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Hot-Melt Adhesives
A. Pizzi
rieure des Technologies et Industries du Bois, Ecole Nationale Supe de Nancy I, Epinal, France Universite

I. INTRODUCTION Hot melts are a widely used class of adhesives that are used for many applications but are rarely used for structural bonding, as seldom are they able to match the tensile strengths of other adhesive classes. Their primary uses are in packaging and in wood for edge veneering and veneer splicing. There are important reasons for employing hot-melt adhesive systems, such as: 1. 2. 3. 4. 5. 6. 7. 8. Ease of Application via high-speed equipment Formation of strong, permanent, and durable bonds within a few seconds of application No environmental hazard and minimal wastage because of 100% solid systems Ease of handling Absence of highly volatile or ammable ingredients Excellent adhesion Wide formulation possibilities to suit individual requirements (e.g., color, viscosity, application temperature, and performance characteristics) Cost-eectiveness

Hot melts are 100% solid thermoplastic materials that are supplied in pellet, slug, block, or irregular-shaped chip form. They require heating via appropriate application equipment, which usually is fairly sophisticated in order to control the required temperature and coverage rate. Upon application, the heat source is removed and the thermoplastics set immediately (within a few seconds). Hot melts are thus well suited to high-speed continuous-bonding operations.

II. A.

ETHYLENEVINYL ACETATE HOT MELTS FOR EDGING Physical Characteristics

Edge veneering requires use of a hot-melt adhesive that is relatively high in viscosity at application temperatures (usually around 200 C). The reasons for this are
Copyright 2003 by Taylor & Francis Group, LLC

as follows: 1. 2. 3. The adhesive must have sucient body to prevent owing from vertical surfaces after application. It must not penetrate the substrate surface too deeply, causing glue starvation. It must have easy spreading and excellent wetting characteristics.

Viscosities of these hot melts are on the order of 50,000 to 60,000 mPa s (cP) at 200 C. Viscosity is achieved through the correct selection of ethylenevinyl acetate (EVA) copolymer grades, coupled with the quantity and type of reinforcing ller that is added to the system. The ball and ring softening point is an early indication of the degree of heat resistance of a particular hot melt. The softening point is inuenced by the combination of ingredients, but to a large extent by the grade and quantity of EVA copolymer and tackifying resin contained in the system. Using a 5.1-g lead ball, the average softening points are between 90 to 105 C. For optimum adhesion, the wetting characteristics (of the hot melt to substrates during application) are vital. Proper wetting is related to viscosity but is again largely inuenced by resin selection and quantity. Stability of the adhesive is another important consideration. During prolonged periods at elevated temperature while contained in the hot-melt applicator, the hot melt must resist oxidation and thermal breakdown of components. This often leads to discoloration, charring, and inferior bonds. As a result of charred material, nozzle blockages can also be encountered.

B.

Formulation Considerations

EVA hot melts consist basically of the following: 1. 2. 3. 4. EVA copolymer Tackifying and adhesion-promoting resins (e.g., hydrocarbon, rosin esters, coumaroneindene, terpene resins) Fillers, usually barium sulfate (barytes) or calcium carbonate (whiting) Antioxidants

1. EVA Copolymer EVA copolymer is the main binder in the system and largely inuences the following: (a) viscosity and rheology characteristics, (b) cohesive strength, (c) exibility, and (d) adhesive strength. A variety of EVA grades are available, allowing the formulator a choice of varying vinyl acetate contents coupled with varying viscosities (melt index). Higher vinyl acetate contents generate greater adhesion to plastics, coupled with increased exibility. The higher the vinyl acetate content, however, the higher the cost. Broadly speaking, EVA-based edge-veneering hot melts utilize grades averaging 28% vinyl acetate, and formulations usually contain 40% binder. 2. Resins

A certain percentage of resin is almost always incorporated into formulations, with resin content varying from 8 to 25%. Hydrocarbon resins are used most often, but rosin esters, terpenes, and indene resins, which are more heat stable, are also common. Resins provide better ow, hot-tack, adhesion, and wetting characteristics.
Copyright 2003 by Taylor & Francis Group, LLC

3. Fillers The heavy llers, such as barytes, are used at levels of up to 50% by weight, but more commonly at around 35 to 40%. The ller imparts cohesive strength and body to the adhesive, and also reduces the cost considerably. Barium sulfate is the ller chosen in most cases because of its high density and hence low pigment volume concentration. Barium sulfate grades vary from beige to dark brown, and this assists in formulating specic opaque colors to match color requirements. Finely ground calcium carbonate is sometimes used as a ller where very light colors are required. Titanium dioxide pigment is commonly used as a toner, at levels of 2 to 5%. 4. Antioxidants Antioxidants are added to protect the organic components, especially resins, from oxidation/discoloration at high temperatures. A large choice exists. These materials are usually added at levels of 0.2 to 0.5%. C. Production Technique and Equipment Because of their relatively high melt viscosities, the EVA hot melts need special manufacturing equipment. For example, a Z-blade mixer such as a Baker Perkins or Winkworth with oil-heated jacketing is required. Mix temperatures are kept as low as possible ( 110 C) to keep bulk thick. The high-viscosity kneading action ensures rapid dissolution of EVA copolymer and resin. Fillers are easily dispersed and a homogeneous mix is achieved rapidly with this type of agitation. Upon completion, the molten product is extruded into ropes approximately 6 mm in diameter, which are cooled through a chilled water trough and then granulated into pellet form. Alternatively, hot-melt slugs are supplied where application equipment utilizes this form. It is essential to ensure that any residual moisture picked up during the cooling process is eliminated via an air-drying cyclone before packing.

