U.S. patent application number 13/139313 was filed with the patent office on 2011-12-08 for bulk polymerization of silicone-containing copolymers.
Invention is credited to Mark F. Ellis, Jeffrey O. Emslander, Ramesh C. Kumar, Sonja S. MacKey, Richard L. Peloquin, Audrey A. Sherman.
Application Number | 20110300296 13/139313 |
Document ID | / |
Family ID | 42310472 |
Filed Date | 2011-12-08 |
United States Patent
Application |
20110300296 |
Kind Code |
A1 |
Sherman; Audrey A. ; et
al. |
December 8, 2011 |
BULK POLYMERIZATION OF SILICONE-CONTAINING COPOLYMERS
Abstract
Methods for preparing silicone-containing polymers by
essentially adiabatic polymerization methods are disclosed. The
polymerization system includes free radically polymerizable
monomers. The monomers include ethylenically unsaturated
cone-containing monomers and/or mercapto-functional silicones as
well as additional free radically polymerizable monomers. The
silicone-containing polymers are useful as adhesives or release
materials.
Inventors: |
Sherman; Audrey A.; (St.
Paul, MN) ; Ellis; Mark F.; (St.Paul, MN) ;
Kumar; Ramesh C.; (Woodbury, MN) ; MacKey; Sonja
S.; (St. Paul, MN) ; Peloquin; Richard L.;
(Maplewood, MN) ; Emslander; Jeffrey O.;
(Stillwater, MN) |
Family ID: |
42310472 |
Appl. No.: |
13/139313 |
Filed: |
November 23, 2009 |
PCT Filed: |
November 23, 2009 |
PCT NO: |
PCT/US09/65519 |
371 Date: |
August 24, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61138211 |
Dec 17, 2008 |
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Current U.S.
Class: |
427/208.4 ;
427/372.2; 524/547; 524/588; 525/479; 526/82 |
Current CPC
Class: |
C08F 220/06 20130101;
C08G 77/20 20130101; C08F 290/068 20130101; C08F 220/18 20130101;
C09J 2451/00 20130101; C08L 51/085 20130101; C08F 283/12 20130101;
C08F 2/02 20130101; C08F 230/08 20130101; C09J 7/381 20180101; C08G
77/442 20130101; C08F 290/068 20130101; C08F 220/06 20130101; C08F
220/18 20130101; C08F 283/12 20130101; C08F 220/06 20130101; C08F
220/18 20130101; C08F 220/44 20130101 |
Class at
Publication: |
427/208.4 ;
526/82; 524/547; 525/479; 524/588; 427/372.2 |
International
Class: |
B05D 5/10 20060101
B05D005/10; B05D 5/08 20060101 B05D005/08; C08F 283/12 20060101
C08F283/12; C09D 183/07 20060101 C09D183/07; C08F 2/38 20060101
C08F002/38; C09D 143/04 20060101 C09D143/04 |
Claims
1. A method comprising: providing a first reaction mixture
comprising: an ethylenically unsaturated silicone-containing
monomer; at least one additional ethylenically unsaturated monomer;
a chain transfer agent; and a thermal initiator; deoxygenating the
first reaction mixture; heating the first reaction mixture to a
temperature above the activation temperature of the thermal
initiator; allowing the first reaction mixture to polymerize under
essentially adiabatic conditions to yield an at least partially
polymerized mixture; cooling the at least partially polymerized
mixture; adding an additional thermal initiator, and a chain
transfer agent to the partially polymerized mixture to form a
second reaction mixture; deoxygenating the second reaction mixture;
heating the second reaction mixture to a temperature above the
activation temperature of the additional thermal initiator;
allowing the second reaction mixture to polymerize under
essentially adiabatic conditions to form a polymer.
2. The method of claim 1 wherein the ethylenically unsaturated
silicone-containing monomer comprises a silicone macromer with the
structure: W-(A).sub.n-Si(R.sup.7).sub.3-mQ.sub.m wherein W is a
vinyl group; A is a divalent linking group; n is zero or 1; m is an
integer of from 1 to 3; R.sup.7 is hydrogen, alkyl, aryl, or
alkoxy; and Q is a monovalent siloxane polymeric moiety having a
number average molecular weight above about 500 and is essentially
unreactive under copolymerization conditions.
3. The method of claim 2 wherein the ethylenically unsaturated
silicone-containing monomer comprises a silicone (meth)acrylate
macromer.
4. The method of claim 2 wherein the first reaction mixture
comprises at least one alkyl (meth)acrylate monomer.
5. The method of claim 4 further comprising at least one polar
ethylenically unsaturated monomer.
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
6. The method of claim 2 wherein the at least one additional
ethylenically unsaturated monomer comprises an alkyl (meth)acrylate
which as a homopolymer has a Tg above about 30.degree. C.
11. (canceled)
7. The method of claim 1 further comprising the steps of: isolating
the polymer; and coating the polymer on a substrate.
8. The method of claim 7 wherein the coating step comprises hot
melt coating, solvent coating or coextrusion.
9. The method of claim 7 wherein the polymer comprises a pressure
sensitive adhesive and the substrate comprises a film, a tape
backing, or a release liner.
10. The method of claim 7 further comprising the step of
photochemically curing the coated pressure sensitive adhesive
polymer.
11. The method of claim 7 wherein the polymer comprises a release
material and the substrate comprises a film or a tape backing.
17. (canceled)
12. The method of claim 11 further comprising the step of blending
the release polymer with a thermoplastic polymer prior to
coating.
13. The method of claim 11 wherein the coating step comprises is
hot melt coating on a pre-tentered film and further comprising the
step of stretching the coated film.
14. A method comprising: providing a first reaction mixture
comprising: an mercapto-functional silicone; at least one
ethylenically unsaturated monomer; and a thermal initiator;
deoxygenating the first reaction mixture; heating the first
reaction mixture to a temperature above the activation temperature
of the thermal initiator; allowing the first reaction mixture to
polymerize under essentially adiabatic conditions to yield an at
least partially polymerized mixture; cooling the at least partially
polymerized mixture; adding an additional thermal initiator to the
partially polymerized mixture to form a second reaction mixture;
deoxygenating the second reaction mixture; heating the second
reaction mixture to a temperature above the activation temperature
of the additional thermal initiator; allowing the second reaction
mixture to polymerize under essentially adiabatic conditions to
form a polymer.
15. The method of claim 14 wherein the mercapto-functional silicone
has the structure:
(R.sup.1).sub.3-x(HSR.sup.2).sub.xSi--(OSiR.sup.5R.sup.6).sub.y--OSi(R.su-
p.3).sub.3-qR.sup.4SH).sub.q wherein each R.sup.1 is independently
an alkyl, aryl, alkaryl, alkoxy, alkylamino, hydroxyl, hydrogen, or
fluoroalkyl group; each R.sup.2 is a divalent linking group; each
R.sup.3 is an alkyl, aryl, alkaryl, alkoxy, alkylamino, hydroxyl,
hydrogen, or fluoroalkyl group; each R.sup.4 is a divalent linking
group; each R.sup.5 is an alkyl, aryl, alkaryl, alkoxy, alkylamino,
hydroxyl, fluoroalkyl, hydrogen, or --ZSH, wherein Z is a divalent
linking group; each R.sup.6 is an alkyl, aryl, alkaryl, alkoxy,
alkylamino, hydroxyl, fluoroalkyl, hydrogen, or --ZSH, wherein Z is
a divalent linking group; x is an integer of 0-3; y is an integer
of 10 or greater; and q is an integer of 0-3.
16. The method of claim 14 wherein the mercapto-functional silicone
has a number average molecular weight of from 2,000-20,000
grams/mole and from 1-20 mole % --CH.sub.2CH.sub.2CH.sub.2SH
groups.
23. (canceled)
17. The method of claim 14 wherein the ethylenically unsaturated
monomer comprises an alkyl (meth)acrylate which as a homopolymer
has a Tg above about 30.degree. C.
25. (canceled)
18. The method of claim 14 further comprising the steps of:
isolating the polymer; and coating the polymer on a substrate.
27. (canceled)
19. The method of claim 18 wherein the polymer comprises a release
material and the substrate comprises a film or a tape backing.
20. The method of claim 14 further comprising the steps of:
isolating the polymer; blending the isolated polymer with a
thermoplastic resin; and hot melt coating or coextruding the
blend.
30. (canceled)
Description
FIELD OF THE DISCLOSURE
[0001] This disclosure relates to bulk polymerization methods to
form silicone-containing polymers, silicone-containing polymers and
articles prepared from silicone-containing polymers.
BACKGROUND
[0002] Silicone-containing copolymers are a class of polymeric
materials that have found a wide variety of uses, including uses
such as coatings (including release coatings), adhesives (including
pressure sensitive adhesives), gaskets, tubing, vibration dampening
materials and the like.
[0003] Many of these silicone-containing copolymers are
polydiorganosiloxane-based copolymers. The unique properties of
these copolymers are derived mainly from the physical and chemical
characteristics of the siloxane bond and the organic substituents.
Typically the outstanding properties of polydiorganosiloxane
copolymers include resistance to ultraviolet light, extremely low
glass transition temperature, good thermal and oxidative stability,
high permeability to many gases, very low surface energy, low index
of refraction, good hydrophobicity and good dielectric
properties.
[0004] Traditionally silicone-containing copolymers have been
prepared in solution. The dissolved copolymer is then cast or
coated and dried. The solvents aid in the polymerization by
solubilizing the reactants and also serve to dissipate the heat
generated during exothermic reactions.
[0005] For a number of reasons, it may be desirable to form
polymers without utilizing solvents or where the use of solvent is
minimized. Environmental concerns, such as the release of solvents
into the atmosphere and the need to recycle and/or dispose of the
solvents after use, are prompting efforts to reduce or eliminate
solvent use. Shipment of polymers dissolved in solvent can be
difficult and expensive. Also, many common solvents are flammable
requiring handling of polymer solutions with added safety
precautions.
SUMMARY
[0006] Disclosed are methods for preparing silicone-containing
polymers under essentially adiabatic polymerization conditions.
Such polymerizations can be carried out without the use of solvent
or with a minimum of solvent and produce polymers which are useful
in a variety of applications, including as adhesives and release
materials.
[0007] In one embodiment, a method is disclosed comprising the
steps of providing a first reaction mixture, deoxygenating the
first reaction mixture, heating the first reaction mixture,
allowing the first reaction mixture to polymerize under essentially
adiabatic conditions to yield an at least partially polymerized
mixture, cooling the at least partially polymerized mixture,
forming a second reaction mixture by adding additional components
to the at least partially polymerized mixture, deoxygenating the
second reaction mixture, heating the second reaction mixture, and
allowing the second reaction mixture to polymerize under
essentially adiabatic conditions to form a polymer. The first
reaction mixture may comprise an ethylenically unsaturated
silicone-containing monomer, at least one additional ethylenically
unsaturated monomer, a chain transfer agent, and a thermal
initiator. The thermal initiator may comprise a single thermal
initiator or may comprise a combination of different thermal
initiators. The second reaction mixture may comprise, in addition
to the partially polymerized first reaction mixture, an additional
thermal initiator, a chain transfer agent, and optionally a
solvent. The heating steps typically comprise heating of the
reaction mixtures to a temperature above the activation temperature
of a thermal initiator present in the reaction mixture
[0008] In some embodiments, the ethylenically unsaturated
silicone-containing monomer comprises a silicone macromer with the
structure W-(A).sub.n-Si(R.sup.7).sub.3-mQ.sub.m, wherein W is a
vinyl group, A is a divalent linking group, n is zero or 1, m is an
integer of from 1 to 3, R.sup.7 is hydrogen, alkyl, aryl, or
alkoxy; and Q is a monovalent siloxane polymeric moiety having a
number average molecular weight above about 500 and is essentially
unreactive under copolymerization conditions.
[0009] In other embodiments, a method is disclosed comprising the
steps of providing a first reaction mixture, deoxygenating the
first reaction mixture, heating the first reaction mixture,
allowing the first reaction mixture to polymerize under essentially
adiabatic conditions to yield an at least partially polymerized
mixture, cooling the at least partially polymerized mixture,
forming a second reaction mixture by adding additional components
to the at least partially polymerized mixture, deoxygenating the
second reaction mixture, heating the second reaction mixture, and
allowing the second reaction mixture to polymerize under
essentially adiabatic conditions to form a polymer. The first
reaction mixture may comprise a mercapto-functional silicone, at
least one ethylenically unsaturated monomer, and a thermal
initiator. The thermal initiator may comprise a single thermal
initiator or may comprise a combination of different thermal
initiators. The second reaction mixture may comprise, in addition
to the partially polymerized first reaction mixture, an additional
thermal initiator, and optionally a solvent. The heating steps
typically comprise heating of the reaction mixtures to a
temperature above the activation temperature of a thermal initiator
present in the reaction mixture.
[0010] In some embodiments, the mercapto-functional silicone has
the structure
(R.sup.1).sub.3-x(HSR.sup.2).sub.xSi--(OSiR.sup.5R.sup.6).sub.y-
--OSi(R.sup.3).sub.3-q(R.sup.4SH).sub.q wherein each R.sup.1 is
independently an alkyl, aryl, alkaryl, alkoxy, alkylamino,
hydroxyl, hydrogen, or fluoroalkyl group, each R.sup.2 is a
divalent linking group, each R.sup.3 is an alkyl, aryl, alkaryl,
alkoxy, alkylamino, hydroxyl, hydrogen, or fluoroalkyl group, each
R.sup.4 is a divalent linking group, each R.sup.5 is an alkyl,
aryl, alkaryl, alkoxy, alkylamino, hydroxyl, fluoroalkyl, hydrogen,
or --ZSH, wherein Z is a divalent linking group, each R.sup.6 is an
alkyl, aryl, alkaryl, alkoxy, alkylamino, hydroxyl, fluoroalkyl,
hydrogen, or --ZSH, wherein Z is a divalent linking group, x is an
integer of 0-3, y is an integer of 10 or greater, and q is an
integer of 0-3.
