United States Patent (19) 11 Patent Number: 4,999,407

Gilch et al. 45 Date of Patent: Mar. 12, 1991

(54) HOT-MELT POLYURETHANE ADHESIVE OTHER PUBLICATIONS

COMPOSITIONS
"Shaping Reactive Hot Melts. Using LMW Copolyes
(75) Inventors: Heinz G. Gilch, Bad Homburg; ters' paper by Adhesives Age, Authors Hans F. Huber
Karl-Heinz Albert, Oberursel, both and Hartmut Muller dated Nov. 1987.
of Fed. Rep. of Germany Moisture Curing Hot Melts, a paper from "Hot Melt
73) Assignee: Bostik, Inc., Middletown, Mass. /TAPPI Symposium" by Dr. Hans Huber and Dr.
Hartmut Muller.
(21) Appl. No.: 347,124
Primary Examiner-John C. Bleutge
22). Filed: May 4, 1989 Assistant Examiner-Thomas Hamilton, III
(30) Foreign Application Priority Data Attorney, Agent, or Firm--David G. Conlin; Gregory D.
May 6, 1988 GB United Kingdom ................. 88.10701 Williams
(57) ABSTRACT
51) Int. Cl........................ C08G 18/10; C08G 18/70
52) U.S. C. .................................... 525/457; 525/453; Quick-setting hot-melt adhesive compositions compris
525/458; 528/60; 528/67 ing a mixture of at least two polyurethane prepolymer,
58) Field of Search ....................... 525/453, 457, 458; each providing a different glass transition point to said
528/60, 66, 67 composition. Preferably one prepolymer has a tig above
(56) References Cited
room temperature and one prepolymer has a tig below
room temperature. These adhesive mixtures show an
U.S. PATENT DOCUMENTS attractive blend of properties, giving quick setting
3,509,232 4/1970 Schollenberger ................... 525/440 bonds which are flexible immediately after bonding and
which after curing have excellent heat stability and
FOREIGN PATENT DOCUMENTS resistance to hydrolytic and chemical attack.
0196749 10/1986 European Pat. Off. .
1385340 2/1975 United Kingdom . 11 Claims, No Drawings
 4,999,407 2
1.
ble at room temperature and temperatures down to the
HOT-MELT POLYURETHANE ADHESIVE transition point of the prepolymer.
COMPOSITIONS A mixture of two prepolymers as defined gives a
desirable combination of the properties, having flexible
BACKGROUND OF THE INVENTION 5 bonds even at low temperatures.
The present invention relates to quick-setting, hot The viscosity and setting time of the adhesives, its
melt adhesive compositions which are solvent-free, tackiness and the toughness of the bonds is determined
reactive compositions which can be applied at rela by the ratio of the two prepolymers. The viscosity of
tively low temperatures. Hitherto hot-melt materials the adhesive and the application temperatures which
including EVA, polyester or polyamide have been used 10 forms bonds with the adhesive is determined by the
for fast bonding processes and automatic adhesive appli glass transition points of the prepolymers. Thus an ad
cation requiring quick setting bonds but these have hesive can be "tailored' for a desired combination of
necessitated high application temperatures. properties.
For example, solvent-free reactive polyurethane hot It is preferred to use two prepolymers which are
15 incompatible since this provides especially good me
melt materials, such as are disclosed in DOS 2609 266,
solve the problem of high application temperatures by chanical properties. Preferable prepolymers are used
application of a low-viscosity hot melt at 100° C. which having molecular weights greater than 1500. Polymers
sets by crystallisation. Such adhesive systems exhibit of lower molecular weight are often compatible so that
good thermolytic and hydrolytic stability when chain 20 only one glass transition point can be observed. Prefera
extended and cross-linked by atmospheric moisture. bly the two polyols used should have different chemical
However, bonds provided by these crystallising poly Structures.
urethane prepolymers have low elasticity before curing Adhesive compositions according to the present in
resulting in low initial peel strength immediately after vention may be prepared either by mixing the two sepa
bonding and have a lower setting rate which depends 25 rately prepared prepolymers or by preparation of the
on the crystallisation rate of the polyester used. Other second prepolymer in the first prepolymer.
reactive crystalline polyurethane hot melts, such as the Bonds made with adhesives according to the inven
adhesive compositions disclosed in DOS 3.236 313, do tion are flexible immediately after setting as can be
show a better elasticity in the uncured state but have an demonstrated by peel strength measurements. After
undesirably high application temperature (approaching curing the bonds are tough and flexible down to the
those of conventional hot-melt materials) and exhibit 30 lower glass transition point and show good bond
pot life problems at application. It is accordingly an strength even at temperatures above the higher glass
object of the present invention to provide quick-setting,
hot-melt adhesive compositions comprising polyure transition point.