III.

POLYAMIDE HOT MELTS

The polyamide hot melts are high-performance systems and are used selectively where good heat resistance is required. Their high cost relative to EVA types makes them rather unattractive for general use. Polyamide resins oer high tensile strengths and high initial tack, often without the need for additional formulating. Their higher melt points ensure good heat-resistance qualities and are responsible for rapid setting on cooling. Their two main drawbacks are cost and the tendency to char easily if kept at high temperatures. Hot-melt polyamide resins are obtained by the reaction of diamines with diacids. While in their simplest form polyamides are the reaction of a particular diamide with a particular diamine, most of the polyamides used in adhesive formulations are complex reaction products obtained by combining several diacids and diamines to obtain the particular properties required. The most common diacid used is a dibasic acid obtained by polymerizing oleic or linoleic acid or other unsaturated fatty acids. This acid can be represented as HOOC R COOH, where R is a hydrocarbon residue of 34 carbon atoms and of indeterminate conguration. Commercial forms of this dimeric diacid also contain preparations of products obtained by polymerization of three or more molecules of
Copyright 2003 by Taylor & Francis Group, LLC

unsaturated fatty acids and thus contain varying quantities of trimeric acids and of higher homologs. Monomeric forms are also present. The most used diamine for this type of adhesive is ethylenediamine, H2N (CH2)2 NH2, but other diamines are also used, responding to the general formula

where X and Y can be H or other chemical groups. Polyamides are then formed according to the schematic reaction

or simply

The reaction occurs with the elimination of water of form amide groups. The high polarity of the amide groups contributes to give, by formation of interchain hydrogen bonds, the characteristic polymer strength and adhesive properties to the polyamides. The basic resins need some form of modication to achieve (1) suitable application viscosities, (2) exibility, and (3) reduction in costs if possible. Suitable polyamide resins (those of the more exible variety) are thus frequently modied by the addition of EVA copolymer (high-viscosity, high-melt-point grade). The amount of EVA that can be added is restricted to a maximum of 25% in most cases because of compatibility problems. The blend is then further modied with selected tackifying resin addition and small quantities of ller, to reach an optimum balance of performance properties. To achieve maximum adhesion, it is common for polyamide hot melts of this type to be used in conjunction with a polyamide resin solution primer system for edging material. The primer is invariably a dilute solution of the base polyamide resin.

IV.

ADHESIVE APPLICATION GUIDELINES

In general, one should ensure that operation of the machine is in accordance with the manufacturers instructions, being sure to set the machine according to the adhesive suppliers specications for line speed, operating temperature, and adhesive coating weight. During application, the following guidelines should be observed: 1. 2. 3. 4. Adhesive reservoir temperature: 204 C Application roller temperature: 191 C (application roller to be 12 to 13 C lower than reservoir temperature) Adhesive application weight: 200 to 250 g/m2 Melting time of adhesive: 11 2 to 3 h

Copyright 2003 by Taylor & Francis Group, LLC

Correct application weight and spread of the hot melt can be checked by bonding a transparent poly(vinyl chloride) (PVC) strip and applying at a pressure of 2 to 4 kg/cm2. If the correct pressure has been applied, the pattern caused by the applicator wheel on the adhesive should disappear, with little or no squeeze-out at the edges. The adhesive reservoir must be lled completely and the lid kept in place, to avoid heat loss. It is necessary to clean gluepots thoroughly at regular intervals, as well as lters, nozzles, and glue lines (every 2 to 4 weeks). Suitable solid hot-melt cleaners, available from adhesive suppliers, have largely replaced the traditional use of cleaning solvents. The applicator wheel or roller is used at a pressure of 2 to 4 kg/cm2.

V. APPLICATION AREAS A. Veneer Splicing

Particleboard with a decorative wooden veneer surface usually employs a hot-melt adhesive to eectively mate veneer edges down the length of the joint. Polyamide hot-melt adhesives are widely used for this veneer splicing process. The adhesive is more often than not supplied as a thread and positioned as such in a zigzag conguration. A heated press is employed to activate the adhesive followed by rapid cooling and setting. The rapid set required is best achieved with polyamide hot-melt adhesives, since their setting temperatures are much higher than, for example, those for EVA types, and since the range between application and setting temperatures achievable with polyamides is narrow. Another important feature of polyamide resins in the context of this application is the low melt viscosities achievable, thus ensuring rapid spreading and wetting of the molten lm.