DETAILED DESCRIPTION
[0011] Typically, reactions to prepare silicone-containing
copolymers, particularly silicone-containing copolymers which are
derived from free radically polymerizable starting materials, such
as ethylenically unsaturated silicone-containing materials and
mercapto-functional silicones, are run in a solvent. One reason for
this is that the compatibility of silicone-containing starting
materials with other reactive materials in the reaction mixture is
generally low. This low compatibility leads to non-homogenous
mixtures and incomplete polymerization reactions. The use of
solvents helps to overcome this difficulty, especially in bulk
reactions.
[0012] The use of adiabatic polymerization techniques have been
used to prepare copolymers from ethylenically unsaturated starting
materials. However, it was unclear whether this technique could be
used with silicone-containing starting materials due to the
incompatibility of silicone-containing materials with other
reactive materials in the reaction mixture. This disclosure
provides bulk polymerization methods for preparing
silicone-containing polymers.
[0013] The polymerization techniques of this disclosure provide for
the preparation of a wide range of silicone-containing polymers.
Dependent upon the composition of the reaction mixture used to form
the silicone-containing polymers, the polymers may be for example,
adhesives, such as pressure sensitive adhesives or release
materials. The reaction mixture comprises a free radically
polymerizable silicone-containing moiety, a free radically
polymerizable co-monomer, a chain transfer agent, and a thermal
initiator. In some embodiments the free radically polymerizable
silicone-containing moiety may be an ethylenically unsaturated
silicone-containing monomer, in other embodiments the free
radically polymerizable silicone-containing moiety may be a
mercapto-functional silicone. In still other embodiments the
reactive mixture may contain a mixture of ethylenically unsaturated
silicone-containing monomer and mercapto-functional silicone.
[0014] The reaction mixture also contains an additional free
radically polymerizable monomer or monomers. The nature of the
additional monomer also determines the properties of the formed
silicone-containing polymer.
[0015] As used herein "polymer" refers to macromolecular materials
having at least five repeating monomeric units, which may or may
not be the same. The term polymer, as used herein, encompasses
homopolymers and copolymers.
[0016] As used herein "free radically polymerizable" refers to
materials which polymerize upon exposure to a free radical.
Ethylenically unsaturated groups and mercapto groups are examples
of free radically polymerizable groups.
[0017] As used herein "ethylenically unsaturated" refers to
materials which contain at least one terminal carbon-carbon double
bond (CH.sub.2.dbd.CR--), where R is H or an alkyl group. Vinyl
groups, allyl groups, acrylate groups, and methacrylate groups are
examples of ethylenically unsaturated groups.
[0018] As used herein "silicone-containing" refers to materials and
polymers which contain siloxane linkages. The terms "silicone" and
"siloxane" are used interchangeably and refer to materials or
polymers which contain the repeat unit (--O--SiR.sub.2--) where
each R is independently an alkyl or aryl group.
[0019] As used herein the term "silicone macromers" refers to
silicone-containing macromers. Macromers are macromolecular
monomers.
[0020] As use herein the term "mercapto-functional silicones"
refers to silicone-containing moieties that contain at least one
mercapto group (--SH). The mercapto group is the sulfur analog to
the hydroxyl group (--OH) and is sometime also referred to as a
thiol group. The mercapto group is a free radically polymerizable
group.
[0021] The term "alkenyl" refers to a monovalent group that is a
radical of an alkene, which is a hydrocarbon with at least one
carbon-carbon double bond. The alkenyl can be linear, branched,
cyclic, or combinations thereof and typically contains 2 to 20
carbon atoms. In some embodiments, the alkenyl contains 2 to 18, 2
to 12, 2 to 10, 4 to 10, 4 to 8, 2 to 8, 2 to 6, or 2 to 4 carbon
atoms. Exemplary alkenyl groups include ethenyl, n-propenyl, and
n-butenyl.
[0022] The term "alkyl" refers to a monovalent group that is a
radical of an alkane, which is a saturated hydrocarbon. The alkyl
can be linear, branched, cyclic, or combinations thereof and
typically has 1 to 20 carbon atoms. In some embodiments, the alkyl
group contains 1 to 18, 1 to 12, 1 to 10, 1 to 8, 1 to 6, or 1 to 4
carbon atoms. Examples of alkyl groups include, but are not limited
to, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl,
tert-butyl, n-pentyl, n-hexyl, cyclohexyl, n-heptyl, n-octyl, and
ethylhexyl.
[0023] The term "alkaryl" refers to an monvalent group which is an
alkyl group substituted with at least one aryl group, of the
general formula --R--Ar. A benzyl group (--CH.sub.2-Ph) is an
example of an alkaryl group.
[0024] The term "halo" refers to fluoro, chloro, bromo, or
iodo.
[0025] The term "haloalkyl" refers to an alkyl having at least one
hydrogen atom replaced with a halo. Some haloalkyl groups are
fluoroalkyl groups, chloroalkyl groups, and bromoalkyl groups. The
term "perfluoroalkyl" refers to an alkyl group in which all
hydrogen atoms are replaced by fluorine atoms.
[0026] The term "aryl" refers to a monovalent group that is
aromatic and carbocyclic. The aryl can have one to five rings that
are connected to or fused to the aromatic ring. The other ring
structures can be aromatic, non-aromatic, or combinations thereof.
Examples of aryl groups include, but are not limited to, phenyl,
biphenyl, terphenyl, anthryl, naphthyl, acenaphthyl,
anthraquinonyl, phenanthryl, anthracenyl, pyrenyl, perylenyl, and
fluorenyl.
[0027] The term "alkylene" refers to a divalent group that is a
radical of an alkane. The alkylene can be straight-chained,
branched, cyclic, or combinations thereof. The alkylene often has 1
to 20 carbon atoms. In some embodiments, the alkylene contains 1 to
18, 1 to 12, 1 to 10, 1 to 8, 1 to 6, or 1 to 4 carbon atoms. The
radical centers of the alkylene can be on the same carbon atom
(i.e., an alkylidene) or on different carbon atoms.
[0028] The term "heteroalkylene" refers to a divalent group that
includes at least two alkylene groups connected by a thio, oxy, or
--NR-- where R is alkyl. The heteroalkylene can be linear,
branched, cyclic, substituted with alkyl groups, or combinations
thereof. Some heteroalkylenes are poloxyyalkylenes where the
heteroatom is oxygen such as for example,
--CH.sub.2CH.sub.2(OCH.sub.2CH.sub.2).sub.nOCH.sub.2CH.sub.2--.
[0029] The term "arylene" refers to a divalent group that is
carbocyclic and aromatic. The group has one to five rings that are
connected, fused, or combinations thereof. The other rings can be
aromatic, non-aromatic, or combinations thereof. In some
embodiments, the arylene group has up to 5 rings, up to 4 rings, up
to 3 rings, up to 2 rings, or one aromatic ring. For example, the
arylene group can be phenylene.
[0030] The term "heteroarylene" refers to a divalent group that is
carbocyclic and aromatic and contains heteroatoms such as sulfur,
oxygen, nitrogen or halogens such as fluorine, chlorine, bromine or
iodine.
[0031] The term "aralkylene" refers to a divalent group of formula
--R.sup.a--Ar.sup.a-- where R.sup.a is an alkylene and Ar.sup.a is
an arylene (i.e., an alkylene is bonded to an arylene).
[0032] The term "alkoxy" refers to a monovalent group of formula
--OR where R is an alkyl group.
[0033] The term "alkylamino" refers to a monovalent group of
formula --R.sup.a--NR.sup.bR.sup.c where R.sup.a is an alkylene and
R.sup.b and R.sup.c are each independently hydrogen, an alkyl, or
an aryl group.
[0034] The term "adhesive" as used herein refers to polymeric
compositions useful to adhere together two adherends. An example of
an adhesive is a pressure sensitive adhesive.
[0035] Pressure sensitive adhesives are well known to one of
ordinary skill in the art to possess properties including the
following: (1) aggressive and permanent tack, (2) adherence with no
more than finger pressure, (3) sufficient ability to hold onto an
adherend, and (4) sufficient cohesive strength to be removed
cleanly from the adherend. Materials that have been found to
function well as pressure sensitive adhesives include polymers
designed and formulated to exhibit the requisite viscoelastic
properties resulting in a desired balance of tack, peel adhesion,
and shear holding power.
[0036] The term "release materials" as used herein refers to
polymeric materials which may be coated onto a substrate to form a
release surface. A release surface is defined as one that possesses
a lack of adhesion, which provides an easy release from substrates,
particularly adhesive coated substrates. Examples of release
surfaces include release liners and low adhesion backsizes (LABs).
LABs are typically used on adhesive articles, such as tapes, where
an adhesive coating is applied to one side of a backing and a
release material is applied to the opposite side. Thus when the
tape is rolled up, the adhesive contacts the LAB permitting the
tape to be unrolled again when used.
[0037] The terms "weight %", "wt %" and "% by weight" are used
interchangeably and refer to the weight of component relative to a
total composition weight. Therefore, if a component has a weight %
of 30, that indicates there are 30 parts by weight of the component
to a total composition weight of 100 parts by weight.
[0038] Acrylate and methacrylate monomers are referred to
collectively herein as "(meth)acrylate" monomers. (Meth)acrylate
polymers may be copolymers, optionally in combination with other,
non-(meth)acrylate, e.g., vinyl-unsaturated, monomers.
[0039] As defined herein, by "essentially adiabatic" it is meant
that the total of the absolute value of any energy exchanged to or
from the batch during the course of reaction will be less than
about 15% of the total energy liberated due to reaction for the
corresponding amount of polymerization that has occurred during the
time that polymerization has occurred. Essentially adiabatic
reactions are exemplified in, for example, U.S. Pat. No. 5,986,011
(Ellis).
[0040] In the methods of this disclosure, free radically
polymerizable reaction mixtures are subjected to essentially
adiabatic polymerization conditions. Although one essentially
adiabatic reaction may be employed, generally two or more
essentially adiabatic reaction cycles are generally employed if
essentially complete conversion of monomer to polymer is desired.
There typically is cooling between the reaction cycles. Cooling of
the reaction mixture between reaction cycles typically is performed
to prevent the temperature of the reaction mixture from increasing
to a point where the product is unstable. This instability can be
manifest by polymer discoloration, polymer oxidation,
depolymerization to produce undesirable low molecular weight
oligomers, etc. The temperature necessary to avoid instability
depends in part on the monomers being used. To avoid such
instability the temperature of the reaction mixture is generally
kept below about 300.degree. C., or even below about 250.degree. C.
The reaction conditions are also typically chosen so that at the
end of the final reaction cycle, the product viscosity is such that
draining from the reaction vessel can be performed (Brookfield
viscosity at draining temperature less than about 500,000
centipoise).
[0041] Optionally, a series of one or more essentially adiabatic
reaction cycles can be used to provide a syrup of polymer dissolved
in monomer, typically in the range of about 40-95 weight % based on
total weight of monomer(s) and polymer where the unreacted monomer
can be optionally stripped from the polymer to provide the final
polymer product rather than running the reaction to completion.
[0042] The method of the present disclosure uses one or more
thermal free radical initiators that under the increasing reaction
temperature profile from essentially adiabatic reaction conditions,
provide free radicals at a rate such that narrow polymer molecular
weight distribution is obtained. The amount of free radicals
generated during the increasing temperature profile is controlled
by the amounts of each initiator used and the temperature
decomposition characteristics of the selected initiators. This
process is capable of achieving polymer molecular weight
distributions essentially the same as or narrower than isothermal
solution polymerization methods.
[0043] As has been discussed previously, for example in U.S. Pat.
No. 5,986,011 (Ellis), when appropriately polymerized, essentially
adiabatic bulk free-radical runaway polymerization in a batch
reactor can present several advantages:
[0044] 1) When adiabatically polymerized, because the reaction
equipment is not being used to cool the reacting mixture, there is
not a significant temperature gradient at the walls of the reaction
equipment. Such a temperature gradient can detrimentally broaden
the molecular weight distribution of the polymer by making high
molecular weight product in the cold boundary layer near the
reactor wall, because of the free-radical reaction kinetics well
known to those skilled in the art. For example, such high molecular
weight components can degrade the coating performance of a hot-melt
coated adhesive or release material.
[0045] 2) The reaction equipment utilized according to the method
of the present disclosure is simple.
[0046] 3) Because heat transfer requirements during reaction are
eliminated, the method of the present disclosure more readily
scales up from lab-scale equipment to large production-scale
equipment than temperature-controlled polymerization methods that
rely on available heat transfer area to control reaction
temperature.
[0047] 4) Continuous polymerization reaction equipment contains
various degrees of "backmixing" where there is a residence time
distribution of the reacting material in the reaction equipment.
Some of the reacting material can remain in the reaction equipment
for extended periods of time to degrade product performance by
continued attack by the free-radical initiator to form cross-linked
polymer. Crosslinked gel particles can degrade product performance,
such as the coating smoothness of a hot-melt coated adhesive or
release material.
[0048] 5) Depending upon the polymer and reaction conditions,
essentially complete conversion of monomer to polymer is possible
according to the method of the present disclosure. Based on
specific product requirements, it may be necessary to react the
final 1-15 weight % of monomer slowly (over a period of one to
several hours) to minimize the formation of low molecular weight
components as monomer depletes. Residence times of hours in
continuous reaction equipment, such as an extruder, can be
economically impractical.
