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6/11/2019 Hot Melt Adhesives: Ingredient Selection & Formulation Tips
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Hot Melt Adhesives: Basics, Ingredient Selection & Formulation Tips

Thanks to the fast setti ng speed, relatively low cost (materials and processing), and low environmental impact, hot melt adhesives are widely used in applications (boo
like any other adhesive formulations, hot melt adhesives require a delicate balancing of constituents relative to the performance and processing properties.
The selection of formulation components is determined primarily by the chemical compatibility of the components both during the formulation stage and during the
properties and performance can only be exhibited by a formulation where all the components are compatible.
Become an expert by learning about:
» Basics of Hot Melt Adhesives

» Main Components Used in Hot Melt Adhesives (Polymers, Tackifiers, Waxes etc.)
» Efficient Mixing of Hot Melt Adhesive Components
» Working Properties of HMA
» HMA Requirements for Hygiene Products
We would like to acknowledge Edward M. Petrie for providing technical information needed to develop this guide.
HMA: Ingredient Selection & What is Hot Melt and How Does it Work?
Formulation Tips
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Hot melts are thermoplastics that are used after melting the polymer beyond its
melting point. Hot melt adhesives majorly comprise of three components:
A polymer/ blend of polymers

A tackifying resin
A wax/oil
Wax and oil are used for the same purpose, the only difference is that oil is liquid, and waxes are solid.
Apart from these ingredients, hot melts may include an antioxidant, filler or UV stabilizer or a pigment
and others.
The hot melt should have very low viscosity in its molten form in order to achieve wetti ng. Also, it must
not cool too rapidly else it will not have time to completely wet the substrate. Special dispensing
equipments are used for the application of hot melt
adhesives.
The main advantage of hot melts over other forms

of adhesives is that they do not require a solvent
and, hence, associated environmental issues are
avoided.
Online Course
They also set rapidly
The dispensing is easy to automate Maximizi
A smaller space is required for storage and use Resistanc
There is wide formulation latitude to meet a Epoxy an
variety of costs and performance needs
Adhesive
Hot melts are used in packaging, paper laminates,
non-wovens, bookbinding, labeling, textiles and
other industries.
They are particularly used in high volume industries due to their short setti ng time. Hot melt
adhesives are available in many forms (pellets, slugs, blocks, sticks…).
They can be applied from a molten tank using heated hoses and dispensed with coaters or nozzles.
They also can be applied directly at the point of assembly using a continuous rope or slug that is
dispensed through a heated handgun.
Films are also available for high area assembly and continuous laminating.
Back to Top
Attention must be paid to the components making up the hot melt formulation. The hot melt adhesive
https://adhesives.specialchem.com/selection-guide/hot-melt-adhesives 1/21
must:
Have a low viscosity in the melt

Wet the substrate,
Solidify into a cohesively strong material
Maintain adequate adhesion properties in service
Before discussing different components used in HMA in details, let’s first understand how hot melt
adhesives work…
Working of Hot Melt Adhesives
The hot melt adhesive is applied from the melt, gaining strength upon solidification and
crystallization
Although certain types of hot melt adhesives can crosslink over time or with an outside energy source,
general purpose hot melt adhesive remain thermoplastic after application and gelling.
The working mechanism of holt melts includes following steps:
Step 1: A hot melt adhesive when heated, melts and becomes a liquid. It is then applied by bringing it
between two substrates. Once cooled, it will set and solidify. Cooling of the drop largely depends on
the size of the droplet, the nature and temperature of the substrate. In case the substrate is not
insulated, it may take a lot of time for the hot melt to cool down.
For e.g. if the hot melt is applied on a cold surface, the hot melt would cool faster, but the adhesion
imparted would be weak as the adhesive will not get enough time to fill in the cavities of the substrate.
On the contrary if the hot melt was applied on a pre heated surface and then allowed to cool gradually
along with the substrate, the adhesion would be stronger.
Step 2: The second substrate is applied to the adhesive, in order to join the two substrates with the
help of hot melt applied between them.
Step 3: The second substrate is pressed, and one can see the adhesive oozing out, in case the contact
surface with the substrate is large. The large surface area of the substrate allows for quicker cooling of
the hot melt. This hot melt after cooling sets, making it impossible to separate the two substrates.
The horizontal access describes the temperature, which decreases with time. The relationship
between temperature and time is never the same.
The vertical axis exhibits the viscosity or the cohesion [modulus] for a period when hot melt is liquid
and cohesion for the later stages of the hot melt.
Now explore various components used in HMA in details along with some important selection tips…
Composition of Hot Melt Adhesives
Hot melt adhesives require a delicate balancing of formulation components relative to their
performance and processing properties. As mentioned above, the major components of a hot melt
adhesive and their role are:
The base polymer is the molecular backbone of the systems, and it is used to provide the inherent
strength and chemical resistance as well as the application characteristics.
Tackifiers are added to improve initial adhesion and to modify the base polymer.
Processing oils and waxes are used to adjust viscosity and set times. Both tackifiers and processing
materials will affect the Tg and Tm of the final product.
Fillers are used to fine tune certain properties such as melt viscosity, thermal expansion coefficient,
set time, etc.
Antioxidants are used to provide oxidation resistance - more for the polymer in the application state
rather than in the final joint.
UV inhibitors are to provide stability against exposure to light. Back to Top
Polymer Selection for Hot Melt Adhesives
Polymers are the workhorse for hot melt adhesives. Any/every polymer could serve the purpose.
Polymers impart benefits like flexibility, strength, improved adhesion and much more.
The base polymer provides the main framework for the adhesive’s overall physical properties.
Since a low melt viscosity is required, most polymers used as bases for hot melt adhesives are semi-
crystalline in character. The most common general-purpose hot melt adhesive is based on ethylene
vinyl acetate (EVA) resins. These are used in the packaging, furniture, bookbinding, and footwear
industries.
For pressure sensitive hot melt formulations, the base polymer is often a block copolymer, such as
styrene-isoprene-styrene (SIS) or styrene-butadiene-styrene (SBS). These products go primarily into
tapes and labels. Other polymers commonly used in hot melt adhesives include:
Low density polyethylene

Polyamides
Ethylene acrylic copolymers
Polypropylene (atactic)
Phenoxy resins
Polyesters
Polyesteramides
Polyurethanes
Butyl rubbers
Polyvinyl acetate and copolymers
Paraffin waxes
» Find the Suitable Polymer for your Hot Melt Formulation
The main types of hot melt adhesive polymers that have generally been used in the manufacture of hot
melt adhesives:
Hot Melt Base Polymer Characteristics
Most frequently used base polymer

Very versatile adhesives
Type and amount of wax and resin can control
set time and tack
Ethylene vinyl acetate (EVA) Filler can be added in some cases
Good compatibility to a wide variety of
tackifiers and waxes
Various melt indices and vinyl acetate
concentrations
Good, general purpose adhesives

Moderate temperature resistance
Well suited for porous substrates but relatively
rigid
Polyolefin (PO) Good thermal stability (color, gel)
Good resistance to acid, grease, oil
Polyethylene and polypropylene with various
molecular weights and branching, blends with
other polymers
Low cost with good acid and fuel resistance

Moderate heat resistance
Soft, tacky, and flexible
Amorphous polyolefin (APO) Long open times and good adhesion
Low surface energy and capability to wet
almost every substrate
Amorphous / crystalline concentration, blends
with other polymers
Low temperature flexibility

