Multi-layer device with self-adhesive film

Abstract

The present invention relates to a novel multi-layer device comprising an environmentally friendly, PVC-free and VOC-free self-adhesive film capable of being transferred onto different substrates without the use of solvents and without the need for a large amount of pretreatment of the surface as in conventional spray / printing applications. The multilayer device comprises at least four layers, a first "base layer" (A), a second "release layer" (B) on the "base layer" (A), a "pressure sensitive adhesive (PSA) layer" (C) on the "release layer" (B) followed by a "top coat" (D) on the "PSA layer" (C). The combination of layer (A) and layer (B) forms a release liner [(A) (B)]. The combination of layer (C) and layer (D) forms a self-adhesive film [(C) (D)] of 15 GSM to 300 GSM and is separable from the release liner [(A) (B)].

Description

Technical field:

[0001] The present invention relates to a novel self-adhesive multilayer device that can be transferred to different substrates without the use of solvents and without extensive pre-treatment of the surface as is required for conventional spray applications. Background technology:

[0002] Conventional spray applications require extensive handling and processing of the surface being sprayed, including long drying times before further processing. In addition, some liquid coatings contain 35ml to 100ml of volatile organic compounds (VOCs) per liter, which are harmful to health and the environment. In some cases, the lingering smell of newly sprayed surfaces can cause allergic reactions and unpleasantness.

[0003] Wallpaper has been seen as an alternative to painted surfaces. However, wallpaper can only be applied on selected surfaces, which require extensive preparation work before the wallpaper can be fixed. In addition, wallpaper is also sensitive to humidity.

[0004] Vinyl products are widely used in the graphics and signage industries, but they are not environmentally friendly.

[0005] There is an unmet need to provide environmentally friendly alternatives to paint, wallpaper and vinyl products in the home, industrial, graphics and signage industries. In addition, there is an unmet need to provide products for these applications that can be used on a variety of surfaces without requiring extensive surface preparation.

[0006] Purpose of the Invention :

[0007] The main object of the present invention is to provide a multilayer device comprising a self-adhesive film which is environmentally friendly, PVC-free, VOC-free, transferable to different surfaces, avoiding the use of solvents and extensive surface preparation, significantly reducing spraying time and avoiding the discomfort associated with lingering odors.

[0008] Another object of the present invention is to enable the film to be printed using different printing inks and printing methods.

[0009] It is another object of the present invention to provide said multilayer device comprising a pigmented film.

[0010] Another object of the present invention is to have the multilayer device comprise a film that can be transferred to a metallic or non-metallic substrate regardless of the surface topography and surface texture.

[0011] Another object of the present invention is to make the membrane washable and water-resistant.

[0012] Another object is to make the film comply with the EN-71 part 3 standard.

[0013] Another object of the present invention is to enable rapid transfer of the film to a surface, thereby significantly reducing the surface coating time compared to conventional spraying processes.

[0014] Another object of the present invention is to make the film wear-resistant.

[0015] Another object of the present invention is to enable the multilayer device to be produced on a cost-effective commercial scale and used for surface protection and decoration.

[0016] Another object of the present invention is to make the multi-layer device easily accessible to the public as a do-it-yourself (DIY) product. SUMMARY OF THE INVENTION :

[0018] According to the present invention, the multilayer device comprises at least four layers, a first "base layer" (A), a second "release layer" (B) on the "base layer" (A), a "pressure sensitive adhesive (PSA) layer" (C) on the "release layer" (B), followed by a "top coating" (D) on the "PSA layer" (C). The combination of layer (A) and layer (B) forms a release liner [(A)(B)]. The combination of layer (C) and layer (D) forms a self-adhesive film [(C)(D)] and can be separated from the release liner [(A)(B)].

[0019] The "base layer (A)" is a liner material, typically selected from paper or plastic. The "release layer" (B) is preferably selected from a reactive agent, and the "PSA layer" (C) comprises a pressure sensitive adhesive (PSA).

[0020] The "top coating" (D) comprises a mixture of hydrophilic and hydrophobic polymers, a synthetic rubber (preferably SBR), a hydroxy-reactive polysilanol and optionally a pigment.

