Blends of high Tg polymer emulsions and pressure sensitive adhesive polymer emulsions useful as pressure sensitive adhesives

Abstract

A pressure sensitive adhesive with a good balance of adhesive and cohesive properties, produced by blending a high Tg polymer emulsion with an aqueous pressure sensitive adhesive polymer emulsion. The high Tg polymer has a Tg of 30° C. to 300° C., a number average particle size (Dn) of 80 to 1000 nm, and a particle size distribution in which less than 25% of the particles are less than 80 nm and less than 25% of the particles are more than 1000 nm.

Description

BACKGROUND OF THE INVENTION

[0002] Pressure sensitive adhesives are widely used for making labels, tapes, and for laminating polymeric films such as poly(vinyl chloride) and polyester, for forming decals and other related products.

[0003] The term “pressure sensitive” is used to designate adhesives that are aggressively and permanently tacky in dry form at room temperature and firmly adhere to a variety of substrates. Most applications for permanent type pressure sensitive adhesives require excellent peel, tack and shear. Repositionable adhesives may require less tack but they must have sufficient tack and cohesive strength to adhere to a substrate and yet can be removed without a portion of the adhesive adhering to the substrate. These pressure sensitive adhesives should also be resistant to oozing from the substrate when applied to a substrate and placed under pressure as in roll stock. Another requirement of aqueous emulsion pressure sensitive adhesives is the ability to coat them on various adhesive substrates such as Mylar, poly(vinyl chloride) and silicone coated papers, and film release liners.

[0004] Pressure sensitive adhesives are derived from copolymers, such as alkyl acrylate and alkyl methacrylate copolymers, that yield soft and tacky polymers having a low glass transition temperature (Tg); by low Tg is meant a Tg of −10 to −90° C. Homopolymers do not have the properties required for pressure sensitive adhesives; they are therefore modified by copolymerization with at least a small amount of other comonomers to form pressures sensitive adhesives. In addition to the comonomer composition required for pressure sensitive adhesives, a significant amount of low molecular weight copolymer has been found to be important in achieving the adhesive properties needed. Chain transfer agents are typically used during the polymerization process to obtain the desired low molecular weight copolymer fraction.

[0005] Attempts to enhance adhesive properties such as adhesion to low density polyethylene or adhesion at sub-ambient temperatures requires a reduction in the modulus and/or Tg of the adhesive. Typically, this will compromise cohesive properties such as shear resistance. Conversely, the addition of higher Tg polymers to improve the cohesion of a soft pressure sensitive adhesive has resulted in a dramatic loss of adhesion.

[0006] Combining high and low Tg polymers has been shown to be useful in coatings. For example: J. Y. Cavaillé, et al., “Structural morphology of poly(styrene)-poly(butyl acrylate) polymer-polymer composites studied by dynamic mechanical measurements,” Colloid and Polymer Science, 1991, Vol. 269, pages 248-258, provides mechanical data on the blend of low Tg poly(butyl acrylate) and higher Tg polystyrene as a film; M. Hidalgo,et al. “Polystyrene(1)/poly(butyl acrylate-methacrylic acid)(2) core-shell emulsion polymers. Part II: Thermomechanical properties of latex films,” Colloid and Polymer Science, 1992, Vol. 270, pages 1208-1221, provides thermomechanical data on films formed from core shell emulsion polymers containing high and low Tg polymers; and S. Lepizzera, et al., “Film Forming Ability and Mechanical Properties of Coalesced Latex Bends,” Journal of Polymer Science Part B, 1997, pages 2093-2101, discloses the film forming ability of blends of hard and soft latexes. It has been found that the low Tg polymers reported in these publications do not have the properties needed to use them as pressure sensitive adhesives.

[0007] Tackifying resins and plasticizers have been used in the past to improve the adhesion of pressure sensitive adhesives to low surface energy surfaces such as low density polyethylene or polypropylene. However the improvement in adhesion is at the expense of cohesive properties.

[0008] EP 0 593231 A1 (1994) discloses the addition of low molecular weight (<7,000) ethylene oxide-block-propylene oxide copolymers to acrylic pressure sensitive adhesives to improve low temperature adhesion. These additives plasticize the polymer and thus reduce cohesive strength. Because these polyether additives are also water soluble, the water resistance and humidity resistance of the pressure sensitive adhesive are compromised.

[0009] Another approach which has been pursued to achieve the requisite balance of cohesion and adhesion in pressure sensitive adhesives has been the incorporation of macromolecular monomers (macromers) during polymerization. U.S. Pat. No. 5,294,668 (1994) discloses pressure sensitive adhesives comprising a blend of a tackifying resin and a graft copolymer of one or more of ethylene and C3-C18 α-olefins and one or more of macromonomers. The macromonomers are a reaction product of at least one of an ethenylarene and a conjugated diene monomer. Similarly, U.S. Pat. No. 4,732,808 (1988) discloses the incorporation of macromers into a solvent-borne pressure sensitive adhesive to achieve a balance of adhesion and cohesion. Macromers, due to their exceedingly low solubility in water, are generally not suitable for incorporation into polymer emulsions.

[0010] JP 5-271645 (1993) discloses pressure sensitive adhesive resin compositions containing, on a solids basis, 60 to 95 wt % of a vinyl copolymer aqueous dispersion having particle diameters of 500 to 2000 nm and a Tg of −40 or lower, and 5 to 40 wt % of a vinyl copolymer aqueous dispersion having particle diameters of about 200 nm or lower and a Tg of 50° C. or higher.

[0011] JP 2001-207146 discloses an aqueous pressure sensitive adhesive composition consisting of an acrylic pressure sensitive adhesive emulsion and 0.5 to 20 parts by weight (solids), based on 100 parts by weight of the acrylic pressure sensitive adhesive emulsion, a copolymer emulsion having particle diameters of 50 to 600 nm and a Tg of −30° C. to +50° C. The mean particle diameters of the acrylic pressure sensitive adhesive emulsion are 200 to 1000 nm.

