US006060550A

United States Patent (19) 11 Patent Number: 6,060,550

Simon et al. (45) Date of Patent: May 9, 2000

54 POLYETHYLENE WAX AS PROCESSING 58 Field of Search ..................................... 524/487,489;

AID FOR HOT-MELTADHESIVE 525/173, 174, 177
COMPOSITIONS
56) References Cited
75 Inventors: Ulrich Simon, Herne; Thorsten Gurke,
Haltern, both of Germany U.S. PATENT DOCUMENTS
73 Assignee: Huels Aktiengesellschaft, Marl, 4,217,426 8/1980 McConnell et al. .................... 525/177
Germany
Primary Examiner Peter A. Szekely
21 Appl. No.: 09/172,267 Attorney, Agent, or Firm-Oblon, Spivak, McClelland,
Maier & Neustadt, P.C.
22 Filed: Oct. 14, 1998
57 ABSTRACT
30 Foreign Application Priority Data
A hot-melt adhesive composition for coating a sheet-like
Oct. 23, 1997 DE Germany ........................... 19746 834 Structure which comprises a hot-melt adhesive powder and
51) Int. Cl." ............................. C08L91/06; CO8L 67/03 a polyethylene wax as processing aid.
52 U.S. Cl. .......................... 524/489; 524/487; 525/173;
525/174; 525/177 21 Claims, No Drawings
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1 2
POLYETHYLENE WAXAS PROCESSING SUMMARY OF THE INVENTION
AID FOR HOT-MELTADHESIVE
COMPOSITIONS The object of the invention is therefore to find a hot-melt
adhesive composition which does not have the processing
BACKGROUND OF THE INVENTION disadvantages described.
1. Field of the Invention It has now Surprisingly been found that hot-melt adhesive
The present invention relates to a hot-melt adhesive compositions, in accordance with the present invention,
composition comprising polyethylene wax as processing aid containing a polyethylene wax, do not have these disadvan
tageS.
and intended for coating sheetlike Structures Such as textiles,
leather, foam materials or plastic films. Although EP-B 0575 900 describes the use of polyeth
2. Discussion of the Related Art ylene wax for detackifying polymer Surfaces, a way of
overcoming the tack problem described in the present appli
Hot-melt adhesive compositions are known which are cation cannot be derived from EP-B O 575 900.
applied preferably in the form of an aqueous paste in a
pattern to a sheetlike Structure that is to be coated, followed The polyethylene wax of the invention must exhibit the
by drying and Sintering. The Sintered product constitutes the
15 following properties:
hot-melt adhesive composition. The coated sheetlike Molecular weight: from 500 to 10,000 g/mol, preferably
Structures, in the form of WebS or cut blanks, are laminated from 1000 to 5000 g/mol
with other sheetlike webs or blanks, under the anion of Softening point: from 100 to 130 C., preferably from 110
preSSure and comparatively mild temperature, to form lami to 115° C.
nates of particularly high washing Stability and adhesion. Viscosity at 150° C.: from 100 to 380mPa's, preferably 140
mPa S.
Numerous hot-melt adhesive compositions for the Screen
printing technique are known. They are composed predomi DESCRIPTIONS OF THE PREFERRED
nantly of aqueous-pastelike mixtures of fine hot-melt adhe EMBODIMENTS
Sive powders which, even in relatively coarse particle form, 25
can be applied per Se directly for coating by the Scatter or Examples of Suitable commercial polyethylene waxes are,
powder dot technique. The hot-melt adhesive compositions available from BASF: AF, AF30, AF31, AF 322, and avail
most commonly employed today are based on able from Hils: VESTOWAX A 616, A 415, A227, A 235,
copolyamides, copolyesters or high-density polyethylene. or an oxidized polyethylene wax such as AO 15125, AO
For pasting up the fine hot-melt adhesive powders to 1535, AO 1539. The oxidized polyethylene waxes have
prepare the adhesive layer, use is made of Special Suspending softening points of from 104 to 130 C., preferably from 106
or dispersing agents, which give the pasted-up formulations to 114 C., and a viscosity of from 100 to 130 mPa's at 120°
cleaner printing properties. In addition, dispersing agents C.
should also bring forth particular attributes, examples being The wax, or the oxidized wax, is incorporated into the
the prevention of Sedimentation of the mixed-in powders, 35 hot-melt adhesive in amounts of from 0.2 to 6% by weight,
crisply contoured print formation, controlled penetration of based on hot-melt adhesive powder. For Scatter coating and
the hot-melt adhesive paste, prevention of outer fabric powder dot coating, the wax is employed in amounts of from
Strikethrough, avoidance of Strikeback in the course of 0.1 to 1% by weight, preferably from 0.2 to 0.5% by weight,
fixing, or the elimination of the phenomenon of edges based on hot-melt adhesive powder. For paste coating, the
Sticking together when the sheetlike Structures are cut to 40 wax is used in amounts of from 2 to 6% by weight,
size. Examples of Such dispersing agents have been preferably from 2 to 3% by weight, based on the overall
described, for example, in the patents DE-B 2007 971, paste.
DE-B 22 29 308, DE-B 24 07 505, DE-B 25 07 504 and In the case of Scatter and powder point application, it is
DE-B35 10 109. Plasticizers can be added to the dispersing advisable to disperse the polyethylene wax as homoge
agents. In many cases, additives comprising high molecular 45 neously as possible in the powder mixture. This means
mass polyethylene oxide are also added, the intention being applying it to the granules prior to grinding, or adding it to
thereby to improve the flow properties of the paste. a masterbatch at the homogenization Stage.
When preparing hot-melt adhesive powders, Stearates (of In the case of paste coating, the polyethylene wax can be
Ca, Mg and Zn) are added in order to improve removal from added Separately, as an additive.
the Screen and to take account of performance requirements. 50
Surprisingly, polyethylene wax brings major advantages
With the aid of these products, it is possible to vary the bulk
density and free-flow properties of the powders. Amorphous in connection with the various application methods.
