| HS Code | 544017 |
| Product Name | EXCEVAL AQ-4104 |
| Manufacturer | Kuraray Co., Ltd. |
| Product Type | Polyvinyl alcohol (PVA) resin |
| Cas Number | 9002-89-5 |
| Appearance | White to off-white powder |
| Solubility | Soluble in water, producing a clear solution |
| Viscosity 4 Percent Solution 20 Degc | 4.0 to 5.0 mPa·s |
| Degree Of Hydrolysis | 98.0 to 99.0 mol% |
| Ph 4 Percent Solution | 5.0 to 7.0 |
| Loss On Drying | <= 5.0% |
| Ash Content | <= 0.5% |
| Bulk Density | 0.4 to 0.7 g/cm³ |
As an accredited EXCEVAL AQ-4104 factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | EXCEVAL AQ-4104 is packaged in 20 kg pails with sealed inner liner, labeled for safe handling and storage. |
| Container Loading (20′ FCL) | 20′ FCL loading: secure drums/IBCs of EXCEVAL AQ-4104, ensure ventilation, avoid overheating, and prevent shifting during transit. |
| Shipping | EXCEVAL AQ-4104 is supplied as an aqueous polymer emulsion in sealed drums or IBCs. Protect from freezing and excessive heat; store upright in a ventilated area. Prevent spills and container damage. Typically transported as non-hazardous goods, but always confirm current classification and handling requirements with the Safety Data Sheet. |
| Storage | Store EXCEVAL AQ-4104 in the original, tightly closed container in a cool, dry, well-ventilated area. Protect from direct sunlight, heat, and ignition sources. Keep away from incompatible materials. Do not freeze; maintain moderate temperatures, ideally between 5–35°C. Avoid temperature extremes. Provide secondary containment to prevent spills. Follow all SDS-specific instructions for shelf life and waste disposal. |
| Shelf Life | Store in original sealed container in a cool, dry place. Typical shelf life of EXCEVAL AQ-4104 is 12 months from production date. |
EXCEVAL AQ-4104 is supplied as an aqueous dispersion of ethylene-vinyl alcohol copolymer with a nominal solids content in the 40 wt% range. The as-received dispersion is diluted with deionized water to 18–25 wt% solids for reverse gravure coating on biaxially oriented polypropylene film. Water quality is controlled before dilution. Conductivity of the dilution water is kept below 10 µS/cm. Higher ionic content can shift dispersion stability and produce micro-flocculation in the coating pan. The diluted mixture is transferred through a vacuum deaeration vessel to remove entrapped air before the coating station.
Biaxially oriented polypropylene film is surface-treated immediately before coating. The target wetting tension is 38–42 mN/m. Treatment is performed with a ceramic electrode treater. The treated web should be coated within 2 h. Storage of treated film without coating reduces wetting tension and causes reticulation in the dry film. A 60° hexagonal gravure cylinder is used for application. The engraving is 80–120 lines/cm with a theoretical cell volume of 18–25 cm³/m². Dry coating weight is maintained at 2.0–3.5 g/m². Coating bath viscosity is monitored continuously. Viscosity drift above the specified range indicates excessive evaporation or particle destabilization.
The coated web passes through a three-zone air flotation dryer. Zone temperatures are set at 70 °C, 90 °C, and 110 °C. Web surface temperature in the first zone is maintained below 60 °C. Rapid surface film formation traps water and generates haze with micro-blisters. Total residence time is 2–4 s. Residual moisture in the dried coating is measured by Karl Fischer titration. The acceptance limit is <0.5 wt% water. Residual water above this limit reduces oxygen barrier after lamination and can create delamination at the tie layer.