BRIEF SUMMARY OF THE INVENTION

[0012] The present invention is directed to a pressure sensitive adhesive with a good balance of adhesive and cohesive properties that is obtained by blending a high Tg polymer emulsion, or dispersion, with an aqueous pressure sensitive polymer emulsion.

[0013] The high Tg polymer has a Tg of 30° C. to 300° C. and a number average particle size (Dn) of 80 to 1000 nm. Suitable monomers for making the high Tg polymer may include any vinyl monomer which, when homo- or copolymerized, will meet the Tg requirement; for example, styrene, acrylate esters, methacrylate esters, vinyl chloride, vinyl esters, acrylonitrile, and methacrylamide. The high Tg polymer dispersions may also include those not made by traditional emulsion polymerization processes, such as polymers made by suspension, bulk or solution polymerization which are subsequently dispersed in water. The high Tg polymer may contain up to 20% of a crosslinking monomer.

[0014] The pressure sensitive adhesive polymer may contain various combinations of monomer units such as alkyl(meth)acrylates, vinyl esters, chloroprene, butadiene, and isoprene. Pressure sensitive adhesive polymer dispersions may also include those not made by traditional emulsion polymerization processes, such as natural rubber latex, polyurethane dispersions, and polysiloxane dispersions. Other examples are block copolymers such as the styrene-isoprene-styrene or styrene-butadiene-styrene polymer offered by Shell Chemical under the Kraton trademark. The block copolymers may be dissolved in a suitable solvent and dispersed in water with subsequent stripping of the solvent.

[0015] The blends are useful in making labels, tapes and other traditional pressure sensitive adhesive constructions. The blends have been found to be particularly useful when used in wet lamination or dry lamination processes in which the blend is coated on siliconized liner and transferred to paper face stock in the manufacture of paper labels. They are also suitable for use on difficult to bond surfaces. Although not all inclusive, examples of difficult to bond surfaces are polyethylene (PE), poly(ethylene terephthalate) (PET), metalized poly(ethylene terephthalate) (MPET), polypropylene, oriented polypropylene (OPP), polyester, aluminum foil, and coated paperboard. Included among the difficult to bond surfaces are surfaces having a surface energy of less than about 40 dynes/cm2.

[0016] The present invention provides several advantages over known methods for achieving a balance between adhesive and cohesive properties of pressure sensitive adhesives. For example it:

[0017] eliminates the need to add plasticizers or tackifier resins to pressure sensitive adhesive emulsions;

[0018] eliminates “bleeding” associated with use of plasticizers in pressure sensitive adhesives;

[0019] provides a simple method of forming an improved pressure sensitive adhesive, without the need for special equipment;

[0020] provides flexibility in tailoring the performance of the pressure sensitive adhesive by merely changing the ratio of high Tg polymer to pressure sensitive adhesive polymer or changing the type of high Tg polymer used in the blend; and

[0021] can be used on difficult-to-bond surfaces.

DETAILED DESCRIPTION OF THE INVENTION

[0022] Emulsion polymerization of ethylenically unsaturated monomers to produce aqueous based pressure sensitive adhesive polymer emulsions is well known. Examples of appropriate monomers that can be used to produce aqueous based pressure sensitive adhesive polymers are: (meth)acrylic acid, C1 to C8 alkyl (meth)acrylate, C1 to C13 hydroxyalkyl(meth)acrylate, di-C1 to C13 alkyl maleate/fumarate, vinyl ester such as vinyl acetate, styrene, butadiene, 2-chloro-1,3-butadiene, and ethylene. The aqueous based pressure sensitive adhesive polymers can also be natural rubber, silicone polymers, polyurethanes, and the like. The preferred number average particle size of the pressure sensitive adhesive polymer emulsion is less than 500 nm. The most preferred number average particle size is less than 300 nm. The pressure sensitive adhesive copolymers are designed to have a Tg of −10° C. to −90° C., preferably −25° C. to −75° C. and a looptack adhesion value greater than 1 pound per linear inch (pli); preferably greater than 1.5 pli, according to Pressure Sensitive Test Council (PSTC) test method, PSTC-5, tested on stainless steel panel.

[0023] The high Tg polymer emulsion, or dispersion, can also be produced by well known emulsion polymerization techniques in which vinyl monomers, including acrylic monomers, are chosen that will produce a polymer or copolymer with a Tg of 30° C. to 300° C.; and a number average particle size (Dn) ranges from 80 to 1000 nm. Suitable monomers include styrene, C1 to C8 alkyl(meth)acrylate, vinyl chloride, vinyl esters such as vinyl acetate, acrylonitrile, methacrylonitrile, and the like. The polymer can also contain 0 to 20 wt % crosslinking monomer. The emulsion polymerization may be conducted in a stage or sequential manner using various combinations of monomers, in order to obtain a polymer or copolymer with an appropriate Tg and number average particle size.

[0024] It is also possible to prepare polymer emulsion particles having a first stage core which is below the target Tg and particle size range, provided that a second stage shell polymer, which is within the target Tg range, is then applied to this core and the total particle size, shell plus core, is within the particle size range.

[0025] The high Tg polymer dispersions may also include those not made by traditional emulsion polymerization processes, such as polymers made by suspension, bulk or solution polymerization which are subsequently isolated and dispersed in water. In addition, high Tg polymer powders can be dispersed in water for use in this invention.

[0026] Polymerization can be initiated by thermal initiators or by a redox system. A thermal initiator is typically used at temperatures at or above about 70° C. and redox systems are preferred at temperatures below about 70° C. The amount of thermal initiator used in the process is 0.1 to 3 wt %, preferably more than about 0.5 wt %, based on total monomers. Thermal initiators are well known in the emulsion polymer art and include, for example, ammonium persulfate, sodium persulfate, and the like. The amount of oxidizing and reducing agent in the redox system is about 0.1 to 3 wt %. Any suitable redox system known in the art can be used; for example, the reducing agent can be a bisulfite, a sulfoxylate, ascorbic acid, erythorbic acid, and the like. The oxidizing agent can include hydrogen peroxide, organic peroxide such as t-butyl peroxide, persulfates, and the like.