Thus the properties of an adhesive composition ac
thane pre-polymers which have improved flexibility 35 cording to the invention may be varied both by adjust
immediately after bonding whilst being heat stable and ing the ratio of the two polymers and by changing the
resistant to hydrolytic and chemical attack after curing. composition of one or both of the prepolymers.
SUMMARY OF THE INVENTION If more prepolymer with the higher glass transition
point
It is a further object of the invention to provide such are tougheris used, the adhesive is more viscous and the bonds
quick-setting adhesive compositions which can be ap tures and hydrolysis. and more resistant against higher tempera
plied at lower temperatures than conventional hot-melt more brittle. If more prepolymer At lower temperatures they are
materials.
with the lower glass
According to the present invention a quick setting, transition point or a different prepolymer with a lower
hot-melt polyurethane adhesive composition comprises tg is used, the adhesive becomes less viscous and the
a mixture of at least two amorphous polyurethane pre 45 bonds are softer and more flexible. The lower glass
polymers, each polyurethane prepolymer providing a transition temperature determines the lowest tempera
different glass transition point for said composition. ture at which bonds are flexible, whilst the higher glass
transition temperature determines application tempera
Preferably the first polyurethane prepolymer has a glass ture,
transition point above room temperature and the second 50 Theviscosity and setting rate.
polyurethane prepolymer has a glass transition point transition temperatureprepolymer
polyurethane
consists of
with the higher glass
a polyol (preferably a
below room temperature.
Such a composition comprising two polyurethane polyester diol) and a polyisocyanate and may optionally
contain plasticisers for lower viscosity. The polyol
prepolymers of differing glass transition point can be should have a molecular weight of more than 1000,
applied at a lower temperature than is usual for conven preferably
tional hot-melt materials, gives quick setting bonds temperaturemore
55 than 2000, is preferably solid at room
and has a glass transition point above 20
which are flexible immediately after bonding, and C.
which after curing have excellent heat stability and For lower viscosity and lower application tempera
resistance to hydrolytic and chemical attack. tures, the tig should be below 120 C., preferably not
The separate polyurethane polymers do not give
satisfactory properties when used in an adhesive com higher The
than 80 C.
polyol used to prepare prepolymers may be a
position. A prepolymer with a glass transition point
above room temperature sets quickly on cooling from terephthaliccopolymer of aromatic acids (such as isophthalic or
the application temperature but is unacceptably brittle acid) and/or aliphatic acids (such as adipic,
immediately after bonding. A prepolymer with a glass acelaic or sebacic acid) and low molecular diols (such as
transition point below room temperature may be ap 65 isocyanate ethylene glycol, butane diol, hexane diol etc). The poly
plied at a lower temperature, even at room temperature, used is preferably an aromatic diisocyanate
such as
but remains tacky and solidifies only on curing to give ene diisocyanate. 4.4 diphenyl methane diisocyanate or 2.4 tolu
an elastic film. Bonds with these prepolymers are flexi However, aliphatic diisocyanates may

H
 4,999,407 4.
3
also be used for polyurethane prepolymers with high the product, which had a glass transition at 34' C., is
u.v. stability. The prepolymer should be prepared with filled in moisture-proof containers or directly mixed
a NCO:OH ratio of 1.1 to 6.0, preferably 2.0 to 3.5 and with the prepolymer of lower tg.
at temperatures above the tig of the polyol, preferably The two prepolymers were melted and mixed to
between 80' and 130' C. 5 gether at 120° C. with 0.05 parts dibutyl tin dilaurate
The polyurethane prepolymer with the lower glass dissolved in 0.15 parts "Mesamoll' (RTM) plasticiser.
transition temperature is also prepared from a polyol After stirring for 30 minutes at 120° C. this mixture was
and a polyisocyanate. The polyol may be a linear or degassed under reduced pressure at 130 C. for 30 min
slightly branched polyester, a polyether or another utes and filled into aluminium cartridges which were
OH-terminated polymer. Particular polyesters such as 10 then sealed.
polycaprolactones or polycarbonates may also be used. At 130 C. (application temperature), the viscosity of
Preferably polyesterdiols are used have a molecular the product was measured to be 32 Pas. Differential
weight greater than 1000, preferably above 2000. Their Scanning Calorimetry (disc) measurement of this prod
glass transition temperature is preferably lower than uct showed glass transitions at -30 C., +7 C. and
room temperature, more preferably below -30°C. The 5 --34 C. The upper and lower transitions are due to the
polyisocyanate is preferably an aromatic diisocyanate respective prepolymers whereas the intermediate transi
such as 4.4 diphenyl methane diisocyanate or 2.4 tolu tion is due to the formation of some copolymer of the
ene diisocyanate but aliphatic diisocyanates may also be prepolymers.