High heat resistance
Used for PSAs and non-PSAs
Styrene Block Copolymer (SBC) Fast set
Styrene-butadiene-styrene, styrene-isoprene-
styrene, styrene-ethylene-butylene-styrene,
blends of these, and blends with other
polymers
Back to Top
Metallocene polyolefin (mPO) Wider temperature range than EVA
Light color, clear, and odorless
Good thermal stability
Fast set and low density
Metallocene catalyzed polyethylene and
metallocene catalyzed polypropylene
Considered to be high performance hot melts

Lower melting points than the polyamides
used for engineering plastics
Polyamides (PA)
Good temperature resistance and need less
additives
Quite expensive
For reactive hot melt with terminal isocyanate

groups
Cross-links after application with humidity
Polyurethane (PUR) When applied to the substrate, the terminal
isocyanate groups tend to react with the
ambient moisture and in turn forms a
thermoset from being a thermoplastic
The application, performance, and cost properties of hot melt adhesives and sealants can vary
significantly depending on the base polymer and the specific formulation employed. Typical properties
of several common fully formulated hot melt adhesives are:
Ethylene
Property Polyamide Polyester Polyethylene
Vinyl Acetate
Softening point, °C 40 100 - -
Melting point, °C 95 - 267 137
Crystallinity L L H H or L
Melt index 6 2 5 5
Tensile strength, psi 2750 2000 4500 2000
Elongation, % 800 300 500 150
Cost L to M M H L
Ethylene Vinyl Acetate (EVA)
EVA resins are highly flexible products, compatible with many other polymers and additives, and easy
to process. The material is essentially a random, amorphous copolymer with regions of crystallinity.
Melt viscosity is very dependent on molecular weight for this material. Melt flow indices ranging from 2
to 200 are possible.
They have high cohesive strength and excellent adhesion to a wide range of substrates. EVA
copolymers can be used in soft, permanently tacky pressure sensitive adhesives or in tough rigid hot
melt compositions used for semi-structural applications.
Key advantages and limitations associated with EVA based hot melt adhesives are:
Advantages Disadvantages
Broad formulating latitude necessary for many

different applications and adhesion to a wide
variety of substrates Cold flow (creep)
Quick setting Attacked by some greases, oils, and solvents
Retention of properties at low temperatures High viscosity needed for maximum
Pressure sensitive systems can be formulated performance
Considered to be safe and non-toxic
Relatively low cost
Generally, for hot melt adhesives EVA resins with vinyl acetate concentration of 18-40% are utilized.
The vinyl acetate content can be a significant parameter in varying the properties of the adhesive.
The materials with high vinyl acetate concentration exhibit reduced crystallinity and increased polarity.
At about 50% vinyl acetate content, all crystallinity is lost. Recrystallization rate or setting speed is
greatly influenced by the choice of specific EVA resin.
Melt index or melt viscosity is another important criterion in choosing the correct EVA resins for
adhesive formulations. Low melt index EVA grades provide high viscosity, strength, and hot tack. In
contrast, high MI grades enable higher polymer content and low application viscosities. Mid-range MI
grades provide formulation flexibility.
Change Due to Decreased Crystallinity Back to Top

Property
(Increasing VA Content)
Stiffness modulus Decreases

Surface hardness Decreases
Crystalline melting (softening) point Decreases
Tensile yield strength Decreases
Chemical resistance Decreases (generally)
Impact strength (especially at low
Increases
temperatures)
Optical clarity Increases
Environmental stress crack resistance Increases
Coefficient of friction Increases
Retention of mechanical strength at high
Increases
filler loadings
Compatibility with other polymers, resins,
Variable
etc.
Change Due to Increased Polarity (Increasing
Property
VA Content)
Dielectric loss factor Increases
Compatibility with polar resins and
Increases
plasticizers
Specific adhesion Increases
Surface printability Increases
Changes in Physical Properties of EVA Due to Increasing Vinyl Acetate Content
The higher vinyl acetate copolymers provide better adhesion to polar substrates such as vinyl,
aluminum, and steel, while the lower vinyl acetate copolymers are often used for bonding low energy
surfaces.
Substrate Vinyl Acetate (VA) Content 18% VA » 40% VA

Kraft paper Little effect
Glassine paper Little effect
Wood Little effect
ABS Slight trend »
Aluminum Major improvement »
Steel Major improvement »
Plasticized vinyl Major improvement »
Rigid vinyl Major improvement »
Polypropylene « Major improvements
High density polyethylene « Major improvement
Effect of Vinyl Acetate Content in EVA Copolymer Hot Melts on Adhesion to Various Substrates
EVA resins exhibit miscibility in the melt with a wide range of modifying resins, tackifiers, and waxes.
This provides the adhesive formulator with a wide latitude of compounding possibilities. While these
polymers, when properly formulated, provide acceptable adhesion, there are a number of drawbacks
that detracted from their usefulness. These included:
EVA show a lack of temperature resistance in the 38°C range (important for resistance to body
temperatures)
The pressure sensitive nature of EVA is generally inferior to other polymers
EVA have a tendency to gel or char when subjected to typical application temperatures such as
150°-175°C resulting in equipment maintenance problems and poor adhesion
These polymers cannot easily be formulated as a multi-purpose adhesive to serve multiple
applications.
Ethylene vinyl acetate (EVA) copolymers are perhaps the most widely used base polymer in general-
purpose hot melt adhesives
Styrene Butadiene Copolymers
Adhesives that are based on styrene butadiene block copolymers are both useful and unusual. They
have the solubility and thermoplastic nature of polystyrene; while at ambient temperature, they
possess the toughness and resilience of an elastomer. This characteristic provides SBC adhesives with
versatile properties in both pressure sensitive and non-pressure sensitive adhesive formulations. A
starting formulation for an SIS elastomeric adhesive is: Back to Top
Components Parts by Weight
Styrene isoprene styrene 20

Tackifier, polyterpene 60
Oil 10-20
Antioxidant 0.5-1.0
Starting Formulation of an SIS Elastomeric Hot Melt Adhesive
As a hot melt adhesive, the low melt viscosity and fast strength development are significant benefits to
converters. Certain SBC polymers are capable of hot melt application temperature in the 150°-170°C
range. This is much lower than most EVA hot melt systems.
Four types of SBC resins are commonly available for adhesive formulation:
Styrene-Butadiene-Styrene (SBS)
Styrene-Isoprene-Styrene (SIS)
Styrene-Ethylene-Butadiene-Styrene (SEBS), the hydrogenated form of SBS
Styrene-Ethylene-Propylene-Styrene (SEPS), the hydrogenated form of SIS
Of these, SBS offers the lowest cost and high levels of cohesive strength. In general, the saturated block
copolymers (SEBS and SEPS) are used where long-term UV, thermo-oxidative, or chemical stability is
critical, or where compatibility with other low polarity ingredients is required. SIS copolymers are
generally used in pressure sensitive adhesives where high tack is necessary and cohesive strength is
less important.
However, one of the most interesting and valuable properties of SBCs is that they offer a physical form
of crosslinking which greatly broadens their applicability. The thermoplastic polystyrene end-segments
on the molecule form “pseudo-crosslinking” sites. This results in a superior resistance to creep while
maintaining a very high cohesive strength and degree of elongation. Due to the pseudo-crosslinking
mechanism associated with SBCs and the glass transition temperatures associated with each phase,
SBCs provide very good properties at both high and low temperatures.
Representation of an SBC structure in bulk
SBC adhesive manufacturers can tailor properties to match a wide range of applications. Besides being
strong, highly extendable, cost effective, processable, and easily formulated, the SBCs have other
attributes that are very beneficial:
No vulcanization required (results in high processing speeds)