[0021] The ratio of hydrophilic polymer to hydrophobic polymer on a solid basis ranges from 1:0 to 1:70, preferably from 1:30 to 1:60, most preferably from 1:40 to 1:50. In the "top coating" (D), the synthetic rubber (preferably SBR) accounts for 1-13% w / w of layer (D), preferably 1-8% w / w of layer (D); the optional pigment accounts for 15-45% w / w of layer (D), preferably 20-25% w / w of layer (D); the hydroxy-reactive polysilanol accounts for 0.1-3% w / w of layer (D), preferably 0.5-1.5% w / w of layer (D). Description of the drawings:

[0022] Figure 1 An apparatus is shown, comprising:

[0023] Base layer (A)

[0024] • A release layer (B) coated on layer A.

[0025] The combination of layer (A) and layer (B) forms the release liner [(A)(B)].

[0026] • A "pressure sensitive adhesive (PSA)" layer (C) coated on layer (B).

[0027] • A "top coating" (D) applied on layer (C).

[0028] The combination of layer (C) and layer (D) forms 15GSM to 300GSM and can be combined with the release liner [(A)

[0029] (B)] Separated self-adhesive film [(C)(D)]. Specific implementation method:

[0030] The present invention is described with reference to the accompanying drawings. However, it should be clear that this description is only illustrative of the present invention and is by no means limiting of the present invention.

[0031] The terms and words used in the following description are not limited to their literal meanings. The description represents illustrative embodiments and examples. The drawings and / or illustrations in no way limit the scope of the present invention. It should be understood that modifications and / or changes to the drawings / illustrations of the present invention, in addition to those specifically set forth herein, can be implemented by those skilled in the art, and these modifications and changes should be considered to fall within the overall scope of the present invention.

[0032] Figure 1 Four layers are shown, namely:

[0033] Base layer (A)

[0034] • A release layer (B) coated on layer A.

[0035] The combination of layer (A) and layer (B) forms the release liner [(A)(B)].

[0036] • A "pressure sensitive adhesive (PSA)" layer (C) coated on layer (B).

[0037] • A "top coating" (D) applied on layer (C).

[0038] The combination of layer (C) and layer (D) forms 15GSM to 300GSM and can be combined with the release liner [(A)

[0039] (B)] Separated self-adhesive film [(C)(D)].

[0040] The additional layer may be coated or applied in the form of a varnish or waterproof coating, or laminated to the membrane.

[0041] Layer A is the liner material, usually paper or plastic film.

[0042] The paper in the "base layer" (A) is selected from supercalendered kraft (SCK) paper, polycoated kraft paper, glassine paper, clay coated kraft (CCK) paper, machine finished kraft (MFK) paper or machine finished glazed (MG) paper.

[0043] In embodiments where the "base layer" (A) is plastic, the plastic is selected from PET film (biaxially oriented), poly-coated BO-PET film, BOPP (biaxially oriented PP film) or other polyolefins, typically including HDPE, LDPE or PP plastic resins.

[0044] The "release layer" (B) is selected from silicone release agents, phosphate esters, alkylated phosphate esters, fluoropolymers, preferably silicone release agents.

[0045] The pressure sensitive adhesive in the "PSA layer" (C) is selected from butyl acrylate, ethylhexyl acrylate, styrene block copolymer, styrene-butadiene-styrene, styrene-isoprene-styrene, preferably butyl acrylate polymer and ethylhexyl acrylate polymer.

[0046] The "top coating" (D) comprises a mixture of hydrophilic and hydrophobic polymers, a synthetic rubber (preferably SBR), a hydroxyl-reactive polysilanol and optionally a pigment. The ratio of hydrophilic polymer to hydrophobic polymer on a solid basis ranges from 1:0 to 1:70, preferably from 1:30 to 1:60, and most preferably from 1:40 to 1:50. In the "top coating" (D), the synthetic rubber (preferably SBR) accounts for 1-13% w / w of layer (D), preferably 1-8% w / w; the optional pigment accounts for 15-45% w / w of layer (D), preferably 20-25% w / w; the hydroxyl-reactive polysilanol accounts for 0.1-3% w / w of layer (D), preferably 0.5-1.5% w / w.

