Solventless Release Coatings With Low-Silicone Adhesive Compatibility
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Solution Overview
Problem
Existing release coating compositions require solvent-based manufacturing methods and often contain high concentrations of silicone, which can compromise adhesive performance and increase costs.
Innovation Solution
Development of a solventless release coating composition comprising at least 50 wt.% of ethylenically unsaturated monomers with a terminal alkyl group of at least 18 carbon atoms, crosslinking components with ethylenically unsaturated groups, and a polymerization initiator, with optional silicone-free or low-silicone options, applied to a substrate and polymerized in situ to form a coating with controlled crystalline properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based manufacturing methods are used for release coating compositions, then the coating can be applied and processed easily, but it increases manufacturing complexity and environmental concerns
Solution Approach 1:
The patent changes the fundamental parameter of the coating composition from solvent-based to solventless, eliminating the need for solvent evaporation and drying steps. This transforms the manufacturing process from multi-step (application, drying, curing) to simplified application and polymerization only, resolving the contradiction between ease of manufacture and process complexity
Solution Approach 2:
The patent extracts and removes the solvent component entirely from the coating composition, leaving only the essential polymerizable monomers and crosslinking agents. This extraction eliminates the harmful effects of solvents and simplifies the manufacturing process by removing solvent-related handling, evaporation, and environmental control requirements
2Reliability
If high concentrations of silicone materials are used in release coating compositions, then release properties are improved, but adhesive performance is compromised and costs increase
Solution Approach 1:
The patent changes the chemical composition parameters by using specific long-chain alkyl groups (C18 or higher) in the polymerizable monomers, which provide release properties through crystalline phase transitions rather than silicone contamination. This parameter change achieves reliable release without the harmful effects of silicone on adhesive performance
Solution Approach 2:
The patent creates a composite coating system combining polymerizable monomers with long-chain alkyl groups and crosslinking agents, where the crystalline structures of the alkyl groups provide the release mechanism. This composite approach achieves release properties without relying on silicone materials, preventing adhesive contamination
3Reliability
If high concentrations of silicone materials are used in release coating compositions, then release properties are improved, but manufacturing costs increase
Solution Approach 1:
The patent replaces expensive silicone materials with more economical polymerizable monomers containing long-chain alkyl groups. These alternative materials achieve the same release function through crystalline phase transitions, reducing the quantity of expensive silicone substances needed while maintaining reliable release properties
Solution Approach 2:
The patent changes the material composition from silicone-based to polymer-based with long-chain alkyl groups, altering the chemical parameters to achieve release properties through a different mechanism (crystalline phase transition vs. silicone surface properties). This parameter change reduces dependence on expensive silicone materials
4Reliability
If monomers with terminal alkyl groups of at least 18 carbon atoms are used, then crystalline properties and release characteristics are improved, but viscosity and application difficulty increase
Solution Approach 1:
The patent applies the coating composition to the substrate before polymerization occurs, in a state where the monomers are still liquid and mobile. This preliminary application allows easy coating despite the eventual crystalline properties, and subsequent polymerization locks in the desired crystalline structure and release characteristics
Solution Approach 2:
The patent utilizes the dynamic state change of the coating material from liquid monomer (easy to apply) to polymerized crystalline structure (provides release properties). The material transitions from a mobile, easily applied state to a structured, functional state after polymerization, resolving the contradiction between ease of operation and crystalline properties
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 solventless and low-silicone coating process enables efficient production of release coatings with tailored release properties, reducing manufacturing costs and maintaining adhesive performance.
Implementation Method 1
polymerizing the monomer(s) and crosslinking component(s) of the release coating after applying the release coating to the substrate
Data Source
AI summary
A method of making a release coated article is described comprising: providing a release coating comprising at least 50 wt. % of monomer(s) comprising an ethylenically unsaturated group and a terminal alkyl group with at least 18 (e.g. contiguous) carbon atoms based on the total amount of ethylenically unsaturated components; crosslinking components(s) comprising at least two ethylenically unsaturated groups; and at least one polymerization initiator. The release coating is substantially solventless, comprising no greater than 1 wt. % of non-polymerizable organic solvent. The method further comprises applying the release coating to a major surface of a substrate; and polymerizing the monomer(s) and crosslinking component(s) of the release coating after applying the release coating to the substrate. Also described are release coating compositions.