U.S. patent number RE42,048 [Application Number 11/715,292] was granted by the patent office on 2011-01-18 for linerless double-sided pressure sensitive adhesive tape.
This patent grant is currently assigned to 3M Innovative Properties Company. Invention is credited to Mark D. Gehlsen, Bradley S. Momchilovich, Peter A. Stark.
United States Patent |
RE42,048 |
Gehlsen , et al. |
January 18, 2011 |
Linerless double-sided pressure sensitive adhesive tape
Abstract
The present invention relates to a double-sided pressure
sensitive adhesive foam tape. In certain embodiments the foam tape
does not require the use of a release liner. Elimination of the
release liner reduces the cost of the tape and also avoids problems
associated with damage to the liner during traditional tape
manufacturing from exposure to e-beam radiation.
Inventors: |
Gehlsen; Mark D. (Cottage
Grove, MN), Stark; Peter A. (Cottage Grove, MN),
Momchilovich; Bradley S. (New Richmond, WI) |
Assignee: |
3M Innovative Properties
Company (Saint Paul, MN)
|
Family
ID: |
33517865 |
Appl.
No.: |
11/715,292 |
Filed: |
March 7, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
10600983 |
Jun 20, 2003 |
06864322 |
Mar 8, 2005 |
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Current U.S.
Class: |
525/227;
428/355AC; 428/355CN; 428/41.4; 428/343 |
Current CPC
Class: |
C09J
7/38 (20180101); C09J 7/22 (20180101); C09J
7/26 (20180101); C09J 2301/124 (20200801); C09J
2433/00 (20130101); C09J 2433/006 (20130101); Y10T
428/2887 (20150115); Y10T 428/1457 (20150115); C09J
2301/1242 (20200801); Y10T 428/2891 (20150115); Y10T
428/28 (20150115) |
Current International
Class: |
C08L
33/08 (20060101) |
Field of
Search: |
;525/227
;428/41.4,355AC,355CN,343 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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0121430 |
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Oct 1984 |
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EP |
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WO-9723577 |
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Jul 1997 |
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WO |
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WO-9942536 |
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Aug 1999 |
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WO |
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WO-03011588 |
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Feb 2003 |
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WO |
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Other References
PCT International Search Report, dated Sep. 9, 2004. (3 pages).
cited by other.
|
Primary Examiner: Cheung; William K
Attorney, Agent or Firm: Lapos-Kuchar; Julie A. Pauly;
Daniel M.
Claims
We claim:
1. A double-sided foam tape, the foam tape comprising: a foam core
having first and second opposed surfaces, the foam core comprising
an acidic polymer derived from a first group of monomers comprising
at least one acidic monomer, and a basic polymer derived from a
second group of monomers comprising at least one basic monomer; a
first pressure sensitive adhesive applied to the first surface of
the foam core; and a second pressure sensitive adhesive applied to
the second surface of the foam core .Iadd.wherein the first
pressure sensitive adhesive and the second pressure sensitive
adhesive are different.Iaddend..
2. The double-sided foam tape of claim 1, wherein the acidic
polymer is a homopolymer and the basic polymer is a copolymer.
3. The double-sided foam tape of claim 1, wherein the acidic
polymer is a copolymer and the basic polymer is a homopolymer.
4. The double-sided foam tape of claim 1, wherein the acidic
polymer is a copolymer and the basic polymer is a copolymer.
5. The double-sided foam tape of claim 1, wherein the first and
second pressure sensitive adhesives do not substantially adhere to
one another.
6. The double-sided foam tape of claim 1, wherein at least one of
the first and second group of monomers comprises at least one
(meth)acrylate monomer.
7. The double-sided foam tape of claim 1, wherein each of the first
and second group of monomers comprises at least one (meth)acrylate
monomer.
8. The double-sided foam tape of claim 1, wherein the first group
of monomers comprises at least one basic monomer.
9. The double-sided foam tape of claim 1, wherein the second group
of monomers comprises at least one acidic monomer.
10. The double-sided foam tape of claim 1, wherein the first group
of monomers is essentially free of basic monomers.
11. The double-sided foam tape of claim 1, wherein the second group
of monomers is essentially free of acidic monomers.
12. The double-sided foam tape of claim 1, wherein the basic
monomer is selected from the group consisting of
N,N-dimethylaminopropyl methacrylamide (DMAPMAm),
N,N-diethylaminopropyl methacrylamide (DEAPMAm),
N,N-dimethylaminoethyl acrylate (DMAA), 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),
4-(N,N-dimethylamino)-styrene (DMAS), 4-(N,N-diethylamino)-styrene
(DEAS), N,N-dimethylaminoethyl vinyl ether (DMAEVE),
N,N-diethylaminoethyl vinyl ether (DEAEVE), vinylpyridine,
vinylimidazole, and mixtures thereof.
13. The double-sided foam tape of claim 1, wherein the acidic
monomer is selected from the group consisting of an ethylenically
unsaturated carboxylic acid, an ethylenically unsaturated sulfonic
acid, an ethylenically unsaturated phosphonic acid, and mixtures
thereof.
14. The double-sided foam tape of claim 1, wherein at least one of
the first and second group of monomers comprises a vinyl
monomer.
15. The double-sided foam tape of claim 1, wherein the second group
of monomers comprises greater than 15% by weight of basic
monomers.
16. The double-sided foam tape of claim 4, wherein one of the
acidic copolymer and the basic copolymer comprises up to about 5%
by weight of the blend.
