substantially continuous coating and subsequently applied to the surface, the coating being subsequently post-heated and then brought into contact with a second substrate.

The invention further relates to laminations, especially lamination of materials such as a transparent film material to a substrate, such as film-on-film laminations, produced by a process which avoids the above-mentioned disadvantages of the prior art and enables the use of non-reactive hot melt adhesives for such film-on-film laminations.

For heat-sensitive substrates, the hot melt adhesive is preferably applied at temperatures below 160°, more preferably below about 125° C, and most preferably at less than about 110° C, in order to reduce heat-induced stresses on the substrates to be coated. Alternatively, the distance between the application device and the substrate to be coated can be increased so that the hot melt adhesive cools sufficiently before touching the heat-sensitive substrate. This is particularly advantageous for coating and mutually bonding thermally sensitive substrates.

The hot melt adhesive preferably has certain rheological properties such that the complex viscosity at application temperature at high shear rates (1,000 rad/s) is less than about 500 poise, and the complex viscosity at

low shear rates (1 rad/s) is less than about 1,000 poise. For the process according to the present invention, mixed composition hot melt adhesives are used because of their ability to independently adjust the viscoelastic properties, open time, etc. Mixed composition hot melt adhesives are also advantageous to ensure adequate adhesion to the carrier substrate or delayed tack loss of the coating after adhesion to the substrate.

The resulting coating produced by this process is useful for applications where a uniform, non-porous, substantially continuous coating is desired. Coating weights of less than 10 g/m ² can be achieved.

The coating process is particularly advantageous in terms of manufacturing as it uses fewer production steps than state-of-the-art coating processes. The productivity as well as the reduction in the application weight per area results in coatings and corresponding articles that are less expensive than those of the state-of-the-art.

Articles as described herein include articles comprising at least a first layer, wherein the first layer is a non-porous substrate, and at least a second layer, wherein the second layer is an adhesive layer, and a third layer which is a non-porous substrate prepared by the coating methods described above.

Short description of the drawings

Figures 1 to 9 illustrate some of the preferred embodiments of the process of the present invention wherein a substantially continuous adhesive coating is formed and adhered to a substrate.

In more detail, Figure IA shows the basic structure of a coating and laminating machine which can be used to carry out the invention;

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Figures IB and IC show the basic structure of similar machines;

Figures 2 to 4 show laminations according to the invention at different positions of the application device;

Figures 5A and B show a laminating and a transfer coating process according to the invention;

Figures 6 to 9 show laminations according to the invention, including adhesive reactivation laminations.

In the process of the present invention, a hot melt adhesive is initially provided in the form of a substantially continuous, non-porous "film" which is later brought into contact with a substrate, transfer roll or other type of support. Generally, the composition is dispensed from an applicator or dispensing device so that it leaves the device in the form of a substantially continuous film. A typical applicator is a slot die which has been used for coating in direct contact with substrates. Therefore, the already known applicators for hot melt adhesives can be used according to the process of the present invention by lifting the slot die off the substrate and adjusting it to be an appropriate distance from the substrate.

As the liquid molten adhesive exits the applicator, it does not contact the substrate, but travels a certain distance as a continuous film suspended between the applicator and the substrate. The applicator may initially be brought into contact with the substrate to anchor or adhere the adhesive to the substrate, provided that the substrate is not thermally or mechanically damaged by contact with the applicator. Alternatively, the adhesive exits the nozzle as a substantially continuous film and falls until it contacts the substrate. The foremost

Edge of the advancing substantially continuous film of adhesive adheres or anchors itself to the substrate upon contact with the substrate. In the case of heat sensitive materials it is advantageous to advance the substrate by means of drive rollers prior to contact of the adhesive with the substrate in order to avoid accumulation of molten material which would melt through the substrate. Machinery suitable for carrying out the methods of the invention is shown schematically in Figures 1A, IB and 1C. Figures 1A and 1B show an embodiment in which an adhesive is dispensed from an applicator (3) onto a first substrate (1) and a second substrate (4) is then placed on the free surface of the applied adhesive by means of a nip roll (5). It is to be understood that this arrangement may be modified in other embodiments, in particular in that the second substrate 4 need not be used in all cases. Then the nip roll (5) can be used to press the adhesive directly onto the first substrate. For such designs, the squeezing roller (5) should be release coated (separation coated); for example, it can be a steel roller with a polytetrafluoroethylene surface coating.

