Release Liner with Polyolefin Base and Adhesive-Bonded PE Layer
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Solution Overview
Problem
There is a need for a release liner that is dimensionally stable at elevated temperatures, provides a sufficient release effect against pressure-sensitive adhesives, and has a gripping aid for easy removal, while maintaining a balance between strength and flexibility to prevent over-stretching and allow curved application without wrinkling.
Innovation Solution
A release liner with a layer structure comprising an external silicone release layer, a polyolefin layer containing at least 50% polypropylene, and an external polyethylene layer with low-density polyethylene, where the polyethylene layer is connected by an adhesive, and thermally welded with handle tabs for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer release liner is used, then the manufacturing process is simple, but it cannot provide both high thermal stability and sufficient release properties against pressure-sensitive adhesives
Solution Approach 1:
The release liner uses a composite structure with a polyolefin base layer providing thermal stability and a silicone release layer providing release properties. This combination of different materials in a single liner structure allows both high thermal stability and sufficient release effect to be achieved simultaneously, resolving the contradiction between reliability and material selection complexity.
Solution Approach 2:
The release liner is divided into functionally distinct layers: a polyolefin base layer for dimensional stability and a silicone release layer for adhesive release. This segmentation allows each layer to be optimized for its specific function, with the base layer providing thermal stability and the release layer providing release properties, thereby achieving both requirements without compromising either.
2Strength
If the release liner is made with high strength materials, then overstretching is prevented, but flexibility for curved application is reduced
Solution Approach 1:
The polyolefin base layer uses specific polymer parameters (low-density polyethylene with controlled molecular weight and composition) to achieve an optimal balance between strength and flexibility. The material parameters are selected to provide sufficient tensile strength to prevent overstretching while maintaining enough elongation capacity to allow curved application without wrinkling.
Solution Approach 2:
The composite structure combines the rigid polyolefin base layer with the more compliant silicone release layer. This material combination allows the overall liner to exhibit both strength from the base layer and flexibility from the release layer, enabling curved application while preventing overstretching of the adhesive tape.
3Stability of the object's composition
If the release liner has high thermal stability, then dimensional stability at elevated temperatures is achieved, but the release effect against pressure-sensitive adhesives may be insufficient
Solution Approach 1:
The liner combines a polyolefin base layer that provides high thermal stability and dimensional stability at elevated temperatures with a silicone release layer that ensures sufficient release effect against pressure-sensitive adhesives. The silicone layer's low surface energy maintains effective release properties even when the base layer remains dimensionally stable at high temperatures.
Solution Approach 2:
The release liner is segmented into a thermally stable polyolefin base layer and a release-functional silicone layer. This segmentation allows the base layer to maintain dimensional stability at elevated temperatures while the release layer independently provides the necessary release effect, with each layer performing its specific function without compromising the other.
4Ease of operation
If gripping aids are added to the release liner, then easy removal is achieved, but the device complexity increases
Solution Approach 1:
The gripping tabs are designed to be self-adhering to the release liner through the same adhesive bonding process used for other components. The tabs utilize the liner's own adhesive properties to attach themselves, eliminating the need for separate attachment mechanisms and reducing overall structural complexity while still providing easy removal functionality.
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 provides thermal stability, allows coating with polyacrylate pressure-sensitive adhesives without shape changes, and enables easy removal of the liner without affecting the bond, while maintaining strength and flexibility for curved applications.
Implementation Method 1
an outer layer (PER) containing at least 80 wt%, based on the total weight of the layer (PER), polyethylene, wherein the layer (PER) is bonded to the next layer in the structure of the release liner by an adhesive
Implementation Method 2
an outer silicone release layer (SR)
Implementation Method 3
thermally welded with handle tabs for easy removal
Data Source
AI summary
A thermally stable release liner for pressure-sensitive adhesives is to be provided, equipped with a lifting aid for easy removal from the adhesive. Furthermore, the release liner should exhibit a balanced ratio of strength to flexibility. This is achieved with a release liner for use on pressure-sensitive adhesives comprising: - an outer silicone release layer (SR); - a layer (POL) containing one or more polyolefins in each of its layers to a total of at least 50 wt.%, based on the total weight of the layer, wherein the layer (POL) contains polypropylene to a total of at least 60 wt.%, based on the total weight of the layer (POL); and - an outer layer (PER) containing polyethylene to a total of at least 80 wt.%, based on the total weight of the layer (PER), wherein the layer (PER) is bonded to the next layer in the release liner structure by an adhesive.