Multi-layer films and adhesive tapes

Description

BACKGROUND

[0001] Electrical tapes, as well as tapes and adhesive sheets for other applications which require stretching, typically use a polyvinylchloride (vinyl) substrate, upon which the adhesive is coated. This material provides excellent mechanical properties such as elongation. Such vinyl materials are highly plasticized, with some containing up to 60 percent by weight (wt-%) plasticizers.

[0002] WO 2005 / 102670 A1 describes a breathable film cover for window structures comprising: a first polymeric polyvinyl chloride film layer including internal metal particles and UV stabilizers; a second polymeric polyvinyl chloride film layer secured to the first polymeric polyvinyl chloride film layer; wherein the second polymeric polyvinyl chloride film layer incorporates UV stabilizers; and an adhesive layer applied to a surface of the first polymeric polyvinyl chloride film layer, wherein the first polymeric polyvinyl chloride film layer, the second polymeric polyvinyl chloride film layer and the adhesive layer are permeable to moisture.

[0003] D4 DE 10 2004 021775 A1 describes an adhesive tape, in particular for covering window flanges of automobiles, comprising a carrier made of two layers arranged one above the other, the first layer consisting of plasticized polyvinyl chloride (soft PVC), the second layer of unstretched polybutylene terephthalate (PBT), and a self-adhesive mass applied to the first or second layer.

[0004] US 2006 / 141247 A1 describes an self-adhesive tape for masking window flanges of automobiles, comprising a backing which is formed of two films disposed one above the other, the first film being composed of soft plasticized polyvinyl chloride (sPVC) and the second of polyethylene terephthalate (PET) and the two films being joined to each other with a laminating adhesive comprised of a crosslinked, tackifier-resin-free acrylic ester polymer having a microshear travel of less than 60 µm (for a coat weight of 25 g / m 2< ) and a delamination force of more than 3 N / cm, and a self-adhesive mass applied to the backing.

[0005] Vinyl electrical tapes and sheets have traditionally been made by first applying a primer layer. This primer helps to isolate the vinyl and its plasticizers from the adhesive while providing the required anchorage of these two (in principle) incompatible layers. New and improved substrates (i.e., backings) for such tapes are desired, as are combinations of backings, primers, and adhesives that provide better control over costs of production and properties of such backings and adhesive tapes.SUMMARY OF THE INVENTION

[0006] The present disclosure provides adhesive tapes that include a multilayer film that includes plasticized polyvinyl chloride. Such multilayer films containing plasticized polyvinyl chloride are particularly useful in electrical tapes.

[0007] Herein the term "vinyl backing" refers to a film containing polyvinyl chloride that may be used as a substrate for an adhesive composition.

[0008] In one aspect of the invention, an adhesive tape is provided that includes: a backing including a multilayer film that includes one or more organic polymers, wherein each layer of the multilayer film comprises plasticized polyvinyl chloride having more than 25 wt-% polyvinyl chloride, based on the total weight of the layer, and at least one layer comprises one or more fillers; a primer layer disposed on at least one major surface of the backing; and a pressure sensitive adhesive layer disposed on the primer layer..

[0009] The terms "backing layer(s)" and "backing" refer to an insulating film used to support the adhesive.

[0010] The terms "primer layer" and "tie-layer" refer to a layer that is coated (disposed) between the backing and an adhesive layer to enhance the anchorage of the adhesive to the backing.

[0011] The terms "polymer" and "polymeric material" include, but are not limited to, organic homopolymers, copolymers, such as for example, block (e.g., diblock, triblock), graft, random and alternating copolymers, and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term "polymer" shall include all possible geometrical configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic symmetries. Furthermore, unless otherwise specifically limited, the term "copolymer" shall include polymers made of two or more different types of monomers, including terpolymers, tetrapolymers, etc.

[0012] Herein, the term "comprises" and variations thereof do not have a limiting meaning where these terms appear in the description and claims. Such terms will be understood to imply the inclusion of a stated step or element or group of steps or elements but not the exclusion of any other step or element or group of steps or elements. By "consisting of" is meant including, and limited to, whatever follows the phrase "consisting of." Thus, the phrase "consisting of" indicates that the listed elements are required or mandatory, and that no other elements may be present. By "consisting essentially of" is meant including any elements listed after the phrase, and limited to other elements that do not interfere with or contribute to the activity or action specified in the disclosure for the listed elements. Thus, the phrase "consisting essentially of" indicates that the listed elements are required or mandatory, but that other elements are optional and may or may not be present depending upon whether or not they materially affect the activity or action of the listed elements.

[0013] The words "preferred" and "preferably" refer to embodiments of the disclosure that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure.

