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WO2003046099
WO2003046099
(30) Priority Data: (84) Designated States (regional): ARIPO patent (GH, GM,
515843 30 November 2001 (30.11.2001) NZ KE, LS, MW, MZ, SD, SL, SZ, TZ, UG, ZM, ZW),
Eurasian patent (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM),
(71) Applicant (for all designated States except US): AUCK European patent (AT, BE, BG, CH, CY, CZ, DE, DK, EE,
LAND UNISERVICES LIMITED [NZ/NZ]; Level 9, 70 ES, FT, FR, GB, GR, IE, IT, LU, MC, NL, PT, SE, SI, SK,
Symonds Street, Auckland (NZ). TR), OAPI patent (BF, BJ, CF, CO, Cl, CM, GA, GN, GQ,
GW, ML, MR, NE, SN, TD, TG).
WO 03/046099 A1 and
(72) Inventors;
(75) Inventors/Applicants (for US only): EASTEAL, Allan,
James [NZ/NZ]; 31 Liverpool Street, Epsom, Auckland Published:
(NZ). DE SILVA, Kaluachchi, Gamage, Karnika [/NZ]; — with international search report
3 Puketutu Rise, Hillsborough, Auckland (NZ).
For two-letter codes and other abbreviations, refer to the "Guid
(74) Agent: BALDWIN SHELSTON WATERS; P.O. Box ance Notes on Codes and Abbreviations" appearing at the begin
852, Wellington (NZ). ning o f each regular issue o f the PCT Gazette.
WO 03/046099 Al
(57) Abstract: A series of aqueous based adhesive compositions including poly(vinyl acetate) with a rubber latex are described. At
least some cross-linking is preferred, and a tackifing agent is also preferred. The adhesives are water-resistant and heat-resistant ad
hesives suitable for use with (for example) wood, having little coloration in exposed joints. Significant and long-lasting wet strength
is obtained. Versions for use in conjunction with paper products can act as releasable adhesives. Coating versions (in conjunction
with paper and cardboard) are also prepared for the printing and packaging industries.
WO 03/046099 PCT/NZ02/00265
BACKGROUND
10 An ideal adhesive would include stability and strength properties as well as being
cheap to produce, non-toxic, and easy to use. The ideal strength properties of an
adhesive would result in substrate bonding which is maintained over a long
period depending on the existing physical and chemical environmental factors.
The desired strength of bonding can range from very high, for constructional
15 adhesives to very low, for removable paper labels and the like.
Ideally the materials involved in preparation of the adhesive are cheaply and
readily available, such as renewable materials.
DEFINITIONS
“Substantially water resistant” means that an adhesive bond formed between two
25 contact adhesive films as defined above is substantially resistant to the effects of
boiling water on the strength of the contact adhesive bond.
The term “activator” is the term given to agents that are added to rubbers or
emulsions of rubbers to help initiate their curing.
30
The term “accelerator” is the term given to agents that are added to rubbers or
emulsions of rubbers to accelerate their curing. Such accelerators include an
organic dithiocarbamate, disulphide or thiozole, such as zinc
diethyldithiocarbamate, tetramethyl thiuram disulphide, mercaptobenzothiozole
35 and the like.
WO 03/046099 PCT/NZ02/00265
5 Abbreviations
20 Under the specific examples outlined in the detailed description, codes like
PALK(8)NR(2) mean 8 parts by volume of PVA alk., 2 parts of natural rubber,
and so on, where the following abbreviations are to mean
P - poly(vinyl acetate)
25
NR- Natural Rubber
TA- Tetraethylenepentamine
5 NC- crosslinked NR
PALK - alk. PVA - is a poly(vinyl acetate) emulsion, alkalised with 22% aqueous
10 ammonia solution to give 1.1% ammoniated PVAemuIsion
N - alk. NR
15
STATEMENT OF INVENTION
More preferably the tackifing agent is used at about 40% by volume based on the
wet weight of the total adhesive component.
5 Preferably the latex of the adhesive composition includes at least one latex
selected from a range including: natural rubber latex; modified natural rubber
latex; compounded natural rubber latex; modified, crosslinked natural rubber
latex; polychloroprene rubber latex and modified polychloroprene rubber latex.
Preferably, the cross linking agent is a zirconium salt in an alkaline medium, such
as zirconium nitrate.
30
Preferably, the activator is an inorganic oxide, such as zinc oxide.
Preferably (in the case of polychloroprene) additional acid acceptors such as zinc
oxide dispersions or aqueous epoxy resins are included so that degradation of
15 the adhesive composition due to release of hydrochloric acid from the
polychloroprene rubber is minimised.
Preferably (in the case of polychloroprene and a natural rubber with poly(vinyl
acetate)), it is preferred that the natural rubber ranging from about 10% to about
20 40% by volume is blended with poly(vinyl acetate) first before polychloroprene is
added.