[0047] The hydrophilic polymer is selected from polyvinyl alcohol, polyvinyl pyrrolidone, starch, dextrin, hydroxyethyl cellulose, hydroxypropyl cellulose, methyl hydroxyethyl cellulose, preferably polyvinyl alcohol and polyvinyl pyrrolidone,

[0048] The hydrophobic polymer is selected from acrylic polymer emulsion / latex (preferably SBR latex) / polyvinyl acetate latex / styrene-acrylic polymer emulsion, acrylic polymer, polyamide, epoxy resin, polyester and polyolefin, and synthetic rubber.

[0049] The solvent for dissolving the hydrophobic polymer may be selected from ketones, esters, alcohols, aromatic hydrocarbons, ester alcohols and alcohol ketones.

[0050] Preparation process of the multilayer device of the present invention

[0051] The process includes the following steps:

[0052] i) Preparation of release liner [(A)(B)]

[0053] A release agent is coated on the "base layer" (A) to obtain a "release layer" (B), and dried at 160°C to 180°C.

[0054] ii) Coating a "PSA layer" (C) on the "release liner" [(A)(B)]

[0055] The pressure sensitive adhesive (PSA) is coated on the "release liner" [(A)(B)] to achieve 5 to 30 GSM and dried at 120 to 140° C. An optional pigment may be added to obtain a colored backing layer.

[0056] iii) coating a "PSA layer" (C) on the "release liner" [(A)(B)] and further coating a "top coating" (D)

[0057] Prepare the "top coating" (D) and then coat it on the "PSA layer" (C) as follows:

[0058] a) stirring the acrylic emulsion polymer / polymer solution at high speed, preferably at a stirring speed of 800 to 1000 rpm,

[0059] b) adding a dispersant to the acrylic emulsion polymer / polymer solution under stirring and then optionally adding titanium dioxide (rutile) and optionally a color fine paste under stirring to achieve homogenization,

[0060] c) adding the hydrophilic polymer solution to the above mixture under stirring, then adding the synthetic rubber (preferably SBR) and the hydroxyl-reactive polysilanol in sequence under stirring, optionally mixing a defoamer, a leveling agent and a dry film preservative, and removing any extraneous matter, if any, to obtain a "coating coating",

[0061] d) coating the "coating coating" of step (c) on the "PSA layer" (C), and drying at 120°C to 130°C to obtain a film of 15 to 300 GSM [(C)(D)],

[0062] e) Optionally applying an additional layer on the membrane [(C)(D)], in the form of a varnish or waterproof coating or laminating layer.

[0063] The present invention is illustrated by way of non-limiting examples

[0064] Example-1:

[0065] Multilayer device with self-adhesive film [(C)(D)]

[0066] i) 90 GSM CCK (clay coated kraft) paper ("base layer" (A)) was taken, coated with silicone ("release layer" (B)), and dried at 170 to 180°C to obtain 1.0 to 1.5 GSM "release layer" (B). This CCK paper coated with silicone was used as "release liner" [(A)(B)].

[0067] ii) A pressure-sensitive adhesive (BONDEX ACR) of 18 g / m2 was applied on the "release layer" (B), and dried at 120 to 130°C to obtain a "PSA layer" (C) on the "release layer" (B).

[0068] iii) The preparation method of the "coating paint" is as follows:

[0069] Add acrylic polymer emulsion (54% solids) to a mixing pot, add 0.4% of the total batch of dispersant under high speed mixing, then add 15% of the total batch of titanium dioxide and add 0.9% of pigment blue paste (Pigment Blue CI 15:3) to obtain the desired hue.

[0070] • Polyvinyl alcohol (13.5% aqueous solution) was then added to give a PVA:acrylic polymer ratio of 1:44.5.

[0071] • Then add 4% of SBR latex and 2.5% of hydroxyl-reactive polysilanol in total with continuous mixing.