[0014] In this application, terms such as "a," "an," and "the" are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terms "a," "an," and "the" are used interchangeably with the term "at least one." The phrases "at least one of" and "comprises at least one of" followed by a list refers to any one of the items in the list and any combination of two or more items in the list.

[0015] As used herein, the term "or" is generally employed in its usual sense including "and / or" unless the content clearly dictates otherwise.

[0016] The term "and / or" means one or all of the listed elements or a combination of any two or more of the listed elements.

[0017] Also herein, all numbers are assumed to be modified by the term "about" and in certain situations, preferably, by the term "exactly." As used herein in connection with a measured quantity, the term "about" refers to that variation in the measured quantity as would be expected by the skilled artisan making the measurement and exercising a level of care commensurate with the objective of the measurement and the precision of the measuring equipment used. Herein, "up to" a number (e.g., up to 50) includes the number (e.g., 50).

[0018] Also herein, the recitations of numerical ranges by endpoints include all numbers subsumed within that range as well as the endpoints (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

[0019] As used herein, the term "room temperature" refers to a temperature of 20°C to 25°C or 22°C to 25°C.

[0020] Reference throughout this specification to "one embodiment," "an embodiment," "certain embodiments," or "some embodiments," etc., means that a particular feature, configuration, composition, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of such phrases in various places throughout this specification are not necessarily referring to the same embodiment of the invention. Furthermore, the particular features, configurations, compositions, or characteristics may be combined in any suitable manner in one or more embodiments.

[0021] The above summary of the present disclosure is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The description that follows more particularly exemplifies illustrative embodiments. In several places throughout the application, guidance is provided through lists of examples, which examples may be used in various combinations. In each instance, the recited list serves only as a representative group and should not be interpreted as an exclusive list.BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Fig. 1A is a cross section view of a tape according to one aspect of the invention. Fig. 1B is a cross section view of the multilayer film backing of the tape of Fig. 1A.

[0023] These figures, which are idealized, are not to scale and are intended to be merely illustrative and nonlimiting.DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0024] The present disclosure describes multilayer films that include plasticized polyvinyl chloride and optionally one or more fillers which are used as backings for adhesive tapes. They are particularly useful in electrical tapes (referred to generally as vinyl electrical tapes).

[0025] In the present invention, an adhesive tape is provided that includes: a backing including a multilayer film that includes one or more organic polymers, wherein each layer of the multilayer film comprises plasticized polyvinyl chloride having more than 25 wt-% polyvinyl chloride, based on the total weight of the layer, and at least one layer comprises one or more fillers; a primer layer disposed on at least one major surface of the backing; and a pressure sensitive adhesive layer disposed on the primer layer. In such tapes, at least one layer of the multilayer film backing includes a plasticized polyvinyl chloride, and at least one layer of the multilayer film backing includes one or more fillers.

[0026] For example, Fig. 1A is a cross section view of a tape 10 that includes a backing film 12, a primer layer 14 disposed on the backing film 12, and a pressure sensitive adhesive 16 disposed on the primer layer 14. In one embodiment of the invention, as is shown in Fig. 1B, the backing film 12 comprises a multilayer film that includes a first surface layer 12a, a core layer 12b, and a second surface layer 12c. In this aspect, the core layer 12b can include one or more fillers. As described further herein, such a core layer can comprise one or more layers.

[0027] In one embodiment, the pressure sensitive adhesive layer disposed on the primer layer is a rubber-based pressure sensitive adhesive layer.Multilayer Films and Backings

[0028] Multilayer films of the adhesive tapes of the present disclosure may have a total thickness of no more than 762 microns (30 mils), or no more than 635 microns (25 mils), or no more than 508 microns (20 mils), or no more than 381 microns (15 mils), or no more than 254 microns (10 mils).

[0029] Each layer of the multilayer films of the present disclosure may be the same or different with respect to thickness. Each layer may have a thickness of at least 2.5 microns (0.1 mil). Each layer may have a thickness of up to 250 microns (10 mils).

[0030] Multilayer films of the present disclosure may include at least 2, or at least 3, or at least 4, or at least 5 layers. In certain embodiments, multilayer films may include up to 15, or up to 14, or up to 13, or up to 12, or up to 11, or up to 10 layers. Such layers may be the same or different with respect to thickness, composition, etc.

[0031] Varying the compositions of the various layers of a multilayer film provides advantages with respect to control of properties and performance, as well as cost. For example, lower cost materials can be used within the inner (core) layers. Also, properties such as cohesive strength, stiffness, cold flow, and tack, as well as chemical resistance and gas permeability may be varied and controlled by varying the compositions of the various layers of the multilayer films of the present disclosure.

