Adhesive compounds
The invention relates to multiphase compositions of matter comprising at least an acrylic phase and a hydrocarbon phase, and more specifically to pressure sensitive adhesive compositions of matter of an acrylic-hydrocarbon polymer and an additional hydrocarbon component which has a molecular weight of at least 1,000 and may include one or both of an oligomeric hydrocarbon and a polymeric hydrocarbon.
1. A pressure-sensitive adhesive composition comprising:
a hybrid acrylic-rubber graft copolymer formed by reacting an acrylic monomer system comprising at least one alkyl acrylate ester containing from about 2 to about 20 carbon atoms in the alkyl group in the presence of a macromer selected from ethylene-butylene macromers, ethylene-propylene macromers, ethylene-butylene-propylene macromers, isobutylene macromers, and mixtures thereof, the graft copolymer including a continuous acrylic phase and a discontinuous hydrocarbon phase;
an additional hydrocarbon compound having a molecular weight of at least 1,000 and compatible with the macromer, the additional hydrocarbon compound is an oligomeric hydrocarbon or polymeric hydrocarbon or a combination of both,
wherein the macromer is present in an amount of from 5% to about 50% by weight of the acrylic monomer system and the macromer,
wherein the additional hydrocarbon comprises from about 5% to about 75% of the total weight of the pressure-sensitive adhesive composition, and
wherein the additional hydrocarbon compound comprises a material selected from the group consisting of hydrogenated liquid polyisoprene, methacrylic functionalized liquid isoprene rubber, maleic anhydride functionalized polypropylenes, carboxyl-terminated polybutadiene, epoxidized hydroxyl terminated polybutadiene resin, hydroxy terminated polybutadiene resin, hydroxyl terminated 1,3-butadiene homopolymer, vinyl functional polybutadiene, and combinations thereof.
2. The pressure-sensitive adhesive of claim 1 , further comprising a cross-linking agent.
3. The pressure-sensitive adhesive of claim 1 , wherein both of the macromer component of the graft copolymer and the hydrocarbon compound are hydrogenated.
4. The pressure-sensitive adhesive of claim 1 , wherein either one or both of the graft copolymer and the hydrocarbon compound are crystalline.
5. The pressure-sensitive adhesive of claim 1 , wherein either one or both of the graft copolymer and the hydrocarbon compound contain reactive sites.
6. The pressure-sensitive adhesive of claim 5 , wherein the reactive sites are selected from carboxylic acid, hydroxyl, anhydride, aldehyde, ketone, acetate, amine, amide, aziridine, epoxide, mercapto, acrylate, methacrylate, vinyl, and mixtures thereof.
7. The pressure-sensitive adhesive of claim 1 , wherein the hydrocarbon compound is made of monomers selected from ethylene, propylene, butadiene, isoprene, isobutylene, hexene, octene, and mixtures thereof.
8. A product comprising:
a layer of foam having two surfaces; and
a pressure-sensitive adhesive composition according to claim 1 ,
wherein the pressure-sensitive adhesive is applied to one or both surfaces of the layer of foam.
9. The product of claim 8 , wherein the foam is made of a material selected from polyolefins, copolymers of polyolefins with other monomers, copolymer of polyolefins with acrylics, copolymer of polyolefins with vinyl acetates, polyurethane, and acrylics.
10. The product of claim 8 , further comprising a barrier layer disposed between the layer of foam and the pressure-sensitive adhesive composition.
11. The product of claim 10 , wherein the barrier layer includes a material selected from polyurethane, poly(ethylene-co-acrylic acid), poly(ethylene-co-acrylic acid) metal salts, poly(ethylene-co-methacrylic acid), poly(ethylene-co-methacrylic acid) metal salts, poly(ethylene-co-methyl acrylate), poly(ethylene-co-vinyl acetate), poly(ethylene-co-vinyl acetate-co-carbon monoxide), poly(vinyl alcohol-co-ethylene), and poly(ethylene-co-acrylic acid).
12. The product of claim 10 , wherein:
the pressure-sensitive adhesive further includes a cross-linking agent; and
the barrier layer has solubility parameters that are higher than corresponding solubility parameters for the tackifier compound and the cross-linking agent.
13. The pressure-sensitive adhesive of claim 1 , wherein the pressure-sensitive adhesive is further cured by radiation selected from ultraviolet radiation and electron beam radiation or by incorporation of a cross-linking agent.