Oxygen transmission is measured after 48 h conditioning at 23 °C and 0% RH. The test method is ASTM D3985. The table below gives representative values from controlled pilot coating trials. At 85% RH, the oxygen barrier of the EVOH layer declines because water plasticizes the copolymer. The coating is therefore specified for dry and low-moisture food lines unless it is buried behind a high-barrier moisture layer.
| Substrate | Dry AQ-4104 weight | Test condition | Oxygen transmission | Standard |
|---|---|---|---|---|
| BOPP film, 20 µm | 0 g/m² | 23 °C, 0% RH | 1,800–2,400 cm³/(m²·day·atm) | ASTM D3985 |
| BOPP film, 20 µm | 3.0 g/m² | 23 °C, 0% RH | <20 cm³/(m²·day·atm) | ASTM D3985 |
| PET film, 12 µm | 2.5 g/m² | 23 °C, 0% RH | <10 cm³/(m²·day·atm) | ASTM D3985 |
| SBS paperboard, 300 g/m² | 6.0 g/m² | 23 °C, 50% RH | <50 cm³/(m²·day·atm) | TAPPI T559 |
Food-contact status is demonstrated on the finished laminate. EU compliance is verified under EU 10/2011 with an overall migration limit of <10 mg/dm² by EN 1186-1. For U.S. structures, the applicable regulation is FDA 21 CFR 177.1350 where the ethylene-vinyl alcohol copolymer is listed for the intended use. The converter must confirm the food-contact statement from the resin supplier. The coated BOPP web is laminated to a polyethylene or cast polypropylene sealant. The final duplex or triplex structure is used for dry bakery products, confectionery bars, and cereal pouches. The AQ-4104 layer is positioned away from direct moisture. This position preserves oxygen barrier performance.
Paperboard surface porosity is the first processing constraint. The cellulosic surface swells when the aqueous dispersion is applied. A basecoat is therefore used. The basecoat is a self-crosslinking acrylic latex or oxidized starch applied at 1.5–2.5 g/m² dry weight. The basecoat seals fibre edges and prevents the AQ-4104 dispersion from soaking into the sheet. Penetration into the board reduces film continuity at the surface. It also increases oxygen transmission through the uncoated back side of the board.
The topcoat is prepared by diluting AQ-4104 to 30–35 wt% solids. Application is by rod or curtain coater. Wet film thickness is set to deliver 4–8 g/m² dry topcoat. Lower weights leave pinholes at fibre overlap points. A non-silicone defoamer may be added at 0.05 wt% of mixed coating if foam is generated during circulation. The coated board is dried in an air flotation oven at 95–120 °C. Board surface temperature is kept below 105 °C to prevent steam blowout. High initial air velocity can cause mottle on the wet film.
Water resistance is measured by TAPPI T441 Cobb 2 min. Coated board commonly gives 3–6 g/m². Oxygen transmission is measured by TAPPI T559 at 23 °C and 50% RH. A dry AQ-4104 weight of 6 g/m² on 300 g/m² solid bleached sulphate board can reduce oxygen transmission to <50 cm³/(m²·day·atm). The result depends strongly on basecoat smoothness and fibre roughness. A rough basecoat requires higher topcoat weight to close the surface defects.
Regulatory status for paperboard food contact is evaluated under FDA 21 CFR 176.170. EU compliance requires the finished article to meet EU 1935/2004 and the good manufacturing practice regulation 2023/2006. Overall migration is measured by EN 1186. Specific migration is assessed for the pre-coat and any defoamer retained in the dry film. Converted articles include folding cartons, cupstock blanks, and tray sleeves. For hot cups, the AQ-4104 layer is buried under a polyethylene extrusion coating. Direct food contact at high moisture is avoided. Water plasticization reduces the oxygen barrier of the EVOH layer.
Unprimed BOPP develops low aluminium adhesion. Low-molecular-weight species migrate from the oxidized film surface. The migration weakens metal bonding and produces metal pick-off during lamination. A thin AQ-4104 primer interrupts the migration path. The primer is diluted to 5–8 wt% solids with deionized water. A nonionic wetting agent may be added at 0.1–0.3 wt% of coating solution. Excess wetting agent creates a soft interfacial layer and reduces metal adhesion after conditioning.