[0032] Multilayer films of the adhesive tapes of the present disclosure include one or more organic polymers, wherein each layer includes a plasticized polyvinyl chloride having more than 25 wt-% polyvinyl chloride, based on the total weight of the layer. At least one layer includes one or more fillers. In certain embodiments, each layer includes one or more fillers.

[0033] In certain embodiments, the amount of polyvinyl chloride in a layer is more than 30 wt-%, or more than 35 wt-%, or more than 40 wt-%, or more than 45 wt-%, or more than 50 wt-%, based on the total weight of the layer.

[0034] Such multilayer films may be used as backings in adhesive tapes, such as electrical tapes.

[0035] Each layer of the multilayer films of the present disclosure may be the same or different (e.g., same or different type and / or amount of filler, same or different type and / or amount of organic polymer, same or different type and / or amount of polyvinyl chloride, same or different type and / or amount of plasticizer).

[0036] Each layer of the multilayer film includes plasticized polyvinyl chloride (which may be the same or different). The plasticized polyvinyl chloride may be selected from filled and unfilled grades of polyvinyl chloride resins, and said polyvinyl chloride resin having a K value of at least 50, or at least 60, or at least 70.

[0037] The one or more organic polymers may include a polyolefin (such as high-density polyethylene (HDPE), low-density polyethylene (LDPE), and polypropylene (PP)), a polyvinyl polymer (such as polyvinyl chloride (PVC) and polyvinyl acetate (PVA)), a polyolefin-based copolymer (such as ethylene-methacrylic acid copolymer (EEMA) and ethylene-vinyl acetate copolymer (EVA)), a block copolymer (such as acrylic block copolymers and styreneisoprene-vinyl acetate copolymer), a thermoplastic elastomer (TPE), or a combination thereof.

[0038] In certain embodiments, the plasticized polyvinyl chloride includes at least 10 wt-%, or at least 15 wt-%, or at least 20 wt-%, of one or more plasticizers, based on the total weight of the plasticized polyvinyl chloride. In certain embodiments, the plasticized polyvinyl chloride comprises up to 60 wt-%, or up to 50 wt-%, or up to 40 wt-%, of one or more plasticizers, based on the total weight of the plasticized polyvinyl chloride.

[0039] Exemplary plasticizers include an epoxidized vegetable oil, an epoxidized linseed oil, a mineral oil, an acetylated castor oil, a hydrogenated castor oil, an acetylated stearate ester, a furandicarboxylate, a dianhydrohexitol diester of 2-ethylheptanoic acid, a phthalate compound (such as diisononyl phthalate (DINP), diisodecyl phthalate (DIDP), and di-2-ethylhexyl phthalate (DEHP)), a terephthalate compound (such as dioctyl terephthalate), an adipate compound (such as di-2-ethylhexyl adipate (DEHA), di-isobutyl adipate (DIBA), di-isodecyl adipate (DIDA), di-isononyl adipate (DINA), and di-tridecyl adipate (DTDA)), and a trimellitate (such as tris(2-ethylhexyl) trimellitate), and a polymeric polyester-type plasticizer. Combinations of plasticizers may be used if desired.

[0040] Suitable fillers for use in multilayer films of the present disclosure may be organic fillers, inorganic fillers, or combinations thereof.

[0041] Exemplary inorganic fillers include nepheline syenite, ceramic, glass, graphite, pigments (such as TiO 2 and boron nitride), oxides (such as zinc oxide, magnesium oxide, antimony trioxide, alumina trihydrate, silicone dioxide (i.e., silica)), hydroxides (such as aluminum hydroxide and magnesium hydroxide), inorganic salts (such as CaCO 3 , BaSO 4 , CaSO 4 , phosphates, and hydrotalcite), silicates (such as talc, mica, kaolin, wollastonite, montmorillonite, diatomite, feldspar), or combinations thereof. In certain embodiments, the inorganic filler includes calcium carbonate.

[0042] Exemplary organic fillers include natural or synthetic polymer fillers, such as cellulose fibers, wood flour, wood fibers, flax, cotton, sisal, starch, recycled rubber crumb, recycled vinyl crumb, flakes, or pellets, or combinations thereof.

[0043] The fillers may include particulate of any of a variety of shapes (including fibers, spheres, beads, irregular particles) and sizes. In certain embodiments, the fillers include nano-sized particulate up to a size that is compatible with the extrusion process and not be so large that the particulate interferes with the film properties. In certain embodiments, the fillers include particulate having an average particle size (largest dimension of the particulate, e.g., diameter of spherical particles or length of fibers) of 1 micron to 50 microns.

