CN105026509A - 热熔性粘合剂 - Google Patents

热熔性粘合剂 Download PDF

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Publication number
CN105026509A
CN105026509A CN201380057190.4A CN201380057190A CN105026509A CN 105026509 A CN105026509 A CN 105026509A CN 201380057190 A CN201380057190 A CN 201380057190A CN 105026509 A CN105026509 A CN 105026509A
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tackiness agent
polymer
amorphous
tackiness
goods
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CN201380057190.4A
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CN105026509B (zh
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W·L·邦内尔
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Procter and Gamble Ltd
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IFS Industries Inc
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Abstract

一种热熔性粘合剂材料和制品，该制品是使用该热熔性粘合剂来组装制品中的结构而制成的。该粘合剂材料典型地通过将无定形聚合物与一种具有结晶度的多相聚合物共混而制造成粘合剂组合物。

Description

热熔性粘合剂
本申请是在2013年9月19日作为PCT国际专利申请以作为所有指定国家的申请人的美国国家公司IFS工业公司(IFS Industries Inc.)、以及作为所有指定国家的发明人的美国公民William L.Bunnelle的名义而提交的，并且要求在2012年9月19日提交的美国临时专利申请号61/702,950和在2013年3月15日提交的美国专利申请13/836,385的优先权，这些专利的内容以其全文通过引用结合在此。
披露了一种通用的热熔性粘合剂材料，该粘合剂材料在制品的构造中可以被施用到基材例如纤维素材料、薄膜、纤维或非织物上。制造该粘合剂组合物来获得足以组装制品并且获得机械稳定的产品的熔体粘度、内聚力和粘合性。该粘合剂典型地包含以获得在制造制品中有用的所希望的和有用的构造特性的比例组合的聚合物材料的共混物。一个实施例是该热熔性粘合剂。一个第二实施例是使用该热熔性粘合剂的构造特性和方面制造的一种制品。
常见热熔性粘合剂是通过将聚合物和添加剂组分以实质上均匀的热塑性共混物进行组合来制成的。需要改进的材料用于改进的施用设备中以及当前和更新的制品构造中。实质性的需要存在于提供获得改进的粘合剂的新的材料配方组合以及共混技术。
该粘合剂组合物包含一种第一无定形聚合物和一种第二多相聚合物。该无定形聚合物包括一种无定形或无规聚合物，该无定形或无规聚合物包括一种包含多数比例的丙烯的α烯烃共聚物。该第二聚合物包括具有无定形特征和至少某一实质性的结晶含量的一种多相α烯烃共聚物。该结晶含量可以处于一种或多种有规立构的聚合物嵌段或序列的形式。在一个实施例中，这些序列或嵌段是实质上可结晶的序列或嵌段。
如在此使用的，“均聚体”是指一种从单一单体的聚合产生的聚合物，即，一种实质上由单一类型的重复单元组成的聚合物。
如在此使用的，术语“一种或多种共聚物”是指通过至少两种不同的单体形成的一种或多种共聚物。例如，术语“共聚物”包括一种单体的共聚合反应产物，该单体为例如丙烯或丁烯，优选1-丁烯和α-烯烃，如例如乙烯、1-己烯或1-辛烯。
如在此使用的，术语“丙烯(propene)共聚物”或“丙烯(propylene)共聚物”是指大于40或50wt.％或更多的丙烯和至少一种选自包括乙烯和C4至C20α-烯烃的组的单体的共聚物。