30 Preferably the natural rubber is a stable aqueous emulsion preserved with a low
ammonia biocide composite system, or any other suitable preservative system.
More preferably at least one of the PVA and the natural rubber is cross-linked.
In a related aspect the invention provides a water based adhesive suitable for
bonding two layers of paper of compositions as previously described in this
section; wherein any one layer of adhesive on a substrate of paper is capable of
25 adhering to a second layer of adhesive on a substrate of paper so that the
adhesive can be used with self-sealing envelopes. In another related aspect the
invention provides a water based adhesive; the adhesive being a removable type
suitable for use with removable paper labels; the adhesive being resistant to
degradation so that a long shelf life can be expected.
30
In a further related aspect the invention provides a water based releasable
adhesive suitable for the manufacture of a range of easily peelable protective
coatings; comprising an outer protective layer selected from a range of materials
including paper, polyethylene, bubble pack, polypropylene and the like, the layer
35 being provided with an inner coating of a releasable composition according to the
WO 03/046099 PCT/NZ02/00265
Preferably the method further includes the step printing on said adhesive
composition, said composition being capable of accepting printable compositions
while still exhibiting an effective amount of moisture and water transmission
15 resistance. Preferably the composition includes, as a water barrier, at least one
substance selected from a range including silicone, Additive 84, Additive 85, and
Oratan 2001, and preferably the substance is incorporated at up to 20% by
weight. (These are commercial additive samples from Rohm and Haas and Dow
Corning Chemical Companies).
20
In a related aspect the invention provides a water based adhesive composition
suitable for the coating of least one surface of a cardboard including the types of
cardboard known as kraft and corrugated boards with a composition according to
this invention; the composition being capable of accepting printable compositions
25 yet exhibiting an effective amount of moisture and water transmission resistance
between an interior of a box and an exterior.
Further aspects of the present invention will become apparent from the following
5 detailed description and figures of the invention, which is provided by way of
example and is not to be taken in any way as limiting the scope or extent of the
invention.
Fig 1: shows graphically the performance of trials 90-99 duringa boiling test.
10 (see Example 5, table 8)
Fig 2: shows graphically the performance of trials 120-129 during a boiling test,
(see Example 5, table 8)
DETAILED DESCRIPTION
15
By way of introduction, the invention is based on poly(vinyl acetate) (PVA)
modified natural rubber emulsions providing water-resistant and heat-resistant
adhesives. The invention originated from experiments intended to enhance the
properties of known PVA adhesives. The blends were prepared using
20 commercially available emulsions and other components as follows.
The emulsions were modified and/or crosslinked as stated below before mixing.
30
The invention also provides an adhesive composition including poly(vinyl acetate)
together with modified natural rubber, another synthetic rubber, or their
combinations.
WO 03/046099 PCT/NZ02/00265
10
1 PALK - PVA emulsion was alkalised with 22% industrial grade ammonia
20 solution to give 1.1% ammoniated PVA emulsion.
2 Ammoniated, crosslinked PVA - (denoted as PC in formulations) -
alkalised PVA was crosslinked using a 0.3 m/l aq. Zr(NOg)^ solution. 1.5
11
Optionally the adhesive composition of the present invention can also contain at
least one water based tackifying agent to promote adhesion, preferably in an
amount of about 1% to about 50% by volume based on the wet weight of the total
15 adhesive component though preferably about 40% by volume based on the wet
weight of the total adhesive component. Suitable tackifing agents for use in the
contact adhesives of the invention include rosin acids, rosin esters, terpene
phenolic resins, hydrocarbon resins, and coumarone indene resins. The tackifier
will generally be used in the form of an aqueous dispersion. One advantage of a
20 tackifing agent is to provide an instant first attachment.
EXAMPLE 1:
25 Contact adhesive suitable for use on self-sealing envelopes:
The formulation outlined in Table 2 below allowed the making of paper envelopes
of the type where two lips, each coated with adhesive, are able to form a good
WO 03/046099 PCT/NZ02/00265
12
bond only with other similarly coated lips. The storage life appears to be good.
(Conventional self-seal envelopes lose bond strength in less than a year).
Standard 80 gsm photocopy paper was coated with adhesive samples prepared
according to the formulations in Table 3. The strength of the bond produced by
making contact between two such coated papers was determined as the force
10 per unit area of coated paper required to separate the two coated paper surfaces
immediately after the bond was formed, and after ageing. The results are given in
Table 3.
13
EXAMPLE 2:
Adhesive for self-sticking note pads similar to the "3M Post-it ™ "type
equivalent to the performance of "3M Post-it ™ " type note pads. No quantitative
tests were carried out.