[0044] Optional additives may be used in the multilayer films of the present disclosure including, for example, colorants, processing aids, flame retardants, crosslinking agents, antioxidants, anti-smoke additives, and the like.

[0045] In certain embodiments, multilayer films of the present disclosure include a core and two surface layers (i.e., skin layers). In certain embodiments, the core includes one or more layers.

[0046] In certain embodiments, at least one layer of the core includes one or more fillers.

[0047] In certain embodiments, there are no internal (core) layers that include a pressure sensitive adhesive.

[0048] In certain embodiments, each surface layer includes one or more fillers. In certain embodiments, each surface layer is the same material. That is, in certain embodiments, each surface layer of a multilayer film includes the same composition (e.g., organic polymer, filler, additives).

[0049] In certain embodiments, the amount and / or type of filler in the core is different than the amount and / or type of filler in the surface layers.

[0050] In certain embodiments, one or more layers include at least 0.01 wt-%, or at least 0.1 wt-%, or at least 1 wt-%, or at least 5 wt-%, or at least 10 wt-%, or at least 15 wt-%, or at least 20 wt-%, of one or more fillers, in a layer.

[0051] In certain embodiments, one or more layers include up to 80 wt-%, or up to 70 wt-%, or up to 60 wt-%, or up to 50 wt-%, or up to 40 wt-%, or up to 30 wt-%, of one or more fillers, in a layer.Adhesives

[0052] The described multilayer films generally formed a substrate on which an adhesive is disposed, thereby forming an adhesive tape.

[0053] The adhesives used in adhesive tapes of the present disclosure are typically pressure sensitive adhesives. It is not particularly restricted and may be any of a wide variety of known pressure sensitive adhesives. Pressure sensitive adhesives are a distinct category of adhesives and a distinct category of thermoplastics, which in dry (solvent-free) form are aggressively, and permanently, tacky at room temperature. They firmly adhere to a variety of dissimilar surfaces upon mere contact without the need of more than finger or hand pressure. Pressure sensitive adhesives require no activation by water, solvent, or heat to exert a strong adhesive holding force. They are sufficiently cohesive and elastic in nature so that, despite their aggressive tackiness, they can be handled with the fingers and removed from smooth surfaces without leaving a residue. Pressure sensitive adhesives can be quantitatively described using the "Dahlquist criteria" which maintains that the elastic modulus of these materials is less than 10 6< dynes / cm 2< at room temperature (see, for example, Pocius, A.V., Adhesion & Adhesives: An Introduction, Hanser Publishers, New York, NY, First Edition, 1997).

[0054] Suitable pressure sensitive adhesives for use in the adhesive tapes of the present disclosure may be made via a wide variety of techniques. They may include an emulsion pressure sensitive adhesive, a solvent-borne pressure sensitive adhesive, a photopolymerizable pressure sensitive adhesive, a hot melt pressure sensitive adhesive (i.e., hot melt extruded pressure sensitive adhesive), or a combination thereof.

[0055] Exemplary pressure sensitive adhesives include an acrylic pressure sensitive adhesive, a rubber-based pressure sensitive adhesive, a vinyl alkyl ether pressure sensitive adhesive, a silicone pressure sensitive adhesive, a polyester pressure sensitive adhesive, a polyamide pressure sensitive adhesive, a urethane pressure sensitive adhesive, a fluorinated pressure sensitive adhesive, an epoxy pressure sensitive adhesive, a block copolymer-based pressure sensitive adhesive, or a combination thereof.

[0056] In certain embodiments, the pressure sensitive adhesive (PSA) includes a rubber-based pressure sensitive adhesive. Rubber-based pressure sensitive adhesives typically include natural or synthetic rubber, a tackifying resin, an antioxidant, and other additives or fillers as required. Exemplary rubber-based adhesive formulations are described in United States Patent Nos. 5,500,293, 6,432,530, and RE36855.

[0057] In certain embodiments, the rubber-based pressure sensitive adhesive includes a styrene-butadiene copolymer, a styrene-isoprene-styrene copolymer, a polyisoprene homopolymer, a polybutadiene homopolymer, or a combination thereof.

[0058] In certain embodiments, the rubber-based pressure sensitive adhesive comprises a polyisoprene homopolymer.