14. The pressure-sensitive adhesive of claim 1 , wherein the hydrocarbon oligomer and the hydrocarbon polymer are in one or more of an acrylic phase of the compound, a first hydrocarbon phase of the compound that contains a hydrocarbon macromonomer, and a second hydrocarbon phase of the compound that contains the hydrocarbon oligomer and the hydrocarbon polymer.
15. The pressure-sensitive adhesive of claim 14 , further comprising a silicone phase.
16. The pressure-sensitive adhesive of claim 14 , further comprising a high glass transition temperature material.
17. The pressure-sensitive adhesive of claim 16 , wherein the high glass transition temperature material is selected from polystyrene and poly methyl methacrylate.
18. The pressure-sensitive adhesive of claim 1 , further comprising a tackifier compound compatible with the hydrocarbon phase and incompatible with the acrylic phase.
19. The pressure-sensitive adhesive of claim 1 , further comprising a tackifier compound that is miscible in at least a portion of the composition.
20. The pressure-sensitive adhesive of claim 1 , wherein the acrylic monomer system is formed from about 35% to 100% total weight of the at least one alkyl acrylate ester containing from about 4 to about 8 carbon atoms in the alkyl group.
21. The pressure-sensitive adhesive of claim 20 , further comprising a tackifier compound compatible with the hydrocarbon phase and incompatible with the acrylic phase.
22. The pressure-sensitive adhesive of claim 20 , further comprising a tackifier compound that is miscible in at least a portion of the composition.
23. The pressure-sensitive adhesive of claim 20 , wherein the acrylic monomer system comprises from about 95% to about 90% by weight 2-ethyl hexyl acrylate and from about 5% to about 10% by weight acrylic acid.
24. The pressure-sensitive adhesive of claim 1 , wherein the acrylic monomer system comprises from about 95% to about 90% by weight 2-ethyl hexyl acrylate and from about 5% to about 10% by weight acrylic acid.
25. The pressure-sensitive adhesive of claim 1 , wherein the additional hydrocarbon compound is fully hydrogenated.
26. The pressure-sensitive adhesive of claim 1 , wherein the additional hydrocarbon compound is hydrogenated liquid polyisoprene or methacrylic functionalized liquid isoprene rubber.
27. The pressure-sensitive adhesive of claim 1 , wherein the additional hydrocarbon compound is maleic anhydride functionalized polypropylene.
28. The pressure-sensitive adhesive of claim 1 , wherein the additional hydrocarbon compound is carboxyl-terminated polybutadiene or epoxidized hydroxyl terminated polybutadiene resin.
29. The pressure-sensitive adhesive of claim 1 , wherein the additional hydrocarbon compound is hydroxyl terminated 1,3-butadiene homopolymer.
30. The pressure-sensitive adhesive of claim 1 , wherein the additional hydrocarbon compound is vinyl functional polybutadiene.
31. The pressure-sensitive adhesive of claim 1 , wherein the additional hydrocarbon compound is hydroxyl terminated polybutadiene resin.
32. A pressure-sensitive adhesive composition comprising:
a hybrid acrylic-rubber copolymer having an acrylic backbone and a pendant macromer formed by reacting an acrylic monomer system comprising at least one alkyl acrylate ester containing from about 2 to about 20 carbon atoms in the alkyl group in the presence of a macromer selected from ethylene-butylene macromers, ethylene-propylene macromers, ethylene-butylene-propylene macromers, isobutylene macromers, and mixtures thereof, the copolymer including a continuous acrylic phase and a discontinuous hydrocarbon phase;
an additional hydrocarbon compound having a molecular weight of at least 1,000 and compatible with the macromer, the additional hydrocarbon compound is an oligomeric hydrocarbon or polymeric hydrocarbon or a combination of both,
wherein the macromer is present in an amount of from 5% to about 50% by weight of the acrylic monomer system and the macromer,
wherein the additional hydrocarbon comprises from about 5% to about 75% of the total weight of the pressure-sensitive adhesive composition, and
wherein the additional hydrocarbon compound comprises a material selected from the group consisting of hydrogenated liquid polyisoprene, methacrylic functionalized liquid isoprene rubber, maleic anhydride functionalized polypropylenes, carboxyl-terminated polybutadiene, epoxidized hydroxyl terminated polybutadiene resin, hydroxyl terminated polybutadiene resin, hydroxyl terminated 1,3-butadiene homopolymer, vinyl functional polybutadiene, and combinations thereof.