Method of processing adhesive compositions

Abstract

A method of applying an adhesive to a substrate is comprised of supplying a liquid adhesive composition, exposing the liquid adhesive composition to an increased temperature sufficient to form a molten adhesive composition, and dispensing the molten adhesive composition onto a substrate. The liquid adhesive composition may be comprised of a polymeric reinforcing phase component and an adsorbent phase component, both as heterogeneously dispersed particulates in an adsorbed liquid component. The reinforcing phase component is substantially incompatible with the liquid component, the adsorbent phase component is compatible or substantially more compatible with the liquid component than is the reinforcing phase component, and the reinforcing phase and adsorbent phase components are partially compatible with one another. Hot-melt or other liquid compositions may also include nanoparticles at least partially exfoliated as a result of shear mixing.

1 . A method of forming an adhesive composition, comprising: 
 mixing a polymeric reinforcing phase component and an adsorbent phase component in a liquid component to form a liquid dispersion;    fusing, melting and shear mixing the liquid dispersion to produce a homogeneous melt-blend; and    subsequently dispensing the melt-blend onto a substrate that is lower in temperature than the melt-blend, so that the melt blend cools to form a solid adhesive on the substrate.    
     
     
         2 . The method of  claim 1 , wherein the liquid dispersion is heated before and/or during the shear mixing.  
     
     
         3 . The method of  claim 2 , wherein the liquid dispersion is pumped through a heated mixer.  
     
     
         4 . The method of  claim 1 , wherein the reinforcing phase component is substantially incompatible with the liquid component, the adsorbent phase component is compatible or substantially more compatible with the liquid component than is the reinforcing phase component, and the reinforcing phase and adsorbent phase components are partially compatible with one another.  
     
     
         5 . A method of forming an adhesive composition, comprising forming a liquid dispersion comprised of a polymeric reinforcing phase component, an adsorbent phase component, and nanoparticles in a liquid component, and subjecting the liquid dispersion to mixing, either mechanical, ultrasound, or both, to achieve substantial exfoliation of the nanoparticles in the liquid dispersion.  
     
     
         6 . A method of forming an adhesive, comprising pre-shear blending nanometer sized particulates into a pre-weighed fraction of a liquid phase component of the adhesive composition to form a liquid concentrate of exfoliated nanoparticles; mixing the liquid concentrate with a polymeric reinforcing phase component, an adsorbent phase component, and any remaining amount of the liquid phase component to form a liquid dispersion, the liquid dispersion then being fused, melted, and shear mixed to produce a homogeneous melt-blend comprised of substantially exfoliated nanoparticles, and dispensing the melt-blend onto a substrate that is lower in temperature than the melt-blend, so that the melt-blend cools on said substrate to form a solid adhesive comprised of substantially exfoliated nanoparticles.  
     
     
         7 . A method of forming a liquid adhesive composition, comprising: 
 shear mixing nanometer sized particulates into a pre-weighed fraction of a liquid phase component of the adhesive composition to form a liquid concentrate of exfoliated nanoparticles;    mixing the liquid concentrate with the remainder of the liquid phase component and with a polymeric reinforcing phase component and an adsorbent phase component to form a liquid dispersion;    fusing, melting and shear mixing the liquid dispersion to produce a homogeneous melt-blend comprised of substantially exfoliated nanoparticles; and    subsequently dispensing the melt-blend onto a substrate that is lower in temperature than the melt-blend, so that the melt-blend cools on said substrate to form a solid adhesive comprised of substantially exfoliated nanoparticles.    
     
     
         8 . A method of processing a hot-melt adhesive composition comprised of substantially aggregated nanoparticles, comprising melting and shear mixing the adhesive composition to produce a homogeneous melt-dispersion comprised of at least partially exfoliated nanoparticles, and subsequently dispensing the melt-dispersion onto a substrate that is lower in temperature than the melt-dispersion, so that the melt-dispersion cools to form a solid adhesive on the substrate, wherein the solid adhesive is comprised of substantially exfoliated nanoparticles.  
     
     
         9 . A method of forming an adhesive composition, comprising: 
 mixing a polymeric reinforcing phase component, an adsorbent phase component and a chemical blowing agent in a liquid component to form a liquid dispersion;    mixing the liquid dispersion while applying heat and pressure thereto to produce a homogeneous melt-blend; and    subsequently dispensing the melt-blend at atmospheric pressure onto a substrate that is lower in temperature than the melt-blend, so that the melt blend forms a foam that solidifies into a closed cell solid, or into a partially closed cell solid, upon cooling.    
     
     
         10 . The method of  claim 9  wherein the liquid dispersion formed is further comprised of nanoparticles.  
     
     
         11 . A method of forming flexible plastics, rigid plastics, structural plastics, caulks, sealants, adhesives or coatings utilizing a liquid plastisol/hot melt hybrid multiple component composition comprised of heterogeneously dispersed particulates within a liquid phase component, where said composition has the rheological characteristics of a liquid dispersion at room temperature, wherein said composition can be fused at elevated temperatures and then solidified into a solid plastic material upon cooling; wherein said plastic material composition comprises a polymeric reinforcing phase component, an adsorbent phase component, and an adsorbed liquid component; such that the reinforcing phase component is substantially incompatible with the liquid component of the plastic material composition, and the reinforcing phase and adsorbent phase components are partially compatible with one another.  
     
     
         12 . A method of forming an adhesive composition, comprising: 
 mixing a polymeric reinforcing phase component and an adsorbent phase component in a liquid component to form a liquid dispersion;    fusing, melting and shear mixing the liquid dispersion to produce a homogeneous melt-blend;    cooling the melt blend to form a solid adhesive;    melting the solid adhesive to form a second melt-blend; and    dispensing the second melt-blend onto a substrate that is lower in temperature than the second melt-blend, so that the second melt blend cools to form a solid adhesive on the substrate.    
     
     
         13 . The method of  claim 12 , wherein the liquid dispersion is further comprised of nanoparticles.  
     
     
         14 . The method of  claim 13 , further comprising blending the second melt-blend with a hot melt adhesive, the hot melt adhesive having been a solid at room temperature, prior to dispensing.  
     
     
         15 . A method of applying an adhesive to a substrate, comprising: 
 supplying a liquid adhesive composition;    exposing the liquid adhesive composition to an increased temperature sufficient to form a molten adhesive composition; and    dispensing the molten adhesive composition onto a substrate.    
     
     
         16 . The method of  claim 16 , the liquid adhesive composition being a liquid dispersion comprised of a polymeric reinforcing phase component and an adsorbent phase component in a liquid.  
     
     
         17 . The method of  claim 16 , further comprising shear mixing the molten adhesive composition.  
     
     
         18 . The method of  claim 16 , further comprising pumping the liquid adhesive composition through a heated mixer.  
     
     
         19 . The method of  claim 16 , wherein the liquid adhesive composition is supplied at room temperature.