[0059] In certain embodiments, the rubber-based pressure sensitive adhesive includes a mixture or blend of polyisoprene homopolymer and a styrene-isoprene-styrene copolymer. In certain embodiments, the rubber-based pressure sensitive adhesive includes at least 13 wt-% of a polyisoprene homopolymer. In certain embodiments, the rubber-based pressure sensitive adhesive includes up to 42 wt-% of a polyisoprene homopolymer. In certain embodiments, the rubber-based pressure sensitive adhesive includes at least 13 wt-% of a styrene-isoprene-styrene copolymer. In certain embodiments, the rubber-based pressure sensitive adhesive includes up to 42 wt-% of a styrene-isoprene-styrene copolymer.

[0060] In certain embodiments, the rubber-based pressure sensitive adhesive further includes an end-block reinforcing resin. Certain adhesive compositions may contain at least 2 wt-%, or at least 5 wt-%, of an end-block reinforcing resin. Certain adhesive compositions may contain up to 20 wt-%, or up to 15 wt-%, of an end-block reinforcing resin. The reinforcing end-block resin may be an aromatic, essentially hydrocarbon resin, which generally has a glass transition temperature higher than that of the adhesive application temperature. Useful resins include low molecular weight oligomers and polymers of styrene and α-methylstyrene and p-methylstyrene, and copolymers thereof. Examples include those commercially available under the tradenames ENDEX 155 and 160, KRISTALEX 5140 and 1120, from Eastman Chemical Company (Kingsport, TN).

[0061] In certain embodiments, the rubber-based pressure sensitive adhesive further includes a solid tackifying agent. Examples of solid tackifying agents (i.e., tackifying resins) include aliphatic resins (e.g., C5 resins), aromatic resins (e.g., C9 resins), terpene-based resins, and rosin resins (e.g., rosin esters, hydrogenated rosin resins, and dimerized rosin resins which can be obtained, for example, from Eastman (Kingsport, TN)). If used, one or more tackifying agents can be used in an amount of at least 25 wt-%, or at least 30 wt-%, based on the total weight of the adhesive composition. If used, one or more tackifying agents can be used in an amount of up to 55 wt-% or up to 45 wt-%, based on the total weight of the adhesive composition.

[0062] In certain embodiments, the rubber-based pressure sensitive adhesive further includes a multifunctional crosslinking agent (particularly a (meth)acrylate crosslinking agent). Examples of multifunctional crosslinking agents include butanediol diacrylate, hexanediol diacrylate, divinylbenzene, and other latent crosslinking agents such as reactive phenolics. If used, one or more crosslinking agents can be used in an amount of at least 0.5 wt-%, or at least 1 wt-%, based on the total weight of the adhesive composition. If used, one or more crosslinking agents can be used in an amount of up to 10 wt-%, or up to 5 wt-%, based on the total weight of the adhesive composition.

[0063] In certain embodiments, pressure sensitive adhesives of the disclosure include one or more fillers. Suitable fillers for use in pressure sensitive adhesives of the present disclosure may be organic fillers, inorganic fillers, or combinations thereof.

[0064] Exemplary inorganic fillers include nepheline syenite, ceramic, glass, graphite, pigments (such as TiO 2 and boron nitride), oxides (such as zinc oxide, magnesium oxide, antimony trioxide, alumina trihydrate, silicone dioxide (i.e., silica)), hydroxides (such as aluminum hydroxide and magnesium hydroxide), inorganic salts (such as CaCO 3 , BaSO 4 , CaSO 4 , phosphates, and hydrotalcite), silicates (such as talc, mica, kaolin, wollastonite, montmorillonite, diatomite, feldspar), or combinations thereof. In certain embodiments, the inorganic filler includes calcium carbonate.

[0065] Exemplary organic fillers include natural or synthetic polymer fillers, such as cellulose fibers, wood flour, wood fibers, flax, cotton, sisal, starch, recycled rubber crumb, recycled vinyl crumb, flakes, or pellets, or combinations thereof.

[0066] The fillers may include particulate of any of a variety of shapes (including fibers, spheres, beads, irregular particles) and sizes. In certain embodiments, the fillers include nano-sized particulate up to a size that is compatible with adhesive processing. In certain embodiments, the fillers include particulate having an average particle size (largest dimension of the particulate, e.g., diameter of spherical particles or length of fibers) of 1 micron to 50 microns.

[0067] In certain embodiments, a PSA layer includes at least 0.01 wt-%, or at least 0.1 wt-%, or at least 1 wt-%, or at least 5 wt-%, or at least 10 wt-%, or at least 15 wt-%, or at least 20 wt-%, of one or more fillers, in the PSA layer.

[0068] In certain embodiments, a PSA layer includes up to 80 wt-%, or up to 70 wt-%, or up to 60 wt-%, or up to 50 wt-%, or up to 40 wt-%, or up to 30 wt-%, of one or more fillers, in the PSA layer.Primers

[0069] Suitable primers for use in enhancing the adhesion of the adhesive to the multilayer adhesive backings described herein can include a variety of materials. The primers can include homopolymers and / or copolymers. The primers typically include an elastomeric polymer.