[0027] Chain transfer agents, well known in the aqueous emulsion polymerization art; are typically used but are not required. Examples include dodecyl mercaptan, mercaptocarboxylic acids, and esters of mercaptocarboxylic acid. The chain transfer agent is added at levels of about 0.01 to 0.5 wt %, preferably 0.02 to 0.15 wt %, based on the weight of monomers.

[0028] Effective emulsion polymerization reaction temperatures range from about 50 to about 100° C.; depending on whether the initiator is a thermal or redox system.

[0029] In addition to the above reaction conditions and components, the polymer latex may be stabilized with conventional emulsifiers and protective colloids. Examples include any of the known and conventional surfactants and emulsifying agents, principally the nonionic and anionic materials, heretofore employed in the emulsion copolymerization. Among the nonionic surfactants found to provide good results are the Igepal surfactants supplied by Rhone-Poulenc. The Igepal surfactants are members of a series of alkylphenoxy-poly(ethyleneoxy)ethanols having alkyl groups containing from about 7-18 carbon atoms, and having from about 4 to 100 ethyleneoxy units, such as the octylphenoxy poly(ethyleneoxy)ethanols, nonylphenoxy poly(ethyleneoxy)ethanols, and dodecylphenoxy poly(ethyleneoxy)ethanols. Examples of nonionic surfactants include polyoxyalkylene derivatives of hexitol (including sorbitans, sorbides, manitans, and mannides) anhydride, partial long-chain fatty acid esters, such as polyoxyalkylene derivatives of sorbitan monolaurate, sorbitan monopalmitate, sorbitan monostearate, sorbitan tristearate, sorbitan monooleate and sorbitan trioleate.

[0030] The high Tg polymer emulsion is blended with the pressure sensitive adhesive polymer emulsion in an amount of 1 to 50 wt %, based on the dry weight of both polymers. It has been found that the required Tg range and particle size range of the high Tg polymer emulsion becomes more restricted as the loading increases. At 1 wt % to approximately 20 wt % of high Tg polymer, the preferred Tg range is 30° C. to 300° C. and the preferred particle size is 80 nm to 1000 nm. At higher levels of high Tg polymer, both the Tg range and the particle size range that will give acceptable performance become narrower. At approximately 20% to 50% level, the preferred Tg is 50° C. to 300° C. and the preferred particle size is 100 to 1000 nm.

[0031] In addition to control of the number average particle size of the high Tg polymer emulsion, control of particle size distribution (PSD), is also necessary to achieve optimum performance. The preferred PSD contains less than 25% of the particle population below 80 nm and less than 25% of the particle population above 1000 nm. The most preferred PSD contains less than 10% of the particle population below 80 nm and less than 10% of the particle population above 1000 nm.

[0032] The polymer blend may be formulated with tackifying resins and other additives known in the pressure sensitive adhesive art. A particular benefit of the invention is that it provides excellent adhesion at much lower tackifier resin levels than are typically required in the prior art. Typical prior art tackifier levels are 25-40 wt % of the total solids. Tackifier levels useful with the current invention are 0-40 wt %, based on the total solids. The preferred tackifier levels are 0-25 wt % and most preferred tackifier levels are 0-15 wt %.

[0033] The invention will be further clarified by a consideration of the following examples, which are intended to be purely exemplary of the use of the invention.

[0034] The test methods used to evaluate the adhesives or coatings in the examples are industry standard tests. They are described in publications of the Pressure Sensitive Tape Council (PSTC), Glenview, Ill. Products used in the examples are:

[0035] Flexcryl® 1624 acrylic copolymer pressure sensitive adhesive latex, Tg=−58° C.

[0036] Flexcryl 1625 acrylic copolymer pressure sensitive adhesive latex, Tg=−48° C.

[0037] Flexcryl 1614 vinyl acetate/dioctylmaleate copolymer pressure sensitive adhesive latex, Tg=−28° C.

[0038] Flexcryl LC−31 tackified acrylic copolymer; Tg −40° C.

[0039] All Flexcryl products supplied by Air Products and Chemicals, Inc.

[0040] Vinnolit P70F poly(vinyl chloride) homopolymer resin powder; supplied by Vinnolit Kunststoff GmbH.; Tg=80° C.

[0041] Dispercoll C74 polychloroprene latex; supplied by Bayer Corp.

[0042] Hartex 101 natural rubber latex; supplied by Firestone Polymers Co.

[0043] Rovene 9410 styrene/butadiene latex, 25% styrene, Tg=−56° C.; supplied by Ameripol Synpol Corp.

[0044] The following abbreviations are used in the examples: DDM=dodecylmercaptan; BA=butyl acrylate; EHA=2-ethylhexyl acrylate; MAA=methacrylic acid; MMA=methyl methacrylate; PBA=poly(butylacrylate); PBA/MMA=poly(butyl acrylate-methyl methacrylate); PBA/VAc=poly(butyl acrylate-vinyl acetate); PMMA=poly(methyl methacrylate); PMMA/MAA=poly(methyl methacrylate-methacrylic acid); PVC=poly(vinyl chloride); PS=polystyrene; PS/MMA=poly(styrene-methyl methacrylate); PVAc=poly(vinyl acetate).

EXAMPLE 1

Comparison of Blends of High and Low Tg Polymers

[0045] Low Tg polymers, reported in the prior art as useful for coatings and adhesives, were prepared and compared to traditional commercial pressure sensitive adhesives. Tests for adhesion, tack, and shear resistance were carried out and the results are reported in Table 1.