B.

Edge Veneering and Edge Banding

Edge veneering and edge banding constitute by far the main area employing hot-melt adhesives which are based predominantly on EVA copolymer resins. For some applications, however, formulated polyamide hot melts are also used, particularly where exceptional heat resistance of the bond is required. Modern materials such as decorative surface board products, used in the manufacture of furniture components, require exposed edges to be covered with suitable edging materials. Most laminated surface board products consist of a decorative melamine or PVC layer bonded to a chipboard substrate. These board products have their own performance characteristics, which may inuence the edge bond. The choice, application, and fabrication method of edging plays a very important part in the manufacturing and nal application of the furniture produced. The choice of correct edging selection, therefore, depends very much on performance requirements and aesthetic value.

VI. GRAVURE APPLICATOR WHEEL TECHNOLOGY A. Application Process

The gravure applicator wheel is the most important individual component on an edgebander. Adhesive transfer to the substrate takes place when the substrate comes into contact with the gravure wheel applicator, which should rotate at the same speed as the
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moving track. Fresh adhesive is resupplied to the applicator wheel via the doctor blade in less than one revolution of the wheel. By adding another doctor blade and reversing the direction of the rotation of the gravure applicator wheel, much more adhesive can be driven onto the substrate. This may be necessary when edging substrates with a low density, wide edges, or edges that require a lot of gap lling (plywood). Worn gravure applicator wheels should be replaced immediately. On replacement, a change in machine performance will take place and equipment adjustments should be carried out. B. Heating

Where a cartridge heater is mounted in the center of the applicator wheel shaft, a hightemperature grease must be used as a heat-conducting medium between cartridge heater and applicator wheel; otherwise, there will be rapid cartridge heater burnout due to overheating. Adhesive temperature at the applicator wheel should be 12 to 13 C cooler than the adhesive temperature in the reservoir, to increase cartridge heater life. C. Behavior of Hot-Melt Adhesives on Gravure Wheel Applicators The single most important component on an edgebander is the gravure wheel applicator. All other components of the machine support the performance of the gravure wheel applicator. It is the gravure wheel application that controls the amount of hot-melt adhesive that is applied to the substrates, which, in turn, determines the number of calories of heat present to keep the hot-melt liquid until the time of bond formation. Of the hot-melt adhesive that is located between the peaks and the doctor blade, only 1% is transferred to the substrate; the balance becomes nothing more than squeeze-out. The volume of adhesive that is found in the groove area is the actual material that is transferred to the substrate edge. The purpose of the doctor blade is not to act as an adjustment to increase or decrease adhesive transfer to the substrate; rather, it serves to replace in the grooves the adhesive that has transferred to the substrate. An incorrect doctor-blade setting will either cause excess squeeze-out or insuciently ll the grooves, which will result in less than maximum adhesive transfer. The volume of adhesive that is transferred to the substrate is the single major controlling factor in determining the open time of the hot-melt adhesive. The volume of adhesive that does transfer is preset at the factory and is determined by the actual dimensions and geometry of the groove area. If the adhesive is too cohesively strong (too cold) or too cohesively weak (too hot), the adhesive will break out of the top of the groove in the gravure applicator wheel, reducing the adhesive transfer. This is exactly why the open time of the hot-melt adhesive is determined by the amount of adhesive transferred, not by raising the application temperature. If the shear force is too low to move the adhesive from the gravure applicator wheel (slow line speed), adhesive transfer is reduced from maximum; too high a shear force (fast line speed) also reduces transfer. Shear force aects the cohesive strength of the hot melt exactly like temperature.

VII.

FORMULATIONS FOR TYPICAL EVA EDGE-VENEERING HOT MELTS

Following are formulas for hot melts in various applications. Ingredients are listed in parts by weight.
Copyright 2003 by Taylor & Francis Group, LLC

A.

General-Purpose Hot Melts for Both Wood and Plastic Veneers

Hydrocarbon resin, 90 C m.p. Rosin ester, 85 C m.p. Coumarone indene resin, 105 C m.p. Butylated hydroxytoluene (BHT) antioxidant

5.50 8.00 5.00 0.20

Hot-Melt Adhesives
White Elvax 250 Elvax 210 Elvax 150 TiO2 pigment Superne light barytes Pink barytes 14.00 10.00 15.00 4.50 37.80 100.00 Natural 14.00 10.00 15.00 0.80 41.50 100.00 Brown 14.00 10.00 15.00 42.30 100.00

B.

Low-Cost Hot Melt for Wooden Veneer Only, Natural Color

Hydrocarbon resin, 90 C m.p. Hydrocarbon resin, 100 C m.p. Elvax 250 BHT antioxidant Superne light barytes TiO2

C. Hot Melt for Difficult Plastic Surfaces (e.g., Deccon, Natural Color)
Polyterpene resin, 115 C m.p. BHT antioxidant Elvax 260 Elvax 250 CaCO3 (15 mm) 30.00 0.20 10.00 35.00 24.80 100.00

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