如在此使用的，术语“丁烯共聚物”是指正丁烯(1-丁烯)或2-丁烯和至少一种选自C2-3和C5-20α烯烃的组的单体的聚合物。丁烯共聚物典型地包含最低量为至少约40或约50wt.％或更多的丁烯单体例如1-丁烯。
术语“多相”聚合物是指可以在冷却的粘合剂块中提供内聚强度的具有无定形特征和至少某一实质性结晶含量(至少5wt.％、10wt.％、20wt.％、40wt.％或50wt.％的结晶含量)的一种聚合物。该结晶含量可以处于有规立构的嵌段或序列的形式。
术语“无定形”是指实质上不存在结晶度，(即)小于5％并且小于1％。
术语“序列或嵌段”是指在组成、结晶度或其他方面上类似的重复单体的聚合物部分。
如在此使用的，术语“晾置时间”是指在将熔融的热熔性粘合剂组合物施用到一个第一基材上与当在基材上的粘合剂的有用的粘性或浸湿由于该粘合剂组合物的固化而有效地停止时的时间之间流逝的时间量。晾置时间还被称为“工作时间”。
如在此使用的，术语“基材”是指具有旨在与热熔性粘合剂组合物接触的、至少部分或完全固化的纤维或平面表面的任何物品。在一些情况下，使相同的面积、圈、珠粒、线、长丝或点的热熔性粘合剂组合物与两个或更多个基材接触，出于在其间产生粘性结合的目的。在一些此类情况下，这些基材是同一物品的一部分：例如，折叠的薄膜或折叠的非织物、折叠的硬纸板的两个面，其中这两个面是粘性结合在一起的。在其他此类情况下，这些基材是不同物品的一部分：例如，被粘性结合到非织物或硬纸板上的塑料薄膜。这些基材可以是不可渗透的、可渗透的、多孔的或无孔的。
如在此使用的，术语“实质上”是指总体上相同或均匀的但允许或具有与定义的特性、定义等等的微小波动。例如，在此所述的一种所测量的特性(例如粘度、熔点等等)中的小的可测量的或不可测量的波动可能产生自人为误差或方法学精度。其他波动是由制造方法中的固有变化、配制品的热经历等等导致的。尽管如此，这些粘合剂组合物将被说成实质上具有如报道的特性。
如在此使用的，术语“多数比例”是指在大于50wt.％下使用一种材料或单体。如在此使用的，术语“主要组分”是指一种材料或单体与其他物质相比是在该混合物或聚合物中更常见的物质或具有更高的浓度，但不能多达50wt.％。
该粘合剂材料包含一种第一聚合物和一种第二聚合物，该第一聚合物包括一种聚烯烃，该聚烯烃包括一种实质上无定形或无规聚合的聚合物材料，该第二聚合物包括一种多相聚合物。
该第一无定形聚合物典型地包含丁烯(例如)1-丁烯并且可以包含乙烯、丙烯或一种第二C4-40烯烃聚合物。这些实质上无定形的低结晶度聚合物具有小于10％并且优选小于5％的结晶特征。
该第二多相烯烃聚合物包含一种包含实质比例(大于40或50摩尔％)的丙烯单体的第一聚α烯烃聚合物并且包含一种具有某一结晶含量的无定形聚合物。
该无定形聚合物是一种基于丁烯的共聚物(最低量是至少约30或40或50wt.％的1-丁烯)，该共聚物还可以被称为一种无规丁烯-α-烯烃共聚物。该丁烯共聚物包括衍生自丙烯的一个或多个单元，即单体单元，衍生自乙烯或包括从4至约20个碳原子的α-烯烃的一个或多个共聚单体单元。
该第一共聚物包含约30摩尔％-约70摩尔％、优选约40摩尔％至约60摩尔％的衍生自丁烯的单元。除了丁烯衍生的单元之外，该共聚物包含从约70摩尔％-约30摩尔％至约60摩尔％-约40摩尔％的衍生自优选乙烯、丙烯或至少一种C5至10α-烯烃单体的单元。
在一个或多个实施例中，该α-烯烃共聚单体单元还可以衍生自其他单体例如乙烯、1-丁烯、1-己烯、4-甲基-1-戊烯和/或1-辛烯。示例性α-烯烃选自下组，该组由以下各项组成：乙烯、丁烯-1、戊烯-1、2-甲基戊烯-1、3甲基丁烯-1、己烯-1、3-甲基戊烯-1、4-甲基戊烯-1、3,3-二甲基丁烯-1、庚烯-1、己烯-1、甲基己烯-1、二甲基戊烯-1、三甲基丁烯-1、乙基戊烯-1、辛烯-1、甲基戊烯-1、二甲基己烯-1、三甲基戊烯-1、乙基己烯-1、甲基乙基戊烯-1、二乙基丁烯-1、丙基戊烷-1、癸烯-1、甲基壬烯-1、壬烯-1、二甲基辛烯-1、三甲基庚烯-1、乙基辛烯-1、甲基乙基丁烯-1、二乙基己烯-1、十二烯-1、以及十六烯-1。
在一个或多个实施例中，无定形共聚物包含约30摩尔％-约70摩尔％、优选约40摩尔％至约60摩尔％的衍生自丁烯的单体以及从约70摩尔％-约30摩尔％至约60摩尔％-约40摩尔％的衍生自至少一种选自乙烯、丙烯、1-己烯或1-辛烯的α-烯烃单体的单元。少量的一种或多种α-烯烃单体可以在约0.1至20摩尔％的范围内使用。该无定形聚合物具有约1,000至约25,000或更小、优选约2,000至20,000的重量平均分子量(Mw)。
