IP Library › Granted Patent US 12,630,723
Granted Patent B2
US 12,630,723 · App. 18/067,856 · Granted May 19, 2026

Hybrid expandable composition and use thereof

Inventors: Tianjian Huang (Hillsborough, NJ); Kristina Thompson (Clinton, NJ)
Assignee: HENKEL AG & CO. KGaA
C09D5/022B65D65/42C09D5/024C09D7/61C09D7/65C09D7/70
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Quick Facts
Patent No.
US 12,630,723
App. No.
18/067,856
Granted
May 19, 2026
Kind
B2
Abstract

A hybrid expandable composition that provides improved expansion and loft properties is disclosed. The hybrid expandable composition is particularly useful in providing insulation and/or cushion to substrates.

Claims (41)

1 . A hybrid expandable composition comprising:

a. a binder system comprising a mixture of (i) a polyvinyl alcohol stabilized vinyl acetate ethylene emulsion polymer binder having a Tg range from about −35° C. to about −5° C. and (ii) a starch or a dextrin;

c. a plurality of pre-expanded or expandable microspheres;

d. a defoamer; and

e. a water-soluble salt.

2 . The hybrid expandable composition of claim 1 , wherein the starch is a native starch or a modified starch.

3 . The hybrid expandable composition of claim 1 , wherein the dextrin has a water solubility range of about 25% to about 75%.

4 . The hybrid expandable composition of claim 1 , wherein the microspheres have shells prepared from natural, semi-synthetic or synthetic polymers.

5 . The hybrid expandable composition of claim 4 , wherein the microspheres are expandable microsphere having a hydrocarbon core and a polyacrylonitrile and/or polyacrylate shell.

6 . The hybrid expandable composition of claim 4 , wherein the microspheres having an onset expandable temperature of about 80° C. to about 120° C.

7 . The hybrid expandable composition of claim 1 , wherein the water-soluble salt is selected from the group consisting of sodium chloride, potassium chloride, sodium nitrate, potassium nitrate, potassium sulphate, ammonium sulphate, and mixtures thereof.

8 . The hybrid expandable composition of claim 1 , further comprising a plasticizer, preservative, surfactant, rheology modifier, filler, pigment, dye, stabilizer, polyvinyl alcohol, humectant, and mixtures thereof.

9 . The hybrid expandable composition of claim 1 comprising:

a. about 30 to about 80 wt % of the binder system;

c. about 1 to about 15 wt % of the microspheres;

d. about 0.1 to about 5 wt % of the water-soluble salt;

e. up to about 5 wt % of the defoamer.

10 . The hybrid expandable composition of claim 1 , wherein the binder system has a shear viscosity greater than about 20,000 cps measured with a rheometer at 25° C. at 0.1 s −1 and a viscosity of less than about 2,000 cps measured with a rheometer at 25° C. at 100 s −1 .

11 . An article comprising the hybrid expandable composition of claim 1 and at least one substrate.

12 . The article of claim 11 , wherein the substrate is cellulosic substrate, wood or plastic film having a melting point greater than about 100° C.

13 . The article of claim 12 , wherein the cellulosic substrate is a fiberboard, corrugated board, solid bleached boards, kraft paper or coated paper.

14 . The article of claim 11 , which is a cup, food container, case, carton, bag, box, lids, package, envelope, wrap or clamshell.

15 . A hybrid expandable material prepared from a hybrid expandable composition comprising:

a. about 30 to about 80 wt % of a binder system, which is a mixture of (1) a polyvinyl alcohol stabilized vinyl acetate ethylene emulsion polymer binder having a Tg range from about −35° C. to about −5° C. and (2) a starch or a dextrin;

c. about 1 to about 15 wt % of a plurality of microspheres;

d. about 0.1 to about 5 wt % of a water-soluble salt; and

e. up to about 5 wt % of a defoamer;

wherein the hybrid expandable material is characterized as having closed cell structure and open cell structure.

16 . A method of forming a hybrid expandable material comprising the step of:

a. preparing a hybrid expandable composition comprising:

(i) about 30 to about 80 wt % of a binder system, which is a mixture of (1) a polyvinyl alcohol stabilized vinyl acetate ethylene emulsion polymer binder having a Tg range from about −35° C. to about −5° C. and (2) a starch or a dextrin;

(ii) about 1 to about 15 wt % of a plurality of microspheres;

(iv) about 0.1 to about 5 wt % of a water-soluble salt; and

(v) up to about 5 wt % of a defoamer;

b. applying the hybrid expandable composition onto a substrate;

c. subjecting the hybrid expandable composition to rapid heating;

d. cooling the hybrid expandable composition;

whereby the hybrid expandable material is formed.

17 . The method of claim 16 , wherein the step b is applied in a configuration selected from the group consisting of dots, stripes, waves, checkerboard patterns, any general polyhedron shapes that have substantially flat bases, cylinders, and combinations thereof.

18 . The method of claim 16 , wherein the step c is conducted with microwave, infrared, radiofrequency, and/or ultrasonic energy.

19 . The method of claim 16 , wherein the step d is conducted with pressure to provide a specific height to the hybrid expandable material.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 5, 2025
From: HENKEL IP & HOLDING GMBH
To: HENKEL AG & CO. KGAA
Reel/Frame 070414/0351 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 10, 2025
From: HUANG, TIANJIAN; THOMPSON, KRISTINA
To: HENKEL IP & HOLDING GMBH
Reel/Frame 070157/0993 →
Continuity (3)
Continuation PCTUS2021037215 · Jun 14, 2021
Provisional Application 63042168 · Jun 22, 2020
Related Publication 20230119653A1 · Apr 20, 2023
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