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WO2018138731A1 - Système de fabrication de bandes adhésives - Google Patents

Système de fabrication de bandes adhésives Download PDF

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Publication number
WO2018138731A1
WO2018138731A1 PCT/IN2017/050094 IN2017050094W WO2018138731A1 WO 2018138731 A1 WO2018138731 A1 WO 2018138731A1 IN 2017050094 W IN2017050094 W IN 2017050094W WO 2018138731 A1 WO2018138731 A1 WO 2018138731A1
Authority
WO
WIPO (PCT)
Prior art keywords
paper
latex
coating
heated
adhesive
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IN2017/050094
Other languages
English (en)
Inventor
Shrikant Prabhakar ATHAVALE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of WO2018138731A1 publication Critical patent/WO2018138731A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B32B2037/243—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/16—Drying; Softening; Cleaning
    • B32B38/164—Drying
    • B32B2038/168—Removing solvent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2405/00—Adhesive articles, e.g. adhesive tapes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J1/00—Adhesives based on inorganic constituents

Definitions

  • This disclosure is related to methods and systems for manufacture of paper based adhesive tapes.
  • Paper based adhesive tapes have wide applications including and not limited to their use as masking tapes, electrical insulation grade paper tapes, cast graphics filmsAapes with self adhesives, as fabrics, foil, or silicone coated paper liners and the like.
  • the production of such tapes is conducted across multiple facilities. For example, the creped paper is generated at one site, the paper is then printed at a different site, the printed paper is then coated with release films at a third site, the adhesive coating is typically placed on the tape at a fourth site.
  • Provi ded herei n are systems and processes for manufacture of paper-based adhesive tapes.
  • systems and processes described herein allow for one-pass production of paper- based adhesive tapes, thereby avoiding the need for using multiple sites for various steps of the manufacturing process.
  • an integrated system for manufacture of paper- based adhesive tapes comprisi ng
  • the integrated system described above is a one pass system which reduces overall waste by up to 10% based on starting material when compared to manufacturing wherein each module described above is operated separately.
  • the manufacturing of paper-based adhesive tapes is substantially water based.
  • the saturation coating is conducted with an aqueous mixture of latex.
  • the latex is naturally occurring latex or synthetic latex.
  • the first module further comprises rollers for squeezing the saturation coated paper
  • the f i rst modul e further compri ses heated di rect contact drum dryers for dry i ng the squeezed saturation coated paper.
  • the heated direct contact drum dryers are heated by circulation of hot water.
  • the fourth module comprises a G ravure rol I coati ng system and a Myer bar meteri ng system
  • the system further comprises a drying tunnel and a rewind station.
  • the system is operated using solar energy.
  • the system is operated using electricity from a power grid.
  • a single pass in the system provides the latex coating and creping, the printing of a mark, the coating of a release coat, and the adhesive coating to provide a paper-based adhesive tape product
  • an integrated process for manufacture of paper based adhesive tapes comprising:
  • step (iii) squeezing out the excess latex from the latex-saturated paper of step (ii) by running the paper between rollers;
  • step (iv) passing the squeeze dried paper of step (iii) over heated direct contact drum dryers to obtain a dry latex i impregnated paper;
  • step (v) runni ng the paper from step ( i v) i nto a paper crepi ng unit to obtai n a I atex impregnated creped paper;
  • step (vi) printing a mark on a first side of the paper of step (v);
  • step (vii) coating a release coat on said printed first side of the paper of step (vi);
  • step (viii) passing the paper of step (vii) through a Gravure roll coating system and a Myer bar metering system thereby coati ng the second side of the paper of step (vi i) with an adhesive;
  • step (ix) passing the paper of step (viii) through a drying tunnel
  • step (x) winding the paper of step (ix) on a rewinding drum
  • steps (i) " (x) are conducted in a single pass.
  • the i ntegrated process described herein reduces overall waste by up to 10% based on starting material when compared to manufacturing wherein modules comprising the steps described above are operated separately.
  • the process is substantially water based.
  • the aqueous solution of latex comprises naturally occurring latex or synthetic latex.
  • the heated direct contact drum dryers in step (iv) are heated by circulation of hot water.
  • the drying tunnel is heated by circulation of hot water.
  • the process is conducted using solar energy. In other embodiments the process is conducted by using electricity from a power grid.
  • Figure 1 is a schematic representation of the integrated system described herein.
  • F igure 2 is a schemati c representati on of the process descri bed herei n.
  • FIG 3 is a detailed schematic for the adhesive coating process at stage 7 of Figure 1.
  • Paper based pressure sensitive adhesive tapes are used i n a wi de range of i ndustri es.
  • S ome non-limiting examples include masking tapes used during paint applications; electrical tapes used for temporary masking of components in industries such as the automobile industry; pressure sensitive paper based tapes used for packaging; sports tapes used by athletes; floor marking tapes used on factory floors, and sterile or therapeutic tapes used by medical professionals.
  • the system and process described herein reduce the overall industrial waste.