在一个或多个实施例中，第一共聚物包含约30摩尔％-约70摩尔％、优选约40摩尔％至约60摩尔％的衍生自丁烯的单体以及从约70摩尔％-约30摩尔％至约60摩尔％-约40摩尔％的衍生自丙烯的单体，而少量的一种或多种α-烯烃单体可以在约0.1至20摩尔％的范围内使用。
该无定形聚合物具有约1,000至约50,000或更小、优选约5,000至45,000的重量平均分子量(Mw)。
当在190℃下通过ASTM D3236测量时，该无定形共聚物具有小于10,000mPa·s的粘度(1厘泊[cps]＝1mPa·s)，例如约2000至8000mPa·s。根据ASTM D-3236测定熔体粘度，该熔体粘度在此也被称为“粘度”和/或“布氏粘度”。
无定形聚烯烃的一些实例包括通过亨斯迈公司(Huntsman)制造的Rextac聚合物，包括Rextac E-62、E-65、2715、2730、2385等等。参见，例如Sustic，美国专利号5,723,546对于这些聚合物的描述并且该专利明确地结合在此。其他有用的无定形聚合物作为和材料出售。
该粘合剂材料包含一种第二聚烯烃，该第二聚烯烃包括一种实质上多相的共聚物。该多相聚烯烃可以包含一种与其他一种或多种共聚单体的丙烯共聚物(即)基于丙烯的聚合物。该基于丙烯的聚合物骨架优选包含丙烯和一种或多种C2或C4-20α-烯烃。该基于丙烯的多相聚合物，例如，可以包含丙烯和乙烯、己烯或任选地其他C2或C4-20α-烯烃。该聚合物包含约99.5至约70wt.％、优选约95至约75wt.％的衍生自丙烯的单元。除了丙烯衍生的单元，该共聚物包含从约0.1至30wt.％、优选从约5至25wt.％的衍生自优选至少C2-4或C5-10α-烯烃的单元。
在一个或多个实施例中，该第二共聚物包含多数比例的丙烯和约0.1至30wt.％、或2至25wt.％的乙烯。在一个或多个实施例中，该第二共聚物包含多数比例的丙烯和约0.1至30wt.％、或2至25wt.％的1-丁烯。
在一个或多个实施例中，该第二共聚物包含多数比例的丙烯和约0.1至30wt.％、或2至25wt.％的1-己烯。在一个或多个实施例中，该第二共聚物包含多数比例的丙烯和约0.1至30wt.％、或2至25wt.％的1-辛烯。
用于该第一或第二聚烯烃中的其他共聚单体包括乙烯或包含4-12个碳原子的α-烯烃。示例性的α-烯烃可以选自下组，该组由以下各项组成：乙烯、1-丁烯、1-戊烯、2-甲基-1-戊烯、3-甲基-1-丁烯、1-己烯-3-甲基-1-戊烯-4-甲基-1-戊烯-3,3-二甲基-1-丁烯、1-庚烯、1-己烯、1-甲基-1-己烯、二甲基-1-戊烯、三甲基-1-丁烯、乙基-1-戊烯、1-辛烯、甲基-1-戊烯、二甲基-1-己烯、三甲基-1-戊烯、乙基-1-己烯、1-甲基乙基-1-戊烯、1-二乙基-1-丁烯、丙基-1-戊烯、1-癸烯、甲基-1-壬烯、1-壬烯、二甲基-1-辛烯、三甲基-1-庚烯、乙基-1-辛烯、甲基乙基-1-丁烯、二乙基-1-己烯、1-十二烯和1-十六烯。优选的C4-10α-烯烃是具有6-8个碳原子的那些，其中最优选的α-烯烃是1-己烯和1-辛烯。
优选的丙烯共聚物是其中该共聚单体是乙烯、1-丁烯、1-己烯或1-辛烯的共聚物。这些聚合物的有规立构的(全同立构的或间同立构的)序列或嵌段含量给予这些聚合物可结晶的含量的多相(部分无定形和部分结晶)特征。如在此使用的并且如应用到半结晶多相共聚物上的，术语“可结晶的”描述了可以在冷却时结晶的那些聚合物序列或嵌段。这些固化的半结晶共聚物的结晶含量增加了热熔性粘合剂的内聚强度。基于茂金属聚合的半结晶共聚物的热熔性粘合剂配制品可以随着时间最终建立足够的晶体含量以实现该配制品中的良好内聚强度。
该第二多相聚合物包含可结晶的聚合物嵌段户序列，优选聚合的单体例如乙烯或丙烯的有规立构序列，这些序列是足够长的以结晶，典型地每个序列至少重复或嵌段单体单元。
在优选的实施例中，这些可结晶的区段可以是有规立构的或全同立构的。这些烯烃序列的全同立构规整度可以通过选择一种希望的催化剂组合物进行聚合来实现。常规地使用DSC或C-13NMR仪器技术测量该全同立构规整度。
该多相聚合物具有至少5wt.％、10wt.％、20wt.％、40wt.％或50wt.％、优选在20％与80％之间、更优选在25％与70％之间的结晶度。
这些多相共聚物的熔解热(通过ASTM E793)是约10J/g至约70J/g并且约15J/g至约70J/g，其中熔点为小于150℃并且约105℃至约135℃。
