Crosslinked Primer Layer for Flexographic Tape Adhesion
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Solution Overview
Problem
Flexographic plate mounting tapes experience adhesive nib formation during washing, which compromises print quality, and existing technologies do not adequately address this issue.
Innovation Solution
A primer layer comprising a crosslinked polymer with specific nitrogen content and a polyaziridine crosslinker is applied to the substrate, enhancing adhesion and reducing adhesive nib formation by forming covalent bonds with the carrier layer, allowing for improved rub resistance and flexibility in manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pressure sensitive adhesive layer is applied directly to the substrate without a primer layer, then the tape structure is simpler and easier to manufacture, but adhesive nib formation occurs during washing which compromises print quality
Solution Approach 1:
A primer layer comprising a crosslinked polymer with high atomic nitrogen content (greater than 6 wt%) is introduced as an intermediary between the substrate and the pressure sensitive adhesive layer. This primer layer acts as a mediator that enhances adhesion and prevents adhesive nib formation during washing, thereby improving print quality without requiring fundamental changes to the tape structure.
Solution Approach 2:
The primer layer is formed by combining a base polymer with a polyaziridine crosslinker to create a composite material with enhanced adhesive properties. The crosslinked polymer structure provides superior bonding strength and resistance to adhesive transfer, while the high nitrogen content (greater than 6 wt%) contributes to improved adhesion characteristics.
2Strength
If conventional primer materials are used without crosslinking, then the manufacturing process is simpler and faster, but adhesion strength and rub resistance are insufficient leading to adhesive nib formation
Solution Approach 1:
The primer material undergoes crosslinking transformation to change its physical and chemical parameters. The crosslinked polymer structure fundamentally alters the adhesive properties, providing enhanced strength and durability. The high atomic nitrogen content (greater than 6 wt%) and controlled oxygen-to-nitrogen ratio (less than 3.0) are critical parameters that optimize adhesion performance.
Solution Approach 2:
The primer layer is applied as a thin intermediate coating specifically at the interface between the substrate and adhesive layer, concentrating the crosslinked polymer's enhanced adhesive properties where they are most needed. This localized application of the crosslinked material provides maximum adhesion strength at the critical bonding interface without requiring the entire tape structure to be complex.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The primer layer significantly reduces adhesive nib formation during washing, improving print quality and providing enhanced rub resistance, while allowing for longer storage and handling of the tapes without immediate adhesive application.
Implementation Method 1
the primer layer comprises a crosslinked polymer... the crosslinked polymer is the reaction product of a base polymer and a crosslinker... the crosslinker is a polyaziridine crosslinker
Implementation Method 2
primer layers for adhesion of a pressure sensitive adhesive material to a substrate
Data Source
AI summary
Primer layers for adhesion of a pressure sensitive adhesive material to a substrate are provided. The primer layer comprises a crosslinked polymer. In some embodiments, the primer layer has an atomic nitrogen content of greater than 6 wt %, and in some a ratio of atomic weight percent of oxygen to nitrogen of less than 3.0. In some embodiments the crosslinked polymer is the reaction product of an amine-functional base polymer such as a polyethylenimine (PEI) and a crosslinker, which may be a polyaziridine crosslinker. Also provided are two-layer constructions comprising the primer layer and a substrate layer; and tapes, such as flexographic plate mounting tapes, comprising the two-layer construction and a pressure sensitive adhesive layer.