Liquid adhesive concentrate

Abstract: The present invention provides a liquid adhesive concentrate composition comprising a water soluble polymer dispersed in a water miscible or emulsifiable substantially non-aqueous solvent, a silicate based rheology modifier and a surfactant. The adhesive composition is especially useful as a paper or paperboard adhesive, for example in hanging wall coverings. A two-pack adhesive composition and a method of making an adhesive composition are also provided.

Description: The present invention relates to a liquid adhesive concentrate composition and, in particular, to a liquid adhesive concentrate composition for hanging wall coverings or as a paper, cardboard or paperboard adhesive. Known adhesives for hanging wall coverings have been mainly based on solid compositions of flake starch ether or powdered methyl cellulose or blends of these materials. These products are sold in dried solid form which require mixing with water before use. These solid products are associated with difficulties in preparation of the adhesive often resulting in lumps of undissolved powder. It is also necessary to stand the prepared paste for some time in order to effect complete dissolution of the flake or powder composition and for the full adhesive properties of the paste to develop. A base for an adhesive composition which obviates the need to mix solid material with water can be obtained by dispersing methyl cellulose in an appropriate solvent. The stability of such compositions tends, however, to be poor and they readily separate out into their liquid and solid phases. Furthermore, it is difficult to redisperse such compositions by shaking. It is also very difficult to control the viscosity and pourability without unduly affecting the stability. The present inventors have now developed a new adhesive composition which addresses these problems and which possesses adhesion properties to match conventional products. EP-A-0 016640 relates to high concentration polymer slurries for use in oil field applications. WO-A-96/13559 relates to a two-pack adhesive composition and a method of manufacture of an adhesive composition therefrom. Accordingly, the present invention provides a stabilised liquid adhesive concentrate composition comprising a water soluble polymer dispersed in an emulsifiable or a water miscible substantially nonaqueous solvent, a silicate-based rheology modifier and a surfactant. Preferably the water soluble polymer is selected from cellulose or starch ethers, natural gums, or synthetic water soluble polymers. Examples include methyl cellulose, ethyl cellulose, hydroxypropyl methyl cellulose, carboxymethyl cellulose, ethylhydroxyethyl cellulose, methyl hydroxyethyl cellulose, hydroxyethyl cellulose, starch or a derivative thereof, natural gum such as guar gum or xanthan gum, or a mixture of two or more thereof. Advantageously these materials have a viscosity in the range of from about 30 to 150,000 mPas, preferably from about 1,000 to 100,000 mPas, for a 2% solution in water at 20°C. The water soluble polymer is preferably provided in the form of particles substantially all of which have a size of ≤ about 180µm, more preferably ≤ about 110µm, still more preferably ≤ about 50µm, resulting in particularly favourable dispersion characteristics. The liquid adhesive concentrate comprises a dispersion of the water soluble polymer in a solvent medium, which is preferably of a high purity. The solvent is preferably one which does not, in itself, cause significant thickening of the water soluble polymer, and suitable examples are non-polar and weakly polar organic solvents. Examples include hydrocarbons, glycol ethers (such as ethylene and propylene glycol ethers) and their esters, including combinations of two or more thereof. The solvent is preferably present in the composition in an amount of from 20 to 80 wt.%, more preferably 35 to 65 wt.%. The ratio of the water soluble polymer to the solvent is preferably in the range of from 3:7 to 5:4. The rheology modifier preferably comprises a clay mineral, an organic derivative thereof or a combination thereof. Examples of suitable clay minerals include kaolinite, halloysite, illite, montmorillonite, bentonite, vermiculite, atapulgite and saponite. The rheology modifier may further comprise mica and/or quartz and may also optionally include a dispersant or an aliphatic amine. Advantageously, the rheology modifier comprises powdered china clay, smectite clay or a combination thereof, including organic derivatives thereof. The rheology modifier is preferably present in the composition in an amount of at least 0.1 wt.%., preferably from 1 to 7 wt.%. The surfactant is preferably of the nonionic type and advantageously comprises an alcohol ethoxylate, a nonyl phenol ethoxylate, a sulphosuccinate, or a mixture of two or more thereof. More preferably the surfactant comprises a primary fatty alcohol ethoxylate. The fatty alcohol is preferably a synthetic middle fraction primary alcohol. The surfactant typically has an ethylene oxide content in the range of from 25 to 75 % and is preferably present in the composition in an amount of from 2 to 10 wt.