17. The double-sided foam tape of claim 1, wherein the first
pressure sensitive adhesive comprises acrylic acid.
18. The double-sided foam tape of claim 1, wherein the second
pressure sensitive adhesive comprises acrylic acid and
acrylonitrile.
19. A double-sided foam tape, the foam tape comprising: a foam core
having first and second opposed surfaces; a first pressure
sensitive adhesive applied to the first surface of the foam core,
the first pressure sensitive adhesive comprising acrylic acid; and
a second pressure sensitive adhesive applied to the second surface
of the foam core, the second pressure sensitive adhesive comprising
acrylic acid and acrylonitrile; wherein the first and second
pressure sensitive adhesives do not substantially adhere to one
another; and wherein the foam core is configured to bond to the
first pressure sensitive adhesive and the second pressure sensitive
adhesive.Iadd., and wherein the first pressure sensitive adhesive
and the second pressure sensitive adhesive are
different.Iaddend..
20. The double-sided foam tape of claim .[.16.]. .Iadd.19.Iaddend.,
wherein the foam core comprises an acidic copolymer derived from a
first group of monomers comprising at least one acidic monomer, and
a basic copolymer derived from a second group of monomers
comprising at least one basic monomer.
21. The double-sided foam tape of claim .[.16.]. .Iadd.19.Iaddend.,
wherein at least one of the first and second group of monomers
comprises a vinyl monomer.
22. The double-sided foam tape of claim .[.16.]. .Iadd.19.Iaddend.,
wherein each of the first and second group of monomers comprises at
least one (meth)acrylate monomer.
23. The double-sided foam tape of claim .[.17.]. .Iadd.20.Iaddend.,
wherein the acidic monomer is selected from the group consisting of
an ethylenically unsaturated carboxylic acid, an ethylenically
unsaturated sulfonic acid, an ethylenically unsaturated phosphonic
acid, and mixtures thereof.
24. The double-sided foam tape of claim .[.17.]. .Iadd.20.Iaddend.,
wherein the basic monomer is selected from the group consisting of
N,N-dimethylaminopropyl methacrylamide (DMAPMAm),
N,N-diethylaminopropyl methacrylamide (DEAPMAm),
N,N-dimethylaminoethyl acrylate (DMAA), 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),
4-(N,N-dimethylamino)-styrene (DMAS), 4-(N,N-diethylamino)-styrene
(DEAS), N,N-dimethylaminoethyl vinyl ether (DMAEVE),
N,N-diethylaminoethyl vinyl ether (DEAEVE), vinylpyridine,
vinylimidazole, and mixtures thereof.
25. The double-sided foam tape of claim .[.17.]. .Iadd.20.Iaddend.,
wherein the first and second pressure sensitive adhesives do not
substantially adhere to one another.
26. A double-sided foam tape, the foam tape comprising: a foam core
having first and second opposed surfaces, the foam core comprising
an acidic copolymer derived from a first group of monomers
comprising at least one acidic monomer, and a basic copolymer
derived from a second group of monomers comprising at least one
basic monomer; a first pressure sensitive adhesive applied to the
first surface of the foam core, the first pressure sensitive
adhesive comprising acrylic acid; and a second pressure sensitive
adhesive applied to the second surface of the foam core, the second
pressure sensitive adhesive comprising acrylic acid and
acrylonitrile; wherein the first and second pressure sensitive
adhesives do not substantially adhere to one another .Iadd.and
wherein the first pressure sensitive adhesive and the second
pressure sensitive adhesive are different.Iaddend..
27. The double-sided foam tape of claim .[.23.]. .Iadd.26.Iaddend.,
wherein the acidic monomer is selected from the group consisting of
an ethylenically unsaturated carboxylic acid, an ethylenically
unsaturated sulfonic acid, an ethylenically unsaturated phosphonic
acid, and mixtures thereof.
28. The double-sided foam tape of claim .[.23.]. .Iadd.26.Iaddend.,
wherein the basic monomer is selected from the group consisting of
N,N-dimethylaminopropyl methacrylamide (DMAPMAm),
N,N-diethylaminopropyl methacrylamide (DEAPMAm),
N,N-dimethylaminoethyl acrylate (DMAA), 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),
4-(N,N-dimethylamino)-styrene (DMAS), 4-(N,N-diethylamino)-styrene
(DEAS), N,N-dimethylaminoethyl vinyl ether (DMAEVE),
N,N-diethylaminoethyl vinyl ether (DEAEVE), vinylpyridine,
vinylimidazole, and mixtures thereof.
Description
.Iadd.RELATED APPLICATIONS
This Application is a reissue application of U.S. Pat. No.
6,864,322, which issued on Mar. 8, 2005. The entire content of this
U.S. patent is incorporated herein by reference..Iaddend.
FIELD OF THE INVENTION
The present invention relates to adhesive tapes, more specifically
to pressure sensitive adhesive tapes. In particular, the invention
relates to double-sided pressure sensitive adhesive tapes.
BACKGROUND
Pressure sensitive adhesive (PSA) compositions are used in a wide
variety of applications. Numerous applications require pressure
sensitive adhesives to support a load at elevated temperatures,
typically in the range of greater than 70.degree. C., for which
high cohesive strength PSAs are required. A standard method of
increasing cohesive strength at elevated temperatures is to
chemically crosslink the PSA using irradiation processes, such as
thermal radiation, ultraviolet (UV) radiation, gamma radiation, and
electron beam (EB) radiation, etc. Although these processes improve
cohesive strength, they often negatively impact other properties,
including peel strength of the PSA.