Precise molecules with a wide range of structure (results in great formulation latitude)
Clean and non-toxic – many formulations are FDA approved
Low melt viscosity
Formulations can be clear
Aggressive adhesion to most substrates including plastics
Cohesive strength adjustable with diblock content
Resistant to water, and most acids and bases
The drawbacks associated with EVA hygienic hot melt adhesives noted above opened the door for new
hygienic adhesives and styrene butadiene copolymers entered the market. The SBC adhesive
formulation provided improvement over the previously employed adhesives; however, they also did
not have all the properties required for maximum usefulness. The primarily drawbacks associated with
SBC adhesive compositions are:
Back to Top
Poor storage stability when left in the adhesive applicator for an extended period of time (increase
in viscosity and ultimately a gel would form due to thermal oxidation)
Creep resistance at elevated temperature, although better than EVA, was still lacking
Certain low coat styrene butadiene copolymers, such as styrene butadiene styrene (SBS) did not
have the elongation required for an elastic attachment adhesive. Styrene isoprene styrene (SIS), was
found to be more flexible, softer, and better suited for elastic substrates.
However, SIS compositions were found to display a low modulus and poor elevated temperature
performance even when formulated with various tackifying resins. When end-block reinforcing
resins were used to improve the heat resistance, the adhesion to polyolefin substrates would suffer.
The SIS based adhesive compositions also showed undesirably high viscosities for certain
applications and could not be used reliably as a multi-purpose adhesive.
Polyolefins
Hot melt adhesives that employ amorphous polypropylene (APP), amorphous polyalpha-olefin
(APAO), and low density metallocene and/or single-site polyolefin elastomers have more recently
become well known in the art. Due to their low crystallinity, adhesives made from these polyolefin
systems generally show good compatibility and long-term thermal aging performance with plasticizing
and tackifying agents commonly used in hot melt formulations.
Due to their low crystallinity, however, these polyolefin species tend to develop properties only slowly
after application that can make them unsuitable for certain construction applications. In generating
laminate structures using porous substrates such as nonwovens, slow set up characterized by the slow
development of modulus upon cooling can lead to over-penetration of the adhesive leading to
blocking, equipment fouling, and even compromised mechanical performance of the final article.
Additionally, adhesives generated solely from polyolefins with limited crystallinity can also display poor
long-term shear strength performance. Adhesives based solely on polyolefin elastomers offer little
resistance to such failure modes.
Hot melt adhesives based on higher crystallinity polyolefins can offer a different set of potential
drawbacks. Polypropylene polymers containing low levels of comonomer can be employed to provide
hot melt adhesive formulations that develop rapidly upon cooling in coating applications. These more
crystalline materials, however, tend to exhibit poor compatibility in hot melt adhesive formulations.
Additionally, hot melt adhesives generated from higher crystallinity polyolefins tend to possess lower
tack due to the higher modulus of these systems when the polypropylene polymer is added at levels
required to provide suitable cohesive strength to provide strong bonds.
Amorphous polyolefins, formed by the copolymerization of alpha-olefins such as ethylene, propylene,

and 1-butene with Ziegler-Natta catalysts have also been found to be useful for the production of
hygienic products. Although they have lower adhesion properties than EVA based adhesives, they are
known to have better thermal stabilities. Other than thermal stability, the problems with amorphous
polyolefin in hygiene hot melt formulations are similar to those described above for EVA adhesives.
High viscosity hot melt systems based on atactic polypropylene have been generally used for the end
seal in diaper construction. The composition of an atactic polypropylene based hot melt adhesive is:
Components Parts by Weight

Atactic polypropylene 70
Tackifier, C-5 hydrocarbon resin 10
Plasticizer, microcrystalline wax 20
Antioxidant 0.5-1.0
Starting Formulation for an Atactic Polypropylene Hot Melt Adhesive for End-Sealing in Diaper Construction
A blend of amorphous polyolefin and styrene ethylene butadiene styrene (SEBS) copolymer was found
to provide thermally stable and more processable hot melt adhesive which could be used as
alternatives for EVA and SBC adhesives. SEBS copolymers as noted above have saturated rubber
midblocks and when formulated with saturated resins, plasticizers, and stabilizers can obtain a good
balance of adhesive properties as well as resistance to degradation by oxidation or UV light. When SEBS
is added to an amorphous polyolefin, the toughness of the hot-melt adhesive was enhanced, and the
viscosity was also increased.
Parts by Weight
Components
Formulation A Formulation B
SEBS Elastomer 20 10
Tackifier 60 60
Mineral oil 20 20
Antioxidant 0.15 0.15
Amorphous polyolefin 0 10
Value
Properties
Formulation A Formulation B
T- peel adhesion, pli 0.05 0.11
Creep resistance, 12 specimens, 8 All 12 passed All 12 passed Back to Top
hrs at 38°C
SEBS Addition to APO in a Hot Melt Adhesive Improves T-peel Strength
Further development of olefinic polymers has been based on metallocene catalyst technology. This
technology results in long chain branching and improved elastomeric and processability characteristics.
Metallocene catalysts offer unique advantages versus conventional catalysts for the production of
polyolefin resins. They allow producing consistent, controllable molecular structures that can be
designed to:
Improve toughness and impact resistance

Provide low off-taste and odor
Allow tailoring of processing characteristics to fit the conversion process
Eliminate non-targeted molecular weight species in resins
Offer a greater control of molecular weight distribution (MWD).
Hygiene construction adhesives formulated using this new technology provide broad temperature
sprayability (good balance of low- and high-temperature sprayability) and excellent adhesion with
excellent thermal and viscosity stability. The narrow molecular weight ranges provide hygiene
construction hot melt adhesives with fast setting times, low-odor, low-color, and clean running
characteristics.
Tables below shows two metallocene catalyzed polypropylene formulations that can produce high
quality nonwoven laminates using either contact or spray application techniques. And hence, provides
property data of these formulations compared to commercial metallocene catalyzed polyethylene and
SBC formulations.
Parts by Weight
Components
A B
Metallocene polypropylene 50 70
Hydrocarbon tackifier 35 20
Oil 15 10
Starting Formulations for a Metallocene Catalyzed Polypropylene Hygiene Adhesive
Value
Properties Formula Formula Commercial Co mercial
A B mPE SIS
Brookfield viscosity, cps, at:
120°C 27000 18000
12500 --- 6000 ---
140°C
4000 3000
160°C
Peel force, gms, measured at 40°C on

nonwoven after spiral spray application at:
100 72
120°C 88 --- 102 ---
140°C 101 110
160°C
Peel force, gms, after:

24 hrs 100 95 105 60
80 80 110 70
1 month
85 85 30 145
14 days at 50° C
Property Comparison of Metallocene Polypropylene Adhesives with Other Commercial Hygiene Adhesives
Polyamides
Polyamide hot melt resins are similar to those used in nylon plastics, but they have a lower melting
point. They are also chemically similar to the polyamide curing agents that are used for epoxy
adhesives; however, those used in hot melt adhesives are unreactive.
Polyamides are mainly generated through reactions of difunctional materials. The reactions of diamine
with a diacid or the homopolymerization of an amino acid are common routes to polyester production.
Additionally, polyamides can be formed through the ring opening polymerization of caprolactam.
There are a great many possible resins in the polyamide family. They can be varied to provide hot melts
of almost any desired temperature over a span of several hundred degrees.
Polyamide hot melt adhesives have better heat resistance than EVA or SBC types and use fewer
additives. However, the base polyamide resin generally costs more than more conventional hot melt
resins that rely on formulation for optimum performance. Certain types of polyamide hot melts can
withstand 200°C over the short term without degradation, although creep is generally a problem.
Polyamide adhesives generally exhibit sufficient properties, such as tack, without the use of additives.
Modification of the physical properties of these adhesives can be achieved by controlling the synthesis Back to Top
of the polyamide (reaction product of diacids and diamines). Polyamides of differing molecular weight
and chemical structure are often employed to provide specific application and performance properties.
The polyamides that are used for adhesives generally fall into three groups that are defined by
molecular weight:
Low molecular weight: can be applied at low temperature using simple, inexpensive equipment
Intermediate molecular weight: Application equipment range from simple to moderately
sophisticated
High molecular weight: Requires very sophisticated extruder type equipment for application. These
are used as high-performance structural adhesive where high temperature performance is not
required.
Table below summarizes the typical properties of these polyamide groups. In all of the above cases it is
important to minimize the time when the molten resin is exposed to oxygen.
Polyamide Molecular Weight

Property
Low Intermediate High
Softening point (ball
95-180 95-200 135-200
and ring), °C
Melt viscosity, poise
5 - Solid 120 - Solid -
• 160°C
1 - 10 20 - 110 250 - 50,000
• 210°C
- 5 - 25 20 - 1000
• 260°C
Tensile strength, psi 160-1600 450-3000 3400-6500
Elongation, % 5-100 25-1000 25-1000
Adhesive tensile-
shear strength, psi 200-1000 700-1900 2200-3700
• Al-Al 200-1000 500-1800 1900-3300
• Steel-Steel
Typical Properties of Polyamide Adhesives of Various Molecular Weight
The use of mixed resins in polyamide hot melt formulations increases the molecular disorder. This
lowers the extent of hydrogen bonding and the melting point. For example, the addition of small
percentages of a high molecular weight polyamide raise the melting point of lower molecular weight
polyamides so that a flexible, tacky material could be achieved. In this way polyamide hot melts can be
formulated that are extremely tough and resistant to impact.
Polyamide hot melt resins offer highly polar groups in the polymer chain which give interchain
hydrogen bonding. This results in high strength at low molecular weights, which is a characteristic that
is not present in many conventional hot melt adhesive resins. A result of this polarity is the retention of
much of the adhesive strength at temperatures up to just below the melting point. However,
polyamides are much more susceptible to moisture permeation than polyesters, since hydrogen bonds
can break when water is absorbed by the polymer.
Polyamide hot melt adhesives are very versatile, and are capable of bonding many different
materials. In addition to metal-to-metal bonding, polyamide hot melt adhesive formulations are used
to bond plastics, foils, and papers.
Major application areas for polyamide hot melt adhesive include:

Shoe
Automotive
Packaging
Electrical / electronic
Woodworking
Polyamide adhesives are available in a variety of forms including pellets, cylinders, film, rod, powder,
and solution.
Polyesters
Thermoplastic polyesters that are used in hot melt adhesives are chemically similar to those used in
the synthetic fiber industry. These resins are also similar to polyamide hot melt resins in that the
monomers in their reaction products are generally adjusted to provide the fine-tuning of application
and performance properties. Thus, the use of additives is minimized. However, at times stabilizers,
plasticizers, and tackifiers are added for special purposes. Occasionally as with the polyamides,
different polyesters are blended for optimal properties.
Polyester hot melt resins are based on the reaction of difunctional acids and diols. Mainly terephthalic
acid but other diacids, such as isophthalic, adipic, and azelaic are also used. The melting points and
glass transition temperature of the polyesters depend on both the acid and diol components and their
concentration.
The chain length of the diol used to form the polyester has a major effect on physical properties:
Back to Top
As the diol chain length decreases so does the melt point of the copolymer.
The percent crystalline material in a polyester is dependent on the chain length of the diol.
Crystallization decreases as diol chain length increases, but the rate of crystallization increases with
chain length
The rate of crystallization is an important criteria in determining the speed at which the hot melt sets to
a reasonable strength.
Polyesters do not have as high a melting point or strength as the polyamides of similar structure.
However, polyesters are much more resistant to moisture permeation and degradation. Other than in
applications where these properties are important, polyesters and polyamides compete for the same
applications.
One of the earliest applications for hot melt polyester adhesives was in the manufacture of shoes
Hot melt polyester adhesives are also commonly used for bonding fabrics such as decorative trim,
draperies, etc.
Polyester hot melt formulations are commonly found in preformed sticks or coils that are used with hot
melt extrusion guns. The adhesive is pushed through the heated nozzle of the gun, and molten product
is applied to the substrate.
Polyester adhesives can be used in their natural state, but often they are compounded heavily to
provide for increased toughness, peel strength, and open time
Polyester hot melt resins have a relatively high melting point of approximately 260°C. Thus, it is often
used as a heat activated film. Polyester hot melts can be formulated to have high tensile strength and
are often employed where high strength and high temperature resistance are required.
Also Read: Biobased Components in Hot Melt Adhesive Formulation (Soy Polymers, Modified Starch
and much more)
Hot Melt Polyurethane Reactive Adhesives
Although hot melt polyurethane reactive (HMPUR) adhesives have been available for 25 years, their
novel properties and the development of diverse products have accelerated their recent growth. They
are now found in many applications as products are developed to fit specific needs.
In general, HMPUR adhesives have these characteristics:
They are solid at room temperature, similar to other hot melt adhesives that are thermoplastic
polymers, such as ethylene vinylacetate (EVA), polyalphaolefin (PAO), polyester and polyamide.
The temperature for application as a melt ranges from 85°C to 140°C (185°F to 284°F), which is less
than that for typical thermoplastic hot melt products. The viscosity at the application temperature
can be designed in a range from 2,000 to 60,000 cPs depending on the specific requirements.
HMPUR adhesives are being produced with open times varying from 10 seconds to 10 minutes to
match application requirements.
The unique property that gives HMPUR adhesives their performance advantage compared to
thermoplastic hot melts is that they cure to a thermoset material that resists melting. This curing
process is the reaction with moisture found in the air or in typical substrates to produce a strong,
tough, temperature-resistant adhesive.
The advantages of HMPUR adhesives result from the properties that were described above. Some of
these advantages are:
The cured adhesive has excellent temperature and environmental resistance. Many of the HMPUR
adhesives can withstand exposure to temperatures from -40°F to +200°F while maintaining strong
bonds.
Minimal fixturing is needed due to the controlled set time and rapid development of green strength
that can be designed into these products. They are typically applied by roll coating, slot-die coating,
gravure printing, screen printing or spray coating (swirl or fiberized) and then briefly nipped or
pressed to provide a bond with handling strength. Final cure and ultimate strength are achieved in a
few hours to a few days depending on the adhesive, substrate and conditions in the plant.
HMPUR adhesives can be designed and developed with widely varying properties for specific
applications. How this is done and some of these applications are described later in this article.
HMPUR adhesives are 100%-solids and therefore have no volatile organic compounds (VOCs) and
do not require drying ovens. This eliminates many of the environmental issues associated with
solvent-based adhesives and the energy requirements for drying water-based and solvent-based
products.
» View all Polyurethanes Available for Hot Melt Adhesives Back to Top
How Specific Properties are Incorporated into HMPUR Adhesives
HMPUR adhesives are manufactured:

By reacting mixtures of polyols with an excess of diisocyanate. The reaction of an isocyanate group
(-NCO) with an alcohol group (-OH) produces the urethane group. The fact that there are excess
diisocyanates present means that the molecular weight of the resulting product is not too high and
that the HMPUR product will have a controlled melt viscosity.
These adhesives are then transferred from the reactor into the container package as a melt.
The container is sealed to prevent exposure to moist air while the adhesive solidifies on cooling.
Typical containers are drums (400 lb), pails (40 lb), slugs (4.4 lb) and cartridges (0.6 lb).
The adhesive is melted using a specifically designed premelter

and then applied to the article to be bonded. During the next
several hours or days after application, the reaction described in
the figure takes place. This reaction of isocyanate with water
forms the highly stable polyurea structure that gives the cured
HMPUR its temperature and environmental performance. The
polyurea structure effectively crosslinks the adhesive to prevent
its remelting or dissolving as can occur with standard
thermoplastic hot melt adhesives.
Specific properties required for varying applications are built into

the adhesive by the use of a variety of polyols, isocyanates and
additives.
Polyols are used to vary the open time, set time and ability to
wet effectively various surfaces to produce effective bonds. Some typical polyols used are:
Polyesters, which can be crystalline or amorphous. The crystalline polyols can be used to give short
set times and rapid green-strength development. Amorphous polyesters can improve adhesion to
specific substrates and increase open time, if required.
Polyethers, which are low-Tg, amorphous liquids. These help lengthen open time, reduce viscosity
and provide good low-temperature flexibility.
Vinyl-polymerized polyols, which are typically high-molecular-weight, glassy solids. These
materials can assist in building green strength and tack while maintaining extended open times.
A mixture of polyols to give the desired performance is reacted with an excess of a diisocyanate.
Methylene diphenylisocyanate (MDI) is used for most HMPUR adhesives. It has a highly reactive
isocyanate group and has a relatively low vapor pressure. Since polyurethanes made with MDI tend to
yellow when exposed to sunlight, a method using HMDI (hydrogenated MDI), which resists yellowing
very effectively, has been developed. It tends to be much slower reacting, so there exists a process to
effectively speed its reaction and make it useful for HMPUR applications.
Tackifiers/ Tackifying resin
Tackifiers is an important class of materials used in

in hot melt adhesives in terms of their effect on
both cost and performance properties. They
normally have low molecular weights and are
resinous, but they have glass transition
temperatures and softening temperatures that are
often significantly above room temperature.
It is this combination of the properties that make

these materials useful for imparting “tack” and
desirable viscoelastic properties in the adhesive
formulation.
» Check Out Various Tackifier Grades Available in the Market Today
Tackifiers are a principal component used to vary and refine both performance and processing
properties of the adhesive
Standard tackifiers are either based on natural or petroleum-based products.
Examples of natural tackifiers are rosin acid derivatives and their esters. Rosin resins (rosin acids
and rosin esters) are sourced from pine tree by-products such as gum rosin. They offer good tack to
most of the polymer types. They are majorly used to tackify natural rubber, ethylene vinyl acetate,
acrylic, styrene butadiene rubber, styrene butadiene copolymers, and polyurethanes. By esterifying
it, you get rosin ester.
Back to Top
Synthetic tackifiers are based on either aromatic or aliphatic petroleum-based resins.
The aromatic resins are further classified into coumarone-indene resins, aromatic petroleum
resins, and other types.
The aliphatic resins are known as C-5 resins since much other chemistry revolves around
polymerized pentene and cyclopentene.
Hydrocarbon resin tackifiers on the other hand are manufactured from petroleum-based feedstock,
and therefore, they have the limitation of being linked to the high prices of oil. When compared to
rosin resins, hydrocarbon resins have a lower compatibility range with base polymers.
Another natural product is that based on a class of materials known as the terpenes. Terpenes are
often referred to as "universal" tackifiers due to their compatibility with a numerous polymers like
EVA, polyethylene, natural rubber, styrene butadiene rubber, styrene butadiene copolymers and
others. Terpene resins show good compatibility with polyolefins and the mid-block of styrene-
isoprene-styrene resins. Terpene tackifiers offer improved adhesion and outstanding initial color for
almost all polymer types. These resins are also compliant to food contact regulations. As a result of
their properties and natural source, terpene tackifiers have a relatively high use but limited supply.
This combination leads to somewhat higher price.
Tackifiers will raise the glass transition temperature of the adhesive formulation and they also provide a
relatively high modulus for a low molecular weight component. As a result, tackifiers are often used to
adjust the Tg and storage modulus in order to optimize properties within a certain temperature range
as illustrated in the figure below.
Tg (glass transition temperature) and G’ (storage modulus) affect the PSA’s application window
A pressure-sensitive adhesive will typically possess optimum tack properties at 20°C above the
adhesive Tg. For non-woven adhesives used in applications where they are positioned close to the skin,
the adhesive Tg should range from 15°C and 20°C, corresponding with body temperature of 37°C.
Targeting these values also ensures that the adhesive remains pressure sensitive even at high process
speeds.
Tackifiers modify the "quick grab" and viscoelastic properties of the adhesive. Once the adhesive has
solidified, the tackifier also modifies (generally increases) the Tg of the solid adhesive. Tackifiers must
have a moderate molecular weight which imparts some cohesive strength and prevents the formation
of weak boundary layers at the interface, a phenomena which happens often with low molecular
weight plasticizers. Tackifiers should also have a relatively low surface tension so as to readily wet the
substrate.
Tackifiers promote adhesion and wetting and contributes to initial adhesion or tack.
Tackifiers that are commonly used in solvent-borne pressure sensitive adhesives are also applicable for
hot melt pressure sensitive adhesive applications.
The first and most important criterion in the selection process is the compatibility between the
tackifier and the base polymer in the adhesive formulation. Certain classes of tackifiers work well with
certain types of polymers. Unless the tackifier is compatible there is no need to extend the selection
process.
Solubility parameters, molecular weight, and molecular weight distribution determine compatibility.
Materials that possess similar solubility parameters are generally assumed to be compatible with each
other. The following table provides a general guide to the selection of tackifiers with various common
polymers used in hot melt and pressure sensitive adhesives.
Polymer SIS SBS SEBS EVA PE

Natural Tackifiers:
Polyterpene √ (1) √ √ √
Terpene
√ (1) √
phenolics
Styrenated
√ (1, 2) √ √ √
polyterpene
Rosin esters √ √ √
Hydrocarbon Tackifiers:
Aliphatic (C5) √ √ √ √
Aliphatic / √ √ √
Aromatic Back to Top
(C5/C9)
Aromatic and
√ (2) √ (2) √ (2)
pure monomer
1-Midblock compatible
2-Endblock compatible
This grouping is based primarily on compatibility and it is a good starting point in the selection of a
tackifier. The formulator will want to contact the suppliers of these types of tackifiers for information
on the specific resins that they supply, their properties and prices, and any specific recommendations
they might make.
Care must be taken in the formulation of block copolymer pressure sensitive hot melt adhesives to
ensure that the tackifier does not dissolve in the polystyrene phase. The polystyrene phase must
remain glassy for optimum cohesive properties. The C-5 resins, which are more compatible in the non-
styrene phase, therefore are more likely to be used in block copolymer-based adhesives. Consideration
must also be given to the heat stability of the tackifier in the melt. Tackifiers with unsaturation could
potentially gel while the adhesive is in the melt.
Plasticizers for Hot Melt Adhesives
In addition to the base polymers and the tackifier, the other most common additive in hot melt
adhesive formulations are plasticizers.
When the base resin is excessively stiff, it is often blended with an elastomeric hydrocarbon, thereby
obtaining a tough material with:
Improved energy dissipation, extrudability, flexibility, workability and stretchability
Reduced glass transition temperature
These materials act opposite to the tackifiers in that they decrease Tg. The plasticizer must be
completely soluble in the base resin and be sufficiently non-volatile as to result in a weak boundary
layer.
Plasticizers or flexibilizers are usually chosen as a second base polymer to improve flexibility and
toughness. The addition of a plasticizer promotes wetting and reduces the melt viscosity of the
formulation
Plasticizers that are used in adhesive formulations are generally chosen on the basis of the following
criteria:
Compatibility with a given polymer or set of component ingredients