TABLE 1
Coating/Adhesive	Tg,	LDPE Peel	Loop-	Shear	Low Temp.
Latex	° C.	Adhesion,1 pli	tack,2 pli	Resistance,3 hrs	Adhesion,4 pli
PBA/MMA	−29	0.06	0.83	14.9	0.01
Lepizzeraa
PBA	−55	0.01	0.91	1.6	0.26
Cavaillé 1991b
Flexcryl 1625	−55	0.7	2.8	11.5	0.90
Flexcryl 1624	−58	0.46	2.5	0.5	1.83
Flexcryl LC-31	−40	0.93	2.92	0.37	1.31
1PSTC-1, 180 degree peel with 30 min dwell
2PSTC-5, tested on stainless steel panel
3PSTC-7, ½ × ½-inch surface with 500 g weight
4PSTC-1, 180 degree peel with 30 min dwell performed in 35° F. cold box on corrugated board
aS. Lepizzera, et al., “Film Forming Ability and Mechanical Properties of Coalesced Latex Bends,” Journal of Polymer Science Part B, 1997, pages 2093-2101
bJ. Y. Cavaillé, et al., “Structural morphology of poly(styrene)-poly(butyl acrylate) polymer-polymer composites studied by dynamic mechanical measurements,” Colloid and Polymer Science, 1991, Vol. 269, pages 248-258

[0046] The data in Table 1 demonstrate that although the prior art polymer emulsions (a and b) are within the Tg range of pressure sensitive adhesives, they do not exhibit pressure sensitive adhesive properties. It is believed that the difference in properties between the prior art examples and the commercial pressure sensitive adhesives is due to several factors, some of which are listed below:

[0047] With regard to Cavaillé 1991:

[0048] No chain transfer agent was present in the synthesis in order to reduce molecular weight and thus achieve pressure sensitivity.

[0049] Monomer was added to reactor all at once without a monomer delay. This would further increase molecular weight due to the nature of polymerization kinetics.

[0050] The method is not commercially feasible due to excessive exotherm resulting in runaway reaction (note that the run in Cavaillé 1991 was prepared at 10% solids to control exotherm; 10% solids is not a commercially viable solids content).

[0051] Polymerization was carried out at a low temperature (i.e., 70° C., with potassium persulfate), which would further increase molecular weight beyond the range for pressure sensitive adhesives.

[0052] Polymer was a butyl acrylate homopolymer; in practice, copolymers are needed to achieve balanced pressure sensitive adhesive performance and stability.

[0053] With regard to Lepizzera, a Tg of −29° C. is relatively high for a pressure sensitive adhesive polymer and would dictate a significant reduction in molecular weight to counter-balance this effect and achieve pressure sensitivity; however no chain transfer agent was present in the method of synthesis in order to reduce molecular weight and thus achieve pressure sensitivity.

EXAMPLE 2

Dry Lamination

[0054] Pressure sensitive adhesive acrylic latexes were prepared as describe below and blended with a variety of high Tg latexes. Tests for adhesion, tack, and shear resistance were carried out and the results of the tests are presented in Table 2.

[0055] High Tg latexes were prepared by methods known in the art and described below. The ratio of the weight average to the number average particle size was typically 1.1-1.2, but latexes of broader polydispersity work equally well, provided they are within the limits discussed above. The number average particle size of each latex is given in Table 2.

[0056] The pressure sensitive adhesive acrylic latexes A, C, D, E, F, and G were a 98/2 ratio of EHA and MAA. Acrylic latex B was a 90.9/7.3/1.8 ratio of EHA/MMA/MAA. The latexes were prepared by a semi-continuous process employing a seed step and a monomer emulsion delay and containing varying levels of dodecylmercaptan chain transfer agent, in order to control molecular weight of the polymer. The Tg of each of A, C, D, E, F, and G was −60° C. The Tg of B was −53° C. The respective number average particle sizes and chain transfer agent levels are noted in Tables 2 and 3.

[0057] Pressure Sensitive Adhesive Emulsion Polymerization Recipe

[0058] Monomer Pre-Emulsion

[0059] 196 g EHA

[0060] 4 g MAA

[0061] 0.05-0.30 g DDM

[0062] 80 g deionized water

[0063] 14 g Stepan B27 nonylphenolethoxylate sulfate surfactant (30% active)

[0064] Initial Reaction Kettle Contents

[0065] 200 g deionized water

[0066] 0.2 g potassium persulfate

[0067] Initial reactor contents were heated to 75° C. while being purged with nitrogen and agitated at 250 rpm. Then 30 g of monomer pre-emulsion (above) was added and the seed formation allowed to proceed. The amount of monomer pre-emulsion and the temperature was varied, as known in the art, to alter the particle size of the seed. After 45 minutes, the temperature was raised to 80° C. and the monomer delay was started to achieve complete addition over a period of 3 hours. An additional 0.2 g of potassium persulfate in 5 ml of water was added. The reaction allowed to proceed for another hour and then cooled.

[0068] High Tg Emulsion Polymerization

[0069] Monomer

[0070] 230 g styrene

[0071] 4.6 g divinylbenzene

[0072] Initial Reaction Kettle Contents

[0073] 400 g deionized water

[0074] 0.15 g potassium persulfate

[0075] 6 g Stepan B-27 surfactant (30% active)

[0076] Surfactant Delay

[0077] 4 g Stepan B27

[0078] 100 g deionized water

[0079] Initial reactor contents were heated to 75° C. while under nitrogen purge and agitated at 350 rpm. Then 30 g of the styrene monomer mixture were added and the reaction allowed to continue for 45 minutes to generate the seed latex. The temperature was raise to 80° C. and the styrene monomer mixture and surfactant delays started to achieve complete addition over a 3-hour period. The temperature was raised to 85° C. and another 0.15 g of potassium persulfate in 5 ml of water was added and the reaction allowed to proceed for another hour and then cooled. This basic procedure was varied using different monomers and conditions to achieve the range of high Tg latexes of varying particle size discussed below. The particle size was controlled by altering the ratio of the seed monomer to the total monomer used.