[0072] In addition, 0.3% of the total amount of defoamer and 0.3% of the leveling agent were added to obtain smooth and uniform quality.

[0073] After filtration, the coating material was obtained.

[0074] iv) A coating layer was applied on the "PSA layer" (C) and dried at 120 to 130°C to obtain a "top coating layer" (D) having a GSM of 110-120 and a film having a GSM of 130-140 [(C)(D)].

[0075] Example-2:

[0076] Multilayer device with self-adhesive film [(C)(D)]

[0077] i. Take 90 GSM CCK (clay coated kraft) paper ("base layer" (A)), coat with silicone ("release layer" (B)), and dry at 170 to 180°C to obtain 1.0 to 1.5 GSM "release layer" (B). This CCK paper coated with silicone is used as "release liner" [(A)(B)].

[0078] ii. A pressure-sensitive adhesive (BONDEX ACR) of 18 g / m2 was applied on the "release layer" (B), and dried at 120 to 130°C to obtain a "PSA layer" (C) on the "release layer" (B).

[0079] iii. The preparation method of "coating coating" is as follows:

[0080] Add acrylic polymer emulsion (54% solids) to a mixing pot, add 0.4% of the total batch of dispersant under high speed mixing, and then add 25% of the total batch of titanium dioxide.

[0081] Then polyvinyl pyrrolidone PVPK-30 (40% aqueous solution) was added to make the ratio of PVPK: acrylic acid polymer 1:33.75.

[0082] • Then add 3% of the total amount of SBR latex and 2% of the hydroxyl-reactive polysilanol with continuous mixing.

[0083] In addition, 0.3% of defoamer and 0.3% of leveling agent were added, followed by 0.7% of dry film preservative and further mixed for 15 minutes to obtain a smooth and uniform quality.

[0084] After filtration, the coating material was obtained.

[0085] iv. A coating coating was applied on the "PSA layer" (C) and dried at 120 to 130°C to obtain a "top coating" (D) having a GSM of 120-130 and a film having a GSM of 140-150 [(C)(D)].

[0086] Example-3:

[0087] Multilayer device with self-adhesive film [(C)(D)]

[0088] a. Take 90 GSM CCK (clay coated kraft) paper ("base layer" (A)), coat with silicone ("release layer" (B)), and dry at 170 to 180°C to obtain 1.0 to 1.5 GSM "release layer" (B). This CCK paper coated with silicone is used as "release liner" [(A)(B)].

[0089] b. A pressure-sensitive adhesive (BONDEX ACR) of 20 g / m2 was applied on the "release layer" (B), and dried at 120 to 130°C to obtain a "PSA layer" (C) on the "release layer" (B).

[0090] c. The preparation method of "coating coating" is as follows:

[0091] Add acrylic polymer emulsion (54% solids) to a mixing pot, add dispersant at 0.4% of the total batch volume under high speed mixing, and then add titanium dioxide at 23% solids of the total batch volume.

[0092] • Polyvinyl alcohol (13.5% in water) was then added to give a PVA:acrylic polymer ratio of 1:20. 2.8% of the total amount of SBR latex and 1% of the hydroxyl-reactive polysilanol were then added with continuous mixing.

[0093] In addition, 0.3% of the total amount of defoamer and 0.3% of the leveling agent were added to obtain smooth and uniform quality.

[0094] After filtration, the coating material was obtained.

[0095] d. A coating coating was applied on the "PSA layer" (C) and dried at 120 to 130°C to obtain a "top coating" (D) having a GSM of 110-120 and a film having a GSM of 130-140 [(C)(D)].

[0096] Example-4:

[0097] Multilayer device with self-adhesive film [(C)(D)]

[0098] a. Take 90 GSM CCK (clay coated kraft) paper ("base layer" (A)), coat with silicone ("release layer" (B)), and dry at 170 to 180°C to obtain 1.0 to 1.5 GSM "release layer" (B). This CCK paper coated with silicone is used as "release liner" [(A)(B)].

[0099] b. A pressure-sensitive adhesive (BONDEX ACR) of 20 g / m2 was applied on the "release layer" (B), and dried at 120 to 130°C to obtain a "PSA layer" (C) on the "release layer" (B).

