Solventless Release Coatings With Low Silicone for PSA Articles
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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 solventless release coating compositions comprising at least 50 wt.% of ethylenically unsaturated monomers with terminal alkyl groups of at least 18 carbon atoms and crosslinking components, with optional silicone-free or low silicone content, applied to a substrate and polymerized in situ to form a crystalline coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based release coating compositions are used, then manufacturing process is established, but solvent removal requirements and environmental concerns increase
Solution Approach 1:
The patent changes the fundamental parameter of the coating composition from solvent-based to solventless, eliminating the need for solvent removal while maintaining coating applicability through careful selection of monomer viscosity and polymerization kinetics
Solution Approach 2:
The patent extracts and eliminates the solvent component entirely from the release coating composition, using only the necessary functional ingredients (monomers, crosslinkers, initiators) to achieve the desired coating performance without carrying unnecessary solvent load
2Reliability
If high concentration of silicone materials are used in release coating, then release properties are improved, but adhesive performance is compromised and costs increase
Solution Approach 1:
The patent changes the silicone concentration parameter from high to low or zero, achieving adequate release properties through the synergistic combination of long alkyl chain monomers and crosslinking agents that provide release function without silicone contamination
Solution Approach 2:
The patent creates a composite release coating system combining long alkyl chain monomers (C18 or higher) with crosslinking agents to achieve release properties previously attributed solely to silicone, eliminating the need for high silicone concentrations
3Object-generated harmful factors
If silicone-free or low silicone release coating compositions are used, then adhesive performance is maintained, but release properties may be compromised
Solution Approach 1:
The patent develops a composite material system where long alkyl chain monomers provide the release function through their crystalline packing behavior, while crosslinking agents enhance this effect and provide structural integrity, replacing the traditional silicone-based release mechanism
Solution Approach 2:
The patent creates local crystalline regions within the coating matrix through the long alkyl chains that provide release functionality at specific locations, while the crosslinked polymer matrix provides overall structural support and adhesion
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 compositions provide improved release properties and reduced manufacturing costs, while maintaining adhesive performance and versatility across various substrates and pressure-sensitive adhesives.
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.