The primer is applied by direct gravure or smooth-roll coating. The dry primer weight is 0.5–1.2 g/m². The coated web is dried at 85–100 °C. The roll is then transferred to a vacuum metallizer. Aluminium is evaporated onto the coated surface. The metallizer optical density is controlled at 2.0–2.8. The primer layer must be uniform. Gauge bands in the primer appear as optical density variation after aluminium deposition. A lower optical density band reduces barrier and creates visible metal streaks.
Metal adhesion is evaluated by ASTM D3359 tape pull. A rating of 5B is expected on fresh film. After 24 h storage at 35 °C, the rating should remain at or above 4B. Oxygen transmission is measured by ASTM D3985 at 23 °C and 0% RH. The metallized substrate with primer typically gives <2 cm³/(m²·day·atm). Water vapour transmission is measured by ASTM F1249 at 38 °C and 90% RH. Typical values are 0.3–0.8 g/(m²·day).
Compliance follows EU 10/2011 for plastic food-contact materials. The aluminium layer is not expected to migrate. Lamination adhesives must be selected from approved lists. The structure is handled under EC 1935/2004. Formulators must verify overall migration on the final laminate. The metallized film is laminated to a polyethylene or cast polypropylene sealant. End products are snack pouches, confectionery overwrap, and barrier bags. The primer also stabilizes metal gloss during reel-to-reel lamination.
EXCEVAL AQ-4104 functions as a formaldehyde-free binder in wet-laid nonwovens. The dispersion is added at 10–20 wt% of dry fibre mass. It is compatible with cellulose, glass microfibre, and polyester staple fibre. The furnish pH is held between 7.0 and 8.5. Sudden pH reduction below 6.0 should be avoided. Acid conditions can accelerate hydrolysis of residual ester groups in the copolymer and reduce wet strength development.
An anionic polyacrylamide retention aid is used at 0.05–0.15 wt% of furnish solids. Cationic retention aids require pre-testing. High cationic demand can destabilize the dispersion and form deposits on the forming wire. The sheet is dewatered by vacuum boxes. It is then passed through a through-air dryer or flatbed oven. The drying path must prevent early surface skin formation. A two-stage profile with initial air temperature below 90 °C is preferred before high-temperature curing.
Curing is carried out at 130–150 °C for 30–90 s. Coalescence of the copolymer particles creates the binder film. Wet strength is increased by adding ammonium zirconium carbonate at 3–5 wt% of binder solids. The crosslinker reacts with hydroxyl groups of the ethylene-vinyl alcohol copolymer. The reaction proceeds during the drying cycle. Overdrying can discolour the nonwoven. Underdrying leaves water-sensitive regions and reduces wet tensile strength.
Tensile strength is measured by ISO 1924-2. Wet tensile strength is tested after 5 min immersion in demineralised water. The wet/dry tensile ratio is expected to exceed 0.40 when the crosslinker is used. Air permeability is measured by ISO 5636-3. At the specified binder level, pore collapse is limited. Regulatory compliance is handled under REACH. No intentional formaldehyde is present. Emission testing can be performed by ISO 16000-3. Finished nonwovens are used in air filtration media, battery separator base mats, and abrasive backing pads. The binder contributes oil resistance and low ash after incineration.
Polypropylene or polystyrene sheet is coated with AQ-4104 before thermoforming. The dry coating weight is 6–10 g/m². This weight is higher than flexible film coating because the coating thins during forming. The draw ratio in tray corners reaches 2:1 to 4:1. Thinner barrier layers in the corners become the oxygen ingress pathway. Barrier performance is therefore limited by the corner thickness rather than the flat sheet transmission rate.
The coated sheet must be dried thoroughly. Residual water is held below 0.5 wt%. Thermoforming is run at sheet surface temperatures of 135–160 °C for polypropylene. Plug assistance is used only on the uncoated side. Metal plugs can stick to the AQ-4104 coating at forming temperature. Silicone release agents are avoided because they interfere with subsequent sealant lamination. The coated side is positioned against the mould cavity. The uncoated side faces the plug.