  • there are four stages in production of paper-based adhesive tapes - (i) saturation coating and creping of paper; (ii) printing of a mark on a first side of the paper obtained from the first stage; (iii) coating of the printed first side of the paper with a release coating; and (iv) coating of the second side of the paper with a pressure sensitive adhesive.
  • modules typically causes about 3% waste based on the starting material, so that the overall waste is about 12% based on the starting material.
  • a further advantage of the system and process described herein is that they are substantially water based (i.e., substantially free of the use of organic solvents) which also reduces waste and allows for environmentally friendly production.
  • the system described herein can be operated on solar energy because the system uses hot water for heating and drying and said hot water, which is circulated, can be obtained using solar panels.
  • an ' integrated , system is a system which combines several stages (modules) of production into a linear single pass production path.
  • the integrated system described herein allows for carrying out multiple steps in the same pass and thereby reduces overall waste based on starting material.
  • ' printing a mark_ on paper refers to printing or embossing one or more than one identifying mark(s) on the paper, where an identifying mark may be a logo, a trade name, a trade mark, a brand name and the like.
  • substantially water based_ system or process refers to a system or process wherein the main solvent used is water, i.e., the system uses less than about 5% or less than about 3% of organic solvents.
  • Gravure roll coating system and a Myer bar metering system refers to the diagram of Figure 3.
  • the paper is shown as black arrows.
  • the Gravure roll coating system and Myer bar metering system comprises a pick up roller for the paper, a rubber pressure roller, a stainless steel tray for holding adhesive and a stainless steel wire wound a rod which is called the "Myer bar or rod".
  • the pick-up roller is rolled in the adhesive tray and picks up the adhesive from the tray at the bottom
  • the picked adhesive is then transferred or coated on to the paper (or the web) which is passed in between the pick-up roller and the rubber pressure roller.
  • the gap (or the nip) between the pick-up roller and the rubber pressure roller allows for application of the adhesive on the paper with a controlled quantity of adhesive.
  • the stainless steel wire wound rod or Myer bar is brought in close contact with the adhesive coated paper. This rod is used to remove any excessive adhesive from the paper.
  • the quantity of the residual adhesive on the paper depends upon the diameter of the stainless steel wire which is wound on the rod. This process of removing excess adhesive is also referred to as ' metering of the adhesive with a Myer rod _.
  • a ' rewind station refers to an apparatus which takes the adhesive-coated and dried paper of the final step and spools the processed paper over a drum to obtain a roll of a paper-based pressure sensitive adhesive tape.
  • a ' first side_ of a paper is a first surface of the paper which is treated in accord with the processes descri bed herei n.
  • a ' second si de_ of the paper is the opposite surface, or the surface different from the fi rst side.
  • ' single pass_ is meant a unified process where an untreated roll of paper can be taken through four coating steps, namely latex coating, printing (ink coating), release film coating, and adhesive coating in a linear sequence without any transportation or separation of intermediate products.
  • the first sequence 1 is unwinding of a roll of paper.
  • the paper is depicted as a solid black line.
  • the paper may have any width up to about 1 meter.
  • the next sequence 2 shows the unwound paper being pulled through a solution of latex to saturate the paper with the latex solution and then squeezing of the paper between rollers.
  • the third sequence 3 shows heated direct contact drum dryers for drying the squeezed latex coated paper. The paper passes over and between the heated drums rotating in opposite directions. The drums are kept at a temperature of about 95 °C to about 100 °C by the action of circulating hot water/steam.
  • the next sequence 4 shows creping of the dried paper.
  • Sequence 5 shows printing of identifying characteristics on a first side (or back side) of the paper.
  • the paper is passed over a series of rollers while the ink is blow dried / air dried.
  • the same first side (back side) of the paper is coated with a release coating as shown in sequence 6.
  • the printed paper with a release coating thereon is subjected to sequence 7, where the second side (or front side) of the paper is coated with an adhesive using a Gravure roll coating system and a Myer bar metering system.
  • the adhesive coated paper is passed through a drying tunnel 8 which is heated by circulating hot water moving in coils wound around the tunnel.
  • the paper is aligned at station 9 and passes to the rewinding station 10 for winding.
  • the meter wide paper / rolls of paper are further cut to size (e.g. to provide 1 inch or 2 inch wide tapes).
  • F igure 2 further delineates the process steps of the system outlined in F igure 1.
  • the length of the tape is vari ed by usi ng additi onal rewi ndi ng steps / stati ons.
  • tape is herein understood an elongated body having a length dimension, a width dimension and a thickness dimension, wherein the length dimension of the tape is at least about the same as its width dimension but preferably greater than its width dimension, and wherein said length dimension is much greater than its thickness dimension.
  • the term tape also comprises the embodiments of a ribbon, a strip, a film and may have a continuous or a discontinuous length with a regular or an irregular cross-section.