该多相聚合物具有约20,000或更小、优选约10,000或更小、优选约500至8,000的重量平均分子量(Mw)。
当在190℃下使用布氏粘度计测量(如通过ASTM D 3236测量的)时，该多相聚合物具有小于20,000mPa·s，例如小于15000mPa·s，在某些应用中，小于10,000mPa·s并且小于5,000mPa·s的粘度(1厘泊[cps]＝1mPa·s)，在此也被称为“粘度”和/或“布氏粘度”。
在这些热熔性粘合剂组合物中有用的多相聚合物的一些实例包括聚烯烃例如聚乙烯、聚丙烯和其共聚物，例如在商品名VISTAMAXXTM下由得克萨斯州休斯顿的埃克森美孚化工公司(ExxonMobil Chemical of Houston)出售的基于聚丙烯的弹性体，以及基于聚乙烯的弹性体例如在商品名AFFINITYTM和ENGAGETM下由密歇根州米德兰的陶氏化学公司(Dow Chemical Company ofMidland)出售的那些。
在这些热熔性粘合剂组合物中有用的其他多相聚合物包括聚烯烃弹性体VISTAMAXXTM 8816、VISTAMAXXTM 2230、和ENGAGETM 8200。AFFINITYTM GA 1900具有根据ASTM D792的0.870g/cm3的密度、46.1J/g的熔解热、和根据ASTMD 1084的177℃下的8200cP的布氏粘度。AFFINITYTM GA 1950具有根据ASTMD792的0.874g/cm3的密度、53.4J/g的熔解热、和根据ASTM D 1084的177℃下的17,000cP的布氏粘度。ENGAGETM 8200具有根据ASTM D792的0.87g/cm3的密度和190℃下5g/10min的熔体指数。这些烯烃弹性体是与在这些热熔性粘合剂组合物中有用的丙烯共聚物相容的并且改进物理特性例如低温粘合性能，而不牺牲有效的硬化时间。
任何常规的聚合合成方法可以制备这些聚烯烃共聚物。优选地，一种或多种催化剂，典型地是金属茂催化剂或齐格勒-纳塔(Zeigler-Natta)催化剂，用于烯烃单体或单体混合物的聚合。聚合方法包括高压、浆料、气体、本体、悬浮液、超临界或溶液相、或其组合，优选使用一种单位点金属茂催化剂体系。这些催化剂可以处于均相溶液、负载的、或其组合的形式。聚合可以通过一种连续的、半连续的或分批方法进行并且可以包括使用链转移剂、清除剂、或其他此类添加剂(如认为适用的)。连续的是指无中断或停止而运行(或旨在运行)的一种系统。例如，一种用于产生聚合物的连续方法将是其中将反应物连续引入一个或多个反应器中并且连续取出聚合物产物的方法。在一个实施例中，使用一种单一聚合催化剂在单个或多个聚合区域中产生在此描述的丙烯共聚物。这些多相聚合物典型地使用获得所希望的多相结构的多种金属茂催化剂共混物来制成。
在此披露的这些组合物还可以包含可减少粘度或改进该粘合剂中的粘性特性的一种增塑剂或增塑油或增量油。本领域的普通技术人员已知的任何增塑剂可以用于在此披露的粘合组合物中。增塑剂的非限制性实例包括烯烃低聚物，低分子量聚烯烃例如液体聚丁烯，低分子量非芳香族聚合物(例如，来自伊士曼化学公司(Eastman Chemical Company)的REGALREZ 101)，邻苯二甲酸酯，矿物油例如环烷的、石蜡的、或氢化的(白色的)油(例如，Kaydol油或ParaLux油(雪佛龙美国公司(Chevron U.S.A.Inc.)))，植物和动物油以及它们的衍生物，石油衍生的油，以及它们的组合。低分子量聚烯烃可以包括具有低至100的Mw的那些，尤其，在从约100至3000的范围内的、在从约250至约2000的范围内和在从约300至约1000范围内的那些。
在一些实施例中，这些增塑剂包括聚丙烯、聚丁烯、氢化的聚异戊二烯、氢化的聚丁二烯、聚戊间二烯、戊间二烯和异戊二烯的共聚物、以及类似物，具有在约350与约10,000之间的平均分子量。在其他实施例中，这些增塑剂包括通常的脂肪酸的甘油酯以及其聚合产物。异丁烯的聚合物。一种优选的增塑剂包括聚异丁烯聚合物。该聚合物可以包括多数比例的异丁烯单元或可以表示为：
[-C(CH3)2-CH2-]n；
其中n＝15至75。聚异丁烯材料是具有约200-20,000、约200-20,000或约500-2,000的分子量的粘性液体。这些优选的材料具有约100至20,000的100℃下的赛氏通用粘度秒数(SUS)。聚异丁烯的特征性特征是低透气性和对酸、碱和盐溶液的作用的高耐受性、以及高介电指数。它们在太阳光和紫外线的作用下逐渐降解(添加炭黑减缓这个过程)。在工业上，聚异丁烯是通过单体在从-80℃至-100℃的温度下的离子(AlCl3催化的)聚合来生产的；它们使用橡胶工业的普通设备进行处理。聚异丁烯容易与天然或合成橡胶、聚乙烯、聚氯乙烯、和酚醛树脂组合。