PSA compositions have been used as tapes, in particular as
double-sided tapes used to adhere two articles together. Such
double-sided PSA tapes are useful, for example, in automotive
manufacturing, numerous consumer products, construction, and for
maintenance and repair of many items. Most conventional
double-sided PSA tapes typically require that at least one side of
the tape be covered with a release liner to prevent the two sides
from sticking together. Although such release liners are
functional, they have the disadvantage of being time consuming to
use, as well as adding expense to the PSA tape and waste to its
application.
For some applications, PSAs formed into foams are desirable because
tapes made of foam can conform better to certain substrates,
thereby giving better adhesion and greater holding power. Foamed
PSA tapes are particularly desirable on irregular shaped surfaces
that would not otherwise provide an adequate surface with which to
contact the PSA.
Therefore, a need exists for an improved PSA tape that does not
require irradiation, and which advantageously can be produced
without the use of a release liner on one or both major surfaces,
and which includes a foam to improve adhesion to irregular
surfaces.
SUMMARY OF THE INVENTION
The present invention relates to a double-sided pressure sensitive
adhesive foam tape. In certain embodiments the foam tape does not
require the use of a release liner. Elimination of the release
liner reduces the cost of the tape and also avoids problems
associated with damage to the liner during traditional tape
manufacturing from exposure to e-beam radiation. The double-sided
pressure sensitive adhesive foam tape is produced, in specific
implementations, without e-beaming to cure the adhesives, although
the tape can be e-beamed in alternate implementations.
In a first aspect of the invention the foam tape comprises a foam
core comprising an acidic polymer derived from at least one acidic
monomer and a basic polymer derived from at least one basic monomer
to form an ionically crosslinked polymeric network (ICPN). A first
pressure sensitive adhesive is applied to one surface of the foam
core; and a second pressure sensitive adhesive applied to a second
surface of the foam core. In one embodiment, the first and second
pressure sensitive adhesives do not substantially adhere to one
another, i.e. when the two pressure sensitive adhesives are brought
into contact with each other they can be separated without causing
cohesive failure of the foam or delamination of either the first or
second pressure sensitive adhesive from the foam.
The acidic monomer of the ICPN can be, for example, an
ethylenically unsaturated carboxylic acid, an ethylenically
unsaturated sulfonic acid, an ethylenically unsaturated phosphonic
acid, and mixtures thereof. In some implementations the basic
monomer is selected from the group consisting of
N,N-dimethylaminopropyl methacrylamide (DMAPMAm),
N,N-diethylaminopropyl methacrylamide (DEAPMAm),
N,N-dimethylaminoethyl acrylate (DMAA), 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),
4-(N,N-dimethylamino)-styrene (DMAS), 4-(N,N-diethylamino)-styrene
(DEAS), N,N-dimethylaminoethyl vinyl ether (DMAEVE),
N,N-diethylaminoethyl vinyl ether (DEAEVE), vinylpyridine,
vinylimidazole, and mixtures thereof.
Various pressure sensitive adhesives can be used with the
invention. In some implementations the first pressure sensitive
adhesive comprises acrylic acid, and the second pressure sensitive
adhesive comprises acrylic acid and acrylonitrile. These two
pressure sensitive adhesives can be selected such that they do not
adhere to one another; yet readily adhere to the ICPN-containing
foam core.
The invention is also directed to a double-sided foam tape
comprising a foam core having first and second opposed surfaces in
which a first pressure sensitive adhesive is applied to the first
surface of the foam core, the first pressure sensitive adhesive
comprising acrylic acid; and a second pressure sensitive adhesive
applied to the second surface of the foam core, the second pressure
sensitive adhesive comprising acrylic acid and acrylonitrile. The
first and second pressure sensitive adhesives do not substantially
adhere to one another; and the foam core is configured to bond to
the first pressure sensitive adhesive and to the second pressure
sensitive adhesive.
Yet another aspect of the invention is directed to a double-sided
foam tape, the foam tape comprising a foam core having first and
second opposed surfaces, the foam core comprising an acidic
copolymer derived from a first group of monomers comprising at
least one acidic monomer, and a basic copolymer derived from a
second group of monomers comprising at least one basic monomer. A
first pressure sensitive adhesive is applied to the first surface
of the foam core, the first pressure sensitive adhesive comprising
acrylic acid; and a second pressure sensitive adhesive is applied
to the second surface of the foam core, the second pressure
sensitive adhesive comprising acrylic acid and acrylonitrile.
Again, the first and second pressure sensitive adhesives do not
substantially adhere to one another.
Other features and advantages of the invention will be apparent
from the following detailed description of the invention and the
claims. The above summary of principles of the disclosure is not
intended to describe each illustrated embodiment or every
implementation of the present disclosure.
BRIEF DESCRIPTION OF THE FIGURE
Other aspects and advantages of the invention will become apparent
upon reading the following detailed description and upon reference
to the drawing in which:
FIG. 1, is a graph showing the tensile and elongation properties of
various double-sided pressure sensitive tapes. In particular, FIG.
