Silicone Release Layer Adhesion via Dual Primer Curing
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Solution Overview
Problem
The existing methods for applying a silicone release layer on a rubber underlayer in digital offset printing systems are inefficient due to the difficulty in forming chemical bonds between silicone and rubber surfaces, and catalyst poisoning by compounds from the underlying substrate, which affects the quality of the resulting silicone release layer.
Innovation Solution
A method involving the application of a first and second curable primer, each with different catalysts, followed by a silicone release formulation, which are then cured simultaneously to form a silicone release layer with excellent adhesion and prevent catalyst inhibition, using a rod coating process and specific organosilanes and catalysts like titanium and platinum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a silicone release layer is applied on a rubber underlayer using known methods, then the release properties are achieved, but the manufacturing process is time-consuming and inefficient
Solution Approach 1:
The patent combines the primer application and silicone release layer application into a single simultaneous curing process. The primer layer and silicone release formulation are applied to the rubber substrate and cured together in one step, eliminating the sequential drying/curing wait time required in traditional methods where the primer must be fully dried or cured before applying the silicone layer.
Solution Approach 2:
The patent applies the primer layer in advance as part of the same coating process as the silicone release formulation, but allows both to cure simultaneously. The primer is prepared and applied beforehand in the mixture, but the actual curing of both layers occurs together, preventing the primer from needing to be fully cured before silicone application.
2Strength
If a primer layer is applied and dried or cured before applying the silicone release layer, then chemical bonds can form between layers, but the process becomes time-consuming
Solution Approach 1:
The patent merges the curing of the primer layer and the silicone release layer into a single simultaneous curing event. Both layers are applied to the rubber substrate together and cured together, eliminating the time required to fully dry or cure the primer before applying the silicone layer, while still ensuring proper chemical bonding between layers.
3Reliability
If a platinum catalyst is used in an addition-cure reaction, then the silicone release layer can be formed, but compounds from the underlying rubber layer can poison the catalyst and stop the curing reaction
Solution Approach 1:
The patent uses a specially formulated primer layer as an intermediary between the rubber substrate and the silicone release formulation. This primer layer contains specific chemicals that prevent compounds from the rubber substrate from reaching and poisoning the platinum catalyst in the silicone release layer, while still allowing the catalyst to function properly for curing the silicone.
Solution Approach 2:
The patent applies the primer layer in advance to counteract the harmful effect of catalyst poisoning. The primer creates a protective barrier before the silicone release formulation is applied, preventing the rubber substrate compounds from interfering with the platinum catalyst, thus preemptively eliminating the harmful effect.
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 method provides a silicone release layer with excellent adhesion to the substrate and prevents catalyst poisoning, resulting in a more efficient and effective manufacturing process compared to traditional methods, with improved quality and reduced curing time.
Implementation Method 1
A first curable primer and a second curable primer, each having a different catalyst, are then applied to the substrate. A silicone release formulation is then applied to the primers.
Implementation Method 2
the desirable release properties of silicone and the properties of rubber also make it difficult to form chemical bonds at their respective surfaces
Implementation Method 3
The primers may be the same or different and each primer may be a mixture of organosilanes that crosslink by condensation or addition reaction to form a crosslinked gel structure
Implementation Method 4
The primers may be the same or different and each primer may be a mixture of organosilanes that crosslink by condensation or addition reaction to form a crosslinked gel structure
Data Source
AI summary
A method of forming a silicone release layer on a substrate, for an intermediate transfer member of a digital offset printing system, the method including:a) providing a curable first primer on the substrate;b) providing a curable second primer on the substrate;c) providing a curable silicone release formulation on the curable first and second primers; andd) curing the first primer, the second primer and the release formulation.