[0049] A batch reactor is used in the method of the present
disclosure. By reacting batch wise is meant that the polymerization
reaction occurs in a vessel where product is drained at the end of
the reaction, not continuously while reacting. The raw materials
can be charged to the vessel at one time prior to reacting, in
steps over time while reacting, or continuously over a time period
while reacting, and the reaction is allowed to proceed for the
necessary amount of time to achieve, in this case, polymer
properties including the desired polymerization amount, molecular
weight, etc. If necessary, additives can be mixed into the batch
prior to draining. When the processing is complete, the product is
drained from the reaction vessel.
[0050] A typical batch reactor for this disclosure will comprise a
pressure vessel constructed of material suitable for the
polymerization, such as stainless steel which is commonly used for
many types of free-radical polymerization. Typically, the pressure
vessel will have ports for charging raw materials, removing
product, emergency pressure relief, pressurizing the reactor with
inert gas, pulling vacuum on the reactor head space, etc.
Typically, the vessel is enclosed partially in a jacket through
which a heat transfer fluid (such as water) is passed for heating
and cooling the contents of the vessel. Typically, the vessel
contains a stirring mechanism such as a motor-driven shaft inserted
into the vessel to which stirring blades are attached. Commercial
batch reaction equipment typically is sized in the range of about
10 to about 20,000 gallons (37.9 to 75,708 liters), and can be
custom-built by the user or can be purchased from vendors such as
Pfaudler-U.S., Inc. of Rochester, N.Y.
[0051] Caution should be exercised to ensure that the reaction
vessel can contain the elevated vapor pressure of the reaction
mixture, at the temperatures that will be encountered, particularly
if the reaction should proceed faster or further than desired
because of an accidental overcharge/mischarge of initiator(s). It
is also very important to ensure the reaction mixture will not
decompose at the temperatures encountered to form gaseous products
that could dangerously elevate the vessel pressure. Small-scale
adiabatic calorimetric experiments, which one skilled in the art
would be readily capable of performing, can be used to determine
the runaway characteristics for particular monomers and initiator
mixtures. For example, the Reactive System Screening Tool (RSST) or
the Vent Sizing Package (VSP), both available from Fauske and
Associates, Inc. of Burr Ridge, Ill., are devices capable of
investigating runaway reaction characteristics and severity.
[0052] The essentially adiabatic polymerization reaction is carried
out with a reaction mixture comprising a free radically
polymerizable silicone-containing moiety, a free radically
polymerizable co-monomer, a chain transfer agent, and a thermal
initiator. The free radically polymerizable silicone-containing
moiety may be an ethylenically unsaturated silicone-containing
monomer, a mecapto-functional silicone, or a combination thereof.
One thermal initiator may be used or a combination of different
thermal initiators may be used.
[0053] A wide variety of ethylenically unsaturated
silicone-containing monomers may be used. For example, a number of
vinyl-functional silicones are commercially available. Particularly
suitable are silicone-containing macromers, especially ones with
the general formula of Formula 1:
W-(A).sub.n-Si(R.sup.7).sub.3-mQ.sub.m Formula 1
where W is a vinyl group, A is a divalent linking group, n is zero
or 1, m is an integer of from 1 to 3; R.sup.7 is hydrogen, lower
alkyl (e.g., methyl, ethyl, or propyl), aryl (e.g., phenyl or
substituted phenyl), or alkoxy, and Q is a monovalent siloxane
polymeric moiety having a number average molecular weight above
about 500 and is essentially unreactive under copolymerization
conditions.
[0054] Such macromers are known and may be prepared by the method
disclosed by Milkovich et al., as described in U.S. Pat. Nos.
3,786,116 and 3,842,059. The preparation of polydimethylsiloxane
macromer and subsequent copolymerization with vinyl monomers have
been described in several papers by Y. Yamashita et al., Polymer J.
14, 913 (1982); ACS Polymer Preprints 25 (1), 245 (1984); Makromol.
Chem. 185, 9 (1984) and in U.S. Pat. No. 4,693,935 (Mazurek). This
method of macromer preparation involves the anionic polymerization
of hexamethylcyclotrisiloxane monomer to form living polymer of
controlled molecular weight, and termination is achieved via
chlorosilane compounds containing a polymerizable vinyl group.
[0055] Suitable monomers for use in the above-mentioned anionic
polymerization are, in general, diorganocyclosiloxanes of the
formula (--Si(R.sup.7).sub.2--O--).sub.r where each R.sup.7 is as
previously defined and r is an integer of 3 to 7. Examples of
useful cyclic siloxanes include, D.sub.3 where r is equal to 3 and
each R.sup.7 is methyl and D.sub.4 where r is equal to 4 and each
R.sup.7 is methyl. The cyclic siloxanes being hereafter designated
D.sub.3 and D.sub.4, respectively. D.sub.3, which is a strained
ring structure, is especially useful.
[0056] Initiators of the anionic polymerization are chosen such
that monofunctional living polymer is produced. Suitable initiators
include alkali metal hydrocarbons such as alkyl or aryl lithium,
sodium, or potassium compounds containing up to 20 carbon atoms in
the alkyl or aryl radical or in some instances up to 8 carbon
atoms. Examples of such compounds are ethylsodium, propylsodium,
phenylsodium, butylpotassium, octylpotassium, methyllithium,
ethyllithium, n-butyllithium, sec-butyllithium, tert-butyllithium,
phenyllithium, and 2-ethylhexyllithium. Lithium compounds are
preferred as initiators. Also suitable as initiators are alkali
metal alkoxides, hydroxides, and amides, as well as
triorganosilanolates of the formula R.sup.8Si(R.sup.7).sub.2--O-M
where M is alkali metal, tetraalkylammonium, or
tetraalkylphosphonium cation and where each R.sup.7, is as
previously defined and R.sup.8 is an alkyl, alkoxy, alkylamino,
aryl, hydroxyl or fluoroalkyl. The triorganosilanolate initiator
lithium trimethylsilanolate (LTMS) is particularly useful. In
general, the use of both strained cyclic monomer and lithium
initiator reduces the likelihood of redistribution reactions and
thereby provides siloxane macromonomer of narrow molecular weight
distribution which is reasonably free of unwanted cyclic
oligomers.
[0057] Molecular weight is determined by the initiator/cyclic
monomer ratio, and thus the amount of initiator may vary from about
0.004 to about 0.4 mole of organometallic initiator per mole of
monomer. Typically, the amount will be from about 0.008 to about
0.04 mole of initiator per mole of monomer.
[0058] For the initiation of the anionic polymerization, an inert,
generally polar organic solvent can be utilized. Anionic
polymerization propagation with lithium counterion typically uses
either a strong polar solvent such as tetrahydrofuran, dimethyl
sulfoxide, or hexamethylphosphorous triamide, or a mixture of such
polar solvent with nonpolar aliphatic, cycloaliphatic, or aromatic
hydrocarbon solvent such as hexane, heptane, octane, cyclohexane,
or toluene. The polar solvent serves to "activate" the silanolate
ion, making propagation possible.
[0059] Generally, the polymerization can be carried out at a
temperature ranging from about -50.degree. C. to about 100.degree.
C., or from about -20.degree. C. to about 30.degree. C. Anhydrous
conditions and an inert atmosphere such as nitrogen, helium, or
argon are usually used.
[0060] Termination of the anionic polymerization is, in general,
achieved via direct reaction of the living polymeric anion with
halogen-containing termination agents, i.e., functionalized
chlorosilanes, to produce vinyl-terminated polymeric monomers. Such
terminating agents may be represented by the general formula
W(A).sub.nSi(R.sup.7).sub.3-mCl.sub.m where Cl is a chlorine atom
and where W, A, n, m, and R.sup.7 have been previously defined. A
preferred terminating agent is
methacryloxypropyldimethylchlorosilane. The termination reaction is
carried out by adding a slight molar excess of the terminating
agent (relative to the amount of initiator) to the living polymer
at the polymerization temperature. According to the aforementioned
papers by Y. Yamashita et al., the reaction mixture may be
ultrasonically irradiated after addition of the terminating agent
in order to enhance functionality of the macromer. Purification of
the macromer can be effected by addition of methanol.
[0061] Polymers prepared from these silicone macromers may have a
wide variety or uses. Depending upon the co-monomers used, these
polymers may be adhesives, such as pressure sensitive adhesives or
they may be release materials. Typically the silicone macromer is
incorporated into the copolymer in the amount of about 0.01 to
about 50% of the total monomer weight to obtain the desired
properties. In some embodiments the amount of silicone macromer is
1-10 weight %, 1-5 weight % or even 3-5 weight %.
[0062] In some embodiments the free radically polymerizable moiety
may be a mercapto-functional silicone. Examples of suitable
mercapto-functional silicones are described, for example in U.S.
Pat. No. 5,032,460 (Kantner et al.). Such mercapto-functional
silicones can be represented by the general formula of Formula
2:
(R.sup.1).sub.3-x(HSR.sup.2).sub.xSi--(OSiR.sup.5R.sup.6).sub.y--OSi(R.s-
up.3).sub.3-q(R.sup.4SH).sub.q Formula 2
[0063] wherein each R.sup.1 is a monovalent moiety which can
independently be the same or different and is selected from the
group consisting of alkyl, aryl, alkaryl, alkoxy, alkylamino,
hydroxyl, hydrogen, and fluoroalkyl;
[0064] each R.sup.2 can independently be the same or different and
is a divalent linking group;
[0065] each R.sup.3 is a monovalent moiety which can independently
be the same or different and is selected from the group consisting
of alkyl, aryl, alkaryl, alkoxy, alkylamino, hydroxyl, hydrogen,
and fluoroalkyl;
[0066] each R.sup.4 can independently be the same or different and
is a divalent linking group;
[0067] each R.sup.5 is a monovalent moiety which can independently
be the same or different and is selected from the group consisting
of alkyl, aryl, alkaryl, alkoxy, alkylamino, hydroxyl, fluoroalkyl,
hydrogen, and --ZSH, wherein Z is a divalent linking group;
[0068] R.sup.6 is a monovalent moiety which can independently be
the same or different and is selected from the group consisting of
alkyl, aryl, alkaryl, alkoxy, alkylamino, hydroxyl, fluoroalkyl,
hydrogen, and --ZSH, wherein Z is a divalent linking group;
[0069] x is an integer of 0-3;
[0070] y is an integer of 10 or greater;
[0071] q is an integer of 0-3;
[0072] R.sup.5 comprises 0-y --ZSH moieties;
[0073] R.sup.6 comprises 0-y --ZSH moieties;
[0074] wherein at least one of the following is true: q is an
integer of at least 1; x is an integer of at least 1; R.sub.5
comprises at least one --ZSH moiety; and R.sub.6 comprises at least
one --ZSH moiety.
[0075] In some embodiments, R.sup.1 comprises either a
C.sub.1-C.sub.4 alkyl group or an hydroxyl group. These groups are
typically chosen for reasons of commercially availability.
Especially useful are embodiments where R.sup.1 is a methyl or
butyl group.
[0076] Typically, the divalent linking group R.sup.2 comprises a
C.sub.1 to C.sub.10 alkylene, arylene, alkarylene and
alkoxyalkylene group. In some embodiments, R.sup.2 is either a
C.sub.1-C.sub.3 alkylene or a C.sub.7-C.sub.10 alkarylene due to
ease of synthesis of these compounds. For reasons of availability,
especially useful are embodiments where R.sup.2 is a --CH.sub.2--;
a --CH.sub.2CH.sub.2CH.sub.2--; or a
--CH.sub.2--(C.sub.6H.sub.4)--CH.sub.2CH.sub.2-- group.
[0077] In some embodiments, R.sup.3 comprises a either a
C.sub.1-C.sub.4 alkyl group or an hydroxyl group. These groups are
typically chosen for reasons of commercially availability.
Especially useful are embodiments where R.sup.3 is a methyl or
butyl group.
[0078] Typically, the divalent linking group R.sup.4 comprises a
C.sub.1 to C.sub.10 alkylene, arylene, alkarylene and
alkoxyalkylene group. In some embodiments, R.sup.4 is either a
C.sub.1-C.sub.3 alkylene or a C.sub.7-C.sub.10 alkarylene due to
ease of synthesis of these compounds. For reasons of availability,
especially useful are embodiments where R.sup.4 is a --CH.sub.2--;
a --CH.sub.2CH.sub.2CH.sub.2--; or a
--CH.sub.2--(C.sub.6H.sub.4)--CH.sub.2CH.sub.2-- group.
[0079] Typically, the groups R.sup.5 and R.sup.6 independently
comprise alkyl, aryl, alkaryl, alkoxy, alkylamino, hydroxyl,
fluoroalkyl, hydrogen, or --ZSH groups, wherein Z is a divalent
linking group. Useful divalent linking groups Z include, for
example, C.sub.1 to C.sub.10 alkylene, alkarylene, arylene, and
alkoxyalkylene groups. Generally, for reasons of commercial
availability, Z is a --CH.sub.2-- or a --CH.sub.2CH.sub.2CH.sub.2--
group. In embodiments where R.sup.5 or R.sup.6 does not comprise a
--ZSH group, they typically comprise a C.sub.1 to C.sub.3 alkyl, a
fluoroalkyl, or a phenyl group. Generally, when R.sup.5 or R.sup.6
does not comprise a --ZSH group, they are methyl groups.