1 shows the tensile and elongation properties of ICPN foam samples
containing 0% (CI), 2% (Example 1), 4% (Example 2), and 6% (Example
3) of an amine-containing polymer (referred to herein as "PIC"). In
addition, a sample of 3M Microfoam.TM. tape is shown as a
comparison. This plot demonstrates that by controlling the level of
PIC (i.e., the ratio of the polymers of the ICPN) in the foam the
properties of the foam can be modified to meet the performance
requirements of the product.
While the invention is susceptible to various modifications and
alternative forms, specifics thereof have been shown by way of
example in the figure and will be described in detail. It should be
understood, however, that the intention is not to limit the
invention to the particular embodiments described. On the contrary,
the intention is to cover all modifications, equivalents, and
alternatives falling within the spirit and scope of the invention
as defined by the appended claims.
DETAILED DESCRIPTION
The present invention is directed to a double-sided pressure
sensitive adhesive foam tape. In certain embodiments the foam tape
does not require the use of a release liner, although a liner may
be used if desired. Elimination of the liner reduces the cost of
the tape, and also avoids problems associated with e-beaming damage
to the liner during traditional tape manufacturing. The
double-sided pressure sensitive adhesive foam tape is produced, in
specific implementations, without e-beaming to cure the adhesives,
although the tape can be e-beamed in alternate implementations.
Specific components of the double-sided pressure sensitive adhesive
tape will now be described in greater detail, including a
discussion of the foam core and the adhesives used to form the
adhesive tape, plus examples of adhesive tapes produced in
accordance with the invention.
I. Foam Core
The foam core of double-sided tapes made in accordance with the
present invention typically comprises a blend of at least one
acidic polymer and at least one basic polymer to form an ionically
crosslinked polymeric network. Thermally reversible chemical
crosslinks form as part of a network of polymeric ionic crosslinks
between the acidic polymer and the basic polymer, allowing the
composition forming the foam core to be easily hot-melt processed,
but provide improved cohesive strength to foams containing the
crosslinker after its application and cooling.
The acidic polymer is generally derived from at least one acidic
monomer. In some implementations the acidic monomer is selected
from ethylenically unsaturated carboxylic acids, ethylenically
unsaturated sulfonic acids, ethylenically unsaturated phosphonic
acids, and mixtures thereof. Suitable acidic monomers include, for
example, ethylenically unsaturated carboxylic acids. When even
stronger acids are desired, particularly preferred acidic monomers
include the ethylenically unsaturated sulfonic acids and
ethylenically unsaturated phosphonic acids.
In some implementations the acidic polymer is an acidic
(meth)acrylate copolymer in which the acidic (meth)acrylate
copolymer is derived from at least one acidic monomer and at least
one (meth)acrylate monomer selected from the group consisting of
monofunctional unsaturated (meth)acrylate esters of non-tertiary
alkyl alcohols, and mixtures thereof, the alkyl groups of which
comprise from about 1 to about 20 carbon atoms, preferably about 1
to about 18 carbon atoms, such as those of Formula (I):
##STR00001## wherein R.sub.1 is H or CH.sub.3, the latter
corresponding to where the (meth)acrylate monomer is a methacrylate
monomer, and R.sub.2 is a linear, branched, aromatic, or cyclic
hydrocarbon group.
The basic polymer is generally derived from at least one basic
monomer. Suitable basic monomers include, for example
non-nucleophilic amine-functional monomers, such as those of
Formula (II): ##STR00002## wherein a is 0 or 1; R is selected from
H-- and CH.sub.3--, X is selected from --O-- and --NH--; Y is a
divalent linking group, preferably comprising about 1 to about 5
carbon atoms for ease of availability; and Am is a tertiary amine
fragment, such as the group: ##STR00003## wherein R.sup.1 and
R.sup.2 are selected from alkyl, aryl, cycloalkyl, and arenyl
groups. R.sup.1 and R.sup.2 in the above group may also form a
heterocycle. Alternatively, Am can be pyridinyl or imidazolyl,
substituted or unsubstituted. In all embodiments, Y, R.sup.1, and
R.sup.2 may also comprise heteroatoms, such as O, S, N, etc.
Exemplary basic monomers include, but are not limited to,
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)), and mixtures
thereof.
In some implementations the basic polymer is a copolymer derived
from at least one basic monomer and at least one non-basic
copolymerizable monomer. Other monomers can be copolymerized with
the basic monomers (e.g., acidic monomers, vinyl monomers, and
(meth)acrylate monomers), as long as the basic copolymer retains
its basicity (i.e., it can still be titrated with an acid).
Typically, the copolymerizable monomers are essentially free of
acidic monomers (i.e., the copolymerizable monomers include about 5
wt. % or less of acidic monomers, but most preferably, the
copolymerizable monomers are free of acidic monomers).
The basic copolymer can be, for example, a basic (meth)acrylate
copolymer. In this embodiment, the basic (meth)acrylate copolymer
is derived from at least one monomer of Formula 1. In one
embodiment, the foam composition comprises a blend of: an acidic
copolymer derived from a first group of monomers comprising at
least one acidic monomer; and a basic copolymer derived from a
second group of monomers comprising at least one basic monomer,
such as those described in Formula (II), wherein at least one of
the first and second group of monomers comprises greater than about
15% by weight of acidic or basic monomers, respectively. That is,
the acidic copolymer is derived from at least 15% by weight of
acidic monomers and/or the basic copolymer is derived from at least
15% by weight of basic monomers, based on total weight of the
respective monomers. In certain embodiments at least one of the
first and second group of monomers comprises at least about 25% by
weight, more preferably at least about 35% by weight, even more
preferably at least about 50% by weight, and most preferably at
least about 60% by weight of the respective acidic or basic
monomers. Advantageously each of the acidic copolymer and the basic
copolymer are derived from monomers comprising at least one
(meth)acrylate monomer, such as an alkyl (meth)acrylate monomer.