[0080] The compositions, containing 30 parts high Tg polymer latex and 70 parts acrylic latex (dry ratio), were applied to 2-mil polyethylene terephthalate (PET) film at a coat weight of 24-26 g/m2 and dried for 10 minutes at 70° C., prior to laminating to siliconized paper liner. After aging for 24 hours at 72° F. (22° C.) and 52% relative humidity (RH), the siliconized liner was removed and the coated PET was bonded with a second substrate; i.e., low density polyethylene (LDPE), stainless steel, and corrugated board. The results of adhesion and cohesion tests are present in Table 2.

TABLE 2
70 Parts Acrylic Latex to 30 Parts High Tg Latex Additive (Dry Ratio)
				LDPE		Shear	Low
	Tg of	Additive	Particle	Peel	Loop-	Resist-	Temp.
	Additive,	Polymer	Size,	Adhesion	tack	ance	Ahesion
Run #	° C.	Type	nm	(1), pli	(2), pli	(3), hrs	(4), pli
ACRYLIC LATEX
A SERIES
585 ppm DDM
Dn = 236 nm
1	none			0.66	2.62	0.20	1.37
2	110	PMMA	211	0.97	2.28	1.62	0.39
3	110	PMMA	164	1.48	2.22	3.0	0.25
4	110	PMMA	155	1.33	2.81	2.7	0.30
5	110	PMMA/MAA	143	1.44	2.16	3.32	0.25
6	110	PMMA	135	1.61	2.44	10.44	0.14
7	110	PMMA	109	1.78	2.70	12.86	0.11
8	105	PS	134	0.96	1.67	4.24	30% fiber
							pick
9	39	PBA/MMA	109	0.07	0.98	0.45	0
10	38	PBA/MMA	180	0.14	0.71	0.63	0
ACRYLIC LATEX
SERIES B
(90.9/7.3/1.8
EHA/MMA/MAA)
573 ppm DDM
Dn = 123 nm
11	none			0.86	2.4	0.28	1.28
12	110	PMMA	135	0.98	1.96	9.60	0.15
13	110	PMMA	76	0.98	1.71	29.9	0
14	110	PMMA	91	0.51	1.72	39.3	0.02
15	39	PBA/MMA	109	0.13	0.80	9.1	0
ACRYLIC LATEX
C SERIES
1463 ppm DDM
Dn = 134 nm
16	none			1.0	3.5	0.05	2.2
17	110	PMMA	155	1.42		0.14	0.57
18	110	PMMA	211	1.16		0.09	0.87
19	78	PVC	201	0.63	1.82	0.10	0.67
20	18	PBA/VAc	250	0.02			0
21	40	PVAc	164	0.03			0
ACRYLIC LATEX
D SERIES
1024 ppm DDM
Dn = 142
22	none			0.5	2.42	0.09	1.58
23	110	PMMA	211	0.71	3.31	0.51	0.23
24 (tackifier) (5)	110	PMMA	211	1.21	3.06	0.6	0.36
25	78	PVC	201	0.48	1.55	0.38	0.89
(1) PSTC-1, 180 degree peel with 30 minutes dwell
(2) PSTC-5, tested on stainless steel panel
(3) PSTC-7, ½ × ½-inch surface with 500 g weight
(4) PSTC-1, 180 degree peel with 30 minutes dwell performed in 35° F. (1.7° C.) cold box on corrugated board
(5) Contained 15 dry wt % mixed rosin/hydrocarbon tackifier having a 85° C. softening point.

[0081] Runs 2-8 show that the addition of high Tg latexes in the Tg range and particle size range of this invention improves the shear resistance of the acrylic pressure sensitive adhesive latex of Run 1 while still maintaining a bond at low temperature. Runs 2-8 also show a surprising improvement in adhesion to LDPE compared to the control Run 1. As stated above, at an approximate 20 to 50% level of high Tg polymer, to achieve acceptable performance, the preferred Tg range is 50° C. to 300° C. and the preferred particle size range is 100 nm to 1000 nm. Runs 2-8 are within the preferred range; however, it is clear that even within this range low temperature adhesion improves in the upper portion of the range.

[0082] Although Runs 9 and 10 show an improvement in shear resistance, there is no bond formed at low temperature and the LDPE adhesion is much lower than that for Runs 1-8. The PBA/MMA copolymers of Runs 9 and 10 are below the Tg range required to provide acceptable performance at a 30% level of high Tg polymer level.

[0083] It is completely counterintuitive and unexpected that a higher Tg latex additive would perform better than a lower Tg latex additive, given that a requisite for pressure sensitivity is that the polymer has a low Tg.

[0084] Run 12 shows the effect of addition of a high Tg latex of the invention to the low Tg pressure sensitive adhesive latex of Run 11. Again, the shear resistance was improved while still maintaining a low temperature bond and good LDPE adhesion.

[0085] Although Runs 13 and 14 are within the desired Tg range, they are below the minimum particle size necessary to yield good performance at the 30% level of high Tg polymer. Runs 13 and 14 retain LDPE adhesion but do not form a low temperature bond.

[0086] Run 15 used a PBA/MMA latex with a Tg below the necessary range at the 30% addition level. LDPE adhesion was compromised and there was no low temperature bond.

[0087] Runs 17-19 used high Tg latexes within the desired Tg and particle size ranges for the 30% addition level. These show shear improvement relative to Run 16 with good low density polyethylene (LDPE) adhesion and bonds at low temperature.

[0088] Runs 20 and 21 are below the required Tg range for the 30% addition level, and have very poor LDPE adhesion and no low temperature bond.

[0089] Runs 23-25 show the use of high Tg latexes within the desired Tg and particle size ranges for the 30% addition level in combination with the pressure sensitive adhesive latex of Run 22. Once again, there is an improvement in shear resistance with good LDPE adhesion while still maintaining a bond at low temperature.

[0090] Run 24 shows that the blends are amenable to addition of tackifier resin. Whereas tackifier addition is known in the art to reduce shear resistance, Run 24 shows that it is retained or slightly improved when used in conjunction with the current invention.