Pinhole density is measured before and after forming. A standard method is ASTM F3039. Flat sheet should have <5 pinholes/m² before forming. After forming, pinhole density rises in the corners. For draw ratios above 3:1, published data for this specific configuration is limited. Tooling trials are required to map corner thickness and barrier retention. The oxygen transmission of the final tray is tested according to ASTM D3985 after conditioning at 23 °C and 0% RH.
The formed tray is used in modified atmosphere packaging. The food-contact layer is a polyethylene or polypropylene inner layer. The AQ-4104 layer is a buried barrier. Compliance is evaluated in the final structure under EU 10/2011 and FDA 21 CFR 177.1350 where applicable. Finished trays are used for sliced meat, cheese, and prepared meal MAP packaging. The barrier layer reduces oxygen ingress. The sealant layer is laminated or coextruded before forming. The AQ-4104 layer does not directly seal.
Emulsion polymerisation reactors use AQ-4104 as a nonionic protective colloid for vinyl acetate-ethylene and acrylate copolymer systems. The dispersion is charged to the aqueous phase at 2–5 wt% based on total monomer feed. It stabilises latex particles during nucleation and growth. The reactor temperature is held at 70–85 °C. The colloid reduces coagulum formation on the reactor wall and impeller shaft. Reactor cleaning frequency is reduced compared with unprotected formulations.
A seeded semi-batch process is used. The initial reactor charge contains 10–15% of total monomer and 40–50% of the AQ-4104 charge. The remaining monomer and initiator are fed over 4–6 h. Particle size is monitored by dynamic light scattering. Final volume mean diameter is typically 250–500 nm. The reactor contents are screened through a 180 µm sieve. Coagulum is limited to <0.5 wt% of wet latex. Higher coagulum indicates protective colloid starvation or initiator feed imbalance.
Latex viscosity is measured at 20 rpm with Brookfield spindle 3. Typical values are 5,000–15,000 mPa·s at 50 wt% solids. Mechanical stability is tested by ISO 2006. No visible coagulum is expected after 5 min at 10,000 rpm. The finished emulsion must meet REACH registration requirements. Residual monomer limits apply to the final formulated product. For food-contact adhesive applications, the product is evaluated under FDA 21 CFR 175.105 or EU 10/2011 depending on the final article. The protective colloid is bound into the polymer matrix.
The latex is used in pressure-sensitive adhesives, paper saturation, and carpet backing. AQ-4104 contributes tack, cohesion, and oil resistance. These properties are measured by loop tack according to FINAT FTM 9 or by shear adhesion failure temperature testing. The final viscosity and peel performance depend on the monomer composition and the degree of grafting between the colloid and the growing polymer chain.
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Supplied as an aqueous solution of a carboxyl-functional, partially hydrolyzed polyvinyl alcohol, EXCEVAL AQ-4104 functions as a protective colloid, aqueous binder, and film former in web coating, emulsion polymerization, ceramic processing, and water-sensitive adhesive systems. Unlike powder PVOH grades that require high-temperature dissolution and filtration, the AQ form is presented as a ready-to-dilute liquid with a nominal nonvolatile content of 15.0 ± 0.5 wt%. The polymer backbone retains an unmodified PVOH structure but carries a controlled anionic charge density that provides electrostatic stabilization in aqueous dispersions. In comparison with standard 88 mol% hydrolyzed PVOH, this charge density shifts the shear-thinning profile toward stronger pseudoplasticity and modifies interaction with cationic additives. The low ash specification is critical for ceramic and electronic applications where residual sodium or calcium oxides on burnout degrade dielectric performance. The product is classified as an aqueous polymer solution, not an emulsion or dispersion, which affects mixing viscosity and drying behavior relative to vinyl acetate-ethylene latexes.