如以上所指出，优选的组合物的实施例是实质上不含可以增加粘合剂材料的晾置时间、基材润湿或粘性中的任一方面的有效量的常规增粘剂材料。避免使用增粘剂减少成本并且使配制者免于使用供应不足的材料。进一步，增粘剂可能给予一次性制品中的不希望的气味并且还可以充当低分子量增塑剂(像用于基于SBC的粘合剂中的操作油)的载体，这些低分子量增塑剂可以削弱婴儿纸尿裤中使用的聚乙烯背膜材料。由于在这些制品中使用的聚乙烯薄膜厚度的尺寸缩小，背膜完整性变得越来越重要。术语“常规的增粘剂树脂”是用于典型的热熔性粘合剂中的在粘合剂领域和工业上常见地可获得的那些树脂。包括在这个范围内的常规的增粘树脂的实例包括脂肪烃树脂、芳香族改性的脂肪烃树脂、氢化的聚环戊二烯树脂、聚环戊二烯树脂、松香、松香酯、木松香、木松香酯、妥尔油松香、妥尔油松香酯、聚萜烯、芳香族改性的聚萜烯、萜烯-酚醛树脂、芳香族改性的氢化聚环戊二烯树脂、氢化的脂肪族树脂、氢化的脂肪族芳香树脂、氢化的萜烯和改性的萜烯以及氢化的松香酯。通常在常规的配方中，此种树脂以从约5至约65wt.％、常常约20至30wt.％的范围的量使用。
在另外的实施例中，在此披露的组合物可以任选地包含一种抗氧化剂或稳定剂。本领域的普通技术人员已知的任何抗氧化剂可以用于在此披露的粘合组合物中。合适的抗氧化剂的非限制性实例包括基于胺的抗氧化剂例如烷基二苯胺、苯基-萘胺、烷基或芳烷基取代的苯基-萘胺、烷基化的对苯二胺、四甲基-二氨基二苯胺和类似物；以及受阻酚化合物例如2,6-二-叔丁基-4-甲基苯酚；1,3,5-三甲基-2,4,6-三(3',5'-二-叔丁基-4'-羟基苄基)苯；四[(亚甲基(3,5-二-叔丁基-4-羟基氢化肉桂酸酯)]甲烷(例如，IRGANOXTM1010，来自纽约的汽巴-嘉基公司(Ciba Geigy))；十八烷基-3,5-二-叔丁基-4-羟基肉桂酸酯(例如，IRGANOXTM 1076，从汽巴-嘉基公司可商购的)以及其组合。在使用时，在该组合物中的抗氧化剂的量可以是该组合物的总重量的从约大于0至约1wt.％、从约0.05至约0.75wt.％、或从约0.1至约0.5wt.％。
在另外的实施例中，在此披露的组合物可以任选地包含可以防止或减少通过辐射导致的该组合物的降解的一种UV稳定剂。本领域的普通技术人员已知的任何UV稳定剂可以用于在此披露的粘合组合物中。合适的UV稳定剂的非限制性实例包括苯甲酮、苯并三唑、芳基酯、草酰苯胺、丙烯酸酯、甲脒炭黑、受阻胺、镍猝灭剂、受阻胺、酚类抗氧剂、金属盐、锌化合物以及其组合。在使用时，在该组合物中的W稳定剂的量可以是该组合物的总重量的从约大于0至约1wt.％、从约0.05至约0.75wt.％、或从约0.1至约0.5wt.％。
在另外的实施例中，在此披露的组合物可以任选地包含一种增亮剂、着色剂或颜料。本领域的普通技术人员已知的任何增着色剂或颜料可以用于在此披露的粘合组合物中。合适的增亮剂、着色剂或颜料的非限制性实例包括荧光材料和颜料例如三嗪-茋、香豆素、咪唑、二唑、二氧化钛和炭黑，酞菁类颜料，以及其他有机颜料例如IRGAZINB、CROMOPHTALB、MONASTRALB、CINQUASIAB、IRGALITEB、ORASOLB，所有这些是从纽约柏油村的汽巴精化公司(CibaSpecialty Chemicals,Tarrytown,N.Y.)可获得的。在使用时，在该组合物中的增亮剂、着色剂或颜料的量可以是该组合物的总重量的从约大于0至约10wt.％、从约0.01至约5wt.％、或从约0.1至约2wt.％。
在此披露的组合物还可以任选地包含一种香料例如芳香或其他增味剂。此种香料可以通过衬层被保留或者被包含在释放剂例如微囊剂中，这些微囊剂可以例如在从该组合物中去除离型衬层或在该组合物上压缩时释放香料。
在另外的实施例中，在此披露的组合物可以任选地包含填充剂。本领域的普通技术人员已知的任何填充剂可以用于在此披露的粘合组合物中。合适的填充剂的非限制性实例包括沙子、滑石、白云石、碳酸钙、粘土、二氧化硅、云母、硅灰石、长石、硅酸铝、氧化铝、水合氧化铝、玻璃珠、玻璃微球、陶瓷微球、热塑性微球、重晶石、木粉、以及其组合。在使用时，在该组合物中的填充剂的量可以是从约大于0至约60wt.％、从约1至约50wt.％、或从约5至约40wt.％。