EXAMPLE 3

Use of Lower Levels of High Tg Polymer

[0091] Compositions, containing 17.5 parts high Tg latex and 82.5 parts acrylic latex or 15 parts high Tg latex and 85 parts acrylic latex, were applied to 2-mil polyethylene terephthalate (PET) film at a coat weight of 24-26 g/m2 and dried for 10 min at 70° C., prior to laminating to siliconized paper liner. After aging for 24 hours at 72° F. (22° C.)and 52% RH, the siliconized liner was removed and the coated PET was bonded with a second substrate; i.e., low density polyethylene (LDPE), stainless steel, and corrugated board. The results of adhesion and cohesion tests are present in Tables 3 and 4.

TABLE 3
17.5 Parts High Tg Additive Latex Blended with 82.5 Parts Acrylic Latex
				LDPE		Shear	Low
	Tg of	Additive	Particle	Peel		Resist-	Temp.
	Additive,	Polymer	Size,	Adhesion	Looptack	ance	Ahesion
Run #	° C.	Type	nm	(1), pli	(2), pli	(3A), hrs	(4), pli
ACRYLIC LATEX
E SERIES
1024 ppm
DDM
Dn = 219 nm
26	none			0.97	2.31	0.32	1.81
27	105	PS/MMA	80	1.36		4.17	1.36
28	105	PS/MMA	179	0.71		1.48	1.21
29	39	PBA/MMA	109	0.24	1.68	6.14	0.40
30	38	PBA/MMA	180	0.54	2.31	2.3	0.85
ACRYLIC LATEX
F SERIES
1024 ppm
DDM
Dn = 149 nm
31	none			1.39	2.92	0.27	2.06
32	105	PS/MMA	80	1.51		1.45	1.51
33	105	PS/MMA	179	0.82		0.90	1.38
ACRYLIC LATEX
G SERIES
1024 ppm
DDM
Dn = 94.7 nm
34	none			0.99	2.37	0.33	2.14
35	105	PS/MMA	80	1.35		0.80	0.96
36	105	PS/MMA	179	0.90		0.66	1.14
(1) Pressure Sensitive Tape Council (PSTC) test method PSTC-1, 180 degree peel with 30 min dwell
(2) PSTC-5, tested on stainless steel panel
(3A) PSTC-7, 1 × 1-inch surface with 1000 g weight
(4) PSTC-1, 180 degree peel with 30 min dwell performed in 35° F. cold box on corrugated board

[0092] Note that the shear resistance test (3A) used in Table 3 is less severe than the test (3) used in Table 2, hence the higher values. Comparisons between the neat acrylic latex and that containing the high Tg polymer are equally valid with either shear resistance test. Results in Table 3 show how the acceptable range of Tg and particle size is broadened when the high Tg polymer is used at a 17.5% level instead of the 30% level of Table 2. As stated above, when the level of high Tg polymer is approximately 1% to 20%, the acceptable Tg range becomes 30 to 300° C. and the acceptable particle size becomes 80 nm to 1000 nm.

[0093] Run 27 which has particle size of 80 nm and a Tg of 105° C. gives very acceptable low temperature performance at the 17.5% level compared to the lack of low temperature adhesion exhibited by Runs 13 and 14 (Table 2) which are of comparable particle size and Tg but at a 30% level.

[0094] Runs 29 and 30 show that acceptable low temperature adhesion can be achieved at a Tg of 38-39° C., if the level of high Tg polymer is 17.5%. The same two high Tg polymers did not exhibit low temperature adhesion when employed at the 30% level (Runs 9 and 10, Table 2). It should also be noted that although the Tg range which gives acceptable performance is broader at the lower level of high Tg polymer, the polymers with a Tg of 105° C. still provide a significant advantage over those with a Tg of 38-39° C., even at the 17.5% level. Runs 31-36 corroborate these conclusions.

TABLE 4
15 Parts High Tg Additive Latex Blended with 85 Parts Acrylic Latex
							Low
	Tg of	Additive	Particle	LDPE Peel	Loop-	Shear	Temp.
	Additive,	Polymer	Size,	Adhesion	tack	Resist-	Adhesion
Run #	C	Type	nm	(1), pli	(2), pli	ance, hrs	(4), pli
ACRYLIC LATEX
C SERIES
1463 ppm DDM
Dn = 134 nm
37	none			1.0	3.5	0.05 (3)	2.2
38	40	PVAc	164	1.2	2.69	0.06 (3)	1.96
39	40	PVAc	293	0.88	2.91	0.06 (3)	2.12
40	38	PVAc	191	0.9	3.29	0.09 (3)	1.94
Flexcryl
1624
41	none			0.5		7.2 (3A)	2.2
42	40	PVAc	164	1.0		22.9 (3A)	0.9
43 (6)	40	PVAc	164	1.4		17.8 (3A)	1.1
(1) Pressure Sensitive Tape Council (PSTC) test method PSTC-1, 180 degree peel with 30 min dwell
(2) PSTC-5, tested on stainless steel panel
(3) PSTC-7, ½ × ½-inch surface with 500 g weight
(3A) PSTC-7, 1 × 1-inch surface with 1000 g weight
(4) PSTC-1, 180 degree peel with 30 min dwell performed in 35° F. cold box on corrugated board
(6) Contained 15 dry wt % mixed rosin/hydrocarbon tackifier with 85° C. softening point

[0095] Runs 37-43 of Table 4 show that PVAc polymer emulsions with a Tg of approximately 40° C. can achieve very good low temperature performance at the 15% level whereas this was not possible at the 30% level (compare to Run 21, Table 2).