In somewhat greater detail, Figure 1A and Figure IB show the substrate 1 (1) passing over a series of idler rollers (2) to ensure that the web is properly aligned before it approaches the applicator (3). The substrate 2 (4) is optionally adhered to the coating surface by means of a nip roller (5). The substrate 1 is defined as the first substrate to be contacted with the substantially continuous film of adhesive. The substrate 1 may be a substrate generally supplied in roll form, such as paper, including release coated paper, and may comprise a wide variety of films, foils and other materials. The embodiment of Figure 1B is particularly suitable when the substrate 1 is non-porous, meaning that air cannot easily escape through the substrate. In the case of film lamination, the substrate 1 is typically a film. The substrate 2 may also be supplied in roll form and may be made of a different material from substrate 1. The substrate 2 may be a release coated sheet material that can be peeled away from the adhesive coating.

Figure 1C shows an embodiment in which the adhesive film is first pressed onto the first substrate (1) by the squeezing roller (5), which is part of a squeezing device as shown later by the rollers A and B in Figures 2 to 9.

In a laminating device formed by rollers C and D, a second substrate (4) is then placed on the free surface which is not in contact with the first substrate (1).

Figures 2 through 9 illustrate various preferred embodiments of the present invention wherein an extruded hot melt adhesive is applied to a first substrate and then laminated to a second substrate. In each of these illustrations, substrate 2 is to be considered optional in that the invention in its broadest sense is simply a single continuous, non-porous film formed in a non-contact application process and applied to a single substrate. In the absence of the second substrate, Figure 5B illustrates a transfer coating application as the molten composition is first applied to a release coated roll which is then brought into contact with a first substrate at the nip.

In embodiments where the hot melt adhesive is contacted with a first substrate in the absence of a second substrate, as shown in Figures 5 to 9, or in the case where the second substrate is porous, it is important to provide a release coating such as silicone, Teflon or release paper on the rollers which come into contact with the adhesive or the porous substrate to prevent adhesion of the adhesive to the roller. The nip roller pushes out the air from between the adhesive coating film and the substrate to ensure that no air is trapped between the first substrate and the adhesive. Roller A may be a steel cylinder to promote heat transfer, whereas roller B, usually the nip roller, is made of rubber. In some cases it may be more preferred that roller A is made of rubber, whereas roller B is a steel cylinder with an outer release coating.

Figures 3 to 9 illustrate that the position of the nozzle with respect to the position

of the substrate can be changed from vertical to parallel positions.

Figures 6 to 9 show a second substrate laminated to the first substrate at a location remote from the applicator. In this embodiment, it is preferred that roller C be heated to reactivate or extend the open time of the hot melt adhesive prior to lamination to the second substrate. The temperature of roller C may vary between about 30 to 100°C for lamination between rollers C and D. Alternatively, roller C may be a chill roller to accelerate the rate of curing of the hot melt adhesive. The substrate laminated in the nip of the rollers may be either in web form or in the form of sheets.

The applicator is mounted at a distance of at least 0.5 mm, preferably at least 2 mm from the substrate (or the release coated roller in the case of transfer coating in the absence of a second substrate - Figure 5B). The maximum distance at which the applicator can be mounted from the substrate is limited solely by practical requirements, particularly when the applicator is positioned in a substantially vertical manner. The distance is preferably less than about 5 m, preferably less than about 3 m, more preferably less than about 1 m, even more preferably less than about 500 mm, and most preferably between about 2 to 20 mm, depending on the properties of the hot melt adhesive to be applied. Typically, it is advantageous to shield the area between the applicator and the substrate from air contaminants and air currents during coating to prevent distortion of the coating before contact with the substrate. This is particularly the case when the distance between the applicator and the substrate is greater than about 500 mm.