10
Table 4: Formulation of adhesive for self-sticking note pads
EXAMPLE 3:
Contact adhesive for bubble wrap-film
14
5 EXAMPLE 4:
Printable water vapour barrier coating for paper and paperboard
This aspect of the invention is applicable to cardboard boxes and the like where
there is a desire to provide both a barrier against the ingress or egress of water,
10 and to provide a substrate on which printing can be applied. The transparency is
an advantage. This aspect of the invention provides a one-coat system whereas
some prior art sealants require a primer layer to be followed by at least one other.
A typical formulation intended by this aspect is outlined in Table 6 below.
15
Table 7A: Water vapour transmission data for PVAc/NR emulsion coatings
CO
2 339.6 57.4
O
CM
5 1 C l = PC(8)/AC(1)/N(1)/R2
O
M = commercial material (#2200) from Michelman Inc.
3 C2 = PC(8)/AC(1 )/N(1)
5 C3 = PC(8)/AC(1)/N(2)
15
16
Table 7B: Water vapour transmission data for PVA/NR emulsion coatings
Sample Formulation _2
Coat weight g m WVT/g m"2 d"1
1 Cl 11 216
2 C2 10 96
3 C3 14 98
4 C4 10 120
5 C5 9 192
6 C6 8 148
7 C7 9 144
8 C8 6 121
9 C9 7 123
10 C10 9 141
- -
5 C l = P(1)/N(5)
C2 = P(1)/N(5)/M(1)
C3 = C l (1 )+ water (0.03)
C4 = P(1)/N(6)
C5 = P(1)/MG1(5)/N(1)
10 C6= P(1)/MG2(5)/N(1)
C7 = C1(1)/APS(0.004)
C8 = C2(1 )/APS(0.004)
C9 = C6(1 )/APS(0.004)
C10 = C4(1)/APS(0.004)/Talc(0.015)
15 MG1 = Poly(methyl methacrylate)-grafted NR latex with 40% total solids
MG2 = Poly(methyl methacrylate)-grafted NR latex with 50% total solids
APS - Ammonium persulphate
AU of the samples in Table 7B are wax-free except for sample C2 which may
contain some waxy material. AU of the samples except sample C2 show good
printability.
WO 03/046099 PCT/NZ02/00265
17
EXAMPLE 5:
Wood Bonding Performance Tests And Results For PVA Based Emulsion
Adhesives
room temperature (~20°C) and kept under compression (20 kg cm"2) for 24
hours, then left under the same conditions (but without compression) for 3-7
10 days. Their shear strength was evaluated in the dry condition.
Water resistance of adhesives was tested as follows. Glued wood blocks were
immersed in water at room temperature for 6 weeks, then dried in an oven at
60°C for 48 hours prior to shear strength determination. (Note that this procedure
15 does not follow the ISO or ASTM standards)
Boiling water tests were carried out according to the JAS-III Standard: the glued
blocks were immersed in boiling water for three hours, then dried at 60°C for 24
hours. The treatment comprising immersion in boiling water for three hours then
20 drying at 60°C for 24 hours was repeated prior to shear strength determination
for those glued blocks that were intact after the first treatment.
18
Notes
Parts by volume in parentheses in the description column.
O
Columns W = maximum load kg cm ,
5 Columns F = Proportion (%) of wood failure (the glue was stronger than the
wood).
* Samples 91, 96, 99, 122, 123, 124, 125, 128 survived the second treatment
The other samples (except 97, 98 and 120) showed weakening but not complete
separation at the glue line. Samples 97, 98, 120 separated in boiling water within
10 about 1 hour.
** Glue joints weakened upon boiling were pressed together and left in an oven
at 60°C for 48 hrs before testing
By way of interpretation, note that for those samples where the wood, not the
15 glue, gave way, the force involved is about 150-180 kg cm-2. The most promising
compositions appear to be those with the highest remaining strength after boiling.
Samples 91, 96, and 125 were good; with 125 being the "best" according to these
tests.
WO 03/046099 PCT/NZ02/00265
19
20
120 PC 1.5
121 PC(8)/NC(2)/R1/TA 1.5
122 PC(8)/NC(2) pass pass
123 PC(8)/N(2) pass 3
124 P(8)/N(1 )/AC(1 )/R2 pass 1
125 PC(8)/NC(1 )/AC(1 )/R2 pass pass
126 PC(8)/N(1 )/AC(1 )/R2 1.5
127 P(8)/N(2) 2.75
128 P(8)/N(2)/R2 pass 2.5
129 PC(8)/N(2)/R2 1.5
21
In Table 9 “pass” in column 3 signifies that the adhesive joint between the wood
blocks remained intact after immersion for three hours in boiling water and drying
at 60°C for 48 hours. “Pass” in column 4 signifies that the adhesive joint
remained intact after subsequent immersion for 4 hours in boiling water. The
5 times recorded in column 3 and column 4 are the times after which the adhesive
joint failed during immersion in boiling water.