表1-示例性的不含增粘剂的粘合剂组合物
这些热熔性粘合剂组合物具有适合于与常规的热熔性粘合剂施用设备一起使用的熔体流变学和热稳定性。这些热熔性粘合剂组合物的共混组分具有在施用温度下的低熔体粘度，从而有助于这些组合物流动穿过涂覆装置，例如涂覆模口或喷嘴，而无需求助于将溶剂或增量油结合到该组合物中。使用Brookfield thermosel RVT粘度计在176.66℃下使用转子数27(50rpm，350°F)，这些热熔性粘合剂组合物的熔体粘度以千帕斯卡-秒或厘泊为单位是在1500cP与3500cP之间或约2000cP至3000cP。这些热熔性粘合剂组合物具有约80℃至140℃、在一些实施例中约115℃至130℃的软化点(ASTM D3461-97梅特勒软化点方法的标准测试方法(Standard Test Method forMettler Softening Point Method))。对于某些应用，这些热熔性粘合剂组合物具有约5秒或更少、例如约0.1秒至5秒、在实施例中约0.1秒至3秒、并且在一些实施例中约0.2秒至1秒的有效硬化时间。这些热熔性粘合剂的有效硬化时间是出乎意料地短的，特别是鉴于晾置时间保持在可接受的范围中。
这些热熔性粘合剂组合物的典型的但非限制性工业应用包括包装，尤其用于低温用途例如用于奶制品或用于食物产品的冷冻包装，以及用于一次性卫生消费制品，例如尿布、女性护垫、餐巾纸等等。传统的最终用途应用例如书籍装订、木材加工和贴标签也将得益于在将这些热熔性粘合剂组合物施用到不同基材上的自动化装置中的最终用途的低温柔性、耐热性和效率。
制品包括具有通过热熔性粘合剂组合物粘性结合的任何两个或更多个基材的物品。制品包括纸箱、盒子、信封、可食容器、书籍、杂志、一次性制品例如尿布或月经带、以及类似物。在此类制品中粘性结合的基材是由以下材料形成的：例如硬纸板、纸、木材、铝、锡、钢，热塑性塑料例如聚酯例如聚对苯二甲酸乙二酯、聚酰胺例如尼龙、或聚丙烯，或者热固性聚合物，玻璃，陶瓷，以及它们的组合、共混物、或层状组合物，并且包括，在一些实施例中，蜡涂层、丙烯酸酯聚合物、或其他材料；着色剂、防腐剂、稳定剂、加工润滑剂、和类似物以及这些材料中任何的组合。这些基材包括固体、无孔物品和板以及多孔物品和板，例如非织造织物、纸、棉絮、以及类似物。
另一个方面是使用这些热熔性粘合剂组合物进行制造的方法。该方法涉及将这些熔融组合物施用到一个基材上，接着在将该粘合剂组合物施用到该第一基材上之后0.1秒至5秒内使该粘合剂组合物与一个第二基材接触，其中该接触产生在这些基材之间的粘性结合。
又另一个方面是制造一种包含这些热熔性粘合剂组合物的制品，其中该制品包括通过一定量的热熔性粘合剂组合物粘性结合的至少两个基材。制造的典型制品包括包装的商品，尤其是旨在用于低温用途的包装的商品，例如用于奶制品中或用于食物产品的冷冻包装；一次性卫生消费制品，例如，尿布、女性护垫、餐巾纸以及类似物；书籍和杂志；贴有标签的制品；木制品例如家具；以及由低能量和更高能量材料的组合形成的制品，例如具有聚乙烯包层和/或聚丙烯标签的纸箱、或具有保护性塑料顶部的木制框架桌。总体上，使用这些热熔性粘合剂组合物有利地粘合的制品得益于在将这些粘合剂组合物施用到基材上的自动化装置中的低温柔性、耐热性和最终用途的效率。
热熔性粘合剂组合物是通过如下所述的熔融共混配制的，其中在以下示出这些组分的具体成分和量。在使用这些粘合剂制造的这些制品中，这些制品可以通过形成在聚合物薄膜与纤维或纤维块之间的粘性结合来制造。该制品还可以包括在聚合物薄膜与非织造织物之间的粘性结合。另外，该制品可以通过形成在一种多层结构之间的粘性结合来制造，该多层结构包括聚合物膜外层和包含纤维地图或非织造织物的多个内部组件。
这些粘合剂材料可以用作在组装常见地可用的一次性消费制品中的一种构造粘合剂。此类制品包括婴儿尿布、成人尿布、床垫、卫生产品、以及其他吸收性制品。将至少一个聚合物薄膜与其他薄膜和纤维材料组合典型地制成这些制品。纤维材料可以包括例如织造或非织造织物的织物，处于纤维桶(vat)、纤维集合、纤维球形式的纤维等等。