Although more may be used, in certain embodiments, one of the
acidic copolymer and the basic copolymer advantageously need only
comprise up to about 5% by weight of the blend, typically about
0.5% to about 5% by weight of the blend.
In another embodiment, the foam composition comprises a blend of an
acidic homopolymer and a basic copolymer derived from a group of
monomers comprising at least one basic monomer. In certain
variations of this embodiment, the group of monomers comprises at
least about 15% by weight of basic monomers; although lower amounts
may also be used. Advantageously, although more may be used, the
acidic homopolymer need only comprise as little as up to about 5%
by weight of the blend, most typically about 0.5% by weight to
about 5% by weight of the blend, in order to achieve foam cores
having cohesive strengths suitable for intended applications.
In yet another embodiment, the foam composition comprises a blend
of: an acidic copolymer derived from monomers comprising at least
one monomer selected from the group consisting of an ethylenically
unsaturated sulfonic acid, an ethylenically unsaturated phosphonic
acid, and mixtures thereof and at least one non-acidic
copolymerizable monomer; and a basic homopolymer.
One suitable polymer for the ICPN composition includes the
copolymer of 40/60
2-ethylhexylacrylate/dimethylaminoethylmethacrylate (2EHA/DMAEMA).
Other suitable ratios include, for example, 30/70 and 20/80 ratios
of 2-ethylhexylacrylate to dimethylaminoethylmethacrylate. Other
suitable polymers are described in WO 99/42536, which is herein
incorporated by reference.
The foam core can include a plurality of expanded polymeric
microspheres to form the foam. The foam may also include one or
more non-expandable microspheres, which may be polymeric or
non-polymeric microspheres (e.g., glass microspheres). The
expandable microspheres typically feature a flexible,
thermoplastic, polymeric shell and a core that includes a liquid
and/or gas that expands upon heating. The core material is
generally an organic substance that has a lower boiling point than
the softening temperature of the polymeric shell. Examples of
suitable core materials include, but are not limited to, propane,
butane, pentane, isobutane, neopentane, and combinations thereof.
Preferred core materials are materials other than air that expand
upon heating. Microspheres suitable for use with the invention
usually have an activation temperature below the temperature needed
to melt mix the copolymer and the polyarylene oxide polymer. Thus,
the activation temperature is generally less than 200.degree. C.,
more typically less than 170.degree. C.
The choice of thermoplastic resin for the polymeric shell of the
microspheres influences the mechanical properties of the foam.
Accordingly, the properties of the foam may be adjusted through
appropriate choice of microspheres, or by using mixtures of
different types of microspheres. For example,
acrylonitrile-containing resins are useful where high tensile and
cohesive strength are desired, particularly where the acrylonitrile
content is at least 50% by weight of the resin, more preferably at
least 60% by weight, and even more preferably at least 70% by
weight. In general, both tensile and cohesive strength increase
with increasing acrylonitrile content. In some cases, it is
possible to prepare foams having higher tensile and cohesive
strength than the polymer matrix alone, even though the foam has a
lower density than the matrix. This provides the capability of
preparing high strength, low density articles.
The amount of expandable microspheres can be selected based upon
the desired properties of the foam tape. Higher microsphere
concentrations generally cause lower density of the foam. The
amount of microspheres generally ranges from about 0.1 parts by
weight to about 50 parts by weight (based upon 100 parts of polymer
mixture), more typically from about 0.5 parts by weight to about 20
parts by weight.
Alternatively, or in conjunction with expandable microspheres, the
pressure sensitive adhesive tapes of the invention may be formed
into a foam by use of blowing agents, including chemical blowing
agents and physical blowing agents. Use of blowing agents instead
of expandable microspheres to form a foam tends to make the
resulting foam more susceptible to irreversible collapse under
pressure. This feature may be desirable in some applications where
conformity to irregular surfaces is desired.
Physical blowing agents useful in the present invention include
various naturally occurring atmospheric materials that are a vapor
at the temperature and pressure at which the foam exits the die.
The physical blowing agent may be introduced into the polymeric
material as a gas or liquid, preferably as a liquid, and may be
introduced in a supercritical state. Suitable physical blowing
agents include, for example, carbon dioxide, nitrogen, SF.sub.6,
nitrous oxide, perfluorinated fluids, such as C.sub.2F.sub.6,
argon, helium, noble gases, such as xenon, air (nitrogen and oxygen
blend), and blends of these materials.
Chemical blowing agents may also be added to the melt mixture.
Suitable chemical blowing agents include, for example, a blend of
sodium bicarbonate and citric acid,
dinitrosopentamethylenetetramine, p-toluenesulfonyl hydrazide,
4--4'-oxybis(benzenesulfonyl hydrazide, azodicarbonamide
(1,1'-azobisformamide), p-toluenesulfonyl semicarbazide,
5-phenyltetrazole, 5-phenyltetrazole analogues,
diisopropylhydrazodicarboxylate,
5-phenyl-3,6-dihydro-1,3,4-oxadiazin-2-one, and sodium
borohydride.