Compounding characteristics
Effect of plasticizer on the rheological properties of the polymer
Desired mechanical and thermal properties of the end formulation
Resistance to water, chemicals, UV, weathering, dirt, microorganisms, general aging
Toxicity
Cost analysis (volume required or plasticizing efficiency, price/pound, etc.)
Mineral Oil & Wax
The most commonly used plasticizers are oils which are primarily hydrocarbon oils, low in aromatic
content and are paraffinic or naphthenic in character. The oils are preferably low in volatility,
transparent and have as little color and odor as possible.
Mineral oil and wax are commonly employed as diluents. When added to the matrix polymer, wax and
oils can negatively affect the adhesion properties because of the shrinkage and hardening of the
adhesive. Waxes are often used in hot melt formulations to lower surface tension and decrease melt
viscosity. Certain waxes such as microcrystalline waxes also reinforce the hot melt by forming
crystallites that resist deformation under load. These are used in formulations that require a relatively
high degree of creep strength.
Adding waxes to hot melts increases the setting speed, improve the heat resistance and lowers
viscosity of hot melts leading to excellent bonding
Given their semicrystalline nature, even mixed polyolefin systems can show lower than required set up
times for end-use applications. For this reason, higher crystallinity materials such as waxes are often
added to polyolefin-based hot melt adhesives to assist the rapid development of properties after
application.
Back to Top
Despite the benefits offered, systems employing low molecular weight, crystalline waxes have
significant limitations.
They may increase the setting speed but can also reduce the wet-out and adhesion of the hot melt.
Additionally, the use of low molecular weight, crystalline waxes at even relatively low levels can
compromise the mechanical properties such as elongation required for hot melt adhesives
employed in elastomeric constructions.
Therefore, there exists a need in the art for hot melt adhesive formulations that display rapid set, a
good balance of mechanical properties, and excellent long-term aging performance.
Waxes used in hot melt adhesive formulations could be:

Natural (carnauba and montan wax),
Petroleum based (paraffins, microcrystalline wax) or
Synthetic, derived from petroleum distillates or residues (polyethylene, polypropylene,
polytetrafluoroethylene, Fischer-Tropsch wax)
EVA hot melts make good use of Fisher-Tropsch wax to adjust the setting time and improve thermal
resistance of the hot melt.
Viscosity at 150°C
CP (°C) DMP (°C) Pen at 25°C (dmm)
(mPas)
PE-like 102 117 1; 10
PE-like 117 112 1 6
PE-like 117 116 2 11
PP 128 >1 40
PE 145 40
Antioxidants in Hot Melt Adhesives
Antioxidants are used in a variety of adhesive formulations to protect against degradation caused by
reaction with atmospheric oxygen. The introduction and type of antioxidant will depend on:
The nature of the base polymer
The processing parameters
The end use application
The antioxidant or stabilizer maintains viscosity, color, and physical properties as well as preventing
thermal degradation
Excessive oxidation generally results in undesirable changes in the adhesive’s mechanical, aesthetic, or
bonding properties. Oxidation can occur at all stages of an adhesive’s life from synthesis to final end-
use. It is usually recognized at high processing temperatures such as during mixing, compounding, or
extrusion (in the case of hot melt adhesives). However, oxidation can also occur at relatively low
temperatures including ambient storage and also on exposure to UV light.
Oxidation Sensitive Components in Hot Melts
Adhesive components especially susceptible to oxidation include:

Base synthetic polymers such as:
Ethylene vinyl acetate
Styrene block copolymers
Polyolefins
Polyamides
Natural rubber
Polychloroprene
Polyurethane
Butyl rubber
Hydrocarbon additives, such as tackifiers and waxes, are also vulnerable to oxidation and can
actually contribute to the oxidation of the base polymer
Metallic and other impurities in the adhesive can accelerate the oxidation process
Depending on the aging environment, most adhesives can benefit from antioxidants.
Typically, the base polymers and hydrocarbon raw materials used in formulating adhesives have a
minimal level of stabilization to withstand processing and warehouse storage. Additional levels of
stabilization are often required by the adhesive formulator to provide the necessary levels of
compounding, storage, application, and end-use properties.
Stabilizers Commonly Used in Hot Melts

Back to Top
Hindered phenols, amines, phosphites and thioester are commonly used stabilizers for hot melt
adhesives. The chemical types of common antioxidants that are most often used in hot melt adhesive
applications are shown in the table below. The hot melt adhesive composition includes from about
0.1% to about 1.0% by weight antioxidant. There are numerous antioxidants and blends of antioxidants
that have proven beneficial for various types of adhesives.
Types Common Resin Applications Comments

Rubber, some pigmented
Arylamines tend to discolor and
Amine polymers, and polyurethane
cause staining
polyols
Phenolics are generally stain
Polyolefins, styrenics, and most resistant and include simple
Phenolic
engineering resins phenolics (BHT), various
polyphenolics, and bisphenolics
Phosphites can improve color
Polyolefins, styrenics, and most stability and property retention,
Organo-phosphite
engineering resins but can be corrosive if
hydrolyzed
The major disadvantage with
Thioester Polyolefins and styrenics thioesters is their odor which is
transferred to the host polymer
There are other properties in addition to preventing oxidation that must be considered when choosing
an antioxidant for a specific adhesive formulation. These properties include:
Volatility
Compatibility
Color stability
Taste and odor
Regulatory issues
Cost is generally not an over-riding issue since most antioxidants are used in small concentrations.
It is important that the stabilizer and its transformation products (which also may provide stability)
not volatilize from the polymer. Many commercial antioxidants have been designed with higher
molecular weights with this in mind. Antioxidants should be soluble in the polymeric matrix or at least
diffuse slowly throughout the matrix. The migration of the additive out of the adhesive could result in a
weak boundary layer and poor adhesion.
Efficient Mixing of Hot Melt Adhesive Components
The various types of equipment and processes that can be used to mix hot melt adhesive components
are particularly diverse, and they are usually determined by either familiarity with existing practice or
the availability of equipment. Typical compounding ingredients include elastomers (30-50%),
thermoplastic resins (20-40%), plasticizers (10-40%), fillers (1-10%), color pigments (0.1-3%), and
stabilizers against oxidation and UV (0.1-3%).
Low softening temperature thermoplastics and their additives and modifiers are generally mixed
without difficulty. These hot melt adhesive formulations can be compounded in several types of mixers
such as:
Vertical mixers
Horizontal mixers (Sigma blade or Kneader)
The most economic method is the vertical mixer. Its advantages and disadvantages are:
Advantages Disadvantages
Easier to pull vacuum during mixing Difficult to produce very high viscosity
products due to its lower shearing
Adhesives offer better aging torque
performance
Heat exchange is somewhat slow
Material change sequence is flexible
Total mixing time is longer than those
No need for skilled labor made with horizontal mixers
The horizontal mixers are normally accompanied by an extruder for easy adhesive mixing and
discharge. Generally, the elastomers are metered individually or as a premix into the feed barrel. The
resins (solid or liquid) and plasticizers are added downstream. For larger quantities, the liquids can be
fed at several locations along the extruder using multiple kneading and homogenizing stages.
The main advantage of the horizontal mixers is that the entire operation can be done on a continuous
basis. This enhances both productivity and quality. A continuous twin screw mixing process is illustrated
below.
Back to Top
Multi-stage Feed Continuous Extruder for Compounding Hot Melt Adhesives
Continuous mixers such as these are claimed to provide 30 percent cost savings. This is primarily due to
lower operating costs and energy savings. Processing aids can also be added to the formulation to even
further improve mixing capability and achieve efficient mixing with less energy.
Typical processing agents that can be used are:

Organosilane or organotitanate dispersing agents
Polyethylene glycol interfacial agents
Continuous mixers provide compounding flexibility as they are capable of utilizing a wide range of
resins and melt temperatures. Slight changes in formulations or complete changes in product can be
accomplished with relatively little effort and minimal cleaning or purging.
The quality of the product is improved due to a higher melt quality and improved process control.
Oxidation of the formulation is significantly reduced since the continuous extruder generates high
shear without high temperatures. The residence time is also short minimizing exposure of heat
sensitive components to high temperatures.
Hot Melt Adhesive Working Properties
The three working properties of hot melts are hot tack, open time and setting speed.
Hot Tack
Tack as the word says, refers to the stickiness of the adhesive. Hot tack here points to the high
temperature of the hot melt applied. In the process of hot tack, wetting occurs. It happens when the
surface tension of the liquid is lower than the surface tension of the substrate.
Then occurs wet adhesion which is a blend of capillary [SP] and viscous forces. The viscous forces play a
significant role in wet adhesion process.
Open Time
Open time is the time taken by the adhesive to create a bond. It can also be defined as the time Back to Top
wherein wetting can still occur to create a bond. Another way of defining it could be the time from the
application of the hot melt till the cooling of the hot melt where it loses it initial adhesive properties.
There are various factors that can influence open time like environment, usage conditions and the type
of hot melt adhesive used.
How to measure open time?
We present before you a very simple way of measuring open time. Place different hot melts on paper
strips. Place these strips in the oven for about 150° C for the temperature of these hot melts to reach
on a higher side.
After this new paper strips are placed perpendicularly on the hot melt strips in time intervals of 4
seconds, 8 seconds, 12 seconds and so on. These strips are then cooled for atleast 24 hours till
crystallization has completed. These strips are then removed and it can be observed that at some
places, strips are successfully removed, but at other places not. Therefore one gets to know that the
open time was over because you couldn't wet that hot melt or the strip anymore. If you have a
standard hot melt over and you know the open time, then you can estimate the open time of other hot
melts.
The Setting Speed
Setting speed of a hot melt can be defined as the time taken by the hot melt to form a bond of
acceptable strength.
HMA Requirements for Hygiene Products
Hot melt adhesives play a strong enabling role in the construction of disposable hygienic products such
as:
Baby diapers (nappies)

Feminine care products
Adult incontinence articles
However, there are also a number of other hygienic

applications for adhesives including medical dressings,
hospital bed pads, and surgical drapes.
All of these hygienic products have a similar basic function

– reliable absorption of liquids and / or solids with no
leakage while promoting comfort and health. These
products are also alike in that they are produced in high speed production processes, and the
substrates generally consist of non-woven sheets and polymeric film.
However, not all applications within the manufacture of a hygiene product are alike as illustrated for
baby diapers as shown below. Specific applications include:
Construction
Core (fluff pad) adhesive
Positioning adhesive
Elastic attachment
Frontal tape adhesive
Side tape adhesive Back to Top
It has been found that a hot melt adhesive used for a particular use must have a specific set of
properties and may be completely unsuitable for other uses or applications.
As a result, the selection of the proper adhesive formulation is a complex and difficult task that
depends on the end-use requirements of the specific application as well as the manufacturing method
employed. In addition, adhesive formulations used are constantly undergoing changes as the
performance requirements change.
Adhesive Use with Non-wovens in Diaper Manufacture

(Credit: Nordson)
Disposable hygiene products consist of an absorbent filler (sometimes referred to as a super absorbent
polymer, SAP) protected on its outer face by a liquid proof polyolefin film and covered internally with a
film of non-woven fabric which is generally polyethylene. The non-woven fabric comes into contact
with the skin and allows body fluids to flow toward the filler. More elaborate products may in addition
contain a leak proof barrier, an elastic band, a wetness indicator, or be made completely of
biodegradable products.
The hygiene adhesive must possess a high degree of adhesion since it is often applied in the form of a
number of stripes such as a spray pattern. The adhesive can be a pressure sensitive or non-pressure
sensitive product depending on the application
To function in manufacturing equipment for hygiene product applications, the hot melt adhesives must
have suitable:
Viscosity
Set speed
Open time
The temperature / viscosity relationship of the adhesive must be controlled to permit easy application
and surface wetting of the liner without wrinkling the liner material.
It must not be excessively absorbed into the non-woven substrate. Yet, low surface energy is also
needed in order to properly wet out the non-wovens as well as polymeric film (e.g., polyethylene) used
in construction.
Once the article is made:

The adhesive and the adhesive joint must remain flexible after long periods of storage
It is also desirable that the adhesive remain white or clear in color
The adhesive must also possess sufficient adhesive and cohesive strength to provide high bond
strength values when subjected to stress so the constructions cannot be separated
Tensile strength and heat resistance of the final bond are important because the diaper must not
come apart and release the fluff wadding (the absorbent material) which may harm the child
Also the adhesive is either in direct contact or near-contact with the skin and, thus, the adhesive will
see temperatures in the 40°C range. The adhesive may also experience warehouse temperatures in
the 40°-55°C range, and the bond strength and flexibility of the adhesive must be preserved during
this period
Other basic requirements for the adhesive are:
Suitable for skin contact Low color and thermal

No staining or bleed-
Low Odor (non-toxic, good stability for high
through
adhesion) temperature application
Excellent initial and Robust application