此类吸收性制品典型地包括一种容纳在该制品内的吸收剂。该吸收剂通常使用非织造内衬覆盖。此类衬层包括将流体或水分从该制品的内部传递到该吸收层中的一种高渗透性材料，例如一种纺粘型非织造结构。在该吸收性制品内形成的吸收层或结构典型地包括一种纤维块垫或纤维素或木浆，用于实质上吸收释放到该吸收性制品中的液体或流体材料的目的。该纤维或蓬松毛可以包括一种纤维素纤维、合成纤维或其混合物，例如木纤维、纤维素纤维、聚乙烯纤维、聚丙烯纤维或常常包括超吸收性物质的其他纤维材料的共混物。超或高吸收性材料用于增加该吸收性制品的吸收能力。此种材料是包括改性的天然树胶和树脂的有机材料，但常常包括合成聚合物材料例如水凝胶。羧基-甲基纤维素、丙烯酸聚合物的碱金属盐、聚丙烯酰胺、聚乙烯醇、聚乙烯酸酐聚合物和共聚物、聚乙烯醚聚合物和共聚物、羟烷基纤维素聚合物和共聚物、聚乙烯磺酸聚合物和共聚物、聚丙烯酸聚合物、聚乙烯-吡咯烷酮聚合物和共聚物可以用于该吸收功能中。
用于此类一次性制品中的非织造织物层典型地是总体上平面的结构，该结构包含天然或合成纤维的粘结组件。
此种非织造材料通常使用各种技术来制成，包括纺粘、熔融粘合等等。此种非织造材料通常是通过以下方式制造的：将纤维或粗纱按实质上随机模式无规地放置并且然后使用这些纤维的固有粘合特征进行热粘合，或者通过使用施用到这些纤维上的树脂材料来粘合这些纤维。不同的聚合物可以用于制造非织造材料，包括聚烯烃、聚酯、乙烯乙酸乙烯酯、乙烯丙烯酸聚合物和其他聚合物。
该制品的外部常常包含一个液体不可渗透的聚合物薄膜。在某些方面，外部聚合物薄膜可以进一步使用另外的外部层进行改性来使该外部聚合物薄膜获得更像布的或非织造的特征。该外部薄膜典型地包括单层的聚合物薄膜但可以是一种多层薄膜结构。典型的聚合物片材包括可以成型为薄膜层的高抗张强度的聚合物，包括聚酯、聚烯烃或其他热塑性片材。该聚烯烃或聚酯聚合物材料常常成型为片材并且进行处理以改进强度、柔性和抗穿刺性。包括双轴取向、热处理或表面处理的技术可以改进这些聚合物薄膜的薄膜特征。此种聚合物薄膜常常具有在从约十或约一百微米范围内的厚度。
我们已经提及的一种吸收性制品的一个实施例包括该不可渗透的聚合物薄膜、一个吸收层衬垫或垫和一个非织造内部层。这种三组件结构使用粘合剂进行组装，使用在将该非织造内部层粘附到该聚合物薄膜上的同时将该吸收层保持在其间的制造技术来施用该粘合剂。
这些粘合剂组合物可以作为一种热熔性粘合剂在熔融条件下被施用到一个基材上，或者可以被涂覆、施用或喷涂到该聚合物薄膜非织物或吸收垫上。典型地按珠粒、点模式、螺旋模式或其他使用此类诺信(Nordson)施用技术的常规模式使用狭缝涂覆、喷涂或雾化特性来施用喷涂用的粘合剂。在一个优选的实施例中，使用狭缝涂覆(使用Nordson true coat或Speed coat slot)在增加的机器速度下将该粘合剂组合物的成分施用到一个基材上。
该材料典型地以约1至约100或约4至约90或约7至约70克/平方米(g-m-2)的所得到的粘合材料来施用。这些粘合剂材料可以用于一次性尿布和餐巾纸构造的弹性附接，并且一次性商品特别优选的应用包括婴儿尿布构造、尿布底体(chassis)构造、尿布内芯稳定化、尿布外罩层压、月经带内芯稳定化、月经带粘合带。
实验
多种热熔性粘合剂组合物通过以下方式来制备：将第一无定形共聚物、第二多相共聚物、聚合物增塑剂/稀释剂和抗氧化剂在混合条件下在升高温度下共混以形成完全均化的流体熔体。混合温度从约135℃至约200℃变化，优选约150℃至约175℃。一种混合器用于保证将组分完全均化成最终粘合剂组合物。
实例1-4
热熔性粘合剂组合物是通过如下所述的熔融共混配制的，其中在以下表2中示出这些组分的具体成分和量。
表2-示例性粘合剂配方
表3-示例性粘合剂粘度数据
布氏粘度 实例1 实例2 实例3 实例4 实例5 实例6 实例7 实例8
121.1℃(250°F) 26200 29750 16600 39000
135℃(275°F) 7710 12125 9725 7500 8425 7100 9100 8750
148.9℃(300°F) 4675 6350 5325 4525 5150 4200 5325 5375
162.8℃(325°F) 3075 4190 3500 2980 3475 2800 3550 3375
176.7℃(350°F) 2220 2945 2450 2080 2315 1920 2385 2275
梅特勒软化点 121℃ 125℃ 125℃ 124℃ 120℃ 118℃ 118℃ 115℃
这些数据表明这些材料将在一次性吸收性制品中提供优异的构造粘合。应注意，粘度在某些条件下与该材料的流动阻力相关。这种区别性特征决定了该熔融聚合物对该基材的可流动性、润湿度和穿透性。它提供了作为一种热熔性粘合剂材料的可加工性和实用性的指示。熔体粘度通常直接与聚合物分子量相关并且使用Brookfield thermosel RVT粘度计在指定温度下使用转子数27以千帕斯卡-秒或厘泊为单位来报道。