The distance is largely dictated by the viscosity and open time of the hot melt adhesive being applied. In the case of barrier films being produced in this way, it is assumed that the hot melt adhesive will cool sufficiently in the suspended state so that it has developed such a viscosity and cohesive force that any threads or fibers on the surface of the substrate will not break this coating.

cannot penetrate, but the hot melt adhesive is still molten enough to adequately adhere to the substrate. The greater the distance between the applicator and the nip roll, the more the hot melt adhesive will cool before contacting the first substrate. For some adhesive compositions, this cooling will adversely affect adhesion (or anchoring) to the substrate. Therefore, the substrate may be passed over a heated roll prior to nip, or a heated nip roll may be used if the distance between the nip roll and the applicator causes the coating or adhesive to cool to such an extent that adequate adhesion or anchoring to the substrate is no longer assured.

The coating may contact the substrate at any angle (see, for example, Figures 3 and 4). However, in some applications, such as barrier films, it has been found particularly advantageous for the coating to ultimately contact the substrate in a substantially horizontal direction, as in Figures 1A, 1B, 2, 6 and 8. To facilitate this, a roller may be provided in the direction of travel of the substrate to give the substrate a substantially vertical, upward direction as the substrate passes the applicator. In addition, the applicator, such as a slot die, may be arranged substantially horizontally adjacent to the roller so that the coating moves from the side toward the surface of the substrate.

The diameter of the applicator roll is preferably about 15 mm to about 50 mm, with the nozzle located slightly above the center of the applicator roll so that the angle at which the hot melt adhesive contacts the substrate is less than about 60° as the substrate moves away from the nozzle. The applicator head will be adjusted by a professional to optimize the even flow and distribution of the hot melt adhesive across the entire width of the application.

Afterwards, the sufficiently cooled coating comes into contact with the surface of the substrate and adheres to the surface without penetrating deeply into the substrate.

The coating is carried out "inline" immediately before further processing. An example of a series process for which the invention is particularly well suited can be found in DE 195 46 272 Cl of Billhöfer Maschinenfabrik GmbH, which is hereby incorporated into the disclosure. The surface of the coating layer facing away from the substrate can be sufficiently tacky so that it can be used as a construction adhesive or for lamination to other substrates, and therefore it can also serve to bond the coated substrate to another substrate layer. Substrates that can be simultaneously bonded or laminated in this way include absorbers, superabsorbent polymer, elastomer strands or webs, fabrics, films, foils, paper, cardboard, metal, as well as various permeable wrapping paper materials such as nonwovens or perforated films. These materials can be in the form of rolls, sheets or parts.

Typical such film materials having a thickness of about 5 μm to about 50 μm include smooth or embossed films made at least substantially of polyethylene or polyesters such as Mylar®, polyacetate, nylon, cellulose acetate, etc. Composite materials are commonly made including film-on-film composites; metallized substrates are also commonly used for laminates. These types of laminates are commonly found in such industries as the graphic arts and packaging industries. Using the process of the present invention, such laminates can be made with non-reactive hot melt adhesives instead of the reactive adhesives commonly used.

Generally, the exit temperature of the hot melt adhesive will be less than about 240°C, and therefore much lower than typical polymer extrusion temperatures which are on the order of about 300°C. Although the temperature of the hot melt adhesive as it exits the applicator may be between about 80°C and about 180°C or more, the non-contact coating system of the present invention allows coating to be carried out at extremely low temperatures. For this embodiment, it is preferred that hot melt adhesive be applied at a temperature of less than 160°C, more

preferably at less than about 140°C, even more preferably at less than 120°C, and most preferably at less than about 110°C. As already mentioned, heat-sensitive materials can also be coated in this way, for example by using high application temperatures in combination with increasing the distance between the applicator and the substrate to be coated, which allows sufficient cooling. Materials that are mechanically and/or thermally too sensitive for conventional coating processes (e.g. very low-thickness films) can therefore be coated using the process according to the invention. Such sensitive materials include low-thickness polyethylene materials, low basis weight nonwovens, and the like.