Good retention of
aged adhesion to low (stable spray application
shape, high softness, High mileage (low cost)
energy (e.g., polyolefin patterns and slot die
and drape
film) substrates coating) Back to Top
Multipurpose adhesives which can be used for more than one application within a single product are
desirable in that they can reduce the number of different adhesive products which must be held in the
manufacturer’s inventory. Furthermore, less adhesive products will reduce the likelihood of the wrong
adhesive being used. However, as explained above, a multipurpose adhesive may be difficult to develop
due to the unique requirements of each application.
The various hygiene adhesive applications can be classified into three main categories:
Construction
Elastic attachment
Garment attachment
Construction
The construction adhesive is used to bond the primary layers of the article together. These layers
generally consist of various non-woven materials and thin polyolefin films. The adhesive that is most
commonly used is a non-pressure sensitive hot melt. Hot melt adhesives having low surface energy are
preferred to assure proper wetting of these low energy substrates.
Very small amounts of adhesive are needed (e.g., 1 gm/m2), and the adhesive covers only a portion of
the substrate. To deliver this requirement while still providing adequate bond strength, adhesives are
often sprayed on, requiring a very 'short' formulation (e.g., one with low melt elasticity). Narrow
molecular weight distribution polymers, such as styrene block copolymers and metallocene catalyzed
polyolefins, are ideal.
Spray coatings apply stringent requirements on hot melt adhesives. The adhesive must have a
sufficiently low melt viscosity (generally less than 15,000 cps at the application temperature). The
adhesive must also be applied at a temperature low enough to avoid heat distortion of the substrate
(e.g., thin gauge polyethylene film). Many other physical factors, especially rheological properties,
come into play in determining the sprayability of the hot melt. A long open time is also needed, as the
small volumes of dispensed adhesive will cool rapidly. Formulations are designed to maximize open
time, while maintaining adequate heat resistance.
Elastic Attachment
The trend in baby diaper construction has definitely been toward form-fitting leg bands which are
stretchable. This requires that the diaper adhesive both adhere to the polyolefin liner and be elastic or
adhere to the elastic band that is inserted in the leg area.
The elastic materials that are added to the hygienic product may be made of Lycra or Spandex fibers,
natural rubber, polyurethane foam, or other elastic laminates. The elastic adhesive will need high
adhesive strength but also high cohesive strength in order to hold onto the stretched elastic. Like
construction adhesives, elastic attachment adhesives also need a low surface tension for good
wetting and low melt temperature viscosity for sprayability.
Garment Attachment
The adhesive strip on the outside of sanitary napkins must bond to panty liners to hold the pad in
place. The pressure sensitive adhesive is usually applied by hot melt transfer coating. This is done in-
line with the production of the napkin itself. The substrates include the napkin (e.g., low energy
polyethylene) and the panty liner. The bond must be sufficient to secure holding and not “snap-back”
or debond after the consumer presses the product in place. As with construction and elastic adhesives,
the garment attachment adhesive must be stable on storage for up to two years without change in its
pressure sensitive adhesive properties.
Because of the manufacturing processes and end-use, the adhesive must provide functions other than
merely supplying a secure attachment. Other requirements include:
Clean-cut off because the adhesive is applied to a defined area

High tack
Light color and no staining of the release liner
Low odor
Non-toxic, as the adhesive will be in close proximity to the skin
No residual adhesive after peeling.
A sometimes overlooked end-market where non-wovens and adhesives come together is as

intermediate attachments used in manufacturing. Here, double-sided pressure-sensitive adhesive tapes
or sheets based on nonwoven carriers impregnated with adhesive provide highly reliable attachment,
with good workability. Solvent-borne or waterborne pressure sensitive adhesives can be used in these
adhesive products as they are produced off-line to the hygiene product manufacturing operation.
However, environmental regulations and production speed are still requirements that mean hot melts
will maintain leadership in this end-market area.
Commercially Available Ingredients for Hot Melt Adhesives
Back to Top
Cardolite® NX-2026
Cardolite
Cardolite® NX-2026 is a high purity cardanol, bio-based diluent, resin modifier, and accelerator
designed for use in adhesives and sealants. It is based on natural, renewable, non-food raw
material... view more
Benzoflex™ 352
Eastman Chemical Company
Benzoflex™ 352 by Eastman Chemical Company is a white flake solid plasticizer with a melt point of
118°C which can offer significant performance advantages in a variety of hot melt adhesive... view
more
View all 189 Eastman Chemical Company products matching your search
Dytek® A (2-Methylpentamethylenediamine)
INVISTA
Dytek® A (2-Methylpentamethylenediamine) by Invista acts as a curing agent. It can be used as an
alternative to hexamethylene diamine to lower melting point. It improves thermal stability and...
view more
Pearlbond™ 301
Lubrizol
Pearlbond™ 301 by Lubrizol is very soft, high performance aromatic polyester-based thermoplastic
polyurethane (TPU) with excellent low temperature flexibility and very low activation temperature.
It... view more
Pearlbond™ 700 EXP

Lubrizol
Pearlbond™ 700 EXP by Lubrizol is a linear, polyester-based polyurethane (TPU). It is supplied in
form of small beige granules, which combines an ultra-fast crystallization rate with an ultra-high...
view more
View all 49 Lubrizol products matching your search
View All Ingredients
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INGREDIENTS SELECTOR SELECTION RESOURCES NEWS & FEEDS

Hot Melt Adhesives: Basics, Ingredient Selection & Formulation Tips

Become an expert by learning about:

» Basics of Hot Melt Adhesives

A polymer/ blend of polymers

The main advantage of hot melts over other forms

Have a low viscosity in the melt

Working of Hot Melt Adhesives

The working mechanism of holt melts includes following steps:

Composition of Hot Melt Adhesives

Polymer Selection for Hot Melt Adhesives

Low density polyethylene

» Find the Suitable Polymer for your Hot Melt Formulation

Hot Melt Base Polymer Characteristics

Most frequently used base polymer

Good, general purpose adhesives

Low cost with good acid and fuel resistance

Low temperature ﬂexibility

Considered to be high performance hot melts

For reactive hot melt with terminal isocyanate

Ethylene Vinyl Acetate (EVA)

Broad formulating latitude necessary for many

Change Due to Decreased Crystallinity Back to Top

Stiﬀness modulus Decreases

Changes in Physical Properties of EVA Due to Increasing Vinyl Acetate Content

Substrate Vinyl Acetate (VA) Content 18% VA » 40% VA

Styrene Butadiene Copolymers

Styrene isoprene styrene 20

Starting Formulation of an SIS Elastomeric Hot Melt Adhesive

Representation of an SBC structure in bulk

No vulcanization required (results in high processing speeds)

Amorphous polyoleﬁns, formed by the copolymerization of alpha-oleﬁns such as ethylene, propylene,

Components Parts by Weight

SEBS Addition to APO in a Hot Melt Adhesive Improves T-peel Strength

Improve toughness and impact resistance

Starting Formulations for a Metallocene Catalyzed Polypropylene Hygiene Adhesive

Peel force, gms, measured at 40°C on

Peel force, gms, after:

Polyamide Molecular Weight

Typical Properties of Polyamide Adhesives of Various Molecular Weight

Major application areas for polyamide hot melt adhesive include:

Hot Melt Polyurethane Reactive Adhesives

In general, HMPUR adhesives have these characteristics:

HMPUR adhesives are manufactured:

The adhesive is melted using a speciﬁcally designed premelter

Speciﬁc properties required for varying applications are built into

Tackiﬁers/ Tackifying resin

Tackiﬁers is an important class of materials used in

It is this combination of the properties that make

» Check Out Various Tackiﬁer Grades Available in the Market Today

Standard tackiﬁers are either based on natural or petroleum-based products.

Polymer SIS SBS SEBS EVA PE

Plasticizers for Hot Melt Adhesives

Compatibility with a given polymer or set of component ingredients

Waxes used in hot melt adhesive formulations could be:

Antioxidants in Hot Melt Adhesives

Oxidation Sensitive Components in Hot Melts

Adhesive components especially susceptible to oxidation include:

Stabilizers Commonly Used in Hot Melts

Types Common Resin Applications Comments

Eﬃcient Mixing of Hot Melt Adhesive Components

Multi-stage Feed Continuous Extruder for Compounding Hot Melt Adhesives