%. The use of an anhydrous surfactant, preferably an anhydrous alcohol ethoxylate, results in an adhesive composition having particularly favourable stability and dispersion characteristics. The liquid adhesive concentrate composition may further comprise one or more components selected from solubility-delaying agents, biocides, binders, plasticisers, anti-settling agents, pH modifiers, cross-linking agents, adhesion promoters and tackifying resins. A preferred solubility-delaying agent is glyoxal, which is advantageously provided as a coating on the water soluble polymer. A preferred binder comprises a polyvinyl acetate homopolymer or copolymer redispersible polymer. Suitable pH modifiers include sodium carbonate and 2-Amino-2-Methyl-1-propanol. The present invention provides an adhesive in the form of a concentrate, which thickens on mixing with water. The liquid concentrate has convenient mixing properties, which enables rapid mixing to give a smooth adhesive, with good stability and performance at least equal to currently available systems. Even if a small degree of separation occurs, the present invention enables the solid constituents of the liquid concentrate to be redispersed with relative ease by manual shaking. Preferably the liquid concentrate composition is mixed with water. The variable selection of the liquid concentrate percentage enables easy adjustment of viscosity. Furthermore, additional concentrate (or water) can be added to adjust the viscosity at any desired stage of mixing. This has previously not been possible with conventional powdered products. When the liquid adhesive concentrate composition according to the present invention is mixed with water a stable adhesive paste results, which preferably has a viscosity (at 20°C) in the range of from 0.5 to 30 Pas. The preferred method of making the adhesive from the concentrate, comprises adding the concentrate to water whilst stirring. However, it is also possible to add the water to the concentrate, whilst stirring. During preparation of the adhesive, from the liquid concentrate, the paste thickens without any risk of lump formation. The viscosity of the final paste can be easily adjusted by addition of further concentrate (to thicken) or further water (to thin). The present invention further provides a two-pack adhesive composition comprising, in a first pack, a water-continuous polymer emulsion and, in a second pack, a liquid adhesive concentrate composition as herein described. The primary purpose of the composition provided in the first pack is to augment the final adhesive properties of the composition in the second pack. The water-continuous polymer emulsion preferably comprises an acrylic copolymer, an acrylated vinyl acetate based copolymer, a polyvinyl acetate homopolymer, a terpolymer of vinyl acetate, acrylic ester and the vinyl ester of a long chain branched organic acid or a copolymer of vinyl acetate and butyl acrylate. The water-continuous polymer emulsion pack may further comprise one or more components selected from biocides, plasticisers, tackifying resins, adhesion promoters (including additional powdered polymers, such as redispersable polymers), surfactants and pH modifiers. The two-pack adhesive composition is preferably provided in a concentrated form such that before use either the first pack or the second pack is added to water or both packs are added to water. Alternatively, the two-pack adhesive composition may be provided for combining together to form a single adhesive composition. The present invention also provides a method of making an adhesive composition comprising mixing at a hand mixing rate a water-continuous polymer emulsion as herein described and a liquid adhesive concentrate composition as herein described until a paste is formed. The water-continuous polymer emulsion and the liquid adhesive concentrate composition may be added simultaneously to water with mixing or, alternatively, the water-continuous polymer emulsion may first be mixed with water before mixing with the liquid adhesive concentrate composition or vice versa. Preferably the adhesive composition in this aspect of the invention comprises in the range of from about 1 to about 25 wt.% of the water-continuous polymer emulsion, from about 1 to about 25 wt.% of the liquid adhesive concentrate composition and the balance of water. The present invention also has within its scope an adhesive composition prepared from the two-pack composition as herein described. In this aspect, the composition preferably comprises from 1 to 20 wt.% of the water-continuous polymer emulsion, from 1 to 20 wt.