A significant advantage of the present invention is that substantially continuous coating layers can be made from hot melt adhesives at very low coating weights. Even with conventional, commercially available hot melt adhesives, continuous layers can be made at coating weights in the range of about 0.5 g/m ² to about 50 to 60 g/m ² , preferably less than 10 g/m ² . However, coating weights of more than 60 g/m ² may be useful for other applications where the reduction of mechanical and heat-induced stresses is of primary importance.

The very thin coatings that can be produced according to the invention not only contribute to the economic advantages of the process according to the invention, but also make it possible to achieve a very greatly reduced stiffness of the material, which therefore comes much closer in its properties to uncoated substrates.

A wide variety of thermoplastic materials can be used according to the present invention, such as various thermoplastic polymers including polyethylene, polypropylene; copolymers of olefins, especially ethylene and (methacrylic acid; copolymers of olefins, especially ethylene, and (meth)acrylic acid derivatives, especially (meth)acrylic acid esters; copolymers of olefins, especially ethylene, and vinyl compounds, especially vinyl carboxylates such as vinyl acetate; thermoplastic elastomers (or synthetic rubbers) such as styrene-isoprene-styrene, styrene-butadiene-

Styrene, styrene-ethylene/butylene-styrene and styrene-ethylene/propylene-styrene block copolymers, commercially available under the brand names Kraton®, Solpren® and Stereon®; metallocene-catalyzed polymers, in particular based on ethylene and/or propylene; polyolefins such as ethylene, polypropylene and amorphous polyolefins (atactic poly-alpha-olefins) such as Vestoplast® 703 (Hüls); polyesters, polyamides, ionomers and corresponding copolymers; and mixtures thereof. Such thermoplastic materials can be used in the coating process of the present invention mixed in the form of hot melt adhesives, which are suitable due to their ability to independently tailor their viscoelastic properties, open time, tack and various other properties. Hot melt adhesives usually have melt flow indices that are required for such processing operations even at low temperatures. Typical hot melt adhesives are fluid enough for such processing operations at temperatures ranging from about 60°C to about 175°C. In addition, a variety of known moisture-curing hot melt compositions are contemplated for use in the present invention.

With suitable hot melt adhesives, such as those described in DE-A-41 21716, it is also possible to produce materials that are impermeable to liquid water but are permeable to water vapor, giving the coating "breathing" properties. In addition to the usual known hot melt adhesives, thermoplastic compositions comprising a water-soluble, saline (body fluid) insoluble polymer, such as Eastman AQ copolyester, commercially available from Eastman, are also particularly useful for producing barrier films that are impermeable to body fluids but are highly water-soluble. This feature is of particular interest for producing flushable and compostable disposable hygiene articles. In addition, there may be applications where water permeability is desired. Accordingly, this coating process may also be suitable for coating water-soluble and/or biodegradable thermoplastic materials.

In the case of laminating adhesives for transparent substrates, thermoplastic polymers are preferred which essentially comprise one or more ethylene/methacrylate polymers

(EMA's) and/or ethylene/n-butyl acrylate copolymers (EnBA's). EnBA copolymers are currently the most preferred of these polymers.

More preferably, the hot melt adhesive has certain rheological properties, such as such that a substantially continuous coating can be produced at coating weights of less than about 10 g/m ² . Generally, the rheological properties fall within a rheological window wherein the complex viscosity is less than about 500 poise at coating temperature and high shear rates (1,000 rad/s), and less than about 1,000 poise at low shear rates (< 1 rad/s). In other words, preferred hot melt adhesives exhibit Newtonian regimes at low shear rates and shear thinning at higher shear rates. Hot melt adhesives with wide application windows are those in which the composition exhibits the appropriate rheological properties at a variety of application settings, especially at low application temperatures. Narrow application windows are those in which the rheological parameters are met only under very specific conditions.

Applicants believe that the complex viscosity and high shear are related to the processing conditions at the slotted outlet. A composition with too high a complex viscosity at 1,000 rad/s would require an unreasonably high pressure to exit the applicator. A mold with a wedge gap greater than 3 mm could be used to process these materials, but this would result in a higher coating weight.