On paper and film coating lines, the solution is diluted with deionized water to 2–6 wt% solids and metered through 100 µm filters before use. The viscosity at supply concentration is controlled to allow positive-displacement pumping at ambient temperature without excessive line pressure. When condensation or high-humidity exposure occurs, the dried film develops tack; pre-drying at 60–80 °C is required for stack rewind stability.
Table 1 summarizes the manufacturer’s typical certificate-of-analysis control ranges. The values are determined on as-supplied solution except where the parameter is reported on solid polymer.
| Parameter | Control range | Test method |
|---|---|---|
| Nonvolatile content | 15.0 ± 0.5 wt% | ISO 3251, forced-air drying at 105 °C for 3 h |
| Brookfield viscosity | 4000–8000 mPa·s at 25 °C | ISO 2555, spindle 3, 30 rpm |
| pH | 4.5–6.0 | ISO 976 |
| Degree of hydrolysis | 87.0–89.0 mol% | ISO 15023-1, modified saponification value |
| Ash on solid polymer | ≤ 0.3 wt% | ISO 3451-1, ignition at 600 °C |
| Residual vinyl acetate monomer | ≤ 20 mg/kg | headspace GC, internal method aligned with ISO 6401 principles |
The nonvolatile content is measured by ISO 3251 using forced-air drying at 105 °C for 3 h; the resulting film is then used for hydrolysis degree and ash analyses. The Brookfield viscosity range is intentionally broad because the solution is shear-sensitive and spindle geometry influences the reading. The pH range of 4.5–6.0 reflects partially neutralized carboxyl groups; outside this window, viscosity can drift through ionic shielding or slow hydrolysis. Residual vinyl acetate monomer is controlled below 20 mg/kg to minimize odor in food-contact lamination and pharmaceutical overwrap lines. The ash value of ≤ 0.3 wt% on solids is the principal difference from commodity PVOH grades and is verified by ISO 3451-1 ignition at 600 °C.
Relative to unmodified PVOH grades of the same nominal hydrolysis, AQ-4104 differs in four measurable ways: anionic charge density, lower ash content, stronger shear-thinning response, and higher sensitivity to multivalent cations. Relative to ethylene-vinyl alcohol copolymer dispersions, AQ-4104 is a solution rather than a dispersion and does not provide oxygen barrier properties. Relative to acrylic solution binders, it exhibits lower tack and higher water solubility. These differences dictate selection when low fired residue, high shear stability, or charge stabilization is required.
In slot-die and rod-metered coating of porous inkjet substrates, the coating liquid experiences extensional and shear fields in the range of 104–106 s-1 at web speeds of 800–1500 m/min. Unmodified PVOH solutions in the same concentration range tend to generate ribbing instabilities when high-molecular-weight fractions elongate under extension and recover slowly. The carboxyl modification in AQ-4104 reduces this elastic relaxation time by limiting intermolecular hydrogen bonding through electrostatic repulsion. In falling-film and capillary-breakup rheometry, the solution shows a pronounced shear-thinning index of approximately 0.55–0.70 over 1–100 s-1, followed by a high-shear plateau. This permits stable metering at high machine speeds without sacrificing binding efficiency after drying.
The anionic charge also interacts with cationic poly-DADMAC fixatives commonly used in inkjet receptor coatings. Formulations must be screened because excessive cationic demand can form colloidal flocs above pH 6.5. Where cationic fixation is required, the co-additive should be prediluted and added under controlled agitation; jar tests should include 100 µm sieve retention checks to detect microgel formation before transfer to the coating line. For anionic silica or precipitated calcium carbonate formulations, the product can be used without such charge-driven incompatibility.