[0080] Typically, y is an integer ranging from about 40 to about
270 in order to provide the silicone segment with a molecular
weight ranging from about 3,000 to about 20,000 in order to provide
suitable release performance. In some embodiments, y is an integer
ranging from about 67 to about 270 in order to provide the silicone
segment with a molecular weight ranging from about 5,000 to about
20,000. In some embodiments the number average molecular weight of
the mercapto-functional silicone is in the range from 2,000-20,000
grams/mole or from 5,000-10,000 grams/mole.
[0081] The number of mercapto-functional groups on the
mercapto-functional silicone compound can vary. The ratio of the
weight of mercapto-functional groups to the total weight of the
mercapto-functional silicone compound can range from about 0.5:99.5
to about 15:85. Typically, the weight ratio of mercapto-functional
groups to mercapto-functional silicone compound ranges from about
2:98 to about 10:90. In some embodiments the mole % of
--CH.sub.2CH.sub.2CH.sub.2SH groups in the mercapto-functional
silicone ranges from 1-20 mole % or from 2-4 mole %.
[0082] Useful mercapto-functional silicone compounds can be
prepared by any known method including, for example, those
presented in U.S. Pat. Nos. 4,238,393; 4,046,795; 4,783,490 and
Canadian Patent No. 1,233,290. A particularly useful
mercapto-functional silicone is commercially available from
ShinEtsu Silicones, Akron, Ohio as "KF-2001''.
[0083] Typically, the amount of mercapto-functional silicone
present in the reactive mixture is in the range of 1-40 weight %,
5-35 weight %, or even 10-30 weight %.
[0084] The free radically polymerizable reaction mixtures of this
disclosure also comprise a free radically polymerizable co-monomer.
A wide variety of free radically polymerizable co-monomers or
mixtures of co-monomers may be used. Examples of suitable monomers
include vinyl monomers, (meth)acrylate monomers and polar
copolymerizable monomers.
[0085] Typically, the polymers formed by the method of this
disclosure contain at least 50% by weight of co-monomers relative
to the total monomer content. In some instances the polymers
contain 60%, 70%, 80% or even 90% or more by weight of co-monomers
relative to the total monomer content.
[0086] The co-monomers used affect the final properties of the
formed polymer, so the proposed use for the polymer will influence
the monomer selection. For example, Tg is one polymer parameter
that may be important in the formed polymer. Typically, when the
polymer is to be used as an adhesive, especially a pressure
sensitive adhesive, the co-monomers are generally chosen such that
the formed polymer has a Tg of less than 20.degree. C. or even less
than 0.degree. C. On the other hand, when the polymer is to be used
as a release material, the co-monomers are generally chosen such
that the formed polymer has a Tg of greater than 20.degree. C. or
even greater than 30.degree. C.
[0087] The substitution and functionality of the co-monomers are
also a factor in determining which co-monomers are used. For
example, in some embodiments it may be desirable to form a pressure
sensitive adhesive polymer which is free of acidic groups. In this
instance when it is desirable to have polar copolymerizable
monomers present in the polymer, acid functional monomers are
generally avoided and basic functional monomers are used
instead.
[0088] Examples of suitable vinyl monomers include, for example,
vinyl esters (e.g., vinyl acetate), styrene, substituted styrenes
(e.g., alpha-methyl styrene), vinyl halides, vinyl propionates, and
mixtures thereof. Other useful vinyl monomers include macromeric
(meth)acrylates such as (meth)acrylate-terminated styrene oligomers
and (meth)acrylate-terminated polyethers, such as are described in
PCT Patent Application WO 84/03837 and European Patent Application
EP 140941.
[0089] (Meth)acrylate monomers are (meth)acrylate esters of
non-tertiary alkyl alcohols, the alkyl groups of which comprise
from about 1 to about 20, or about 1 to about 18 carbon atoms, such
as those of Formula 3:
H.sub.2C.dbd.CR.sup.9--C(O)--OR.sup.10 Formula 3
[0090] wherein R.sup.9 is H or CH.sub.3, the latter corresponding
to where the (meth)acrylate monomer is a methacrylate monomer, and
R.sup.10 is a linear, branched, aromatic, or cyclic hydrocarbon
group, and --C(O)-- represents a carbonyl group. When R.sup.10 is a
hydrocarbon group, it can also include heteroatoms (e.g., oxygen or
sulfur).
[0091] Examples of suitable (meth)acrylate monomers useful in the
present disclosure include, but are not limited to, benzyl
methacrylate, n-butyl acrylate, n-butyl methacrylate, cyclohexyl
acrylate, cyclohexyl methacrylate, decyl acrylate, 2-ethoxy ethyl
acrylate, 2-ethoxy ethyl methacrylate, ethyl acrylate, 2-ethylhexyl
acrylate, ethyl methacrylate, n-hexadecyl acrylate, n-hexadecyl
methacrylate, hexyl acrylate, hydroxy-ethyl methacrylate, hydroxy
ethyl acrylate, isoamyl acrylate, isobornyl acrylate, isobornyl
methacrylate, isobutyl acrylate, isodecyl acrylate, isodecyl
methacrylate, isononyl acrylate, isooctyl acrylate, isooctyl
methacrylate, isotridecyl acrylate, lauryl acrylate, lauryl
methacrylate, 2-methoxy ethyl acrylate, methyl acrylate, methyl
methacrylate, 2-methyl butyl acrylate, 4-methyl-2-pentyl acrylate,
1-methylcyclohexyl methacrylate, 2-methylcyclohexyl methacrylate,
3-methylcyclohexyl methacrylate, 4-methylcyclohexyl methacrylate,
octadecyl acrylate, octadecyl methacrylate, n-octyl acrylate,
n-octyl methacrylate, 2-phenoxy ethyl methacrylate, 2-phenoxy ethyl
acrylate, propyl acrylate, propyl methacrylate, n-tetradecyl
acrylate, n-tetradecyl methacrylate, and mixtures thereof.
[0092] In some embodiments, particularly release materials, it may
be desirable to choose (meth)acrylate co-monomers which as
homopolymers have Tg greater than 20.degree. C. or even greater
than 30.degree. C. Examples of suitable (meth)acrylate monomers
include, but are not limited to, t-butyl acrylate, methyl
methacrylate, ethyl methacrylate, isopropyl methacrylate, n-butyl
methacrylate, isobutyl methacrylate, s-butyl methacrylate, t-butyl
methacrylate, stearyl methacrylate, phenyl methacrylate, cyclohexyl
methacrylate, isobornyl acrylate, isobornyl methacrylate, benzyl
methacrylate, bromoethyl methacrylate, 2-hydroxyethyl methacrylate,
hydroxypropyl methacrylate, glycidyl methacrylate, allyl
methacrylate,
[0093] In some embodiments, in which the formed polymers are either
adhesives or release materials, it may be desirable to include
copolymerizable polar monomers. Examples of such polar monomers
include: acid functional monomers such as acid functional
(meth)acrylates; basic functional monomers such as
(meth)acrylamides, substituted (meth)acrylamides, and
amine-containing (meth)acrylates; and neutral polar monomers such
as hydroxyalkyl (meth)acrylates, and cyanoalkyl
(meth)acrylates.
[0094] Useful acidic functional monomers include, but are not
limited to, those selected from ethylenically unsaturated
carboxylic acids, ethylenically unsaturated sulfonic acids,
ethylenically unsaturated phosphonic acids, and mixtures thereof.
Examples of such compounds include those selected from acrylic
acid, methacrylic acid, itaconic acid, fumaric acid, crotonic acid,
citraconic acid, maleic acid, oleic acid, B-carboxyethyl acrylate,
2-sulfoethyl methacrylate, styrene sulfonic acid,
2-acrylamido-2-methylpropane sulfonic acid, vinyl phosphonic acid,
and the like, and mixtures thereof. Due to their availability,
typically ethylenically unsaturated carboxylic acids are used.
[0095] When acidic (meth)acrylate co-monomers are used, typically
they are added in amounts ranging from about 2% by weight to about
30% by weight, or about 2% by weight to about 15% by weight,
relative to the total monomer content. Generally, as the proportion
of acidic monomers used in preparing the acidic copolymer
increases, cohesive strength of the resulting polymer
increases.
[0096] A wide variety of basic monomers are useful. In some
embodiments, the basic monomer is a nitrogen-containing monomer,
such as those of Formula 4:
R.sup.11R.sup.12C.dbd.CR.sup.13--X.sub.a--Y Formula 4
[0097] wherein
[0098] a is 0 or 1;
[0099] R.sup.11, R.sup.12, and R.sup.13 are independently selected
from H-- and CH.sub.3-- or other alkyl group,
[0100] X is selected from an ester or amide group; and
[0101] Y is an alkyl group, a nitrogen-containing aromatic,
nitrogen-containing group, such as the group:
--(Z).sub.b--NR.sub.14R.sub.15
[0102] wherein
[0103] Z is a divalent linking group (typically about 1 to 5 carbon
atoms);
[0104] b is 0 or 1; and
[0105] R.sup.14 and R.sup.15 are selected from hydrogen, alkyl,
aryl, cycloalkyl, and alkaryl groups.
[0106] R.sup.14 and R.sup.15 in the above group may also form a
heterocycle. In all embodiments, Y, R.sup.11, and R.sup.12 may also
comprise heteroatoms, such as O, S, N, etc. While Formula 4
summarizes the majority of basic monomers useful in the present
disclosure, other nitrogen-containing monomers are possible if they
meet the definition of a basic monomer (i.e., can be titrated with
an acid).
[0107] Exemplary basic monomers include N,N-dimethylaminopropyl
methacrylamide (DMAPMAm); N,N-diethylaminopropyl methacrylamide
(DEAPMAm); N,N-dimethylaminoethyl acrylate (DMAEA);
N,N-diethylaminoethyl acrylate (DEAEA); N,N-dimethylaminopropyl
acrylate (DMAPA); N,N-diethylaminopropyl acrylate (DEAPA);
N,N-dimethylaminoethyl methacrylate (DMAEMA); N,N-diethylaminoethyl
methacrylate (DEAEMA); N,N-dimethylaminoethyl acrylamide (DMAEAm);
N,N-dimethylaminoethyl methacrylamide (DMAEMAm);
N,N-diethylaminoethyl acrylamide (DEAEAm); N,N-diethylaminoethyl
methacrylamide (DEAEMAm); N,N-dimethylaminoethyl vinyl ether
(DMAEVE); N,N-diethylaminoethyl vinyl ether (DEAEVE); and mixtures
thereof. Other useful basic monomers include vinylpyridine,
vinylimidazole, tertiary amino-functionalized styrene (e.g.,
4-(N,N-dimethylamino)-styrene (DMAS),4-(N,N-diethylamino)-styrene
(DEAS)), N-vinyl pyrrolidone, N-vinyl caprolactam, acrylonitrile,
N-vinyl formamide, (meth)acrylamide, and mixtures thereof.
[0108] When basic co-monomers are used, typically they are added in
amounts ranging from about 2% by weight to about 30% by weight, or
about 2% by weight to about 15% by weight, relative to the total
monomer content. Generally, as the proportion of basic monomers
used in preparing the basic copolymer increases, cohesive strength
of the resulting polymer increases.
[0109] Another useful class of co-monomers which may be included in
the reaction mixture are co-monomers that may be described as
copolymerizable initiators. This class of co-monomers comprise a
free radically polymerizable group and an initiator group. The
initiator group may be a thermally initiated group or a
photoinitiated group. Comonomers which are copolymerizable
photoinitiators are particularly suitable to provide crosslinking.
This is particularly true for polymers which may be hot melt
processed and subsequently crosslinked. This type of crosslinking,
also known as post curing, usually comprises exposing the coated
material to some form of radiant energy, such as electron beam, or
ultraviolet light with the use of a chemical crosslinking agent.
Examples of useful copolymerizable photoinitiators are disclosed,
for example, in U.S. Pat. Nos. 6,369,123 (Stark et al.), 5,407,971
(Everaerts et al.), and 4,737,559 (Kellen et al.). The
copolymerizable photocrosslinking agents either generate free
radicals directly or abstract hydrogen atoms to generate free
radicals. Examples of hydrogen abstraction type photocrosslinkers
include, for example, those based on benzophenones, acetophenones,
anthraquinones, and the like. Examples of suitable copolymerizable
hydrogen abstraction crosslinking compounds include
mono-ethylenically unsaturated aromatic ketone monomers free of
orthoaromatic hydroxyl groups. Examples of suitable free-radical
generating copolymerizable crosslinking agents include but are not
limited to those selected from the group consisting of
4-acryloxybenzophenone (ABP), para-acryloxyethoxybenophenone, and
para-N-(methacryloxyethyl)-carbamoylethoxybenophenone.
Copolymerizable initiators, when used, are typically included in
the amount of about 0% to about 2%, or in the amount of about
0.025% to about 0.5%, based on the total monomer content.
[0110] The reaction mixture also comprises a chain transfer agent.
Chain transfer agents are well known in the polymerization art to
control the molecular weight or other polymer properties. The term
"chain transfer agent" as used herein also includes "telogens".
Suitable chain transfer agents include, but are not limited to,
those selected from the group consisting of carbon tetrabromide,
hexanebromoethane, bromotrichloromethane, 2-mercaptoethanol,
t-dodecylmercaptan, isooctylthioglycoate,
3-mercapto-1,2-propanediol, cumene, and mixtures thereof. Depending
on the reactivity of a particular chain transfer agent and the
amount of chain transfer desired, typically 0.1 to about 5 percent
by weight of chain transfer agent is used, or 0.1 to about 1.0
percent by weight or even 0.1 to 0.5 percent by weight, based upon
the total monomer content.