The complex viscosity and low shear are related to the deposition of the coating on the substrate after the time it is suspended above the substrate. If the low shear value is too high, the coating may not adhere adequately to the substrate and/or the hot melt adhesives will pile up at the nozzle causing a streaky, discontinuous coating. If the low shear viscosity is too low, the coating may seep into the substrate causing poor barrier properties.

Also, extensional viscosity, which was not measured, can greatly affect melt strength. Higher levels of branching or the addition of a small concentration of high molecular weight material can greatly affect melt strength. More preferred are compositions that achieve the targeted rheological parameters at low application temperatures of less than about 177°C, preferably less than about 160°C, more preferably less than 140°C, even more preferably less than about 125°C, and most preferably less than about 110°C.

Accordingly, many known hot melt adhesive compositions are well suited for use in the coating process of this invention. Hot melt adhesives typically comprise at least one thermoplastic polymer, at least one plasticizer, and at least one tackifying resin. Preferably, such suitable hot melt adhesives comprise up to 50% by weight of a thermoplastic polymer, up to 40% by weight of a plasticizer, and up to 70% by weight of a tackifying resin, and generally wax in concentrations of up to about 30% by weight.

In general, the hot melt adhesives of the invention will additionally contain one or more tackifying resins, plasticizers, or oils and waxes as well as conventional additives and auxiliaries such as stabilizers, antioxidants, pigments, UV stabilizers or absorbers, fillers, etc. Plasticizers and tackifying resins used in hot melt adhesives are known.

Oils such as naphthenic oils are preferred plasticizers. In the case of tackifying resins, the resins already known for these purposes are generally suitable, particularly aliphatic, cycloaliphatic and/or aromatic hydrocarbon resins, ester resins and other such compatible resins. At present, the use of either aliphatic or aromatic modified hydrocarbon resins is preferred. Preferred aliphatic resins are hydrogenated aliphatic hydrocarbon resins, for example, the Escorez® 5000 series available from Exxon Chemical Co. of Houston, TX; as well as the Arkon® P and M series available from Arakawa Chemical Co. and the Regalite® series available from Hercules Inc. of Wilmington, DE.

Rosin and rosin ester resins are also useful in the present invention. One such hydrogenated resino acid adhesive resin is Foral® AX, available from Hercules. Modified hydrocarbon resins such as modified terpenes including the styrene derivatives of terpenes such as the Zonatac® series available from Arizone Chemical Co., Panama City, FL and the Kristalex® series of alphamethylstyrene resins available from Hercules, Inc. and the Uratack® series available from Arizona Chemical are also useful in the present invention. The components are mixed and processed in a conventional manner to prepare the hot melt adhesives which can be used in the present invention.

Waxes are also useful in the present invention. These include high melting point synthetic waxes such as Fischer-Tropsch waxes available from Sasol (South Africa) under the brand name Paraflint® or from Shell Malaysia under the brand name Petrolit, and high density low molecular weight polyethylene waxes available from Marcus Chemical Co. under the brand name Marcus®. AC 8 is another useful polyethylene wax available from Allied Chemical. Microcrystalline waxes and paraffin waxes are also useful in the present invention.

Laminating adhesives will preferably comprise up to 100% of at least one thermoplastic polymer as described above, plus 0 to 50% of an aliphatic hydrocarbon resin, 0 to 20% of an aromatic hydrocarbon resin, 0 to 40% rosin and 0 to 20% wax, the components and their amounts being selected so that the adhesive can be applied in-line to a laminating material and/or a laminating substrate for subsequent in-line lamination of the laminating material to the substrate.

More preferably, in the case of film lamination, the adhesive will comprise the following components: up to 100% of at least one EMA and/or EnBA copolymer, 0 to 50% hydrogenated aliphatic hydrocarbon resin, 0 to 20% alpha-methylstyrene resin, 0-40% hydrogenated rosin and 0 to 20% polyethylene wax.