II. Pressure Sensitive Adhesives
The double-sided pressure sensitive tape typically contains a
different pressure sensitive adhesive on each side of the tape. The
pressure-sensitive adhesive compositions (referred to herein as the
first PSA (PSA-1) and second PSA (PSA-2)) useful in this invention
can be in the form of solutions, emulsions, or dispersions, or as
solventless adhesive compositions. A first PSA includes acrylate
and methacrylate polymers or copolymers that do not contain
acrylonitrile or methacrylonitrile. Such polymers can be formed by
polymerizing 50 to 100 parts by weight of one or more monomelic
acrylic or methacrylic esters of non-tertiary alkyl alcohols, with
the alkyl groups having from 1 to 20 carbon atoms (e.g. from 3 to
18 carbon atoms). Suitable acrylate monomers include, for example,
methyl acrylate, ethyl acrylate, n-butyl acrylate, lauryl acrylate,
2-ethylhexyl acrylate, cyclohexyl acrylate, iso-octyl acrylate,
octadecyl acrylate, nonyl acrylate, decyl acrylate, isobornyl
acrylate, and dodecyl acrylate. Also useful are aromatic acrylates,
e.g., benzyl acrylate and cyclobenzyl acrylate. Optionally, one or
more monoethylenically unsaturated co-monomers may be polymerized
with the acrylate or methacrylate monomers; the particular amount
of co-monomer is selected based upon the desired properties of the
polymer. One group of useful co-monomers includes those having a
homopolymer glass transition temperature greater than the glass
transition temperature of the acrylate homopolymer. Examples of
suitable co-monomers falling within this group include, but are not
limited to, acrylic acid, acrylamide, methacrylamide, substituted
acrylamides such as N,N-dimethyl acrylamide, itaconic acid,
methacrylic acid, vinyl acetate, N-vinyl pyrrolidone, isobornyl
acrylate, cyano ethyl acrylate, N-vinylcaprolactam, maleic
anhydride, hydroxyalkylacrylates, N,N-dimethyl aminoethyl
(meth)acrylate, N,N-diethylacrylamide, beta-carboxyethyl acrylate,
vinyl esters of neodecanoic, neononanoic, neopentanoic,
2-ethylhexanoic, or propionic acids (e.g., available from Union
Carbide Corp. of Danbury, Conn. under the designation "Vynates",
vinylidene chloride, styrene, vinyl toluene, and alkyl vinyl
ethers.
A second group of monoethylenically unsaturated co-monomers which
may be polymerized with the acrylate or methacrylate monomers
includes those having a homopolymer glass transition temperature
less than the glass transition temperature of the acrylate
homopolymer. Examples of suitable co-monomers falling within this
class include ethyloxyethoxy ethyl acrylate (Tg=-71.degree. C.) and
a methoxypolyethylene glycol 400 acrylate (Tg=-65.degree. C.;
available from Shin Nakamura Chemical Co., Ltd. under the
designation "NK Ester AM-90G"). [See, e.g., Ulrich, U.S. Pat. No.
2,884,126; Martens U.S. Pat. No. 4,181,752; Hamer U.S. Pat. No.
6,294,249; and Ellis U.S. Pat. No. 5,753,768].
The second PSA can include acrylate and methacrylate copolymers
that contain acrylonitrile or methacrylonitrile. Such polymers can
be formed by polymerizing 50 to 100 parts by weight of one or more
monomeric acrylic or methacrylic esters of non-tertiary alkyl
alcohols, with the alkyl groups having from 1 to 20 carbon atoms
(e.g. from 3 to 18 carbon atoms). Suitable acrylate monomers
include, for example, methyl acrylate, ethyl acrylate, n-butyl
acrylate, lauryl acrylate, 2-ethylhexyl acrylate, cyclohexyl
acrylate, iso-octyl acrylate, octadecyl acrylate, nonyl acrylate,
decyl acrylate, isobornyl acrylate, and dodecyl acrylate. Also
useful are aromatic acrylates, e.g., benzyl acrylate and
cyclobenzyl acrylate. Optionally, one or more monoethylenically
unsaturated co-monomers may be polymerized with the acrylate or
methacrylate monomers; the particular amount of co-monomer is
selected based upon the desired properties of the polymer. One
group of useful co-monomers includes those having a homopolymer
glass transition temperature greater than the glass transition
temperature of the acrylate homopolymer. Examples of suitable
co-monomers falling within this group include, but are not limited
to, acrylic acid, acrylamide, methacrylamide, substituted
acrylamides such as N,N-dimethyl acrylamide, itaconic acid,
methacrylic acid, acrylonitrile, methacrylonitrile, vinyl acetate,
N-vinyl pyrrolidone, isobornyl acrylate, cyano ethyl acrylate,
N-vinylcaprolactam, maleic anhydride, hydroxyalkylacrylates,
N,N-dimethyl aminoethyl (meth)acrylate, N,N-diethylacrylamide,
beta-carboxyethyl acrylate, vinyl esters of neodecanoic,
neononanoic, neopentanoic, 2-ethylhexanoic, or propionic acids
(e.g., available from Union Carbide Corp. of Danbury, Conn. under
the designation "Vynates", vinylidene chloride, styrene, vinyl
toluene, and alkyl vinyl ethers.