fine powder fractions (from 0 to 80 um), however, tend to In the case of Scatter coating, it prevents Sticking to
form lumps even when the amount is relatively large (0.5%). calender rolls when coating with amorphous copolyamides
However, in connection with the processing of low 55 and copolyesters or when Scattering on large amounts, even
melting, amorphous polyester and polyamide hot-melt adhe of crystalline hot-melt adhesives which still have a very high
Sives of low Viscosity there is a known coating problem, heat content (amount deployed from about 0.2 to 0.5%).
namely excessive tack after the coated inliner leaves the In the case of paste coating, good dispersion of hot-melt
drying oven. When considering the tack, or tackiness, of a adhesive powders in aqueous Systems is obtained. In
coated Surface, a distinction is made between permanent 60 addition, Sticking together of the individual sheets in the
tack and temporary tack. Temporary tack is the time until course of winding is prevented when plasticized, low
recrystallization, i.e. the time until the adhesive falls below melting, amorphous polyamides or polyesters are being used
the melting temperature. The result is Sticking to the cal (amount deployed about 3%).
ender walls (Scatter coating) or Sticking together of the In the case of powder coatings, a marked improvement in
individual plies on the winder, which in the course of further 65 the coating image is observed. The individual dots are more
processing leads to great difficulties (material showing, raised and each dot is rounder and Smoother. There are fewer
lengthening). residues in the recesses of the application rollers. Here too,
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more rapid recrystallization of the melt is observed and the Saladin unit: 2 m wide
coating tack disappears So that there are no problems in the Coating temperature after
course of winding. The washing results at 60° C. are leaving the infrared field: 135° C.
markedly better in the case of polyester coatings if 0.2% of Speed:
Calendeng
polyethylene wax is added to the powder. Powder12add-on:
m/min80 g/m
In the course of the milling, Screening and dispensing of Needlefelt: Polypropylene (beige)
amorphous polyesters, the free-flow properties are improved Coating powders:
and the powders no longer tend to form lumps in the course a) VESTAMELT 350-P 4 Standard
of transportation. b) VESTAMELT 350-P4 with 0.5% polyethylene wax
The following Examples are described also in the priority 10 Scatter pattern:
document, German patent application 19746 834.9 filed Nobelt polywaxa) Powder flowed prematurely from the needle
of the Scatterer, resulting in irregular application.
Oct. 23, 1997, which is incorporated in its entirety herein by with polywax b) Powder held up well in the needle belt of
reference.
the Scatterer, resulting in uniform powder application.
EXAMPLES 15 Coating behavior:
a) After just a short time, powder was observed to have
A 40 g/m plain-woven ecru cotton batiste inliner was transferred from the coated needlefelt to the calender
powder dot coated on a 1 m wide Saladin unit with 30 mesh. rolls. Treatment of the chrome rolls with silicone fluid
Machine parameters: brought only temporary relief.
Heating roll temperature: 220 C. b) After 1 hour of coating with the powder of the invention,
2O still no transfer to the calender rolls was observed.
Engraved roll temperature: 45 C. What is claimed is:
Speed: 20 m/min 1. A sheet coating composition comprising an amorphous
Coating powders: polymeric hot-melt adhesive powder and a polyethylene
Experiment a) VESTAMELT 4680-P816 Standard wax present in an amount of from 0.1 to 6% by weight,
Experiment b) VESTAMELT 4680-P 816 made up with 25 based on the hot-melt adhesive powder.
0.2% polyethylene wax (VESTOWAX A 616 SF) in a 2. The composition of claim 1, wherein Said polyethylene
high-speed mixer. VESTAMELT 4680 is a copolyester wax is present in an amount of from 0.2 to 6% by weight,
hot-melt adhesive available from Huls. The polyesters are based on the hot-melt adhesive powder.
formed from isophthalic acid, terephthalic acid, 3. The composition of claim 1, wherein said polyethylene
butanediol, hexanediol and C to C. dicarboxylic acids. 30 Wax is present in an amount of from 0.1 to 1% by Weight,
VESTAWAX A 616 SF (available from Hils) is a wax based
having a dropping point of from 118 to 128 C., a molar
on the hot-melt adhesive powder.
4. The composition of claim 1, wherein Said polyethylene
mass of about 1600 g/mol and a viscosity at 150° C.<140
mPa S.
wax is present in an amount of from 2 to 6% by weight,
based on the total composition.
Flow properties and dot pattern: is 5. The composition of claim 1, wherein said polyethylene
Experiment a) gave a slightly torn, rough dot. wax is present in an amount of from 2 to 3% by weight,
Experiment b) gave a clean, uniform dot pattern with a Soft bids [Link]"
textile handle. Each individual dot was circular and raised p s
wherein said polyelny
polvethvlene
Peel test and washing stability: wax is present in an amount of from 0.2 to 0.5% by weight,
-0 based on the hot-melt adhesive powder.
Both inliners coated as described above were pressed 40 7. The composition of claim 1, wherein Said polyethylene
together with a cotton Shirt material at a joining temperature wax has a molecular weight of from 500 to 10,000 g/mol.
of 127 C., with a fixing time of 10 seconds and a linear 8. The composition of claim 1, wherein said polyethylene
pressure of 4N. After 24 hours, the bonded materials were wax has a molecular weight of from 1000 to 5000 g/mol.
cut into 5 cm wide Strips and a peel test was conducted. 9. The composition of claim 1, wherein said polyethylene
1) Primary adhesion 45 wax has a softening point of from 100 to 130 C. and a
2) After 1 and 3 washes at 60° C. viscosity at 150° C. of from 100 to 380 mPa's.
TABLE 1.
Primary 1 x 60° C. 3 x 60° C.
adhesion wash wash Surface assessment Add-on