EXAMPLE 4

Wet Lamination

[0096] In this example, the bonded adhesive constructions were formed without drying the adhesive, prior to mating the two surfaces. The blends of high Tg latex with commercial low Tg pressure sensitive adhesive acrylic latex (PSA Component) were coated on polyethylene terephthalate (PET), metalized PET (MPET), or untreated oriented polypropylene (OPP), and immediately laminated to cotton cloth. After aging 24 hours at ambient temperature, the samples were pulled apart in a standard T-peel test. In each case the pressures sensitive adhesive acrylic latex was blended with the high Tg PVC latex of Run 19 (Table 2) at several different ratios. The results are presented in Table 5.

TABLE 5
Addition of PVC Latex (Tg = 78° C.; particle size = 201 nm)
		Low	T-Peel	T-Peel	T-Peel	Shear
Run		Tg/High Tg	Adhesion,	Adhesion,	Adhesion,	Resistance,
#	PSA Component	Blend Ratio	PET, pli	MPET, pli	OPP, pli	hours
44	Flexcryl 1624	100/0	0.20	0.35	0.08	0.56
45		85/15	0.19	0.33	0.10
46		70/30	0.23	0.31	0.11	2.07
47	Flexcryl 1625	100/0	0.91	1.62	0.22	8.88
48		85/15	0.75	1.18	0.29
49		70/30	0.91	0.99	0.32	>50
50		50/50	0.59	0.25	0.26
51	Flexcryl 1614	100/0	1.06	1.00	0.94	0.46
52		70/30	0.63	0.22	0.65	7.80
53	Tackified	100/0	0.22	0.72	0.16
54	Rovene 9410*	70/30	0.31	0.78	0.14
55	Tackified Hartex	100/0	0.06	0.03	0.08
56	101*	70/30	0.20	0.09	0.25
57	Tackified	100/0	0.78	0.20	0.31
58	Dispercoll C74*	70/30	0.51	0.24	0.40
*Contained 30 dry weight mixed rosin/hydrocarbon tackifier having an 85° C. softening point

[0097] Runs 44-52 demonstrate that the shear resistance of the pressures sensitive adhesive can be substantially increased while maintaining a good balance of adhesion performance, when a high Tg polymer emulsion is added to a pressure sensitive adhesive polymer emulsion. Particularly noteworthy is the fact that adhesion to OPP, which is the most difficult to bond surface, is improved in almost every case.

[0098] Runs 53-58 show that the invention can be applied to various polymer chemistries which are known in the pressure sensitive adhesive industry.

EXAMPLE 5

Dry Powder High Tg Polymer Additive

[0099] A powder of a high Tg PVC was dispersed in water under high shear conditions prior to adding it to Acrylic Latex D; 30 parts of PVC were added per 70 parts of acrylic polymer. The particle size of the high Tg polymer particles were much larger than the high Tg latex polymer particles in Examples 1-3. Adhesion tests were performed, as in Example 1; data is presented in Table 6.

TABLE 6
				LDPE			Low
	Tg of	Additive	Particle	Peel		Shear	Temperature
Run	Additive,	Polymer	Size,	Adhesion	Looptack	Resistance	Adhesion (4),
#	° C.	Type	nm	(1), pli	(2), pli	(3), hrs	pli
Acrylic Latex
Series D
59	none			0.5	2.42	0.09	1.58
60	78	Vinnolit	1000	0.25	1.18	0.24	0.23
		P70F,
		PVC
		Powder

[0100] The data in Table 4 show that addition of PVC powder resulted in an improvement in shear resistance while still retaining a bond at low temperature.

EXAMPLE 6

Particle Polydispersity

[0101] This example shows the effect of using a blend of three high Tg polymer latexes with different particle sizes. To 70 parts by weight of Acrylic B was added 10 parts each of polystyrene (PS) having a number average particle size of 91.8, 115.4, and 134.2 nm. Each of the individual components had a polydispersity of 1.1-1.2. The calculated number average particle size of the three-component blend was 113.8 nm. Adhesion tests were carried out as in Example 1 and results are presented in Table 7.

TABLE 7
	Tg of	Additive		LDPE Peel		Shear
Run	Additive,	Polymer	Particle	Adhesion	Looptack	Resistance
#	° C.	Type	Size, nm	(1), pli	(2), pli	(3), hrs
Acrylic Latex
Series B
61	none			0.86	2.4	0.28
62	105	Three PS	Dn1 = 91.8	0.86	1.63	13.5
		latexes;	Dn2 = 115.4
		calculated	Dn3 = 134.2
		Dn(blend) =
		113.8

[0102] The data in Table 7 show that the shear resistance was improved and LDPE peel was maintained.

EXAMPLE 7

Effect of Tackifier

[0103] This example shows the effect of adding a tackifier to an acrylic latex pressure sensitive adhesive alone and to a blend of an acrylic latex pressure sensitive adhesive and a polystyrene. Paper labels were coated at 20-22 g/m2 coat weight, conditioned overnight in a constant temperature and humidity room, applied under Pressure Sensitive Tape Council conditions, 30 minutes dwell, and peeled at a rate of 12 inches/minute. The LDPE Peel test is a modification of Pressure Sensitive Tape Council (PSTC) test method PSTC-1, 90-degree peel with 30 min dwell. The tackifier was a rosin ester with a softening point of +83° C. The results of the 90° LDPE peel are presented in Table 8.

TABLE 8
				Particle		LDPE
	Tg of	Additive		Size of		Peel
	Additive,	Polymer	Low Tg/High	Additive,	Tackifier,	Adhesion
Latex	° C.	Type	Tg blend ratio	nm	wt %	pli
Acrylic	100:0		0	0.92
Latex H
Dn = 256 nm
Tg = −55° C.
Acrylic			100:0		10	0.89
Latex H
Acrylic	98	Polystyrene	85:15	130	10	2*
Latex H
Flexcryl			100:0			1
1625
PSA
Flexcryl			100:0		30	1.6
1625
PSA
*Paper tear

[0104] The data in Table 8 show the benefit of tackifier when combined with a blend of this invention; i.e., a blend of acrylic latex H and polystyrene. They show the performance of Flexcryl 1625 acrylic copolymer pressure sensitive adhesive latex, both neat and with 30% tackifier. The addition of 30% tackifier provides a significant increase in adhesion; however, the blend of acrylic latex H and polystyrene with only 10% tackifier provides even better adhesion. It is particularly noteworthy that only the adhesive with polystyrene yields a destructive bond, i.e., paper tear. The other surprising result is that the current invention allows one to use much lower levels of tackifier resin than the amount normally employed in pressure sensitive adhesives. Acrylic pressure sensitive adhesives are commonly formulated with approximately 30% tackifier. While tackifier is beneficial to some adhesion properties it is deleterious to others, as already mentioned. Therefore, industry seeks to minimize the amount of tackifier which is needed to achieve the target performance.