% of the liquid adhesive concentrate composition and the balance of water. The present invention also has within its scope the use of an adhesive composition as herein described for hanging wall coverings or as a paper, cardboard or paperboard adhesive. The adhesive composition is suitable as an adhesive for a range of weights of wallpaper. It possesses high adhesion qualities to all common building surfaces. The present invention will now be described further with reference to the following examples, in which: Examples 1 to 19 relate to a liquid adhesive concentrate composition according to the present invention (Examples 2 and 3 are control examples and do not fall within the scope of the invention); and Examples A to K relate to a water-continuous polymer emulsion for use in the first pack of the two-pack adhesive composition according to the present invention. Table 1 sets out the various constituents of the compositions in respect of Examples 1 to 19. Table 2 provides a summary of dispersion characteristics in respect of Examples 1 to 19. Table 3 sets out the various constituents of the compositions in respect of Examples A to K. Table 4 provides details of solution characteristics, i.e. viscosity and adhesion, for combinations of certain of Examples 1 to 19 with certain of Examples A to K. The liquid adhesive concentrate composition for each of Examples 1 to 19 was prepared in the following manner. All of the powdered ingredients were weighed out into a glass jar and the jar was then sealed and shaken to ensure a thorough mix. Next, the liquid ingredients were weighed into the jar and the jar was then again sealed and shaken. The resulting dispersion was then mixed on a Silverson L4RT laboratory high shear mixer @ 6000 RPM for 3 minutes. The dispersion characteristics of the compositions were then assessed after up to 28 days and the results are given in Table 2. All of the examples, apart from the control examples, showed little separation of the solid and liquid phases and could be redispersed with ease by manual shaking for about 30 seconds. The water-continuous polymer emulsion composition for each of Examples A to K was prepared in the following manner. All of the liquid ingredients were weighed out into a glass jar and the jar was then sealed and shaken to ensure a thorough mix. The resulting emulsion was then mixed on a Silverson L4RT laboratory high shear mixer @ 6000 RPM for 3 minutes. Two-pack adhesive compositions according to the present invention were prepared by mixing certain of the compositions of Examples 1 to 19 with certain of those of Examples A to K and water by the following method. First, 180 g of water was weighed out into a 400 ml container. 10 g of the water-continuous polymer emulsion composition was then weighed out into the water. The resulting mixture was then transferred to a Haake VT500/FL100 spindle @ 20S -1 . As soon as the spindle started to turn, 10 g of liquid adhesive concentrate was added to the said mixture. The viscosity development was automatically recorded and the results are given in Table 4. Adhesion tests were carried out using a standard 180° peel test using a roller blind fabric on an emulsion painted substrate. If, however, the dispersion contains a pH modifier (e.g. Examples 18 and 19), it can be used as a one-pack adhesive composition. The two-pack adhesive composition prepared by mixing the composition of Example 10 with the composition of Examples A and water was used to hang a wood-chip wallpaper onto bare plaster. The adhesive was easy to brush out, had good wet tack and slip properties and adhesion properties meeting the current British Standard for wall covering adhesives BS3046 1981 (1991). SUMMARY OF DISPERSION CHARACTERISTICS No. Dispersion Characteristics 1 Off white mobile dispersion, with little separation. Quite thick. Very easy to redisperse 2 (CONTROL) Approx. 25% Clear liquid separated. Easy to redisperse 3 (CONTROL) Approx. 25% Clear liquid separated. Easy to redisperse 4 Off white mobile dispersion, with little separation. Very easy to redisperse 5 Off white dispersion - No separation but is viscous. 6 Off white mobile dispersion, with little separation. Very easy to redisperse 7 Off white mobile dispersion, with little separation. Very easy to redisperse 8 Off white mobile dispersion, with little separation. Very easy to redisperse 9 Off white mobile dispersion, with little separation. Quite thick. Very easy to redisperse 10 Very mobile dispersion with little separation. Very easy to redisperse 11 Off white mobile dispersion, with little separation. Very easy to redisperse 12 Off white mobile dispersion, with little separation. Very easy to redisperse 13 Off white dispersion, viscous. 14 Off white dispersion, viscous. 15 Off white mobile dispersion, with little separation. Very easy to redisperse 16 Off white mobile dispersion, with little separation. Very easy to redisperse 17 Off white mobile dispersion, with little separation. Very easy to redisperse 18 Off white mobile dispersion, with little separation. Very easy to redisperse 19 Off white mobile dispersion, with little separation. Very easy to redisperse