The hot melt adhesive used to carry out the process according to the invention can, in the simplest case, consist essentially or even entirely of one or more

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Classes of EMA or EnBA copolymers exist. EMA and EnBA copolymers are available from Elf Atochem under the brand name Lotryl®, from Quantum Chemical Co. and from Exxon Chemical Co. under the brand name Optema®. A variety of different classes of EMA and EnBA copolymers are available. They differ mainly in ester content, melt flow index (MFI) and melting point.

In presently preferred specific embodiments, the hot melt adhesive consists essentially of 35 to 60% EnBA or EMA, 30 to 50% hydrogenated aliphatic hydrocarbon resin or about 10% alpha-methylstyrene resin, 0 to 30% hydrogenated rosin, and 0-10% polyethylene wax, plus minor amounts of stabilizer. In some preferred embodiments, the thermoplastic polymer of the hot melt adhesive is a single grade of EnBA copolymers, usually at the lower end of the MFI range (e.g., MFI less than 10 g/10 min). In other preferred embodiments, the thermoplastic polymer comprises more than one grade of EnBA, and in these cases two or three different grades, with at least two of the grades preferably having MFI's that differ by at least a factor of 4 and up to a factor of 10 (e.g., one grade has an MFI greater than 4 times that of the other grade).

The hot melt adhesives of the invention can be used at application temperatures (or processing temperatures) low enough to prevent distortion of such heat-sensitive plastic films, which at the same time exhibit excellent flow properties at such low temperatures. For example, it is possible to apply and coat the hot melt adhesive of the invention onto the materials to be laminated. Non-contact application is particularly advantageous for heat-sensitive films. Excellent film-forming properties are achieved and the coated products exhibit high gloss.

The coating adhesives of the invention provide good transparency of the hot melt coating so that high gloss is achieved while the readability and color reproduction of, for example, prints on the substrate are not impaired.

The hot melt adhesives according to the invention show excellent (high) hot tack and open time properties, as well as setting properties in the process of the present invention. They meet the requirements of machine conditions, in-line embossing and cutting, e.g. in the graphic industry.

Laminations according to the invention exhibit high heat resistance and high UV resistance and accordingly little delamination or yellowing. Even after heat forming and embossing, no delamination is observed when the hot melt formulations of this invention are used.

The following non-limiting examples further help to illustrate the present invention. The following examples illustrate the invention regardless of which type of hot melt adhesive and which substrate or substrates are used and are applicable to the materials used for the laminations of the present invention if other materials are used.

Examples

Hot melt adhesives were prepared using various thermoplastic polymers, adhesives and plasticizers as shown in Table 1 below:

Examples 1-8: Table I

Components ExI Ex2 Ex3 Ex4 Ex5 Ex6 Ex7 Ex8 Lotryl® 17 BA 07
EnBA copolymer 23 40 35 10 23 - - - Lotryl® 35 BA 40
EnBA copolymer 15 - - 20 15 20 15 15 Lotryl® 35 BA 320
EnBA copolymer 17 - - 30 17 10 16 15 Escorene®UL150-19
EVA Copylmer - - - - - 20 24 23 AC-8
Polyethylene wax 5 10 - - 5 - 5 - Paraflint® C 80
Polyethylene wax - - - - - 10 - - Mobil Wax 145
Paraffin wax - - - - - - - 5 Escorez® 5300
Hydrocarbon resin 28 38 38 38 - 23 28 30 Foral® AX
Reosinic acid resin 10 10 25 - 28 15 10 10 Kristalex® F 85
Alphamethylstyrene resin - - - - 10 - - -

Hot melt adhesives according to the compositions shown in Examples 1 and 7 were applied to substrates using a modified PAK 600 laminating machine from Kroenert, Hamburg, Germany. The design of this machine is basically similar to that shown in Figure IB. With this type of machine it is possible to press the adhesive film directly onto the first substrate (1) by means of a nip roll (5), or to press a second substrate (4) onto the first substrate and the adhesive again by means of a nip roll (5). Both methods were tried in the tests. The dispensing temperature of the hot melt adhesive was 140°C for the composition of Example 1 and 110°C for the composition of Example 7. These compositions show advantageous low viscosities as can be seen in the attached diagram Figure 5. This diagram illustrates the viscosities of Examples 1 and 7.