A second group of monoethylenically unsaturated co-monomers which
may be polymerized with the acrylate or methacrylate monomers
includes those having a homopolymer glass transition temperature
less than the glass transition temperature of the acrylate
homopolymer. Examples of suitable co-monomers falling within this
class include ethyloxyethoxy ethyl acrylate (Tg=-71.degree. C.) and
a methoxypolyethylene glycol 400 acrylate (Tg=-65.degree. C.;
available from Shin Nakamura Chemical Co., Ltd. under the
designation "NK Ester AM-90G"). [See e.g., Ulrich, U.S. Pat. No.
3,008,850; Martens U.S. Pat. No. 4,181,752; Hamer U.S. Pat. No.
6,294,249; and Ellis U.S. Pat. No. 5,753,768].
III. Other Additional Ingredients
Additional ingredients may be added to augment properties of the
pressure-sensitive adhesive foam. These include, for example, a
relatively high modulus polymer that can stiffen the foam. Suitable
polymers include, e.g., semicrystalline polymers such as polyamides
and polyesters, and relatively low modulus polymer compositions
that can increase the flexibility of the article, e.g., plasticized
polyvinyl chloride. Relatively immiscible polymer compositions can
act to form fibrous networks to further reinforce the cohesive
strength of the article when the immiscible phases are elongated
under stretching forces. Examples of such structures containing
fiber-like reinforcing networks are disclosed in WO 97/23577
"Blended Pressure-Sensitive Adhesives", which is incorporated
herein by reference.
The foamed pressure sensitive adhesive may contain agents in
addition to microspheres, the choice of which is dictated by the
properties appropriate for the intended application of the article.
Examples of suitable additives include, but are not limited to,
tackifiers (e.g., rosin esters, terpenes, phenols, and aliphatic,
aromatic, or mixtures of aliphatic and aromatic synthetic
hydrocarbon resins), plasticizers, oils, pigments, dyes,
non-expandable polymeric or glass microspheres, reinforcing agents,
hydrophobic or hydrophilic silica, calcium carbonate, toughening
agents, fire retardants, antioxidants, finely ground polymeric
particles such as polyester, nylon, or polypropylene, stabilizers,
and combinations thereof. These additives are included in amounts
sufficient to obtain the desired end properties.
The invention will now be more particularly illustrated by the
following examples, which are not intended to be limiting in any
way.
IV. EXAMPLES
A. Test Methods
Density
The densities of the foams of the invention were measured using the
following procedure. Samples of the foam were cut into 13
mm.times.25 mm pieces, weighed on a Mettler high precision balance
and then placed underwater. The mass of the displaced water was
measured. The water temperature was approximately 25.degree. C.
Using the density of the water as 1 g/cm.sup.3, the mass of the
displaced water divided by the density of the water gives the
volume of the sample. The mass of the sample is then divided by the
volume of the sample to generate the density of the sample. Two
replicates were measured and averaged together.
Static Shear
The bond strengths (in shear mode) of the tapes of the invention to
a standard aluminum panel were measured using the following
procedure. A 1.3 cm (0.5 in) wide piece of tape with a release
liner on one side and exposed adhesive on the other side was
adhered to a 1.6 cm wide strip of a 0.127 mm thick aluminum foil.
The release liner was then removed from the non-adhered side and
the tape was then adhered to a clean rigid anodized aluminum panel
using four passes of a 2 kg (4.5 lb) hard rubber roller such that a
1.3 cm by 2.5 cm portion of the tape was in firm contact with the
panel. A non-adhered end portion of the tape extended beyond the
panel. The panel was then hung in a constant temperature and
humidity chamber (22.degree. C.; 50% relative humidity). The panel
was positioned 2 degrees from the vertical to prevent a peel mode
failure. A 1000 gram weight was then hung from the non-adhered end
of the tape sample and the time required for the weight to fall off
was recorded in minutes. If no failure occurred within 10,000
minutes, the test was discontinued and results were recorded as
10,000+minutes. If the tape fell off in fewer than 10,000 minutes,
the time was recorded and the mode of failure noted as either
cohesive failure within the adhesive, or an adhesive failure when
the adhesive pulled cleanly from the panel. All examples exhibited
adhesive failure. Three replicates were measured and averaged
together.
Adhesive Anchorage
The bond strength of the pressure sensitive adhesive layers to the
foam core was measured using the following procedure. The
double-sided foam tapes were conditioned for 48 hours at 23.degree.
C. and 50% humidity. Strips of anodized aluminum foil were
laminated to both sides of the foam tape using two passes of a 2.3
kilogram hard rubber roller rolled at 30.5 cm/min followed by 24
hour conditioning at 23.degree. C. and 50% humidity. The aluminum
strips were peeled away from the foam tape at a 180 degree angle.
If the aluminum strip pulled the adhesive away from the foam core
the test result was recorded as FAIL, indicating that the bond of
the adhesive to the foil was greater than the bond of the adhesive
to the foam core. If the foam core itself underwent cohesive
failure then the test result was recorded as PASS.
Stress-strain Properties
The mechanical properties of the foam cores were measured according
to ASTM D-638 using an INSTRON Tensile Tester (Instron Corp.,
Canton, Mass.). The foam cores were conditioned for 48 hours at
23.degree. C. and 50% humidity. Type IV dogbone shape specimens
were die cut from the foam cores having dimensions of 2.54 cm by
1.27 cm in the narrow test section. The thickness of the specimens
in the narrow test section was measured and recorded. The specimens
were mounted into the tensile tester and elongated to their break
point at a crosshead speed of 25.4 cm/min. The maximum stress and
elongation at the maximum stress were recorded. Three replicates
were measured and averaged together.