[0100] c. The preparation method of "coating coating" is as follows:

[0101] Add acrylic polymer solution (50% solid content) to the mixing pot, then add 0.4% dispersant under high-speed stirring, then add titanium dioxide (ATR 312, rutile) paste (75% solid content) with a solid content of 20% of the total batch, 3.0% SBR and 2.0% hydroxyl-reactive polysilanol.

[0102] Continue mixing, add PVPK-30 (polyvinyl pyrrolidone K-30) solution (30% solid content) under stirring, keep the ratio of PVPK: acrylic polymer at 1:45, then add 0.8% dry film preservative and mix for 10 minutes. Filter to obtain "coating coating".

[0103] d. Apply the "PSA layer" (C) using the "coating coating" and dry at 120-130°C to obtain a coating of 90-100 GSM for the "top coating" (D), thereby forming a film with a total GSM of 110-120 [(C)(D)].

[0104] Application of the multilayer device of the invention

[0105] a. Cleaning the substrate surface to which the film [(C)(D)] is to be transferred,

[0106] b. Peel off the film [(C)(D)] from the "release liner" [(A)(B)],

[0107] c. laying the adhesive side of the film [(C)(D)] on the substrate surface to which the film is to be transferred,

[0108] d. applying pressure on the film to adhere to the surface,

[0109] e. Remove air bubbles, if any, between the transferred film and the surface using known methods.

[0110] advantage :

[0111] In addition to overcoming the shortcomings of existing products, technologies and practices related to the coatings industry, the present invention provides a multi-layer device including a printable self-adhesive film having significant advantages:

[0112] 1. Environmentally friendly, PVC-free, VOC-free, transferable to any surface, no need to use solvents, extensive surface pre-treatment, greatly shortening spraying time, avoiding problems caused by lingering paint odor, and meeting the requirements of EN-71 Part 3.

[0113] 2. It can be transferred to metal and non-metal, such as walls, interlayers, metal, tiles, glass, wood, stone, cement or plastic, regardless of the surface shape and texture of the substrate.

[0114] 3. Capable of being loaded with pigments and / or printed using different printing inks and printing methods.

[0115] 4. Washable and waterproof.

[0116] 5. Capable of being produced on a commercial scale in a cost-effective manner and used for surface protection and decoration.

[0117] 6. Easy to use as a do-it-yourself (DIY) product for the public.

[0118] 7. Suitable for interior wall coatings, printed graphic applications, advertising, promotions, labels and other marketing activities, and surface coverings in residential and commercial institutions.

Claims

1. A multilayer device having a self-adhesive film, the self-adhesive film comprising a base layer (A), a release layer (B) coated on the layer A, a "pressure-sensitive adhesive (PSA)" layer (C) coated on the layer (B), and a "top coating" (D) coated on the layer (C), the combination of the layer (A) and the layer (B) forming a release liner [(A)(B)], the combination of the layer (C) and the layer (D) forming a film [(C)(D)] that can be separated from the release liner [(A)(B)], wherein the layer (D) comprises a hydrophilic polymer and a hydrophobic polymer.

2. The self-adhesive multilayer device according to claim 1, comprising an additional layer coated or applied thereto in the form of a varnish or waterproof coating or laminated to the film [(C)(D)].

3. A method for producing a self-adhesive multilayer device according to claim 1, comprising the following steps: i. coating a release agent on the "base layer" (A) to obtain a "release layer" (B), and drying at 160 ℃ to 180 ℃ to obtain a "release liner" [(A) (B)]; ii. coating a pressure-sensitive adhesive (PSA) on the top surface of the release layer (B) of the release liner [(A)(B)] and drying at 120° C. to 140° C. to obtain a PSA layer (C), iii. applying a "coating coating" on the top surface of the PSA layer (C) to obtain a "top coating" (D), Here are the steps: a) adding the dispersant to the hydrophobic polymer emulsion / solution under stirring and then optionally adding titanium dioxide (rutile) and / or pigment under stirring, b) adding the hydrophilic polymer solution to the mixture of step (a), and then successively adding the synthetic rubber, preferably SBR, and the hydroxyl-reactive polysilanol under stirring, optionally mixing a defoamer, a leveling agent and a dry film preservative, and removing any extraneous matter, if any, to obtain a "coating coating", c) coating the "coating coating" of step (b) on the top surface of the PSA layer (C), Drying is carried out at 120°C to 130°C to obtain a "top coating" (D), the combination of layer (C) and layer (D) forming a "film" [(C)(D)], d) Optionally applying an additional layer on the membrane [(C)(D)], said additional layer being in the form of a varnish or a waterproof coating or a laminating layer.