[0070] A primer layer can be solvent coated onto one surface of the backing layer or coextruded with and formed on one side of the backing layer. Although in certain embodiments, the primer layer is solventless, it can include residual solvent, particularly if coated out of solvent.

[0071] Exemplary elastomeric polymers for use in the primers of the present disclosure include an epoxidized polymer. In certain embodiments, the epoxidized polymer includes a concentration of epoxidized units of at least 0.5 wt-%. In certain embodiments, the epoxidized polymer has a concentration of epoxidized units of at least 1 wt-%, or at least 2 wt-%, or at least 3 wt-%, or at least 4 wt-%, or at least 5 wt-%. In certain embodiments, the epoxidized polymer has a concentration of epoxidized units of up to 10 wt-%.

[0072] Examples of such epoxidized polymers include an epoxidized conjugated diene polymer, an epoxidized butadiene-containing copolymer, an epoxidized styrene-butadiene copolymer, an epoxidized styrene-isoprene polymer, and an epoxidized acrylonitrile-butadiene copolymer. For example, epoxidized styrene-butadiene block copolymers are available under the tradename EPOFRIEND from Daicel Corporation (Fort Lee, NJ).Methods

[0073] As would be understood by one of ordinary skill in the art given the present description, the multilayer film and tape embodiments described herein can be formed using any number of well-known processes / techniques. Exemplary well-known processes / techniques are described in U.S. Patent Nos. 4,713,273, 5,407,970, 5,804,610, and 6,040,027, U.S. Patent Publication Nos. 2014 / 0039083, 2013 / 30238, and 2013 / 0184393, International Publication Nos. WO 2013 / 130238 and 2014 / 093139, and Australian Patent No. AU614623.EXAMPLES Materials

[0074] DesignationDescriptionPVC1Geon ™< Vinyl Flexible D6500 Flexible Polyvinyl Chloride from PolyOne (Avon Lake, OH) black.PVC2Geon ™< Vinyl Flexible A7000 Trans 9423 Flexible Polyvinyl Chloride from PolyOne (Avon Lake, OH).PVC3Geon ™< Vinyl Flexible C7000 Flexible Polyvinyl Chloride from PolyOne (Avon Lake, OH) white.Wingtack PLUSWingtack ®< PLUS, C5, C9 is a highly aliphatic tackifying resin available from Total Cray Valley (Exton, PA).Endex 160Endex ™< 160 Hydrocarbon Resin, a water-white thermoplastic end blocking resin made from purified aromatic hydrocarbon monomers available from Eastman Chemical Company (Kingsport, TN).D1161Kraton ®< D1161 Polymer is a clear, linear triblock copolymer based on styrene and isoprene, with a polystyrene content of 15% available from Kraton Polymers U.S. LLC (Houston, TX).N2210Natsyn 2210 is a high cis-1,4 (98.5% Typical) polyisoprene containing a nonstaining antioxidant available from Goodyear Chemical (Akron, OH).EPOEPOFRIEND AT501 is an epoxy-modified styrene-butadienestyrene copolymer available from Daicel Corporation (Tokyo, Japan). Test Methods Vinyl Layer Thickness Measurement

[0075] The thickness of each layer was determined using a Keyence VHX-1000 digital optical microscope.Total Thickness Measurement

[0076] The total sample thicknesses were measured with a Mahr Federal µmaxµm II XL thickness gauge.Adhesion

[0077] Peel adhesion to a given substrate was determined with a method based on ASTM D1000 except dwell times were 10 minutes against each substrate. For example, when testing the adhesion to steel (ATS), a 10 in. long by up to 1 inch wide sample was applied to a cleaned stainless steel plate with two passes of a 4.4 lbs. roller. An IMASS TL-2200 peel tester was used to test adhesion to steel at 180° and 12 inches / minute.