  • the width dimension of the tape is much greater than its thickness dimension.
  • the ratio of width to thickness is at least 10, more preferably at least 50, even more preferably at least 100, and most preferably at least 500.
  • width is herein understood the largest dimension between two points on the perimeter of a cross-section of the tape, said cross-section being orthogonal to the length of the tape.
  • thickness is herein understood a distance between two points on the perimeter of said cross-section, said distance being perpendicular on the width of the tape.
  • the width and the thickness of a tape can be measured according to known methods in the art, e.g. with the help of a rul er and a mi croscope or a mi crometer, respectively.
  • T he I ength di mensi on of a tape may vary from a few feet to meters.
  • ' pressure sensitive adhesives_ are adhesive compositions that have the ability at, or at about, room temperature to sufficiently wet a substrate under gentle pressure and to form a useful bond.
  • the term ' useful bond_ differs depending on the substrate application and refers to a corresponding balance of adhesive and cohesive strength.
  • Pressure sensitive adhesives are normally tacky at room temperature (e.g.
  • the latex solution used in the system and process described herein may comprise natural latex obtained from rubber trees, or synthetic latex such as neoprene latex or nitrile latex. Any concentration of latex may be used, with a typical concentration of latex in the solution ranging from about 50% to about 55% by weight of the solution.
  • the release coating may comprise one or more than one non-si I i cone coatings.
  • Non- limiting examples include polyvinyl octadecyl carbamate dispersions (used, e.g., in manufacture of adhesive labels, films, tapes), polysaccharide solutions/emulsions of modified starches (used e.g., in manufacture of writeable / inkjet printable paper), acrylic polymer emulsions (used, e.g., in manufacture of tapes and labels), and aliphatic modified polyurethane aqueous dispersions (used e.g., in manufacture of controlled release of adhesive properties).
  • the release coatings comprise aqueous emulsions of acrylic polymers.
  • the release coatings are substantially solvent free and are water borne / water based in the systems and processes described herein.
  • the adhesive coating may comprise one or more than one pressure sensitive adhesives.
  • Pressure sensitive adhesives are usually based on an elastomer compounded with a suitable tackifier (e.g., a rosin ester).
  • the elastomers can be based on acrylics, which can have sufficient tack on their own and do not require a tackifier.; bio-based acrylates (e.g., a biological -based macromonomer grafted onto a backbone of acrylate so that the resulting pressure sensitive adhesice uses 60% bio-based materials), butyl rubber, ethyl ene-vinyl acetate with high vinyl acetate content, natural rubber, nitriles, silicone rubbers, styrene block copolymers. Styrene copolymer adhesives and rubber-based adhesives have good low-temperature flexibility, high elongation, and high heat resistance.
  • bio-based acrylates e.g., a biological -based macromonomer grafted onto a backbone of acrylate so that the resulting pressure sensitive adhesice uses 60% bio-based materials
  • butyl rubber ethyl ene-vinyl acetate with high vinyl
  • Resins associated with endblocks (cumarone-indene, a-methyl styrene, vinyl toluene, aromatic hydrocarbons, etc.) improve adhesion and alter viscosity.
  • Resins associated with midblocks (aliphatic olefins, rosin esters, polyterpenes, terpene phenolics) improve adhesion, processing and pressure-sensitive properties. Addition of plasticizers reduces cost, improves pressure-sensitive tack, decrease melt viscosity, decrease hardness, and improves low-temperature flexibility.
  • the A-B-A structure promotes a phase separation of the polymer, binding together the endblocks, with the central elastic parts acting as cross-links.
  • adhesives comprising polychloroprenes; styrene- butadiene-styrene used in high-strength pressure sensitive adhesive applications; styrene- ethylene buty I ene- styrene used in low self-adhering non-woven applications; styrene- ethylene propylene and styrene- isoprene-styrene used in low-viscosity high-tack pressure sensitive adhesive applications; and vinyl ether based adhesives.
  • Acrylic polymer suspensions in water are used for a wide variety of formulated adhesives because of their compatibility with inorganic fillers.
  • non-pressure-sensitive formulations are also contemplated within the scope of embodiments of the systems and processes presented herein.
  • the adhesive coatings are substantially solvent free and are water borne / water based in the systems and processes described herein.
  • N on- limiting examples of industries served by the methods and systems described herein are foam and furniture fabrication, flexible packaging and converting, recreati onal vehi cl e and mari ne markets, and vari ous assembly operati ons for the automotive and truck industries.
  • the paper used in the manufacturing process is about 50 micron thick and weighs 40 grams per square meter.
  • the latex coating deposited on the paper is about 8-10 grams per square meter.
  • the release coating deposited on the latex coated creped printed paper is about 0.3-0.4 grams per square meter, and the adhesive coating deposited on the back side of the paper is about 25 -26 grams per square meter.
  • the drying temperature typically ranges from about 75 °C to about 85 °C, or from about 75 °C to about 95 °C, and any coating or drying speed is a minimum of about 25 meters of paper per minute to a maximum of about 50 meters of paper per minutes. Other thicknesses of paper and deposited coatings are contemplated within the scope of embodiments presented herein. Other temperatures and rates of drying / coating are contemplated within the scope of embodiments presented herein.