[0111] The reaction mixture also comprises at least one thermal
initiator. Thermal initiators are species which generate free
radicals upon heating. Many possible thermal free radical
initiators are known in the art of vinyl monomer polymerization and
may be used. Typical thermal free radical polymerization initiators
which are useful herein are organic peroxides, organic
hydroperoxides, and azo-group initiators which produce free
radicals. Useful organic peroxides include but are not limited to
compounds such as benzoyl peroxide, di-t-amyl peroxide, t-butyl
peroxy benzoate, and di-cumyl peroxide. Useful organic
hydroperoxides include but are not limited to compounds such as
t-amyl hydroperoxide and t-butyl hydroperoxide. Useful azo-group
initiators include but are not limited to the VAZO compounds
manufactured by DuPont, such as VAZO 52
(2,2'-azobis(2,4-dimethylpentanenitrile)), VAZO 64
(2,2'-azobis(2-methylpropanenitrile)), VAZO 67
(2,2'-azobis(2-methylbutanenitrile)), and VAZO 88
(2,2'-azobis(cyclohexanecarbonitrile)). Additional commercially
available thermal initiators include, for example, LUPERSOL 130
(2,5-dimethyl-2,5-Di-(t-butylperoxy)hexyne-3) available from Elf
Atochem, Philadelphia, Pa., and LUPEROX 101
(2,5-dimethyl-2,5-di-(tert-butylperoxoxy)hexane) available from
Arkema Canada, Inc., Oakville,
[0112] When the initiator(s) have been mixed into the monomers,
there will be a temperature above which the mixture begins to react
substantially (rate of temperature rise typically greater than
about 0.1.degree. C./minute for essentially adiabatic conditions).
This temperature, which depends on factors including the monomer(s)
being reacted, the relative amounts of monomer(s), the particular
initiator(s) being used, the amounts of initiator(s) used, and the
amount of any polymer and/or any solvent in the reaction mixture,
will be defined herein as the "runaway onset temperature". As an
example, as the amount of an initiator is increased, its runaway
onset temperature in the reaction mixture will decrease. At
temperatures below the runaway onset temperature, the amount of
polymerization proceeding will be practically negligible. At the
runaway onset temperature, assuming the absence of reaction
inhibitors and the presence of essentially adiabatic reaction
conditions, the free radical polymerization begins to proceed at a
meaningful rate and the temperature will start to accelerate
upwards, commencing the runaway reaction.
[0113] A sufficient amount of initiator(s) typically is used to
carry the polymerization to the desired temperature and conversion.
If too much initiator(s) is used, an excess of low molecular weight
polymer will be produced thus broadening the molecular weight
distribution. Low molecular weight components can degrade the
polymer product performance. If too little initiator is used, the
polymerization will not proceed appreciably and the reaction will
either stop or will proceed at an impractical rate. The amount of
an individual initiator used depends on factors including its
efficiency, its molecular weight, the molecular weight(s) of the
monomer(s), the heat(s) of reaction of the monomer(s), the types
and amounts of other initiators included, etc. The total initiator
amount, that for all initiator(s), typically is used in the range
of about 0.0005 weight % to about 0.5 weight % or in the range of
about 0.001 weight % to about 0.1 weight % based on the total
monomer content.
[0114] When more than one initiator is used in the reaction, as the
first initiator depletes during an essentially adiabatic reaction
(with the corresponding increasing reaction temperature), the
second initiator may be selected such that it is thermally
activated when the first initiator is becoming depleted. That is,
as the first initiator is depleting, the reaction has brought the
reaction mixture to the runaway onset temperature for the second
initiator in the reaction mixture. An overlap is preferred such
that before one initiator completely depletes another initiator
activates (reaches its runaway onset temperature). Without an
overlap, the polymerization rate can slow or essentially stop
without external heating to bring the mixture to the runaway onset
temperature of the next initiator in the series. This use of
external heating defeats one of the benefits of the inventive
process by adding the potential for nonuniform temperature
distribution in the reaction mixture due to the external heating.
However, polymerization still occurs under essentially adiabatic
conditions.
[0115] Until the temperature increases towards the runaway onset
temperature for an individual initiator in the batch, the initiator
is essentially dormant, not appreciably decomposing to form free
radicals. It will remain dormant until the reaction temperature
increases towards its runaway onset temperature in the reaction
mixture and/or until external heat is applied.
[0116] The succession of one initiator depleting and another
reaching its runaway onset temperature can continue as the
temperature rises for virtually any number of thermal initiators in
the reaction system. In the limit, a succession of virtually an
infinite number of different initiators could be used with nearly
complete overlap of the active temperature ranges between adjacent
initiators in the succession to bring about the polymerization and
the corresponding adiabatic temperature rise. In this case, the
amount of each initiator used would need to be virtually
infinitesimally small so as to not detrimentally broaden the
molecular weight distribution.
[0117] Practically, to minimize raw material handling requirements,
a reasonable minimum number of initiators should be used to achieve
the desired amount of adiabatic polymerization and obtain the
necessary polymer properties. Typically, 1 to 5 different
initiators (more typically 2 to 5) are used during a particular
reaction cycle. In some circumstances it may be advantageous to use
2, 3, 4, or 5 different initiators per reaction cycle.
[0118] To estimate the amount of overlap between successive
initiators in a series during an essentially adiabatic
polymerization, standard polymerization modeling techniques can be
employed as described in U.S. Pat. No. 5,986,011 (Ellis).
[0119] In the case that there will be more than one reaction cycle,
the initiator(s) for the first essentially adiabatic reaction cycle
are typically selected to bring the reaction to a
temperature/conversion level where:
[0120] 1) The polymerization reaction virtually stops when the
initiator(s) have essentially depleted (i.e., initiator(s) more
than 99% depleted). The temperature of the reaction mixture is such
that thermal polymerization of the monomers (polymerization in the
absence of added free radical initiators) in the polymer/monomer
reaction mixture is practically negligible. This is important so
that the reaction can be stopped with available heat transfer from
the reactor jacket (and potentially augmented with external cooling
such as that from external cooling from pumping the reaction fluid
through a heat exchanger, etc.).
[0121] 2) The solution viscosity is such that when the reaction
mixture is cooled prior to the next reaction cycle, the next
initiator(s), optional chain transfer agent, optional additional
monomers, optional polymer, etc., can be mixed into the batch. This
viscosity will be typically less than about 200,000 centipoise
(Brookfield viscosity at mixing temperature) for a common batch
reactor system.
[0122] Typically the polymerization reactions of this disclosure
proceed as follows. The monomers are charged to the reactor in the
desired amounts. The temperature of the reaction vessel must be
cool enough so that virtually no thermal polymerization of the
monomers will occur and also cool enough so that virtually no
polymerization will occur when the initiator(s) are added to the
batch. Also, care should be taken to ensure the reactor is dry, in
particular, free of any undesired volatile solvent (such as reactor
cleaning solvent) which potentially could dangerously elevate the
pressure of the reaction vessel as the temperature increases due to
heat of polymerization. The initiator(s), chain transfer agents,
and optional additional materials are also charged to the
reactor.
[0123] Prior to warming the reaction mixture as described below (or
optionally simultaneously while warming the batch), after adding
all components to the batch as described above, the batch is purged
of oxygen, a free-radical polymerization inhibitor. De-oxygenation
procedures are well known to those skilled in the art of
free-radical polymerization. For example, de-oxygenation can be
accomplished by bubbling an inert gas such as nitrogen through the
batch to displace dissolved oxygen.
[0124] After completing the de-oxygenation, the head space in the
reactor is typically pressurized with an inert gas such as nitrogen
to a level necessary to suppress boiling of the reaction mixture as
the temperature rises during reaction. The inert gas pressure also
prevents oxygen from entering the polymerization mixture through
possible small leaks in the reaction equipment while polymerization
is in progress.
[0125] From heating provided by the jacket on the reactor, the
reaction mixture temperature typically is raised to or in a range
about 1.degree. C. to about 5.degree. C. above the runaway onset
temperature with sufficient mixing in the batch to have an
essentially uniform temperature in the batch. The batch temperature
controller is typically set temporarily to maintain the batch at
the runaway onset temperature. Once the jacket temperature begins
to drop as necessary to hold the batch at the runaway onset
temperature, this indicates that the polymerization has begun. The
reaction may not proceed immediately when the batch is brought to
the runaway onset temperature because it may take time to deplete
reaction inhibitors that are typically shipped with the monomer (to
prevent unwanted polymerization during shipping and handling),
other trace impurities, or any oxygen still dissolved in the
reaction mixture. As soon as the jacket temperature drops, the
reactor jacket temperature control system is set to track the batch
temperature as it increases, due to reaction, to facilitate
essentially adiabatic reaction conditions. In practice, it has been
found beneficial to have the jacket track about 1.degree. C. to
about 10.degree. C. above the batch to warm the reactor walls from
the jacket as opposed to warming the reactor walls from the heat of
reaction of the mixture, making the reacting system more adiabatic.
Acknowledged is the fact that perfect adiabiticity is probably not
attainable because there will typically be a small amount of heat
transferred from the reacting medium to the internal agitator
blades and shaft as well as the mixing baffles in the reactor. In
practice, the effect of heat loss to heating the agitator shaft and
blades, baffles, temperature probes, etc., has been found to be
negligible.
[0126] An alternate heating approach would be to gently warm the
batch past the runaway onset temperature with heat input from the
jacket to warm the batch at a rate of about 0. 1.degree. C./min to
about 0.5.degree. C./min and continue the heating through the
reaction cycle (similar to the heating approach above with the
jacket tracking about 1.degree. C. to about 10.degree. C. above the
batch temperature). As in the heating approach above, continued
heating through the reaction cycle would serve to offset the heat
loss to the reaction equipment and maintain essentially adiabatic
reaction conditions. In practice, the first heating approach
described above appears preferable because it ensures the reaction
will always commence at the same temperature which seems to produce
more reproducible product from batch to batch.
[0127] Once the reaction temperature has peaked, due to the
depletion of the thermal initiator(s) as well as negligible
reaction of the monomers from thermal polymerization, the polymer
content at this point is typically about 30-80% by weight based on
the total weight of monomer(s) and polymer.
[0128] If desired, the polymerization cycles can be stopped at this
point and the unreacted monomer stripped from the reaction mixture
or further polymerized in other equipment. Stripping apparatuses
for the purpose of removing residual monomer are well known to
those skilled in polymerization art. One potential stripping
apparatus is an extractor-extruder operating with sections vented
to vacuum chambers wherein the monomer can be condensed and
optionally reused in subsequent polymerizations. Typical
extractor-extruders are referred to in Modern Plastics
Encyclopedia, Volume 45, October 1968 and Volume 46, October 1969,
both published by McGraw-Hill.
[0129] A potential benefit of stopping the polymerization without
reacting to completion is that the molecular weight distribution
has been found to broaden as conversion increases towards
completion. Product property requirements could warrant the extra
effort and cost of stripping versus reacting to completion. Another
reason to cease the polymerization process at partial conversion
would be to limit the solution viscosity at manageable levels. For
example, as the polymer molecular weight increases, the solution
viscosity will increase. If high molecular weight polymer is to be
produced and the 100% conversion melt viscosity is not manageable,
i.e. greater than about 200,000 to about 500,000 centipoise
(Brookfield viscosity at temperature), stopping the reaction at
less than 100% conversion could be beneficial.
[0130] When the reaction system is to be further polymerized in one
or more essentially adiabatic reaction cycles, the batch
temperature typically is cooled prior to beginning the next
reaction cycle. Generally the batch is cooled about 5-20.degree. C.
below the runway onset temperature of the initiator used in the
next reaction cycle. If more than one initiator is used the batch
temperature is typically cooled at least about 5-20.degree. C.
below the runaway onset temperature of the initiator having the
lowest runaway onset temperature.
[0131] As the partially polymerized reaction mixture cools, its
viscosity will increase. Optionally, if necessary, additional
monomer(s) can be added to the batch before it has fully cooled to
compensate for the increasing viscosity. Typically, if necessary, a
relatively small amount will be added. Charging additional monomer
in the amount less than about 30 weight % of the amount of monomer
added in the first reaction cycle is preferred. While the batch is
cooling or when it has cooled to the desired temperature,
optionally more monomer(s) can be added to adjust monomer ratios to
compensate for unequal reactivity ratios of the monomers in the
previous reaction cycle. Similarly, monomer(s) not included in an
earlier reaction cycle can be added to tailor the polymer
properties as needed. Monomer addition may also be performed as an
in-process correction to compensate for slight batch-to-batch
variations in the amount of reaction conversion obtained in a
previous reaction cycle.
[0132] When the batch has cooled to the desired temperature, the
additional initiator(s) are added to the batch. Optionally,
additional chain transfer agent(s) can be added. Adjusting the
amount of chain transfer agent can provide an in-process correction
for the product molecular weight obtained from the previous
reaction cycle. Other additives, including optional
photocrosslinking agents, and optional solvent, can also be added
at this time.
[0133] The batch is de-oxygenated, warmed to the runway onset
temperature of the initiator having the lowest runaway onset
temperature, and reacted essentially adiabatically as described
above for the previous reaction cycle.
[0134] If necessary, additional reaction cycles can be performed to
continue increasing conversion to the desired level.
[0135] Optionally, when all of the reaction cycles are complete,
unreacted monomer can be stripped from the batch by pulling vacuum
on the hot reaction product in the batch reactor by external vacuum
equipment such as a vacuum pump and optionally condensing monomer
vapors in an external heat exchanger with cooling.