4. The “base layer (A)” according to claims 1-3 is a lining material, which is selected from paper, such as super calendered kraft (SCK) paper, poly coated kraft paper, glassine paper, clay coated kraft (CCK) paper, machine finished kraft (MFK) paper or machine finished glazed (MG) paper.

5. The "base layer (A)" according to claims 1-3 is a lining material, which is selected from plastics, such as PET film (biaxially oriented), poly-coated BO-PET film, BOPP (biaxially oriented PP film) or other polyolefins, typically including HDPE, LDPE or PP plastic resins.

6. The "release layer" (B) according to claims 1-3 is selected from silicone release agents, phosphate esters, alkylated phosphate esters, fluoropolymers, preferably silicone release agents.

7. The pressure-sensitive adhesive in the "PSA layer" (C) according to claims 1-3 is selected from butyl acrylate, ethylhexyl acrylate, styrene block copolymers, styrene-butadiene-styrene, styrene-isoprene-styrene, preferably butyl acrylate polymer and ethylhexyl acrylate polymer.

8. The "top coating" (D) according to claims 1-3 comprises: A mixture of a hydrophilic polymer and a hydrophobic polymer, the ratio of hydrophilic polymer to hydrophobic polymer on a solid basis ranges from 1:0 to 1:70, preferably from 1:30 to 1:60, most preferably from 1:40 to 1:50; a synthetic rubber, preferably SBR, accounting for 1-13% w / w of layer (D), preferably 1-8% w / w; an optional pigment, accounting for 15-45% w / w of layer (D), preferably 20-25% w / w; and a hydroxy-reactive polysilicone, accounting for 0.1-3% w / w of layer (D), preferably 0.5-1.5% w / w.

9. The hydrophilic polymer in the "top coating" (D) according to claims 1-3 and 8 is selected from polyvinyl alcohol, polyvinyl pyrrolidone, starch, dextrin, hydroxyethyl cellulose, hydroxypropyl cellulose, methyl hydroxyethyl cellulose, preferably polyvinyl alcohol and polyvinyl pyrrolidone.

10. The hydrophobic polymer in the "top coating" (D) according to claims 1-3 and 8 is selected from acrylic polymer emulsions / latex, preferably SBR latex / polyvinyl acetate latex / styrene-acrylic polymer emulsions, preferably styrene-acrylic polymer emulsions, acrylic polymers, polyamides, epoxy resins, polyesters and polyolefins, and synthetic rubbers.

11. The "PSA layer" (C) according to claims 1-3 is in the range of 5 to 30 GSM.

12. The film according to claims 1-3 [(C)(D)] in the range of 15 to 300 GSM.

13. The multi-layer device of claims 1-12 comprising a washable, water-resistant, self-adhesive film that can be transferred to any surface.

14. The multi-layer device according to claims 1 to 13 is environmentally friendly, PVC-free and VOC-free.

15. A process for applying a film [(C)(D)] of a multilayer device according to claims 1 to 14 onto any metallic or non-metallic surface regardless of the surface shape and texture, comprising the steps of: a. cleaning the substrate surface onto which the film [(C)(D)] is to be transferred, b. Peeling the film [(C)(D)] from the "release liner" [(A)(B)], c. laying the adhesive side of the film [(C)(D)] on the substrate surface to which the film is to be transferred, d. applying pressure on the film to adhere to the surface, e. Remove air bubbles, if any, between the transferred film and the surface using known methods.

Images