Block copolymer hot-melt processable adhesives, methods of their preparation, and articles therefrom
First Claim
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1. A composition comprising:
- 100 parts by weight of at least one block copolymer comprising at least two A blocks and at least one B block, wherein the A block is derived from at least one monoethylenically unsaturated monomer selected from the group consisting of (meth)acrylates, styrenes and vinyl esters, and wherein the B block is derived from at least one monoethylenically unsaturated monomer selected from the group consisting of (meth)acrylates, acrylamides and vinyl esters, and the boundaries between microdomains comprising the A blocks and a continuous phase comprising the B blocks are essentially free of tapered structures; and
at least 40 parts by weight of at least one tackifier based on total weight of the block copolymer;
wherein said composition is a hot melt processable adhesive.
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Abstract
Hot-melt processable adhesive, such as pressure-sensitive-adhesive (PSA) or heat-activatable adhesive, compositions of the present invention possess a broad formulation latitude and adequate cohesive strength after application for use in high performance applications. Hot-melt processable adhesives of the invention comprise at least one block copolymer comprising at least two A blocks and at least one B block. The A and B blocks are derived from monoethylenically unsaturated monomers, which monomers result in saturated polymer backbones without the need for subsequent hydrogenation upon their polymerization. Preferably, the block copolymer is a (meth)acrylate block copolymer.
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Citations
51 Claims
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1. A composition comprising:
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100 parts by weight of at least one block copolymer comprising at least two A blocks and at least one B block, wherein the A block is derived from at least one monoethylenically unsaturated monomer selected from the group consisting of (meth)acrylates, styrenes and vinyl esters, and wherein the B block is derived from at least one monoethylenically unsaturated monomer selected from the group consisting of (meth)acrylates, acrylamides and vinyl esters, and the boundaries between microdomains comprising the A blocks and a continuous phase comprising the B blocks are essentially free of tapered structures; and
at least 40 parts by weight of at least one tackifier based on total weight of the block copolymer;
wherein said composition is a hot melt processable adhesive. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44)
wherein; R1 is H or CH3; and
R2 is a hydrocarbon group, such that R2 for each A block has a total number of carbon atoms differing by at least two from R2 for the B block.
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22. The composition of claim 1, wherein the B block has a weight average molecular weight of about 30,000 to about 500,000 grams per mole.
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23. The composition of claim 1, wherein the B block has a weight average molecular weight of about 70,000 to about 200,000 grams per mole.
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24. The composition of claim 1, wherein the block copolymer is polymerized via a living free-radical polymerization method.
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25. The composition of claim 1, wherein the block copolymer is polymerized via living anionic polymerization.
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26. The composition of claim 1, wherein polydispersity of the block copolymer is about 2.0 or less.
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27. The composition of claim 1, wherein polydispersity of the block copolymer is about 1.5 or less.
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28. The composition of claim 1, wherein the A blocks are each essentially free of segments derived from a monomer used to prepare the B block.
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29. The composition of claim 1, wherein the B block is essentially free of segments derived from a monomer used to prepare the A blocks.
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30. The composition of claim 1, wherein the block copolymer is polymerized without using iniferters.
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31. The composition of claim 1, wherein the block copolymer is essentially free of iniferter residue.
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32. The composition of claim 1, further comprising at least one additive.
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33. The composition of claim 32, wherein the additive is compatible with the B block.
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34. The composition of claim 32, wherein the additive is selected from the group consisting of A-block compatible resins, (A-B) diblock copolymers, plasticizers, photocrosslinkers, stabilizers, pigments, fillers, and medicaments.
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35. The composition of claim 1, wherein elastomeric components in the composition consist essentially of the block copolymer.
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36. The composition of claim 1, wherein the composition comprises an (A-B-A) triblock copolymer and an (A-B) diblock copolymer.
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37. The composition of claim 1, wherein the tackifier comprises about 60 parts by weight to about 140 parts by weight based on total weight of the block copolymer.
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38. The composition of claim 1, wherein the tackifier comprises about 80 parts by weight to about 120 parts by weight based on total weight of the block copolymer.
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39. The composition of claim 1, wherein the adhesive composition is a pressure-sensitive-adhesive composition.
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40. The composition of claim 1, wherein the adhesive composition is a heat-activatable adhesive composition.
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41. A substrate at least partially coated with the composition of claim 1.
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42. The substrate of claim 41, wherein the composition is chemically crosslinked.
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43. A tape comprising:
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a backing having a first and second side; and
the composition of claim 1 coated on at least a portion of the first side of the backing.
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44. The tape of claim 43, wherein the composition of claim 1 is solvent-coated on the first side of the backing.
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45. A method of preparing a hot-melt processable adhesive, comprising the steps of:
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providing 100 parts by weight of at least one block copolymer comprising at least two A blocks and at least one B block, wherein the A block is derived from at least one monoethylenically unsaturated monomer selected from the group consisting of (meth)acrylates, styrenes and vinyl esters, and wherein the B block is derived from at least one monoethylenically unsaturated monomer selected from the group consisting of (meth)acrylates, acrylamides and vinyl esters, and wherein the boundaries between microdomains comprising the A blocks and a continuous phase comprising the B blocks are essentially free of tapered structures; and
blending at least 40 parts by weight of at least one tackifier based on total weight of the block copolymer with the block copolymer. - View Dependent Claims (46, 47, 48, 49)
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50. A composition comprising:
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100 parts by weight of at least one block copolymer comprising at least two A blocks and at least one B block, wherein the B block is derived from monoethylenically unsaturated monomers comprising at least one of a (meth)acrylate monomer or a vinyl-terminated monomer, which as a homopolymer has a glass transition temperature (Tg) of less than about 20°
C., and the A blocks are polymers independently derived from a (meth)acrylate monomer, which as a homopolymer has a glass transition temperature (Tg) of greater than about 20°
C., and the boundaries between microdomains comprising the A blocks and a continuous phase comprising the B blocks are essentially free of tapered structures; and
at least 40 parts by weight of at least one tackifier based on total weight of the block copolymer;
wherein said composition is a hot melt processable adhesive.
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51. A composition comprising:
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100 parts by weight of at least one block copolymer comprising at least two A blocks and at least one B block, wherein the A and B blocks are each independently derived from a monomer having a structure as follows;
wherein;
R1 is H or CH3; and
R2 is a hydrocarbon group, such that R2 for each A block has a total number of carbon atoms differing by at least two from R2 for the B block, and the boundaries between microdomains comprising the at least two A blocks and a continuous phase comprising the at least one B block are essentially free of tapered structures; and
at least 40 parts by weight of at least one tackifier based on total weight of the block copolymer;
wherein said composition is a hot melt processable adhesive.
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Specification