Example 1
A double-sided pressure sensitive adhesive tape was produced by
first extruding a foam core layer consisting of a blend of 90 parts
of isooctyl acrylate, 10 parts of acrylic acid, 0.006 parts of 2,2'
azobis(2,4-dimethylpentanenitrile) (VAZO 52, Dupont, Wilmington,
Del.), 0.0028 parts 2,2' azobis(cyclohexanecarbonitrile) (VAZO 88,
Dupont, Wilmington, Del.), 0.004 parts di-t-amyl peroxide, 0.11
parts carbon tetrabromide, 0.75 parts of a 26% solids mixture of
4-acryloxy benzophenone in ethyl acetate, 0.097 parts of IRGANOX
1010 (tetrakis(methylene(3,5
di-tert-butyl-4-hydroxyhydrocinnamate))methane) (Ciba Specialty
Chemicals, Tarrytown, N.Y.). The core material was polymerized as
described in Example 1 of U.S. Pat. No. 5,753,768 incorporated
herein by reference. The resulting blend had an intrinsic viscosity
of about 0.61 deciliters/gram, Mw of 2.7.times.10.sup.5 g/mol and
Mn of 1.5.times.10.sup.4 g/mol. The blend was further mixed with
expandable microspheres (F80D, Pierce-Stevens Co., Buffalo, N.Y.)
in an 18 mm co-rotating twin screw extruder equipped with several
forward kneading, reverse kneading and self-wiping screw elements.
A screw speed of 100 RPM was used resulting in a flow rate of
approximately 2.3 kg/hr. A flat barrel profile of 107.degree. C.
was used with hose and die temperatures set at 177.degree. C. The
acrylic composition was softened using a Dynatec Grid-melter set at
177.degree. C. and then fed into the first zone of the extruder. A
copolymer of 2-ethylhexylacrylate/dimethyl aminoethylmethacrylate
(2EHA/DMAEMA 40/60) (referred to herein as "PIC") in a solution of
67% phthalate plasticizer n-butyl benzyl (Santicizer 160, Ferro
Corp., Bridgeport, N.J.) was metered into the second zone of the
extruder using a Zenith gear pump at a rate of 2 parts of PIC per
hundred parts of acrylic composition. The expandable microspheres
were metered into the fourth zone of the extruder using a Ktron T20
feeder at rate of 45 g/hr. The extrudate was pumped through a
rotary rod die operated at 177.degree. C. to cast a foam having a
thickness of approximately 635 microns onto a silicone-coated paper
liner wrapped around a 7.degree. C. chill roll at a speed of
approximately 0.6-0.9 meters/min. (Rohm & Haas Co.,
Philadelphia, Pa.).
The foam was then laminated to two pressure-sensitive adhesives:
PSA-1 and PSA-2, one on each side of the foam. PSA-1 is a blend of
95.5% isooctylacrylate and 4.5% acrylic acid polymerized with 1.4%
Triton X-200 and t-dodecyl mercaptan as the chain transfer agent.
The polymerized composition was dried and dissolved into a 70%
heptane/30% isopropyl alcohol blend at 22% solids. PSA-2 is a blend
of 89.5% isooctylacrylate, 10% acrylonitrile and 10.5% acrylic acid
polymerized with 1.5% sodium dodecylbenzene sulfonate (SIPONATE
DS-10 Rhodia Inc., Cranberry, N.J.) and carbon tetrabromide as the
chain transfer agent. The polymerized composition was dried and
dissolved into a 60% heptane/31% toluene/9% isopropyl alcohol blend
at 25% solids. Each of the two PSA's were solvent cast onto a
silicone-coated paper liner and then dried resulting in a 50 micron
thick adhesive. The foam core was then transfer coated with PSA-1
followed by transfer coating of PSA-2 to the foam core, resulting
in a double-coated foam tape.
Example 2
A double-sided pressure sensitive adhesive tape was produced as in
Example 1 except the PIC was metered into the extruder at a rate of
4 parts of PIC per hundred parts of acrylic composition to increase
the degree of crosslinking and the tensile strength of the
foam.
Example 3
A double-sided pressure sensitive adhesive tape was produced as in
Example 1 except the PIC was metered into the extruder at a rate of
6 parts of PIC per hundred parts of acrylic composition to increase
the degree of crosslinking and the tensile strength of the
foam.
Comparative Example C1
A double-sided pressure sensitive adhesive tape was produced as in
Example 1 except no PIC was used. The foam had relatively low
tensile strength and poor anchorage to PSA-2.
TABLE-US-00001 TABLE 1 Adhesive Adhesive Foam Core Static Tensile
Tensile PIC conc. Anchorage Anchorage Density Shear Stress Strain
Example (pph) (PSA-1 to core) (PSA-2 to core) (g/cm.sup.2) (min)
(kg/cm.sup.2) (%) C1 0 Pass Fail 0.5635 154 23.5 2500+ 1 2 Pass
Pass 0.5939 702 31.6 2500+ 2 4 Pass Pass 0.6091 4717 37.3 417 3 6
Pass Pass 0.6127 10,000+ 48.2 317
The foregoing detailed description and examples have been given for
clarity of understanding only. No unnecessary limitations are to be
understood therefrom. The invention is not limited to the exact
details shown and described, for variations obvious to one skilled
in the art will be included within the invention defined by the
claims.
All publications, patents, and patent applications mentioned herein
are hereby incorporated herein by reference.
* * * * *