Coatings were prepared on polyester film (Polyester RN 36, manufactured by Pütz Folien, Taunusstein-Wehen, Germany) and high-density polyethylene films (HDPE KC 3664.00, obtained from Mildenberger + Willing, Gronau, Germany).

These films were also used as a second substrate (where used). In other experiments, silicone paper was used instead. Tests were also carried out with printed paper sheets as a second substrate.

Coating weights of 5 to 6 g/m ² at machine speeds of approximately 70 m/min were used.

The adhesive film was dispensed from the slot nozzle at various distances between the first substrate (1) to be coated and the adhesive in a variety of tests. In another series of experiments with a vertical configuration (similar to Figures 3 to 5, 7 and 9) it was found that the distance of the slot nozzle from the substrate could be varied between a few millimetres and up to 500 mm and more without materially affecting the quality of the coating.

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In these experiments, in which the adhesive film was dispensed from the slot die directly onto the first substrate by means of a nip roll (5) equipped with a release coating, it was found that the adhesive did not adhere to the nip roll. The nip pressure was not measured, but the nip roll was pressed against the substrate with a laminating pressure of 7 to 8 bar.

It was found that the adhesive applied to the first substrate exited the squeezer without air trapped between the adhesive and the first substrate.

In other tests, a second substrate was laminated to the adhesive layer using a second set of rollers placed upstream of the nip roll (5) in the direction of substrate flow. These coatings, using the same films or release coated paper as mentioned above, were also tested for streaking, entrapped air and other lamination defects.

The laminations produced in this way were all defect-free. No streaking, trapped air or any other defects were observed.

Similarly, laminations were made using the same type of films, but using the other adhesives from Examples 2 to 6 of Table 1. The results were as good as those obtained with the adhesive compositions of Examples 1 and 7.

25 a

Explanations for Figure IA

Substrate 1 (1) Substrate 2 (4) Idle rollers (2) Application device (3) Squeeze roller (5)

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Claims (32)