[0078] To test the adhesion of the adhesive to the backing material (ATB), a length of the exemplary sample is applied to the surface of a steel plates such that the free end are wrapped around the ends of the plate. Next a test sample 10 inches long and up to 1 inch wide is applied over the adhered sample and rolled down with two passes of a 4.4 lbs. roller. Similar equipment and test conditions are used for adhesion to backing tests. The adhesion results for the adhesive tape comprising a multilayer vinyl films are provided in Table 4.Tensile and Elongation:

[0079] A 4.5-6" long and 0.5" wide sample was placed between the grips of an Instron MTS Insight 5, which were set at a gap of 4". The head speed was at 12" / min. The tests were performed in triplicate for each sample. The elongation and tensile strength were recorded for each sample, and the percent elongation was calculated. The tensile and elongation results for the multilayer vinyl films and the adhesive tape comprising a multilayer vinyl films are provided in Table 4.Sample Preparation Preparation of the vinyl multilayer films

[0080] Two-layer vinyl films were formed by feeding the pre-compounded, plasticized polyvinyl chloride into a 1" diameter single screw extruder now available from Davis-Standard, LLC (Pawcatuck, CT) that was outfitted with a 6 in. (15.24 cm) film die now available from Nordson Extrusion Dies Industries, LLC (Chippewa Falls, WI). The extruder and die temperatures were set to 350°F (177°C), and the extruder ran at 25 revolutions per minute. A second vinyl compound was fed through the same extruder and film-forming die. The extruder and die temperatures were additionally set to 350°F (177°C), and the extruder ran at 25 revolutions per minute

[0081] Thirty-inch (0.76-m) samples of the secondary vinyl material were applied to the surface of the first vinyl layer and laminated together by feeding through a nip roll (at 50°C).

[0082] Multilayer vinyl films constructions having more than two vinyl layers were prepared by stacking designated two-layer vinyl film samples and laminating them together in a Midvale-Heppenstall (Nicetown, Philadelphia, PA, USA) hot press with the platens at 374 °F and at 10,000 lbs-f of pressure for 10 seconds.

[0083] Exemplary multilayer vinyl film constructions are provided in Table 1 with the thickness of each layer provided in Table 2. Table 1. Multilayer vinyl film constructionsExampleLayer 1Layer 2Layer 3Layer 4Layer 5Layer 61PVC1PVC22PVC2PVC33PVC1PVC34PVC1PVC3PVC1PVC35PVC1PVC2PVC1PVC26PVC2PVC3PVC2PVC37PVC2PVC3PVC1PVC3PVC1PVC2 Table 2. Layer thicknesses in multilayer vinyl films ExampleLayer 1 (mm)Layer 2 (mm)Layer 3 (mm)Layer 4 (mm)Layer 5 (mm)Layer 6 (mm)10.190.1220.140.1730.190.1540.150.170.170.1150.110.070.120.0760.140.110.100.1570.090.120.110.110.110.09 Preparation of the adhesive

[0084] Examples were prepared using a compounding and coating apparatus for processing natural and synthetic non-thermoplastic elastomer hot melt based PSA described in U.S. Pat. No. 5,539,033 (Bredahl et al.).

[0085] Styrene-isoprene-styrene block copolymer (Kraton D1161) was fed into Barrel Section 1 of a 30 mm diameter fully intermeshing co-rotating TSE (Werner- Pfleiderer (now Coperion GmbH) Model ZSK-30, having a LID of 36:1) having conveying and kneading sections, at a rate of 18.0 g / min using a K-Tron (Coperion K-Tron, Sewell, NJ), loss-in-weight feeder which continuously monitored the weight of the material in the hopper. A C5, C9 is a highly aliphatic tackifiying resin (Wingtack ®< PLUS) was added into Barrel Zone 1 of the twin screw extruder at a rate of 3.6 g / min using a K-Tron loss-in-weight feeder which continuously monitored the weight of the material in the hopper. Cis-1,4 polyisoprene resin (Natsyn 2210) was added into Barrel Zone 2 of the twin screw extruder at a rate of 18.0 g / min using a bulk feeder available from Bonnot Company (Green, OH, Model No. B-6661), a 3.0 cc / rev ZENITH gear pump. (Zenith Pumps / Colfax Corporation, Monroe, NC) and a flexible hose, all at a temperature of 121°C. An additional 25.2 g / min C5, C9 is a highly aliphatic tackifiying resin was added to Barrel Zone 4 of the twin screw extruder at a rate of 3.6 g / min using a K-Tron loss-in-weight feeder which continuously monitored the weight of the material in the hopper. 10.8 g / min of a thermoplastic end blocking hydrocarbon resin (Endex ™< 160) was added to Barrel Zone 6 of the twin screw extruder using a K-Tron loss-in-weight feeder which continuously monitored the weight of the material in the hopper.