Landscapes

  • Adhesive Tapes (AREA)
  • Adhesives Or Adhesive Processes (AREA)

Abstract

L'invention concerne un système intégré et un procédé de fabrication de bandes adhésives à base de papier, permettant de réaliser des économies de coûts et d'augmenter l'efficacité dudit procédé.
PCT/IN2017/050094 2017-01-24 2017-03-16 Système de fabrication de bandes adhésives Ceased WO2018138731A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN201721002674 2017-01-24
IN201721002674 2017-01-24

Publications (1)

Publication Number Publication Date
WO2018138731A1 true WO2018138731A1 (fr) 2018-08-02

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PCT/IN2017/050094 Ceased WO2018138731A1 (fr) 2017-01-24 2017-03-16 Système de fabrication de bandes adhésives

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115610134A (zh) * 2022-09-22 2023-01-17 安正文化用品(江门)有限公司 新型便利贴制作工艺及新型便利贴

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0522788A1 (fr) * 1991-07-08 1993-01-13 Rohm And Haas Company Article adhésif sensible à la pression pouvant recevoir des impressions
JP2005213360A (ja) * 2004-01-29 2005-08-11 Nitto Denko Corp 粘着テープの製造方法、及び該製造方法により作製された粘着テープ
WO2012122623A1 (fr) * 2011-03-11 2012-09-20 Langeman Manufacturing Limited Ruban-cache multicouche

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0522788A1 (fr) * 1991-07-08 1993-01-13 Rohm And Haas Company Article adhésif sensible à la pression pouvant recevoir des impressions
JP2005213360A (ja) * 2004-01-29 2005-08-11 Nitto Denko Corp 粘着テープの製造方法、及び該製造方法により作製された粘着テープ
WO2012122623A1 (fr) * 2011-03-11 2012-09-20 Langeman Manufacturing Limited Ruban-cache multicouche

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115610134A (zh) * 2022-09-22 2023-01-17 安正文化用品(江门)有限公司 新型便利贴制作工艺及新型便利贴

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