used. The prepolymer is prepared with a NCO:OH ratio This adhesive composition sets quickly. Bonds with
higher than 1 to 6.0, preferably at 1.5-2.0, at tempera 20 this adhesive have a good bond strength at lower and
tures between room temperature and 160° C., prefera higher temperatures as is illustrated in Table 2. They
bly between 60 and 100° C. have an improved hydrolytic resistance which is shown
The mixture may also contain usual adjuncts such as by fulfilling the stringent requirements of the German
fillers, tackifying resins, catalysts and/or plasticisers. furniture industry (B4/10 test according to DIN 68603;
The mixture is usually an opaque solid at room tempera 25 after storage of beechwood bonds 6 hours in boiling
ture. It is applied at temperatures above the higher tg, water and 2 hours drying at ambient conditions, tensile
preferably between 100 and 140 C. strength must be higher than 8 N/mm2). (For detailed
results see Table 3).
DETAILED DESCRIPTION OF THE
INVENTION 30
EXAMPLE 2
In order that the present invention be better under A adhesive according to the invention was prepared
stood, it will now be described in greater detail with as a one-part formulation.
reference to preferred Examples and a Comparative 9.1 parts per weight of 4.4 diphenyl methane diisocy
Adhesive. anate and 0.2 parts tosyl isocyanate were melted at 60'
35 C. for 30 minutes under dry nitrogen. 65.5 parts of the
EXAMPLE 1. molten polyester with a glass transition point of 34 C.
An adhesive according to the present invention was same as used in Example 1 were added whilst stirring to
prepared from a mixture of two separately-prepared provide a NCO/OH ratio of 2.7.
polyurethane prepolymers having different glass transi The polyester with the higher tig was a hydroxyl-ter
tion points. minated, substantially linear polyester diol prepared
A prepolymer with a lower glass transition point was from a mixture of ethylene glycol, neopentylglycol and
synthesised from a hydroxyl-terminated, substantially 1.6. hexane diol with a mixture of terephthalic and iso
linear polyester from 1.6 hexane diol and a mixture of phthalic acid and had a molecular weight of 5600 (OH
adipic acid and isophthalic acid with a molecular number 20 and acid number 0.8). After stirring this
weight of 3.500 (OH number 33 and acid number 0.4) 45 mixture for 30 minutes at 120' C., 3.2 parts of 4.4" di
and 4.4 diphenyl methane diisocyanate in a molar ratio phenyl methane diisocyanate were added. Stirring was
to provide a NCO/OH ratio of 2.0, 86.0 parts by weight continued for 30 minutes. Then 21.8 parts of a polyester
of this poiyester was melted at 100 C. in a reactor, with a lower glass transition point are added to provide
equipped with an efficient stirrer, 0.25 parts tosyl isocy a NCO/OH ratio of 2.4. This polyester with the lower
anate and 13.75 parts di: henyl methane diisocyanate 50 tg was a hydroxyl-terminated, substantially linear poly
were added to the polyester whilst stirring. After stir ester prepared from 1.6 hexane diol and a mixture of
ring this mixture for 1 hour at 100 C., the product was adipic acid and isophthalic acid and had a molecular
filled into moisture-proof containers. The prepolymer weight of 3500 (OH number 33 and acid number 0.4).
had a viscosity of 18 Pas at 100 C. and a glass transition After 30 minutes stirring at 120' C., the mixture v. is
point of -39 C. 55 completed by addition of 0.05 parts dibutyl tin dilaurate
A prepolymer with a higher tig was prepared from dissolved in 0.15 parts "Mesamoll' (RTM) plasticiser.
another hydroxyl-terminat: , substantially linear poly This mixture was stirred for 30 minutes at 120' C. and
ester having a molecular weight of 5600 (OH number 20 then degassed under vacuum at 130 C. for 30 minutes.
and acid number 0.8) made from a mixture of ethylene The product was filled into aluminium cartridges which
glycol, neopentyl glycol and 1.6 hexane diol with a 60 were then sealed.
mixture of terephthaic and isophthalic acid. This poly This product has a viscosity of 91 Pas at 130' C. and
ester is reacted wit. 4,4'-diphenyl methane diisocya of 47 Pas at 150' C. The disc measurement of this prod
nate, in a molar rati o provide a NCO/OH ratio of 3.5. uct shows glass transitions at - 17 C. and +32 C.
