Radiation-Induced Polymerisation for Solvent-Free Adhesive Tapes
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Solution Overview
Problem
Existing methods for producing pressure-sensitive adhesive tapes with solvent-free compositions face challenges in handling high viscosity adhesives, particularly in achieving uniform drying without skin formation, leading to residual solvent or moisture issues, which limits production efficiency and surface quality.
Innovation Solution
The method involves applying a polymerisable pressure-sensitive adhesive composition to a web-shaped substrate and activating polymerisation using electromagnetic radiation or accelerated ions, allowing for delayed cross-linking and efficient film formation at room temperature, enabling the production of high-quality tapes with reduced energy input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional drying methods are used for solvent-free pressure-sensitive adhesive compositions, then uniform drying can be achieved, but skin formation occurs on the surface that impedes evaporation and leads to residual solvent or moisture
Solution Approach 1:
The patent replaces conventional thermal drying with radiation-induced polymerization. Instead of using heat to evaporate solvents, the invention uses electromagnetic radiation (UV or electron beams) to initiate polymerization of the adhesive composition, transforming the chemical structure and achieving film formation without thermal drying processes that cause skin formation.
Solution Approach 2:
The invention changes the fundamental parameter of the drying process from thermal evaporation to radiation-induced chemical transformation. By using radiation energy instead of thermal energy, the process achieves adhesive film formation without the harmful skin formation effect that occurs with conventional drying methods.
2Ease of operation
If high temperatures are maintained for processing solvent-free pressure-sensitive adhesive compositions, then handling becomes easier, but energy consumption increases and quality flaws occur
Solution Approach 1:
The patent replaces thermal processing with radiation processing. Instead of maintaining high temperatures to handle and process the adhesive, the invention uses electromagnetic radiation or electron beams to induce polymerization at lower temperatures, reducing energy consumption while maintaining ease of operation.
Solution Approach 2:
The invention utilizes the phase transition from monomer to polymer through radiation-induced polymerization. This chemical phase transition allows the adhesive to be handled in a liquid state and then transformed into a solid film without requiring sustained high temperatures, thereby reducing energy consumption.
3Ease of operation
If slow drying and long drying channels are used, then gentle drying is achieved without skin formation, but production speed decreases
Solution Approach 1:
The patent replaces slow thermal drying with fast radiation-induced polymerization. The radiation process achieves complete film formation in seconds or minutes compared to the long drying channels required for conventional methods, dramatically increasing production speed while maintaining gentle processing conditions.
Solution Approach 2:
The invention applies the adhesive composition to the substrate first, then immediately follows with radiation treatment to induce polymerization. This preliminary application followed by rapid curing eliminates the need for long drying channels and slow processing, enabling high-speed production.
4Strength
If high application weights are used, then better adhesion is achieved, but conventional drying processes cannot handle them without skin formation and bubbly surfaces
Solution Approach 1:
The patent replaces thermal drying with radiation-induced polymerization, enabling the processing of high application weights without skin formation or bubbly surfaces. The radiation process penetrates through the adhesive layer to initiate uniform polymerization throughout, achieving both high adhesion and excellent surface quality.
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
This approach enables the production of solvent-free pressure-sensitive adhesive tapes with improved handling and efficient, homogeneous film formation, achieving strong adhesion and durability suitable for the construction industry, while minimizing energy consumption and avoiding skin formation during drying.
Implementation Method 1
wherein polymerisation is activated by acting upon the polymerisable pressure-sensitive adhesive composition with electromagnetic radiation
Implementation Method 2
polymerisation is activated by acting upon the polymerisable pressure-sensitive adhesive composition with electromagnetic radiation, electrons or accelerated ions
Data Source
AI summary
A method for the production of pressure-sensitive adhesive tapes includes providing a web-shaped substrate, providing a pressure-sensitive adhesive composition and/or a precursor for a pressure-sensitive adhesive composition, wherein the pressure-sensitive adhesive composition and/or the precursor for a pressure-sensitive adhesive composition comprising at least one polymerisable (meth)acrylate monomer and/or (meth)acrylate oligomer and/or (meth)acrylate polymer and at least one polymerisation initiator and having a solvent content of <5% by weight, based on the total mass of the pressure-sensitive adhesive composition, applying the pressure-sensitive adhesive composition and/or its precursor to one or both sides of at least sections of the web-shaped substrate, transporting a web-shaped substrate to which the pressure-sensitive adhesive composition and/or its precursor has been applied along a predetermined transport path, wherein the transport path extending at least in sections in the region of influence of an emitter for electromagnetic radiation, electrons or accelerated ions, electrons or accelerated ions, activation of the polymerisation initiator by acting upon with electromagnetic radiation, electrons or accelerated ions during the transport of the web-shaped substrate along the predetermined transport path, and polymerisation of the pressure-sensitive adhesive composition and/or of the precursor for a pressure-sensitive adhesive composition on the web-shaped substrate during its transport. Furthermore, an apparatus for carrying out this method and a pressure-sensitive adhesive tape produced according to this method are disclosed.