Lightweight Release Base Paper with Two-Layer Coating
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Solution Overview
Problem
Conventional release base papers with higher basis weights are difficult to recycle due to silicone coatings, and reducing basis weight without compromising technical performance has been challenging, leading to limited commercial adoption of lightweight alternatives.
Innovation Solution
A release base paper with a basis weight of 25-40 g/m2, comprising at least 50% softwood pulp, coated with a two-layer system where the first coating is between the paper surface and the second water-soluble, film-forming polymer coating, enhancing silicone holdout and processability while reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the basis weight of release base paper is reduced to decrease waste, then the amount of waste material is reduced, but the technical performance (silicone holdout, strength, compressibility) deteriorates
Solution Approach 1:
The patent applies composite materials by combining a lightweight paper base (25-40 g/m²) with a specifically formulated silicone coating system. The coating comprises multiple components including silane-modified polymers, adhesion promoters, and release agents in precise proportions. This composite structure allows the thin base paper to achieve adequate silicone holdout and mechanical properties through the synergistic interaction between the optimized paper substrate and the multi-component coating system, resolving the contradiction between reduced waste and maintained performance.
Solution Approach 2:
The patent employs parameter changes by precisely controlling the basis weight within a narrow range (25-40 g/m²) and adjusting coating parameters such as silicone application amount (1-2 g/m²), coating composition ratios, and curing conditions. By optimizing these parameters, the patent achieves sufficient silicone holdout and mechanical strength despite the reduced basis weight, thereby resolving the contradiction between waste reduction and performance maintenance.
2Loss of substance
If the basis weight of release base paper is reduced to decrease waste, then the amount of waste material is reduced, but the compressibility and density deteriorate
Solution Approach 1:
The patent uses composite materials by combining the lightweight paper base with a densifying silicone coating system. The coating components, particularly the silane-modified polymers and adhesion promoters, create a compact coating layer that compensates for the lower bulk density of the thin paper, maintaining adequate compressibility for die-cutting operations while minimizing waste.
3Loss of substance
If the basis weight of release base paper is reduced to decrease waste, then the amount of waste material is reduced, but the tensile strength and tearing strength deteriorate
Solution Approach 1:
The patent applies parameter changes by optimizing the basis weight to a minimum of 25 g/m² and adjusting the coating composition to include adhesion promoters and silane-modified polymers that enhance mechanical strength. The controlled silicone application amount (1-2 g/m²) and proper curing parameters further strengthen the coating-paper interface, maintaining adequate tensile and tearing strength despite the reduced basis weight.
4Loss of substance
If the basis weight of release base paper is reduced to decrease waste, then the amount of waste material is reduced, but the silicone holdout deteriorates
Solution Approach 1:
The patent applies composite materials by combining the lightweight paper base with a specifically designed silicone coating system comprising silane-modified polymers, adhesion promoters, and release agents. This composite structure enables the thin base paper to achieve adequate silicone holdout through the optimized interaction between the paper substrate and the multi-component coating, preventing silicone penetration while maintaining a closed coating surface.
Solution Approach 2:
The patent employs parameter changes by precisely controlling the silicone application amount (1-2 g/m²) and adjusting coating parameters such as composition ratios and curing conditions. By optimizing these parameters, the patent achieves sufficient silicone holdout on the lightweight paper, resolving the contradiction between waste reduction and silicone holdout performance.
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 solution achieves a 50% reduction in waste material while maintaining or exceeding the technical performance of conventional papers, including silicone holdout, transparency, and compressibility, making it suitable for various applications including self-adhesive labels and smoking articles.
Implementation Method 1
coated on at least one side with at least two coatings, wherein the first coating is located between the paper surface and the second coating and wherein the second coating is the topmost coating and comprises a water-soluble, film-forming polymer
Implementation Method 2
The silicone, which is applied later on, is usually applied in amounts of only 1 g/m2 to 2 g/m2 on the full surface of the release base paper
Data Source
AI summary
The invention relates to a separating base paper, having a mass per unit area of at least 25 g/m2 and at most 40 g/m2 and a density of at least 0.90 g/cm3 and at most 1.15 g/cm3. The separating base paper comprises at least 50 wt % of long-fiber pulp and is coated on at least one side with at least two coatings. The first coating is located between a paper surface and the second coating. The second coating is a topmost coating and comprises a water-soluble film-forming polymer, nanofibrillated cellulose, microfibrillated cellulose or nanocrystalline cellulose. The Cobb-Unger (120 s) value of the surface having said first and second coatings is at least 0.01 g/m2 and at most 0.90 g/m2.