[0086] Barrel Zone 1 was set at a temperature of 60°C. Barrel Zone 2 was set at a temperature of 66°C. Barrel Zone 3 was set at a temperature of 66°C. Barrel Zone 4 was set at a temperature of 66°C. Barrel Zone 5 was set at a temperature of 93°C. Barrel Zone 6 was set at a temperature of 93°C. Barrel Zones 7 through 12 were set at a temperature of 149°C. The adhesive was transported through the remaining zones of the extruder and delivered to a 3.0 cc / rev ZENITH gear pump. (Zenith Pumps / Colfax Corporation, Monroe, NC). The gear pump was set to deliver 75.6 g / min of adhesive to a 6 inch extrusion die as described in U.S. Reissue Pat. No. 36,855 (Bredahl et al.) set at a temperature of 149°C which coated the adhesive on a commercial release liner. An adhesive film was produced having a thickness of approximately 1.2 mils (30.5 microns).Preparation of adhesive tape samples comprising a multilayer vinyl films

[0087] A 10% solution of EPO dissolved in toluene was coated with a #14 Meyer bar onto a section of a multilayer vinyl film. The coating was dried at ambient conditions for more than 24 hours prior to laminating the adhesive film to the EPO primer layer surface. The adhesive was place against the primer surface and the adhesive / primer / vinyl construction was laminated together at 90°C on an LPA 3301 laminator, available from Fujipla, Inc. at a speed setting of 2. The constructions were passed through the laminator twice.

[0088] The multilayer vinyl films from examples 2 and 7 were pressed in a Midvale-Heppenstall (Nicetown, Philadelphia, PA, USA) hot press, where the platens were at 374 °F, at 10,000 lbs.-f of pressure for 10 seconds and shims of 0.25 mm (5 mil) thickness were placed between the platens to ensure a thickness of at least 0.25 mm (5 mil) of the pressed multilayer vinyl film. These pressed multilayer vinyl films were treated the same as the previously described adhesive samples and are referred to as examples 11 and 12, respectively, in the table below

[0089] Exemplary adhesive tape constructions are summarized in Table 3. Table 3. Adhesive tape constructions comprising multilayer vinyl filmsExampleLayer 1Layer 2Layer 3Layer 4Layer 5Layer 6Layer 7Layer 88AdhesiveEPOPVC1PVC29AdhesiveEPOPVC2PVC310AdhesiveEPOPVC1PVC311AdhesiveEPOPVC2PVC312AdhesiveEPOPVC2PVC3PVC1PVC3PVC1PVC2 Table 4: Mechanical properties of the multilayer vinyl films and adhesion properties of the adhesive tapes comprising multilayer vinyl films ExampleTotal Sample Thickness (mm)% Elongation at BreakTensile Strength (MPa)ATS (N / dm)ATB (N / dm)10.333298.5320.292748.1330.323148.0640.591524.5750.452416.3160.432397.3570.561885.3680.353728.770.840.3990.343618.890.860.41100.333739.980.640.52110.231.230.46120.241.470.42

[0090] The scope of the disclosure is defined by the claims set forth herein as follows.

Claims

1. An adhesive tape comprising: a backing comprising a multilayer film comprising one or more organic polymers, wherein each layer of the multilayer film comprises plasticized polyvinyl chloride having more than 25 wt-% polyvinyl chloride, based on the total weight of the layer, and at least one layer comprises one or more fillers; a primer layer disposed on at least one major surface of the backing; and a pressure sensitive adhesive layer disposed on the primer layer.

2. The adhesive tape of claim 1 wherein the multilayer film backing comprises up to 15 layers.

3. The adhesive tape of claim 1 wherein the multilayer film backing comprises a core and two surface layers.

4. The adhesive tape of claim 3 wherein the core comprises one or more layers.

5. The adhesive tape of claim 4 wherein at least one layer of the core comprises one or more fillers.

6. The adhesive tape of claim 3 wherein each surface layer comprises one or more fillers.

7. The adhesive tape of claim 1 wherein each layer of the multilayer film backing comprises one or more fillers.

8. The adhesive tape of claim 1 wherein the pressure sensitive adhesive comprises an emulsion pressure sensitive adhesive, a solvent-borne pressure sensitive adhesive, a photopolymerizable pressure sensitive adhesive, a hot melt pressure sensitive adhesive (i.e., hot melt extruded pressure sensitive adhesive), or a combination thereof.

9. The adhesive tape of claim 8 wherein the pressure sensitive adhesive comprises a rubber-based pressure sensitive adhesive.

10. The adhesive tape of claim 9 wherein the rubber-based pressure sensitive adhesive comprises a styrene-butadiene copolymer, a styrene-isoprene-styrene copolymer, a polyisoprene homopolymer, a polybutadiene homopolymer, or a combination thereof.

11. The adhesive tape of claim 1 wherein the primer is solventless.

12. The adhesive tape of claim 11 wherein the primer comprises an elastomeric epoxidized polymer, wherein the epoxidized polymer comprises a concentration of epoxidized units of at least 0.5 wt-%.