During continuous vinyl acetate-ethylene emulsion polymerization, AQ-4104 is introduced as a prediluted feed in the aqueous phase of a jacketed stainless-steel reactor equipped with dual pitched-blade turbines. The use concentration, typically 2–4 wt% on total monomer, influences particle size distribution and shear stability of the resulting latex. Because the carboxyl groups are partially ionized at reactor pH, AQ-4104 provides both steric and electrostatic stabilization; this permits higher solids operation above 60 wt% without excessive coagulum when the initiator feed is maintained within 0.10–0.15 wt% ammonium persulfate on monomer. The predilution step is critical: direct addition of the as-supplied solution to a hot monomer phase can create local viscosity spikes and gel particles due to thermal shock. Use deionized water with conductivity below 5 µS/cm to avoid hard-water carboxylate precipitation. Multivalent cations such as calcium, magnesium, or aluminum must be excluded; at concentrations above 50 mg/L, ionic crosslinking of carboxyl groups produces filter-blocking aggregates. Unlike fully hydrolyzed PVOH, the AQ-4104 grade does not require heating above 90 °C for dissolution; however, storage below 5 °C can cause phase separation.
In low-temperature co-fired ceramic tape casting, the binder must deliver green strength at low addition levels and burn out cleanly without leaving conductive alkali residues. AQ-4104 is used at 2–4 wt% solids on ceramic powder in an aqueous or water-reduced slip. The anionic charge improves adsorption onto alumina and barium titanate surfaces, producing a more uniform green tape microstructure with fewer binder-rich regions. Three-point flexural strength of green tapes is influenced by drying rate and plasticizer ratio; typical formulations pair the product with polypropylene glycol at a plasticizer-to-binder ratio of 0.2–0.4. The low ash content permits burnout profiles below 450 °C in air with minimal carbon residue. When the same furnace profile is used with sodium-rich commodity PVOH, residual sodium carbonate can contribute to surface blooming and dielectric loss anomalies. The difference in thermogravimetric decomposition onset is small; the key distinction is the reduced nonvolatile metal oxide inventory.
| Comparison point | EXCEVAL AQ-4104 | Conventional PVOH 88 mol% | Relevant method |
|---|---|---|---|
| Ionic character | carboxyl-functional anionic | nonionic | colloid titration |
| Ash on solid polymer | ≤ 0.3 wt% | 0.5–1.0 wt% | ISO 3451-1 |
| Solution viscosity stability after 7 d at 40 °C | stable, minor pH drift | stable | ISO 2555 |
| Compatibility with cationic fixatives | limited; flocculation above pH 6.5 | compatible in many systems | jar test |
| Green tape burnout residue | lower alkali residue | higher sodium/potassium ash | ISO 3451-1 |
For high-speed inkjet receptor coatings and paper surface size applications, the product is normally diluted to 1–5 wt% solids and combined with fumed silica or precipitated calcium carbonate pigments. The diluted solution is compatible with nonionic and anionic dispersants; addition of poly-DADMAC or alum-based fixing agents must be performed under controlled pH and with predilution. In inkjet coatings, the dried film must absorb solvent rapidly while maintaining sufficient wet strength to resist wheel tracking. The carboxyl groups improve adhesion to silica surfaces through hydrogen bonding and coordinate with polyvalent metal salts used as crosslinkers. However, adding zirconium carbonate or ammonium zirconium carbonate above 0.3 wt% on total solids can raise viscosity and reduce pot stability; pilot mixing is required. Published data for this specific configuration is limited; formulators should verify lot-to-lot compatibility before scale-up.
The supplied solution is freeze-sensitive. Storage below 0 °C can cause irreversible phase separation; if frozen, the product should not be redistributed by direct steam injection. Recommended storage is 5–35 °C in closed polyethylene or stainless steel vessels, with a shelf life of 9–12 months from the date of manufacture when protected from direct sunlight. Avoid prolonged contact with carbon steel, copper, and zinc, as these metals can discolor the solution and generate insolubles. Borax and boric acid must be excluded because borate ions crosslink adjacent alcohol groups and produce immediate viscosity rise or gelation. Strong mineral acids below pH 2 hydrolyze residual acetate groups and alter solubility. The product is typically supplied under EU REACH registration and is suitable for food-contact adhesives when formulated within FDA 21 CFR 175.105 or BfR XXXVI conditions, subject to end-use compliance verification.