Claims

1. A method for enhancing the adhesive properties of aqueous pressure sensitive adhesive polymer emulsions which comprises blending a high Tg polymer emulsion with an aqueous pressure sensitive adhesive polymer emulsion to form a pressure sensitive adhesive polymer emulsion blend, said high Tg polymer having a Tg of 30° C. to 300° C., a number average particle size of 80 nm to 1000 nm, and a particle size distribution in which less than 10% of the total particles are less than 80 nm, and less than 10% of the total particles are greater than 1000 nm.

2. The method of claim 1 wherein less than 25% of total particles are less than 80 nm, and less than 25% of total particles are greater than 1000 nm.

3. The method of claim 1 wherein said high Tg polymer is blended in an amount of 1 wt % to 50 wt %, based on the total dry weight of said high Tg polymer and said pressure sensitive adhesive polymer.

4. The method of claim 1 wherein said high Tg polymer is blended in an amount of 1 wt % to 20 wt %, based on the total dry weight of said high Tg polymer and said pressure sensitive adhesive polymer.

5. The method of claim 1 wherein said high Tg polymer has an average particle size of 100 nm to 1000 nm and a Tg of 50° C. to 300° C. and is blended in an amount of 20 wt % to 50 wt %, based on the total dry weight of said high Tg polymer and said pressure sensitive adhesive polymer.

6. The method of claim 1 wherein said high Tg polymer emulsion is formed by emulsion polymerization of monomers selected from the group consisting of styrene, a C1 to C8 alkyl acrylate, C1 to C8 alkyl methacrylate, vinyl chloride, vinyl acetate, acrylonitrile, methacrylonitrile, and mixtures thereof.

7. The method of claim 1 wherein said high Tg emulsion polymer is selected from poly(methyl methacrylate), poly(methyl methacrylate-methacrylic acid), polystyrene, poly(styrene-methyl methacrylate), poly(butyl acrylate-methyl methacrylate), poly(vinyl acetate), or poly(vinyl chloride).

8. The method of claim 1 wherein the blend also comprises 0 to 40 wt % tackifier, based on the total solids in the blend.

9. The method of claim 8 wherein the tackifier is 0 to 25 wt %.

10. The method of claim 8 wherein the tackifier is 0 to 15 wt %.

11. A method for enhancing the adhesive properties of aqueous pressure sensitive adhesive polymer emulsions which comprises blending a high Tg polymer emulsion with an aqueous pressure sensitive adhesive polymer emulsion to form a pressure sensitive adhesive polymer emulsion blend, said high Tg polymer having a Tg of 50° C. to 300° C. and a number average particle size of 80 nm to 1000 nm, said aqueous pressure sensitive adhesive polymer emulsion having a number average particle size of less than 500 nm.

12. An aqueous based pressure sensitive adhesive emulsion blend comprising an aqueous pressure sensitive adhesive polymer emulsion and a high Tg polymer emulsion, said high Tg polymer having a Tg of 30° C. to 300° C., a number average particle size of 80 nm to 1000 nm, and a particle size distribution in which less than 10% of total particles are less than 80 nm, and less than 10% of the total particles are greater than 1000 nm.

13. The blend of claim 12 wherein less than 25% of total particles are less than 80 nm, and less than 25% of total particles are greater than 1000 nm.

14. The blend of claim 12 wherein the dry weight of said high Tg polymer emulsion in said blend is 1 wt % to 50 wt %, based on the total dry weight of said pressure sensitive adhesive emulsion polymer and said high Tg emulsion polymer.

15. The blend of claim 12 wherein said high Tg polymer has an average particle size of 100 nm to 1000 nm, a Tg of 50° C. to 300° C., and is blended in an amount of 20 wt % to 50 wt %, based on the total dry weight of said high Tg polymer and said pressure sensitive adhesive polymer.

16. The blend of claim 12 wherein said high Tg polymer emulsion is formed by emulsion polymerization of monomers selected from the group consisting of styrene, a C1 to C8 alkyl acrylate, C1 to C8 alkyl methacrylate, vinyl chloride, vinyl acetate, acrylonitrile, methacrylonitrile, and mixtures thereof.

17. The blend of claim 12 wherein said high Tg emulsion polymer is selected from poly(methyl methacrylate), poly(methyl methacrylate-methacrylic acid), polystyrene, poly(styrene-methyl methacrylate), poly(butyl acrylate-methyl methacrylate), poly(vinyl acetate), or poly(vinyl chloride).

18. The blend of claim 12 wherein the tackifier is 0 to 25 wt %.

19. The blend of claim 18 wherein the tackifier is 0 to 15 wt %.

20. An aqueous based pressure sensitive adhesive emulsion blend comprising an aqueous pressure sensitive adhesive polymer emulsion and a high Tg polymer emulsion, said high Tg polymer having a Tg of 50° C. to 300° C. and a number average particle size of 80 nm to 1000 nm, said aqueous pressure sensitive adhesive polymer emulsion having a number average particle size of less than 500 nm.

21. A pressure sensitive paper label containing a blend of claim 12 applied to a surface of said label.

22. A siliconized release liner containing a blend of claim 12 applied to a surface of said liner.

23. A difficult to bond substrate containing a blend of claim 12 applied to a surface of said substrate.