[0136] The reaction mixture's viscosity at the temperature at the
end of the final reaction cycle is typically less than about
200,000 to about 500,000 centipoise (Brookfield viscosity at
draining temperature) to permit draining of the molten polymer from
the reactor and optionally mixing additives into the batch.
Typically, inert gas (such as nitrogen) pressure in the head space
of the reactor car be used to hasten the draining of the product
from the reactor.
[0137] After the reaction mixture is drained, an apparatus such as
an extractor-extruder can be used to strip unreacted monomer and/or
any solvent that optionally was added to the batch, or further
process the polymer by mixing in additives comprising plasticizers,
tackifiers, antioxidants and/or stabilizers, and extruding the
polymer into the physical form that it is intended to be used (i.e.
in sheet form for a pressure sensitive adhesive or a release
material). One particularly useful antioxidant is IRGANOX 1010
(tetrakis(methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate))methane)
available from Ciba Specialty Chemicals, Tarrytown, N.Y. The
silicone-containing copolymer can also be dissolved in a solvent to
permit the polymer to be solvent coated.
[0138] The silicone-containing copolymers may be adhesives,
especially pressure sensitive adhesives. The adhesive composition
may be coated in a variety of different ways, either out of solvent
or via hot-melt coating to form adhesive articles. In some
embodiments the coating process may be followed by crosslinking,
such as, for example by photocrosslinking by exposure to actinic
radiation such as UV light.
[0139] When the adhesive composition is solvent coated, it may be
applied by any conventional application method, including but not
limited to gravure coating, curtain coating, slot coating, spin
coating, screen coating, transfer coating, brush or roller coating,
inkjet printing and the like. The thickness of a coated adhesive
layer, typically in the form of a liquid is in part dependent on
the nature of the materials used and the specific properties
desired. Exemplary thicknesses of an adhesive layer may be in the
range from about 1 to about 250 micrometers, 12 to about 200
micrometers or about 25 to 100 micrometers.
[0140] When hot melt processing is used, the adhesive composition
can be formed into a film or coating by either continuous or batch
processes. An example of a batch process is the placement of a
portion of the adhesive between a substrate to which the film or
coating is to be adhered and a surface capable of releasing the
adhesive film or coating to form a composite structure. The
composite structure can then be compressed at a sufficient
temperature and pressure to form an adhesive coating or film of a
desired thickness after cooling. Alternatively, the adhesive can be
compressed between two release surfaces and cooled to form an
adhesive transfer tape useful in laminating applications. As with
solvent coated processes, the thickness of the adhesive coating may
be in the range from about 1 to about 250 micrometers, 12 to about
200 micrometers or about 25 to 100 micrometers.
[0141] Continuous forming methods include drawing the adhesive out
of a film die and subsequently contacting the drawn adhesive to a
moving plastic web or other suitable substrate. A related
continuous method involves extruding the adhesive and a coextruded
backing material from a film die and cooling the layered product to
form an adhesive tape. Other continuous forming methods involve
directly contacting the adhesive to a rapidly moving plastic web or
other suitable preformed substrate. Using this method, the adhesive
is applied to the moving preformed web using a die having flexible
die lips, such as a rotary rod die. After forming by any of these
continuous methods, the adhesive films or layers can be solidified
by quenching using both direct methods (e.g., chill rolls or water
baths) and indirect methods (e.g., air or gas impingement).
[0142] The adhesive composition may be disposed on a substrate
either by solvent coating or hot melt coating. The substrate may be
a release liner, a rigid surface, a tape backing, a film, or a
sheet. The adhesive composition can be coated onto a release liner,
coated directly onto a substrate, a film or a backing, or formed as
a separate layer (e.g., coated onto a release liner) and then
laminated to a substrate or film. In some embodiments the adhesive
is a transfer tape, i.e. it is disposed between two release
liners.
[0143] In some embodiments it may be desirable to impart a
microstructured surface to one or both major surfaces of the
adhesive. It may be desirable to have a microstructured surface on
at least one surface of the adhesive to aid air egress during
lamination. If it is desired to have a microstructured surface on
one or both surfaces of the adhesive film, the adhesive coating or
film may be placed on a tool or a liner containing
microstructuring. The liner or tool can then be removed to expose
an adhesive film having a microstructured surface. Generally with
optical applications it is desirable that the microstructure
disappear over time to prevent interference with optical
properties.
[0144] The substrate included in the adhesive article can contain
polymeric materials, glass materials, ceramic materials,
metal-containing materials (e.g., metals or metal oxides), or a
combination thereof. The substrate can include multiple layers of
material such as a support layer, a primer layer, a hard coat
layer, a decorative design, and the like. The substrate can be
permanently or temporarily attached to an adhesive film. For
example, a release liner can be temporarily attached and then
removed for attachment of the adhesive film to another
substrate.
[0145] The substrate can have a variety of functions such as, for
example, providing flexibility, rigidity, strength, support, or
optical properties such as, for example, reflectivity,
antireflectivity, polarization, or transmissivity (e.g., selective
with respect to different wavelengths). That is, the substrate can
be flexible or rigid; reflective or non-reflective; visibly clear,
colored but transmissive, or opaque (e.g., not transmissive); and
polarizing or non-polarizing.
[0146] Representative examples of polymeric substrates include
those that contain polycarbonates, polyesters (e.g., polyethylene
terephthalates and polyethylene naphthalates), polyurethanes,
poly(meth)acrylates (e.g., polymethyl methacrylates), polyvinyl
alcohols, polyolefins such as polyethylenes and polypropylenes,
polyvinyl chlorides, polyimides, cellulose triacetates,
acrylonitrile-butadiene-styrene copolymers, and the like.
[0147] In other embodiments, the substrate is a release liner. Any
suitable release liner can be used. Examples of suitable liners
include paper, e.g., kraft paper, or polymeric films, e.g.,
polyethylene, polypropylene or polyester. At least one surface of
the liner can be treated with a release agent such as silicone, a
fluorochemical, or other low surface energy based release material
to provide a release liner. Suitable release liners and methods for
treating liners are described in, e.g., U.S. Pat. Nos. 4,472,480,
4,980,443 and 4,736,048. The liner can have a microstructure on its
surface that is imparted to the adhesive to form a microstructure
on the surface of the adhesive film. The liner can then be removed
to expose an adhesive film having a microstructured surface.
[0148] The silicone-containing copolymer may be used alone as an
adhesive or it may contain a variety of additives. For example,
additional adhesive polymers or elastomeric polymers may be blended
with the silicone-containing copolymer to form the adhesive
composition. Additionally, other optional property modifying
additives can be mixed with the adhesive composition. Typical
property modifiers include tackifying agents (tackifiers) and
plasticizing agents (plasticizers) to modify the adhesive
performance of the formed adhesive composition. In addition, other
property modifiers, such as fillers, may be added if desired,
provided that if and when incorporated, such additives are not
detrimental to the properties desired in the final composition.
Fillers, such as fumed silica, fibers (e.g., glass, metal,
inorganic, or organic fibers), carbon black, glass or ceramic
beads/bubbles, particles (e.g., metal, inorganic, or organic
particles), polyaramids (e.g., those available from DuPont Chemical
Company; Wilmington, Del. under the trade designation, KEVLAR), and
the like which can be added in amounts up to about 30% by weight.
Other additives such as dyes, inert fluids (e.g., hydrocarbon
oils), pigments, flame retardants, stabilizers, antioxidants,
compatibilizers, antimicrobial agents (e.g., zinc oxide),
electrical conductors, thermal conductors (e.g., aluminum oxide,
boron nitride, aluminum nitride, and nickel particles), and the
like can be blended into these systems in amounts of generally from
about 1 to about 50 percent by total volume of the composition.
[0149] The silicone-containing copolymers may be release materials.
Release materials are materials that exhibit low adhesion to an
adhesive, such as a pressure sensitive adhesive, so that separation
can occur substantially between the adhesive and release material
interface. Release coatings can be used as a "liner" for adhesive
articles, such as labels or medical dressing bandages, and the like
where the adhesive article is generally supplied as a sheet-like
construction, as opposed to a roll-like construction. In tape
applications, a release material is often referred to as a "low
adhesion backsize," or LAB. In this form, the adhesive surface
contacts the back surface of the article. The LAB prevents the
adhesive from permanently adhering to the back surface of the
article and allows that article to be unwound.
[0150] A wide variety of release articles may be prepared using the
silicone-containing polymers of this disclosure. Among the articles
are release liners, tape constructions, and sheet constructions.
Generally, the release performance requirements are different for
release liners than for LAB materials. Typically it is desirable to
have higher adhesion levels between the adhesive and the release
components in tape constructions (LABs) because it is desirable for
the tape to not spontaneously unroll. Spontaneous unrolling and
similar phenomena may occur if the adhesion level between the
release and adhesive component are too low.
[0151] The composition of the copolymer is such as to provide the
copolymer with a surface release value not greater than about 50
N/dm. It should be understood that this upper limit of 50 N/dm
applies to use with highly aggressive pressure sensitive adhesives
which have peel adhesion values of 100 N/dm or higher. Pressure
sensitive adhesives as a group may be categorized into three broad
categories (1) low (5-15 N/dm), (2) intermediate (25-50 N/dm), and
(3) high (60-100 plus N/dm) peel adhesion ranges. The degree of
release can be selected to match the aggressiveness of the pressure
sensitive adhesive with which it will be in contact and it is only
for the most aggressive pressure sensitive adhesives that a release
value as high as 50 N/dm would be selected. Release coatings for
less aggressive pressure sensitive adhesives would be selected to
be correspondingly lower.
[0152] Coatings of the silicone-containing copolymer of this
disclosure may have release levels for a given pressure sensitive
adhesive that can be systematically changed from a tight low
adhesion backsize level (15 to 30 N/dm) to a premium release liner
level (0.2 to 0.6 N/dm) by variation in the amount and type of
silicone present. This, coupled with utility for a variety of
pressure sensitive adhesive types, allows for these release
materials to satisfy a wide range of application needs. Since
silicone constitutes only a portion of the coating (even at easy
levels of release suitable for release liner applications), these
copolymer compositions provide a potential cost savings over
conventional 100% silicone release compositions and numerous
blends.
[0153] The release composition may be coated in a variety of
different ways, either out of solvent or via hot-melt coating,
including by co-extrusion, to form articles. In some embodiments
the coating process may be followed by crosslinking, such as, for
example by photocrosslinking by exposure to actinic radiation such
as UV light.
[0154] When the release composition is solvent coated, it may be
applied by any conventional application method, including but not
limited to gravure coating, curtain coating, slot coating, spin
coating, screen coating, transfer coating, brush or roller coating,
inkjet printing and the like. The thickness of a coated release
layer, typically in the form of a liquid is in part dependent on
the nature of the materials used and the specific properties
desired. Exemplary thicknesses of a release layer may be in the
range from about 0.01 to about 2.5 micrometers, or about 0.5 to 1.0
micrometers.
[0155] When hot melt processing is used, typically continuous
processes are used. Continuous forming methods include drawing the
release material out of a film die and subsequently contacting the
drawn release material to a moving plastic web or other suitable
substrate. A related continuous method involves extruding the
release material and a coextruded backing material from a film die
and cooling the layered product to form a release article. Other
continuous forming methods involve directly contacting the release
material to a rapidly moving plastic web or other suitable
preformed substrate. Using this method, the release material is
applied to the moving preformed web using a die having flexible die
lips, such as a rotary rod die. After forming by any of these
continuous methods, the release films or layers can be solidified
by quenching using both direct methods (e.g., chill rolls or water
baths) and indirect methods (e.g., air or gas impingement).
[0156] The release coatings may comprise the silicone-containing
copolymer alone, or may comprise such copolymers blended with a
compatible homopolymer, copolymer, etc. The low percentage of
silicone block contained in the copolymers makes the copolymers
readily compatible with polymers of similar composition to the
vinyl polymeric blocks or segments. Examples of suitable polymers
and copolymers include, for example, thermoplastic polymers such as
olefins, polyesters, or renewable polymers such as polylactic acid,
and the like. Particularly suitable polymers include olefins such
as polyethylene, polypropylene, copolymers of ethylene and
propylene, and the like. Fillers or pigments (e.g., alumina,
silica, titania, or calcium carbonate) may, of course, be added to
the copolymer compositions to reduce gloss and also impart a
surface texture that is more receptive to marking with pencils and
roller ball pens.
[0157] A blend of the silicone-containing copolymer and a
thermoplastic polymer may be coated onto a substrate via coating
(such as hot melt coating) or coextrusion, or the blend may be
extruded as a stand alone film.
[0158] The silicone-containing release copolymers may be used as a
coating for a solid substrate, which may be a sheet, fiber, or
shaped object. Among the preferred substrates are flexible
substates used for pressure sensitive adhesive products. Suitable
substrates include paper, metal sheets and foils, non-woven
fabrics, and films of thermoplastic resins such as polyesters,
polyamides, polyolefins, polycarbonates, polyvinyl chloride, etc.,
although any surface requiring release toward adhesives can be
used. Primers known in the art can be utilized to aid in adhesion
of the coating to the substrate, but they are not generally
necessary.
[0159] The release coating compositions may be applied to suitable
substrates by means of conventional coating techniques such as
wire-wound rod, direct gravure, offset gravure, reverse roll,
air-knife, and trailing blade coating; hot melt coating is also
possible. The resultant coatings provide effective release for a
wide variety of conventional pressure sensitive adhesives such as
natural rubber-based, acrylic, and other synthetic film-forming
elastomeric materials.