1. Lamination, in particular for the packaging industry, producible by a process in which a thermally flowable hot melt adhesive, excluding pressure-sensitive hot melt adhesives, is dispensed from a slot nozzle onto a first substrate comprising a polyethylene film, a polyamide film or a polyester film and is then bonded "inline" to a second substrate comprising a polyethylene film, a polyamide film or a polyester film, characterized in that the hot melt adhesive is provided as a substantially continuous, non-porous film without contact between the slot nozzle and the first substrate and is subsequently applied to the surface of the first substrate, the hot melt adhesive comprising at least one thermoplastic polymer, at least one tackifying resin, at least one plasticizer and optionally at least one wax and has a complex viscosity of less than 1000 poise at 1 radian/sec at an application temperature of less than 177°C and the coating has a basis weight of less than 10 g/m ² . 2. The lamination of claim 1, wherein the second substrate is laminated to the first substrate at a location remote from the applicator. 3. Lamination, in particular for the packaging industry, producible by a process in which a thermally flowable hot-melt adhesive, excluding pressure-sensitive hot-melt adhesives, is dispensed from a slot nozzle between a first and a second substrate, both independently of one another comprising a polyethylene film, a polyamide film or a polyester film, and bonds the two substrates together, characterized in that the hot-melt adhesive is provided as a substantially continuous, non-porous film without contact between the slot nozzle and the two substrates and is introduced between the two substrates, the hot-melt adhesive comprising at least one thermoplastic polymer, at least one tackifying resin, at least one plasticizer and optionally at least one wax and has a complex viscosity of less than 1000 poise at 1 radian/sec at an application temperature of less than 177°C and the adhesive layer has a basis weight of less than 10 g/m ² . 4. Lamination according to claims 1 to 3, wherein the hot melt adhesive is transfer coated onto the first substrate. 5. Lamination according to claims 1, 2 and 4, wherein the adhesive is post-heated and then brought into contact with the second substrate. 6. Lamination according to one of claims 1 to 5, wherein the adhesive has a complex viscosity of less than 1000 poise at 1 radian/sec at an application temperature of less than 160°C 7. A lamination according to any one of claims 1 to 6, wherein the adhesive has a complex viscosity of less than 1000 poise at 1 radian/sec at an application temperature of less than 140°C, preferably less than 125°C, and most preferably less than 110°C. 8. A lamination according to any one of claims 1 to 7, wherein the adhesive has a complex viscosity of less than 500 poise at 1000 radians/sec at an application temperature of less than 177°C. 9. A lamination according to any one of claims 1 to 8, wherein the adhesive has a complex viscosity of less than 500 poise at 1000 radians/sec at an application temperature of less than 160°C. 10. A lamination according to any one of claims 1 to 9, wherein the adhesive has a complex viscosity of less than 500 poise at 1000 radians/sec at an application temperature of less than 140°C, preferably less than 125°C, and most preferably less than 110°C. 11. Lamination according to one of claims 1 to 10, wherein the adhesive is dispensed from a slot nozzle at less than 240°C. 12. Lamination according to one of claims 1 to 11, wherein the adhesive is dispensed from a slot nozzle at less than 160°C. 13. Lamination according to one of claims 1 to 12, wherein the adhesive is dispensed from a slot nozzle at less than 110°C. 14. Lamination according to one of claims 1 to 13, wherein the adhesive is applied at a temperature of less than 160°C. 15. Lamination according to one of claims 1 to 14, wherein the adhesive is applied at a temperature of less than 140°C. 16. Lamination according to one of claims 1 to 15, wherein the adhesive is applied at a temperature of less than 120°C. 17. Lamination according to one of claims 1 to 16, wherein the adhesive is applied at a temperature of less than 110°C. 18. A lamination according to any one of claims 1 to 17, wherein one of the substrates comprises a heat seal material. 19. Lamination according to one of claims 1 to 18, wherein the distance between the slot nozzle and the substrate or substrates is greater than 20 mm. 20. Lamination according to one of claims 1 to 19, wherein the distance between the slot nozzle and the substrate or substrates is between 2 and 20 mm. 21. A lamination according to any one of claims 1 to 20, wherein the adhesive comprises up to 50% by weight of at least one thermoplastic polymer, up to 70% by weight of at least one tackifying resin, up to 40% by weight of at least one plasticizer and up to 30% by weight of at least one wax. 22. Lamination according to one of claims 1 to 21, wherein the adhesive comprises an ethylene/n-butyl acrylate polymer and/or an ethylene/methyl acrylate polymer. 23. A lamination according to any one of claims 1 to 22, wherein the adhesive comprises a thermoplastic polymer, an aliphatic hydrocarbon resin, an aromatic hydrocarbon resin, rosin and wax. 24. A lamination according to any one of claims 1 to 23, wherein the adhesive comprises 35-60 wt.% ethylene/n-butyl acrylate polymer and/or ethylene/methyl acrylate polymer, 30-50 wt.% hydrogenated aliphatic hydrocarbon resin, about 10 wt.% alpha-methyl styrene resin, 0-30 wt.% hydrogenated rosin and 0-10 wt.% polyethylene wax and minor amounts of stabilizer. 25. A lamination according to any one of claims 1 to 24, wherein one or both of the substrates comprises a metallized substrate. 26. A lamination according to any one of claims 1 to 25, wherein one or both of the substrates comprise a transparent film material. 27. Lamination according to one of claims 1 to 26, wherein the application device is a slot nozzle used for coating hot melt adhesives in direct contact with the substrate. 28. Lamination according to one of claims 1 to 27, wherein the lamination of a first substrate, an adhesive layer and a second substrate or the adhesive-coated first substrate is pressed together by means of two rollers. 29. The lamination of claim 28, wherein in the case of the adhesive coated first substrate, the roller contacting the adhesive layer is release coated. 30. A lamination according to any one of claims 1 to 29, wherein the adhesive is non-reactive. 31. A lamination according to any one of claims 1 to 29, wherein the adhesive is reactive. 32. The lamination of claim 31, wherein the adhesive is moisture curing.