Claims: A liquid adhesive concentrate composition comprising a water soluble polymer dispersed in a water miscible or emulsifiable substantially nonaqueous solvent, a silicate-based rheology modifier and a surfactant. A liquid adhesive concentrate composition as claimed in claim 1, wherein the water soluble polymer comprises methyl cellulose, ethyl cellulose, hydroxypropyl methyl cellulose, carboxymethyl cellulose, ethylhydroxyethyl cellulose, methyl hydroxyethyl cellulose, hydroxyethyl cellulose, starch or a derivative thereof, natural gum or a mixture of two or more thereof. A liquid adhesive concentrate composition as claimed in claim 1 or claim 2, wherein the water soluble polymer is provided as particles substantially all of which have a size of ≤ 180µm. A liquid adhesive concentrate composition as claimed in any one of the preceding claims, wherein the solvent comprises a hydrocarbon, a glycol ether or an ester thereof, or a mixture of two or more thereof. A liquid adhesive concentrate composition as claimed in any one of the preceding claims, wherein the ratio of the water soluble polymer to the solvent is from 3:7 to 5:4. A liquid adhesive concentrate composition as claimed in any one of the preceding claims, wherein the rheology modifier comprises a clay mineral, an organic derivative thereof or a combination thereof, and optionally mica and/or quartz. A liquid adhesive concentrate composition as claimed in any one of the preceding claims, wherein the rheology modifier comprises powdered china clay, smectite clay or a combination thereof, including organic derivatives thereof. A liquid adhesive concentrate composition as claimed in any one of the preceding claims comprising at least 0.1 wt.% of the rheology modifier. A liquid adhesive concentrate composition as claimed in any one of the preceding claims, wherein the surfactant is of the nonionic type. A liquid adhesive concentrate composition as claimed in any one of the preceding claims, wherein the surfactant comprises an alcohol ethoxylate, a nonyl phenol ethoxylate, a sulphosuccinate, or a mixture of two or more thereof. A liquid adhesive concentrate composition as claimed in any one of the preceding claims comprising from 2 to 10 wt.% of the surfactant. A liquid adhesive concentrate composition as claimed in any one of the preceding claims, further comprising one or more components selected from solubility-delaying agents, biocides, binders, plasticisers, anti-settling agents, pH modifiers and cross-linking agents. An adhesive paste composition comprising a liquid adhesive concentrate as claimed in any one of the preceding claims and water. A two-pack adhesive composition comprising, in a first pack a water-continuous polymer emulsion and in a second pack a liquid adhesive concentrate composition as claimed in any one of claims 1 to 12. A two-pack adhesive composition as claimed in claim 14,which is in concentrated form such that before use either the first pack or the second pack is added to water or both packs are added to water. A two-pack adhesive composition as claimed in claim 14 or claim 15, wherein the water-continuous polymer emulsion comprises an acrylic copolymer, an acrylated vinyl acetate based copolymer, a polyvinyl acetate homopolymer, a terpolymer of vinyl acetate, acrylic ester and the vinyl ester of a long chain branched organic acid or a copolymer of vinyl acetate and butyl acrylate, and optionally one or more components selected from biocides, plasticisers, tackifying resins, adhesion promoters, surfactants and pH modifiers. A method of making an adhesive composition comprising mixing at a hand mixing rate a water-continuous polymer emulsion and a liquid adhesive concentrate composition as claimed in any one of claims 1 to 12 until a thick paste is formed. A method of making an adhesive composition as claimed in claim 17, wherein the water-continuous polymer emulsion comprises an acrylic copolymer, an acrylated vinyl acetate based copolymer, a polyvinyl acetate homopolymer, a terpolymer of vinyl acetate, acrylic ester and the vinyl ester of a long chain branched organic acid or a copolymer of vinyl acetate and butyl acrylate. A method as claimed in claim 17 or claim 18, wherein the water-continuous polymer emulsion and the liquid adhesive concentrate composition are added simultaneously to water with mixing, or the water-continuous polymer emulsion is first mixed with water before mixing with the liquid adhesive concentrate composition. A method as claimed in claim 19, wherein the adhesive composition comprises from 1-25 wt.% of the water-continuous polymer emulsion, from 1-25 wt.% of the liquid adhesive concentrate composition and the balance of water. An adhesive composition prepared from the two-pack composition as claimed in any one of claims 14 to 16. An adhesive composition as claimed in claim 21 and comprising from 1 to 20 wt.% of the water-continuous polymer emulsion, from 1 to 20 wt.% of the liquid adhesive concentrate composition and the balance of water. Use of an adhesive paste composition as claimed in claim 13 or an adhesive composition as claimed in claim 21 or claim 22 for hanging wall coverings or as a paper, cardboard or paperboard adhesive.

Inventors: CHARNOCK RONALD SCOTT, DEAMER DERRICK FREDERICK, HARRIS ANTONY JOHN, HOLLOWAY JAMES DUNCAN, CHARNOCK, RONALD SCOTT, DEAMER, DERRICK FREDERICK, HARRIS, ANTONY JOHN, HOLLOWAY, JAMES DUNCAN
Applicants: POLYCELL PROD LTD, POLYCELL PRODUCTS LIMITED
Application year: 1997
Main classification: C09J101
IPC codes: C09J103, C09J105, C09J101