[0160] The present disclosure provides a roll of tape which
includes a flexible backing member, a pressure sensitive adhesive
coating one major surface of the backing member, and a release
coating on the opposite major surface of the backing comprising the
polymer defined above. The disclosure further provides a tape
comprising a flexible backing member, a pressure sensitive adhesive
coating one major surface of the backing member and a release liner
comprising a flexible sheet coated over the major surface adhered
to the pressure sensitive coating with the copolymer defined above.
The disclosure further provides a transfer tape comprising a film
of pressure sensitive adhesive between two release liners, at least
one being coated with the copolymer.
[0161] The disclosure also provides a coated sheet material wherein
the release agent is on one side of the sheet and the adhesive is
on the other side. The disclosure further provides a coated sheet
material wherein the adhesive is a normally tacky and pressure
sensitive adhesive. The disclosure also provides a stack of
superimposed sheets of the coated sheet material, the pressure
sensitive adhesive on each sheet being in contact with the release
agent on an immediately adjacent sheet.
[0162] The disclosure also provides a fanfolded web formed from the
coated sheet material, the adhesive on each segment of the web
being in contact with the release agent on an immediately adjacent
segment. The disclosure also provides the coated sheet material
wherein the adhesive is present in a band adjacent one edge of the
sheet. The disclosure also provides a stack of individual sheets
formed from the coated sheet material, the adhesive bands of
adjacent sheets lying along opposite edges. The disclosure further
provides a coated sheet material having a release agent on one side
and an adhesive on the other side wherein said coated sheet
material can be wound convolutedly on itself about a core to form a
roll. The disclosure further provides the coated sheet material
wherein the adhesive is a normally tacky pressure sensitive
adhesive.
[0163] The disclosure further provides a coated sheet material
wherein the release agent covers a first portion of one side and a
normal tacky and pressure sensitive adhesive covers a second
portion of the same side. The disclosure further provides a coated
sheet material wherein the sheet is an elongate strip having spaced
alternating areas of release agent and an adhesive. The disclosure
also further provides the coated sheet material wherein the sheet
is generally rectangular, the release agent being present in a band
adjacent one edge and the pressure sensitive adhesive being present
in a band adjacent the opposite edge.
[0164] The silicone-containing copolymers comprising the release
coating have a well-defined structure. When such copolymers are
coated on a substrate, the silicone segment is thought to present a
low energy, "siliconized" release surface, and the higher energy
copolymerized polymeric blocks or segments are thought to provide
adhesion to the base material. Similarly, if the
silicone-containing copolymers are coextruded with other polymeric
materials to form a release article, the higher energy
copolymerized blocks or segments are thought to provide improved
compatibility with these materials. The chemical nature or
composition of the higher energy copolymerized blocks or segments
can be modified independently of the free radically polymerizable
silicone-containing monomer(s) to alter properties other than the
release properties. Such properties include, for example, adhesion
to the substrate, water dispersability, ink receptivity, etc. which
can be altered without any serious perturbation of the surface
characteristics of the film. The release properties of the coating
are determined by both the silicone content (weight percentage) of
the copolymer and the molecular weight of the silicone segment,
with higher silicone content and/or molecular weight providing
easier release. A copolymer or copolymer blend can, therefore, be
chemically tailored to provide a specific level of release which
can be reproduced with consistency, thus making possible the
variation of the release properties of a backing over a range of
values in a controlled fashion.
[0165] The silicone-containing release copolymers of this
disclosure can be used to prepare structured adhesive articles.
Several approaches to structuring adhesives are known, including
those shown in, for example, U.S. Pat. Nos. 5,296,277 and 5,362,516
(both Wilson et al.); 5,141,790 and 5,897,930 (both Calhoun et
al.); and 6,197,397 (Sher et. al). These patents disclose how the
structure in the adhesive is built from the interface between the
adhesive and the release liner.
[0166] These release liners are generally manufactured by
structuring a thermoplastic polymer surface of the liner. Current
methods of making release liners having microstructured patterns
include cast extrusion onto a microstructured tool that imparts the
desired pattern to the liner followed by silicone release coating
where required, or by pressing a pattern into a thermoplastic
polymer surface, with or without a silicone release coating,
between structured nips to impart a pattern. These manufacturing
steps form the topography on the liner, which is then used to
impart topography into an adhesive.
EXAMPLES
[0167] These examples are merely for illustrative purposes only and
are not meant to be limiting on the scope of the appended claims.
All parts, percentages, ratios, etc. in the examples and the rest
of the specification are by weight, unless noted otherwise.
Solvents and other reagents used were obtained from Sigma-Aldrich
Chemical Company; Milwaukee, Wis. unless otherwise noted.
TABLE-US-00001 Table of Abbreviations Abbreviation or Trade
Designation Description Initiator-1 Thermal free radical initiator
of 2,2'-azobis(2,4 dimethylpentanenitrile) commercially available
from E.I. duPont de Nemours &Co, Wilmington, DE as "VAZO 52".
Initiator-2 Thermal free radical initiator of
2,2'-azobis(cyclohexanecarbonitrile) commercially available from
E.I. duPont de Nemours &Co, Wilmington, DE as "VAZO 88".
Antioxidant-1 Antioxidant tetrakis(methylene(3,5-di-tert-butyl-4-
hydroxyhydrocinnamate))methane commercially available from Ciba
Specialty Chemicals, Tarrytown, NY as "IRGANOX 1010". Initiator-3
Thermal free radical initiator of
2,2'-azobis(2-methylbutyronitrile) commercially available from E.I.
duPont de Nemours &Co, Wilmington, DE as "VAZO 67". Initiator-4
Thermal free radical initiator of 2,5-dimethyl-2,5-Di-(t-
butylperoxy)hexyne-3 commercially available from Elf Atochem,
Philadelphia, PA as "LUPERSOL 130". Initiator-5 Thermal free
radical initiator of azo-bis(isobutyronitrile) commercially
available from E.I. duPont de Nemours &Co, Wilmington, DE as
"VAZO 64". Initiator-6 Thermal free radical initiator of
2,5-dimethyl-2,5-di-(tert- butylperoxoxy)hexane commercially
available from Arkema Canada, Inc., Oakville, ON as "LUPEROX 101".
IOA Isooctyl acrylate ABP Copolymerizable photoinitiator of
4-acryloxy benzophenone, prepared according to U.S. Pat. No.
4,737,559 (Kellen et al.). IOTG Isooctylthioglycoate commercially
available from Dow Chemical, Midland, MI. SiMac Silicone macromer,
methacrylate terminated polydimethylsiloxane, prepared as described
in Synthesis Example S1 below. EA Ethyl acetate PET Film An
aminated-polybutadiene primed polyester film of polyethylene
terephthalate having a thickness of 38 micrometers. ODA Octadecyl
acrylate MA Methyl acrylate AA Acrylic Acid MMA Methyl methacrylate
MAA Methacrylic acid AN Acrylonitrile MFS Mercapto-functional
polydimethylsiloxane, commercially available from ShinEtsu
Silicones, Akron, OH as "KF-2001". LDPE Low density polyethylene,
commercially available as EXXON 129.24 from ExxonMobil, Houston,
TX. Additive-1 A color concentrate of 4% of silver black #3 in LDPE
resin available from PolyOne, Elk Grove Village, IL as
"CC10100332WE". Additive-2 A light stabilizer concentrate in LDPE
available from Ampacet Corp., Tarrytown, NY as "10407". Packaging
Tape Tape of 4.8 centimeter (1.88 inch) width commercially
available from3M Company, St. Paul, MN as "3M SCOTCH Box Sealing
Tape3750". The tape was cut to 2.54 centimeter (1 inch) width for
use in the testing. THF tetrahydrofuran
Test Methods
Inherent Viscosity (IV)
[0168] Average inherent viscosities (IV) were measured at
30.degree. C. using a Canon-Fenske viscometer (Model No. 50 P296)
in a THF solution at 30.degree. C. at a concentration of 0.2 g/dL.
Inherent viscosities of the materials tested were found to be
essentially independent of concentration in the range of 0.1 to 0.4
g/dL. The average inherent viscosities were averaged over 3 or more
runs. Any variations for determining average inherent viscosities
are set forth in specific Examples.
180.degree. Peel Adhesion
[0169] This peel adhesion test is similar to the test method
described in ASTM D 3330-90, substituting a glass substrate for the
stainless steel substrate described in the test. Adhesive coatings
on polyester film were cut into 1.27 centimeter by 15 centimeter
strips. Each strip was then adhered to a 10 centimeter by 20
centimeter clean, solvent washed glass coupon using a 2-kilogram
roller passed once over the strip. The bonded assembly dwelled at
room temperature for about one minute and was tested for
180.degree. peel adhesion using an IMASS slip/peel tester (Model
3M90, commercially available from Instrumentors Inc., Strongsville,
Ohio) at a rate of 2.3 meters/minute (90 inches/minute) over a five
second data collection time. Two samples were tested; the reported
peel adhesion value is an average of the peel adhesion value from
each of the two samples. The data was recorded in ounces per inch
and converted to Newtons per decimeter (N/dm).
Release Test
[0170] Samples were prepared for release testing by attaching
laminates of adhesive tape on the experimental release film to a
15.2 centimeter by 30.5 centimeter glass panel using double-coated
adhesive tape (commercially available from 3M Company under the
trade designation "410B") via the non-release side of the release
film using a 2 kg rubber roller. The laminated adhesive tape was
then peeled from the experimental release liner at 180.degree. at a
rate of 2.3 meters/minute (90 inches/minute). All tests were done
in a facility at constant temperature (20.degree. C.) and constant
humidity (50% RE). In the case of shocky peel, the minimum, maximum
and average peel values are all reported to indicate the level of
shockiness and a description of the peel was also included. To
determine the readhesion value, the peeled adhesive tape was
applied to the surface of a clean glass plate by means of a 2 kg
rubber roller. The readhesion value was a measure of the force
required to pull the tape from the glass surface at an angle of
180.degree. at a rate of 2.3 meters/minute (90 inches/minute). The
peel tester used for all examples was an IMass slip/peel tester
(Model 3M90, commercially available from Instrumentors Inc.,
Strongville, Ohio). Measurements were obtained in ounces/inch and
converted to Newtons per decimeter.
Synthesis Examples
Synthesis Example S1
Preparation of SiMac
[0171] A methacrylate-terminated polydimethylsiloxane macromer was
prepared as described in U.S. Pat. No. 4,693,935 (Mazurek) "Monomer
C.sub.3b". The macromer, having an average molecular weight of
about 10,000 grams/mole, was prepared using BuLi initiator. A
flame-dried 1 liter three-necked flask equipped with a mechanical
stirrer, condenser, and septum and purged with dry argon was
charged with a dilute solution of D.sub.3 (1 gram) in heptane (100
milliliters), both freshly dried. 5.5 milliliters of BuLi (1.7 M in
hexane) (9.35 mmoles) was introduced and the initiation reaction
was continued overnight at room temperature. 198.7 grams (0.89
mole) of D.sub.3 in THF (496.8 g) was introduced into the reaction
flask via polytetrafluoroethylene (PTFE) tubing and the
polymerization was continued for 8 hours with the reaction mixture
maintained at room temperature. Progress of the reaction was
monitored by GC analysis of the reaction mixture. Thereafter the
capping agent, 3-methacryloxypropyldimethylchlorosilane (2.26 g,
10.3 mmoles), was introduced and the reaction mixture was stirred
for 1 hour, while additionally agitated with an ultrasonic bath
which raised the temperature to about 40.degree. C. The resultant
polymer solution was poured into an excess of methanol with
vigorous stirring. The separated polymer fraction was dissolved in
ethyl ether and washed with water. The organic layer was dried with
magnesium sulfate, filtered, and evaporated. The resultant polymer
did not contain detectable quantities of low molecular weight
materials, such as oligomeric siloxanes. The macromer produced was
analyzed by gel permeation chromatography which gave the following
results: M.sub.n=12,881, M.sub.W=14,756, and polydispersity of
1.14.
Comparative Example C-1
[0172] A sample was prepared as described in U.S. Pat. No.
4,693,935 (Mazurek) Example 64. In a glass reaction bottle was
placed 83 parts by weight IOA, 7 parts by weight AA, 10 parts by
weight SiMac, 0.3 parts by weight Initiator-5 and 150 parts by
weight EA. The reaction bottle was purged with nitrogen and sealed.
It was placed in a 55.degree. C. bath and tumbled therein for 24
hours. The resulting polymer solution was diluted with 250 parts by
weight EA and knife coated onto a PET film and dried to provide a
dry coating thickness of 25 micrometers.
Examples 1-4
[0173] For Examples 1-4 essentially adiabatic polymerizations were
carried out by a two step reaction within a VSP2 adiabatic reaction
apparatus equipped with a 316 stainless steel test can (available
from Fauske and Associates Inc, Burr Ridge Ill.). In the VSP2
reaction vessel was placed IOA, AA, SiMac, Initiator-1, IOTG and
ABP in the amounts shown in Table 1. The reactor was sealed and
purged of oxygen. The reaction mixture was heated to 60.degree. C.
and the reaction proceeded adiabatically. Typical reaction peak
temperature was 150.degree. C. When the reaction was complete, the
mixture was cooled to below 50.degree. C. To the reaction product
of the first step was added 0.7 grams of a mixture, (the contents
of the additive mixture are shown in Table 2) and 0.2188 grams of
ABP. The reactor was sealed and purged of oxygen. The reaction
mixture was heated to 60.degree. C. and the reaction proceeded
adiabatically. Typical reaction peak temperature was 160.degree. C.