84.45 parts by weigii of the polyester, being melted at This adhesive composition sets quickly. Bonds with
130° C. in a reactor equipped with an efficient stirrer. 65 this adhesive exhibit a good bond strength at lower and
0.25 parts tosyl isocyanate and 15.30 parts diphenyl higher temperatures as is again illustrated in Table 2.
methane diisocyanate were added to the polyester while They have an improved hydrolytic resistance and again
stirring. After stirring this mixture for 1 hour at 120' C., were able to meet requirements set down by the Ger
 4,999,407 6
5
man furniture industry (for results of the B 4/10 test water and then seven days drying at 23' C./50% rh. (B
according to DIN 68 603 see Table 3). 4/10 test according to DIN 68603)
TABLE 3
COMPARATIVE ADHESIVE Hydrolysis resistance
For purposes of comparison, a polyurethane prepoly Tensile shear strength of beechwood bonds after 6 hours in
boiling water followed by 2 hours in cold water and then
mer hot-melt adhesive was prepared in accordance with seven days drying at 23' C./50% r.h. (B 4/10 test according
DOS 2 609266. This adhesive is based on a crystallising to DIN 68603)
polyester having a crystalline melting point of 60 C. Comparative pu Adhesive 6.6 N/mm.
but showing a single glass transition at -35 C. The 10 EXAMPLE 1 8.1 N/mm2
properties of initial and final bond strength of the Com EXAMPLE 2 9.5 N/mm2
parative Adhesive are compared with those of the two
Examples of the present invention. I claim:
Tests were made with beechwood samples (bonding 1. A quick setting, hot-melt polyurethane adhesive
area 12X25 mm) for tensile shear strength measure 15 composition comprising:
ments and canvas samples (bonding area 80x25mm2) a mixture of at least two amorphous polyurethane
for peel strength measurements. The data are collated in prepolymers, wherein at least one polyurethane
Tables 1-3. prepolymer has a glass transition point above room
Application temperature was 100° C. for the compar temperature and at least one polyurethane prepoly
ative adhesive and for the two adhesives according to 20 mer has a glass transition point below room tem
the Examples was 130° C. perature.
2. A polyurethane adhesive composition according to
TABLE 1. claim 1, wherein the two polyols used to prepare the
Initial Bond Strength (Peel strength as N/cm) two prepolymers have different chemical structures.
25 3. A polyurethane adhesive composition according to
TABLE 1. claim 1 wherein the prepolymers used have molecular
initial Bond Strength (Peel strength as N/cm) weights greater than 1500.
(a) (b) (c) 4. A polyurethane adhesive composition according to
after 30 sec after 1 min after 5 min claim 1 wherein the prepolymers are prepared from
Comparative Adhesive 0 0 2 30 polyols and polyisocyanates at a NCO:OH ratio of
EXAMPLE 1. 17 23 30 about 1.1 to 6.0 at a temperature above the tig of the
EXAMPLE 2 32 47 5 polyol.
5. A polyurethane adhesive composition according to
claim 4 comprising polyols having a molecular weight
TABLE 2 35 of greater than about 1000 and a glass transition point
above 20' C.
Final Bond Strength (fully cured after 24 hours at 6. A polyurethane adhesive composition according to
Room Temperature) claim 4 wherein the glass transition point of the polyols
TABLE 2 is below about 120.
Final Bond Strength 40 7. A polyurethane adhesive composition according to
(fully cured after 24 hours at Room Temperature) claim 4 wherein the prepolymers are prepared at a tem
Tensile Shear Strength perature of between about 80 and 130 C.
(N/mm) 8. A polyurethane adhesive composition according to
(a) claim 1 wherein the prepolymers are prepared from
Peel at Toon 45 polyols and polyisocyanates at a NCO:OH ratio of
Strength tempera- (b) (c) (d) about 2.0 to 3.5 at a temperature about the tg of the
(N/cm) tre -20 C. 100 C. 150' C. polyol.
Comparative 53 10 13 mb. 1.0 0.1 9. A polyurethane adhesive composition according to
Adhesive
EXAMPLE 54 9 12 Inb 2.8 0.8
claim 8 wherein the prepolymers are prepared at a tem
EXAMPLE 2 72 10 12 mb. 2.5 0.7 50 perature of between about 80' and 130 C.
10. A polyurethane adhesive composition according
mb - material breakdown to claim 4 comprising polyols having a molecular
weight of greater than about 2000 and a glass transition
TABLE 3 point about 20 C.
55 11. A polyurethane adhesive composition acocording
Hydrolysis resistance to claim 4 wherein the glass transition point of the poly
Tensile shear strength of beechwood bonds after 6 ols is less than about 80s C.k k
hours in boiling water followed by 2 hours in cold
60

65