以摄氏度数或华氏度数为单位的梅特勒软化点典型地使用ASTM D3104来测量。这些聚烯烃材料的无定形性质产生不清晰或不确定的熔点。相反地，随着温度升高，无定形聚合物从固体逐渐变软并且然后变为液体材料。常常记录下未清楚定义的玻璃化转变温度或熔点温度。这个温度测试通常测量精确温度，在该精确温度下在2℃/分钟或10°F/分钟的速率下加热的一个聚合物样品盘变得足够软以允许测试对象，一个钢珠(克)，下落穿过该样品。以摄氏度数或华氏度数报道的聚合物的软化点是重要的，因为它典型地表明该聚合物的耐热性、有用的施用温度和固化点。
权利要求书可以合适地包括所披露的或列举出的要素中的任一项、由其组成、或主要由其组成、或实质上不含其任一项。在此说明性地披露的本发明可以在缺乏未在此具体披露的任何要素的情况下合适地实施。以上所述的不同实施例仅通过说明的方式来提供并且不应被解释为将所附的权利要求书限制于此。可以不遵循在此说明并描述的这些示例实施例和应用，并且在不脱离以下权利要求书的真实精神和范围的情况下进行各种修改和变化。

Claims (16)

1.一种热熔性粘合剂组合物，包含：
(i)一种无定形聚烯烃组合物；
(ii)包含无定形特征和结晶嵌段的一种多相聚烯烃组合物。
2.如权利要求1和3-5中任一项所述的粘合剂，其中该无定形聚烯烃具有小于5wt.％的结晶度，该多相聚烯烃在至少一个序列或嵌段中包含至少约5wt.％的结晶度；其中该无定形聚合物提供粘合性并且该多相聚合物提供内聚强度。
3.如权利要求1-2和4-5中任一项所述的粘合剂，其中该无定形聚合物包含大于40wt.％的丁烯和小于50wt.％的一种或多种α烯烃C2或C4-20单体。
4.如权利要求1-3和5中任一项所述的粘合剂，其中该多相聚合物包含大于40wt.％的丙烯和小于60wt.％的一种或多种α烯烃C2或C2-20单体并且包含具有大于10％的结晶度的聚合物嵌段或序列。
5.如权利要求所述的粘合剂，其中该粘合剂实质上不含增粘剂。
6.如权利要求1-4中任一项所述的粘合剂，其中存在约50至90wt.％的该无定形聚合物和约10至50wt.％的该多相聚合物，该多相聚合物包含至少30wt.％的结晶度。
7.一种热熔性粘合剂组合物，主要由以下各项组成：
(i)约90至10wt.％的一种无定形聚烯烃组合物，该无定形聚烯烃组合物包含1-丁烯；
(ii)约10至90wt.％的一种多相聚烯烃组合物，该多相聚烯烃组合物包含丙烯和乙烯、1-己烯或1-辛烯并且包含无定形嵌段和结晶嵌段；以及
(iii)约0.1至30wt.％的一种增塑剂；其中该粘合剂从该多相聚合物提供内聚强度并且从该无定形聚合物提供粘合强度。
8.如权利要求6和8-12中任一项所述的粘合剂，其中该多相聚烯烃包含至少约5wt.％的结晶序列或嵌段。
9.如权利要求6-7和9-12中任一项所述的粘合剂，其中该无定形聚合物包含大于40wt.％的丁烯和小于50wt.％的一种或多种α烯烃C2或C4-20单体。
10.如权利要求6-8和10-12中任一项所述的粘合剂，其中该多相聚合物包含大于40wt.％的丙烯和小于60wt.％的一种或多种α烯烃C2或C2-20单体并且具有大于10％的结晶度。
11.如权利要求6-9和11-12中任一项所述的粘合剂，其中该粘合剂实质上不含增粘剂。
12.如权利要求6-10和12中任一项所述的粘合剂，其中存在约50至80wt.％的该无定形聚合物和约10至50wt.％的该多相聚合物。
13.如权利要求6-11中任一项所述的粘合剂，其中该增塑剂包含具有约500至2000的分子量的聚异丁烯。
14.一种制品，该制品包括一个基材和一个薄膜、纤维、纤维素板或非织物，具有一种在其间的粘合剂结合，该粘合剂结合包含如权利要求1所述的粘合剂，其中该粘合剂从该多相聚合物提供内聚强度并且从该无定形聚合物提供粘合强度。
15.一种制品，该制品包括一个基材和一个薄膜、纤维、纤维素板或非织物，具有一种在其间的粘合剂结合，该粘合剂结合包含如权利要求5所述的粘合剂，其中该粘合剂从该多相聚合物提供内聚强度并且从该无定形聚合物提供粘合强度。
16.一种制品，该制品包括一个基材和一个薄膜、纤维、纤维素板或非织物，具有一种在其间的粘合剂结合，该粘合剂结合包含如权利要求7所述的粘合剂，其中该粘合剂从该多相聚合物提供内聚强度并且从该无定形聚合物提供粘合强度。
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