The samples were removed from the reactor, Inherent Viscosity (IV)
was measured using the Test Method given above and is shown in
Table 3. The polymer samples were dissolved in THF at approximately
30% solids. The polymer solutions were knife coated onto a PET film
and dried to provide a dry coating thickness of 25 micrometers. The
coated samples were post-crosslinked by passing under a high
intensity UV source ("D" or "H" bulb) such that each pass gave a UV
dose of 600 milliJoules per square centimeter. Samples were tested
for 180.degree. Peel Adhesion using the Test Method given above,
both immediately after adhering and after dwelling for 24 hours.
These data are shown in Table 3.
TABLE-US-00002 TABLE 1 IOA AA SiMac Initiator-1 IOTG ABP Example
(parts) (parts) (parts) (parts) (parts) (parts) 1 85 10 5 0.004
0.045 0.3125 2 80 10 10 0.004 0.06 0.3125 3 80 10 10 0.004 0.08
0.3125 4 80 10 10 0.004 0.15 0.3125
TABLE-US-00003 TABLE 2 Example Additive IOTG Initiator-1
Initiator-2 Initiator-4 EA Mixture (parts) (parts) (parts) (parts)
(parts) 1 4.2 0.5 0.1 0.15 45.05 2 5.58 0.5 0.1 0.15 43.67 3 7.44
0.5 0.1 0.15 41.81 4 13.95 0.5 0.1 0.15 35.3
TABLE-US-00004 TABLE 3 180.degree. Peel UV Cure Initial 180.degree.
Adhesion after IV (Number of Peel Adhesion 24 Hour Dwell Example
(dl/g) passes) (N/dm) (N/dm) 1 0.55 1 8.6 110.7 2 0.62 1 1.9 100.3
3 0.37 3 40.3 111.0 4 0.29 4 8.6 100.4 C1 0.61 NA 42.6 88.5 NA =
Not Applicable
Examples 5-7
[0174] For Examples 5-7 essentially adiabatic polymerization was
carried out by a two step reaction within a VSP2 adiabatic reaction
apparatus equipped with a 316 stainless steel test can (available
from Fauske and Associates Inc, Burr Ridge Ill.). In the VSP2
reaction vessel was placed ODA, AN, MA, AA, IOTG and SiMac or MFS
in the amounts shown in Table 4. To the mixture was added 0.1 grams
of Antioxidant-1 and 1.03 grams of a mixture (the contents of the
additive mixture are shown in Table 5). The reactor was sealed and
purged of oxygen. The reaction mixture was heated to 63.degree. C.
and the reaction proceeded adiabatically. Typical reaction peak
temperature was 165.degree. C. When the reaction was complete, the
mixture was cooled to below 75.degree. C. To about 70 grams of the
reaction product of the first step was added 0.7 grams of a mixture
(the contents of the additive mixture are shown in Table 6) and in
Example 5, added 0.35 grams IOTG. The reactor was sealed and purged
of oxygen. The reaction mixture was heated to 65.degree. C. and the
reaction proceeded adiabatically. Typical reaction peak temperature
was 160.degree. C. The samples were removed from the reactor,
Inherent Viscosity (IV) was measured using the Test Method given
above, with the exception that Examples 6 and 7 were in a 70:30
THF/toluene solution at a concentration of about 0.7 g/dL and
Example 5 was in EA at a concentration of 0.3 g/dL, and provided
the results shown in Table 7.
[0175] Samples of the polymer from Examples 5 and 7 were dissolved
in EA to 5% solids solutions, coated onto PET using a Number 6
Mayer rod and dried in a 65.degree. C. oven for 30 minutes to yield
a release surface. The release surface was tested by adhering
samples of SCOTCH MAGIC tape 810 (commercially available from 3M
Company, St. Paul, Minn.) to the release surface, aging for the
specified time period and conditions, and conducting the Release
Test described in the Test Method above. The Results are shown in
Tables 8 and 9.
Examples 8 and 9
[0176] For Examples 8-9 essentially adiabatic polymerizations were
carried out by a one step reaction within a VSP2 adiabatic reaction
apparatus equipped with a 316 stainless steel test can (available
from Fauske and Associates Inc, Burr Ridge Ill.). In the VSP2
reaction vessel was placed ODA, AN, MA, AA and MFS in the amounts
shown in Table 4. To the mixture were added 0.1 grams of
Antioxidant-1 and 1.03 grams of a mixture (the contents of the
additive mixture are shown in Table 5). The reactor was sealed and
purged of oxygen. The reaction mixture was heated to 63.degree. C.
and the reaction proceeded adiabatically. Typical reaction peak
temperature was 165.degree. C. The samples were removed from the
reactor, Inherent Viscosity (IV) was measured using the Test Method
given above, with the exception that Examples 8 and 9 were in a
70:30 THF/toluene solution at a concentration of about 0.5 g/dL and
provided the results shown in Table 7.
TABLE-US-00005 TABLE 4 Ex- am- ODA AN MA AA SiMac MFS IOTG ple
(parts) (parts) (parts) (parts) (parts) (parts) (parts) 5 30 25 10
5 30 0 3 6 30 25 10 5 30 0 1 7 30 25 10 5 0 30 0 8 30 22 5 3 0 40 0
9 27 15 5 3 0 50 0
TABLE-US-00006 TABLE 5 Example Additive Initiator-1 Initiator-2
Initiator-6 Initiator-4 MA Mixture (parts) (parts) (parts) (parts)
(parts) 5 0.1 0.1 0.05 0 10 6 0.1 0.1 0 0 10 7 0.1 0.1 0.05 0 10 8
0.1 0.1 0.05 0.05 10 9 0.1 0.1 0.05 0.05 10
TABLE-US-00007 TABLE 6 Example Initi- Initi- Additive IOTG ator-1
ator-2 Initiator-4 Initiator-6 EA Mixture (parts) (parts) (parts)
(parts) (parts) (parts) 5 0 0.5 0.5 0.1 0.5 48.4 6 3.5 0.5 0.5 0.1
0.5 44.9 7 0 0.5 0.5 0.1 0.5 48.4
TABLE-US-00008 TABLE 7 Wt % Solids IV (based on total Example
(dl/g) wt of mixture) 5 0.11 93.5 6 0.14 95.2 7 0.09 85.2 8 0.13
90.0 9 0.19 98.3
Comparative Example C2
[0177] A double layer of SCOTCH MAGIC tape 810 (commercially
available from 3M Company, St. Paul, Minn.) was peeled from a roll
and aged for the specified time period and conditions. The top
layer of the double layer was tested for peel and readhesion as
described in the Test Method above. The Results are in Tables 8 and
9.
TABLE-US-00009 TABLE 8 180.degree. Peel Readhesion 180.degree. Peel
Readhesion after after after after 3 days 3 days 3 days 3 days at
RT at RT at 65.degree. C. at 65.degree. C. Example (N/dm) (N/dm)
(N/dm) (N/dm) 7 2.26 25.6 4.88 18.6 C2 7.47 10.1 19.91 9.19
TABLE-US-00010 TABLE 9 180.degree. Peel Readhesion 180.degree. Peel
Readhesion after after after after 2 days 2 days 2 days 2 days at
RT at RT at 65.degree. C. at 65.degree. C. Example (N/dm) (N/dm)
(N/dm) (N/dm) 5 1.89 10.8 1.98 0.77 C2 5.76 8.8 23.64 10.8
Example 10
[0178] Extruded release film was prepared using a dry blended
mixture of 95 parts by weight LDPE and 5 parts by weight the
polymer produced in Example 7. The mixture was fed into a 1.9
centimeter (0.75 inch) Brabender extruder with a mixing screw.
After melting and mixing, the extrudate was forced through a 15.2
centimeter (6 inch) flat cast extrusion die to form a molten film.
Extrusion temperatures of 110, 115, 120, 140, and 140.degree. C.
were used, extrusion pressure was 2,960 to 3,450 kiloPascals (430
to 500 pounds) at a rate of 90 RPM. The molten film was passed
through a chilled roll stack to cool and solidify the resins into
final finished film form. The resultant film was transparent. To
generate samples for release testing, the adhesive side of 3M
SCOTCHCAL ELECTROCUT Graphic Film 7725-10 (commercially available
from 3M Company, St. Paul, Minn.) was laminated to the molten
polymer before entering the chilled nip. Upon cooling and aging
approximately one week, 2.54 centimeter (1 inch) wide strips were
cut from the roll and tested for release value using the Test
Method described above (readhesion testing was not carried out),
giving a release value of 2.62 N/dm.
Comparative Example C3
[0179] Extruded release film was prepared as described in Example 7
using only LDPE. Extrusion temperatures of 185, 190, 195, 200, and
200.degree. C. were used. To generate samples for release testing,
the adhesive side of 3M SCOTCHCAL ELECTROCUT Graphic Film 7725-10
(commercially available from 3M Company, St. Paul, Minn.) was
laminated to the molten polymer before entering the chilled nip.
Upon cooling and aging approximately one week, 2.54 centimeter (1
inch) wide strips were cut from the roll and tested for release
value using the Test Method described above (readhesion testing was
not carried out), giving a release value of 4.47 N/dm.
Example 11
[0180] For Example 11, essentially adiabatic polymerization was
carried out by a two step reaction within a VSP2 adiabatic reaction
apparatus equipped with a 316 stainless steel test can (available
from Fauske and Associates Inc, Burr Ridge Ill.). In the VSP2
reaction vessel was placed MA (49 grams), MMA (20 grams), MAA (5
grams), IOTG (0.3 grams) and MFS (25 grams). To the mixture was
added 0.1 grams of Antioxidant-1 and 1.02 grams of a mixture
containing: Initiator-1 (0.1 gram) and Initiator-3 (0.1 gram)
dissolved in 10 grams of MA. The reactor was sealed and purged of
oxygen. The reaction mixture was heated to 59.degree. C. and the
reaction proceeded adiabatically. Typical reaction peak temperature
was 170.degree. C. When the reaction was complete, the mixture was
cooled to below 65.degree. C. To about 70 grams of the reaction
product of the first step was added 0.7 grams of a mixture
containing: Initiator-1 (0.2 gram), Initiator-2 (0.2 gram),
Initiator-4 (0.04 gram) and Initiator-6 (0.2 gram) dissolved in
19.36 grams of EA. The reactor was sealed and purged of oxygen. The
reaction mixture was heated to 59.degree. C. and the reaction
proceeded adiabatically. Typical reaction peak temperature was
190.degree. C. The samples were removed from the reactor, Inherent
Viscosity (IV) was measured using the Test Method given above and
was found to be 0.25 dl/gm.
Example 12
[0181] The polymer produced in Example 11 was cooled with liquid
nitrogen and fed through an IKA Werke MF-10 grinder at 3000 rpm
with a 2.0 mm sieve at the outlet of the grinder to provide a
granular material. This material (10 parts by weight) was dry
blended with LDPE (90 parts by weight) and fed into a 1.0 inch twin
screw conical extruder with a mixing screw. The extrudate was
passed through a strand die into a 0.degree. C. water bath and the
resulting strand was cut into 0.125 inch round pellets. The pellets
were dried in a 65.5.degree. C. oven for 24 hours.
[0182] The blended pellets from above (50 parts) were further dry
blended with LDPE (45 parts), Additive-1 (1 part) and Additive-2 (4
parts). The mixture was fed into a 1.9 centimeter (0.75 inch)
Brabender extruder with a mixing screw (top layer). Another 1.9
centimeter (0.75 inch) Brabender extruder with a mixing screw
(bottom layer) was fed with a dry blended mixture of LDPE (96
parts) and Additive-2 (4 parts). The extrudate from the two
extruders was forced through a 15.2 centimeter (6 inch) flat cast
2-layer extrusion die to form a molten film with approximately 1:2
ratio of top layer:bottom layer. Extrusion temperatures of 160,
170, and 190.degree. C. were used. The molten film was passed
through a chilled roll stack to cool and solidify the resins into
final finished film form. The resultant film was semi-transparent
with a silver tone. Samples of the film were laminated with
Packaging Tape. The samples were placed in a 65.degree. C. oven for
10 days, then cooled to 20.degree. C. prior to testing. The samples
were tested for peel and readhesion as described in the Release
Test Method above. The data are presented in Table 10.
Example 13
[0183] The blended pellets from Example 12 (70 parts) were further
dry blended with LDPE (25 parts), Additive-1 (1 part) and
Additive-2 (4 parts). The mixture was fed into a 1.9 centimeter
(0.75 inch) Brabender extruder with a mixing screw (top layer).
Another 1.9 centimeter (0.75 inch) Brabender extruder with a mixing
screw (bottom layer) was fed with LDPE. The extrudate from the two
extruders was forced through a 15.2 centimeter (6 inch) flat cast
2-layer extrusion die to form a molten film with approximately 1:2
ratio of top layer:bottom layer. The molten film was passed through
a chilled roll stack to cool and solidify the resins into final
finished film form. The resultant film was semi-transparent with a
silver tone. Samples of the film were laminated with Packaging
Tape. The samples were placed in a 65.degree. C. oven for 10 days,
then cooled to 20.degree. C. prior to testing. The samples were
tested for peel and readhesion as described in the Release Test
Method above. The data are presented in Table 10.
Comparative Example C4
[0184] The reverse side of the film from Example 12 was laminated
with Packaging Tape. The samples were placed in a 65.degree. C.
oven for 10 days, then cooled to 20.degree. C. prior to testing.
The samples were tested for peel and readhesion as described in the
Release Test Method above. The data are presented in Table 10.
TABLE-US-00011 TABLE 10 180.degree. Peel after Readhesion after 10
days at 65.degree. C. 10 days at 65.degree. C. Example (N/dm)
(N/dm) 12 32.2 22.5 13 34.0 16.4 C4 44.9 15.8
* * * * *