Experiment a) 8 N/5 cm 4 N/5 cm No adhesion smooth bubbly large bubbles 10 g/m’

In the absence of polywax
Experiment b) 11 NF5 cm 10 N/5 cm 6 N/5 in smooth smooth slight bubbles 11 g/m
In the presence of polywax

Advantages of the coating System of the invention: 10. The composition of claim 1, wherein said polyethyl
1) Better coating behavior (more circular dot, more uniform ene wax has a softening point of from 110 to 115 C. and a
dot pattern); 60 viscosity at 150° C. of 140 mPa's.
2) Better primary adhesion; 11. The composition of claim 1, wherein said polyethyl
3) Better stability to 60° C. wash. ene wax is an oxidate of the polyethylene wax.
Scatter coating of a needlefelt for producing parcel shelves: 12. The composition of claim 11, wherein said oxidate of
Scatter coating was carried out with VESTAMELT 350-P4 the polyethylene wax has a Softening point of from 104 to
Standard and VESTAMELT 350-P4 with VESTOWAXA 65 130° C. and a viscosity at 120° C. of from 100 to 130 mPa's.
616 SF 13. A method for coating a sheet, comprising an amor
Machine parameters: phous polymeric hot-melt adhesive powder and a polyeth
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ylene wax present in an amount of from 0.1 to 6% by weight, 18. The method of claim 13, wherein said method com
based on the hot-melt adhesive powder. prises powder dot coating and Said polyethylene wax is
14. The method of claim 13, wherein said method com present in an amount of from 0.1 to 1% by weight, based on
prises Scatter coating and Said polyethylene wax is present in the hot-melt adhesive powder.
an amount of from 0.1 to 1% by weight, based on the 19. The method of claim 13, wherein said method com
hot-melt adhesive powder. prises powder dot coating and Said polyethylene wax is
15. The method of claim 13, wherein said method com
prises Scatter coating and Said polyethylene wax is present in present in an amount of from 0.2 to 0.5% by weight, based
an amount of from 0.2 to 0.5% by weight, based on the on the hot-melt adhesive powder.
hot-melt adhesive powder. 20. The method of claim 14 or 15, wherein said polyeth
16. The method of claim 13, wherein said method com ylene wax is distributed Substantially homogeneously into
prises paste coating and Said polyethylene wax is present in Said composition.
an amount of from 2 to 6% by weight, based on the total 21. The method of claim 16, wherein said polyethylene
paste. wax is added as an additive in the course of paste coating
17. The method of claim 13, wherein said method com 15 preparation.
prises paste coating and Said polyethylene wax is present in
an amount of from 2 to 3% by weight, based on the total
paste.