Sample 90, sample 95, sample 121 and sample 122 coagulated after standing at
ambient temperature for 1 week.
10
EXAMPLE 6:
Particle Boards Using Natural Rubber/ Pva Adhesives
A number of processes to consume wood chips and convert them into boards
15 rely on forming a matrix of mutually adherent chips set into a solid mass. The
non-toxic and waterproof nature of adhesives according to this invention permit
the manufacture of a water-resistant version of particle board, useful for
bathrooms and shower floors as well as other areas likely to be exposed to
water. In particular, the traditionally employed adhesive in particle board is likely
20 to release trace amounts of potentially toxic formaldehyde over an extended
period and there is a good deal of consumer resistance in some societies to the
risk of exposure to this gas.
EXAMPLE 7:
25 Grafted Natural Rubbers In PVA Adhesives
By way of a yet further variation the present invention also provides adhesive
compositions including modified natural rubber, another synthetic rubber, or their
combinations with PVA. Preferably, such natural and synthetic rubbers have
30 unsaturated chains derived from units such as butadiene or have units derived
from C4 to C10 conjugated dienes, such as styrene or methyl methacrylate.
Natural rubber is commercially available as modified general-purpose latex. For
example, modified latex is available under the tradenames MEGAPOLY latex, as
MG 49, and as MG 30 (rubber latexes grafted with methyl methacrylate to
35 increase the polarity and thereby the adhesion of the adhesive compositions.
WO 03/046099 PCT/NZ02/00265
22
23
Finally, it will be understood that the scope of this invention as described and/or
10 illustrated within this provisional specification is not limited to the preferred
embodiments described herein for illustrative purposes. Those of skill will
appreciate that various modifications, additions, and substitutions are possible
without departing from the scope and spirit of the invention as set forth.
WO 03/046099 PCT/NZ02/00265
24
CLAIM S
25
26
27
28
first substrate;
c) contacting the adhesive applied surface to a second substrate
surface; and
d) forming an adhesive bond between the first and second
substrates.
29
48 The method according to claim 47 wherein the PVA and the natural
30 rubber is cross-linked.
30
Int. Cl. 7; C09J 131/04, 107/02, 111/02; E04C 2/16; B 27N 3/04; C08J 5/18, 7/04
According to International Patent Classification (IPC) or to both national classification and IPC
B. FIELDS SEARCHED
Minimum documentation searched (classification system followed by classification symbols)
IPC: C09J 131/04, 107/02, 111/02; D 21H 21/18; D 2 I H 21/20; E04C 2/16; B 27N 3/04; C09D; 131/04, 107/02, 111/02;
CO8J 5 /1 8 ,7 /0 4
Documentation searched other than minimum documentation to the extent that such documents are included in the fields searched
Electronic data base consulted during the international search (name of data base and, where practicable, search terms used)
D E R W E N T: W P A T , JAPIO
Category* Citation of document, with indication, where appropriate, of the relevant passages Relevant to
claim No.
X Further documents are listed in the continuation o f Box C X See patent family annex
Date of the actual completion of the international search Date of mailing of the international search report
21 February 2003 2 6 FEB 2003
Name and mailing address of the ISA/AU Authorized officer
AUSTRALIAN PATENT OFFICE
PO BOX 200, WODEN ACT 2606, AUSTRALIA
E-mail address: pct@ipaustralia.gov.au DR. A TESSEMA
FacsimileNo. (02)6285 3929 TelephoneNo : (02) 6283 2271
Category* Citation of document, with indication, where appropriate, of the relevant passages Relevant to
claim No.
Derwent Abstract Accession Number 94-018645/03, Class A81 G03 ( A l 8 A 25), and JP
5-320601 A (S E K IS U IC H E M IN D CO L T D ) 3 December 1993
X abstract 1-46
EP 052938 A ( M IN N E S O T A M IN IN G A N D M A N U F A C T U R IN G C O M P A N Y ) 15
January 1986
X col. 3, lines 34-47; col. 5, lines 16-44; claims 1-8 53
Y 54
U S 5407895 A ( E G A S H IR A et al. ) 18 A pril 1995
Y col. 2, line 59 - col. 3, line 13; examples 1 ,2 5 3 ,5 4
This Annex lists the known "A" publication level patent family members relating to the patent documents cited in the
above-mentioned international search report. The Australian Patent Office is in no way liable for these particulars
which are merely given for the purpose o f information.________________________________________________________
US 6440259
WO 200035596 US 6187865
US 5132183
us 4299930 NONE
EP 1008639 NONE
us 4804573 BE 905477
E N D OF A N N E X