CN1109728C - 新型片材 - Google Patents

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CN1109728C
CN1109728C CN95191412A CN95191412A CN1109728C CN 1109728 C CN1109728 C CN 1109728C CN 95191412 A CN95191412 A CN 95191412A CN 95191412 A CN95191412 A CN 95191412A CN 1109728 C CN1109728 C CN 1109728C
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CN1139947A (zh
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S.R.迈耶
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Abstract

一种片材，包括：(i)一种含有丙烯酸酯基压敏胶粘剂聚合物的压敏胶粘剂膜，(ii)一种含有密度不超过0.90g/cm3的聚烯烃聚合物的剥离膜。所述的压敏胶粘剂膜与聚烯烃聚合物接触。

Description

新型片材
发明的领域
本发明涉及用于压敏胶粘带的剥离材料。
发明的背景
剥离涂层在压敏胶粘带工业是众所周知的，它提供了剥离表面，从而使胶粘带从卷筒展开时不会粘附在其背面。剥离涂层也可被涂布在衬里上，衬里用作压敏胶粘转移带或双面涂布胶粘带的基底，而这二种胶粘带在其两面都有粘性。
通常用于剥离表面和涂层的材料是硅氧烷组合物，这是由于硅氧烷组合物能配制成从“优级剥离”(即：使胶粘带展开所施力很小)到“低粘合力背面涂层的剥离”(使胶粘带展开所施力一般较大)的剥离难易程度不同的剥离层。
硅氧烷剥离涂层的主要缺点是存在着与其有关的污染倾向，当操作人员处理硅氧烷剥离涂层胶粘带或衬里时，硅氧烷可转移到他们的手、工作服或工作手套上，硅氧烷又可能进一步从他们的手上转移到被涂表面，从而引起诸如涂料难于粘结在受污染的表面，以及涂料在存在硅氧烷的表面区域难于润湿等问题。硅剥离材料也往往导致价格昂贵，而且硅涂布材料可能是难于再生利用的。
聚乙烯也用作剥离材料，并可涂布在牛皮纸上用作剥离衬里，或者它可用作单层膜，或者与诸如高密度聚乙烯之类的基层共挤塑或层叠在其上构成多层膜。高密度聚乙烯在用于某些粘结剂上受限制，并发现其不适用于干粘性非常强的压敏粘结剂，这是由于聚乙烯和粘结剂间的粘结力很强，从而可能使衬里剥离难以开始。由于所施的剥离力大，在人们试图使粘结剂从衬里上分开时，粘结剂和/或衬里也可能受损。
对用于无硅氧烷剥离层的压敏粘结剂的受控剥离衬里(controlled releaseliners)仍保持着需要。
发明的概述
本发明提供一种新型片材，它包括：(i)压敏粘结膜，该膜包括丙烯酸酯基压敏胶粘聚合物，以及(ii)剥离膜，该膜包括含有密度小于0.90g/cc而CDBI大于70％的聚烯烃聚合物的第一层压敏粘结膜与剥离膜的第一层接触。
在优选的实施例中，提供了一种基本上不含任何硅氧烷剥离涂层的片材。
在另一优选实施例中，剥离膜包括较佳为聚丁烯的第二层。本发明的详细描述
在本发明的实施中，剥离膜第一层所用的材料是乙烯和具有3-10个碳原子的α-烯烃的共聚物。适用的α-烯烃包括丁烯-1，己烯-1，辛烯-1，及其组合物。乙烯和丁烯-1的共聚物优选用于丙烯酸酯基压敏胶粘剂。
所述共聚物类别上属超低密度聚乙烯(VLDPE)，它被称为“塑性体”，这是一种具有热塑性和胶弹性的聚合物。优选共聚物的密度小于0.90g/cc，更优选共聚物的密度小于0.89g/cc，最优选共聚物的密度小于0.88g/cc。较低密度的共聚物被发现具有较低的剥离值，该剥离值可随不同类型的混合共聚物而变化。所用的共聚物优选具有窄分子量分布的，即其多分散度为1-4的，更优选的为其多分散度为1.5-3.5。多分散度定义为重均分子量对数均分子量之比。
所用的共聚物可以“组分分布宽度指数”(以下包括权利要求中都称为“CD-BI”)为特征的参数来限定，CDBI定义为其共聚单体含量在共聚单体总摩尔含量中间值的50％(即±50％)以内的共聚物分子所占的重量百分数。CDBI及其测定方法可参见美国专利No.5,206,075，本文引为参考。适用于本发明的共聚物的CDBI优选为大于70％，更优选为大于80％，最优选为大于90％。
从市场上购得的适用共聚物可用Exxon出品的商品名为Exxon的产品。这些共聚物形成的膜在室温下缠绕于卷筒上时，不易熔，也不粘连，即粘附于其下层。
在优选实施例中剥离衬里的第一层主要由密度小于0.90g/cc的共聚物组成，它基本上不含任何密度大于0.91g/cc的聚乙烯。
本文中所用术语：剥离衬里，衬里，以及剥离膜可相互替换使用。剥离膜可作为无第二层的单一自承膜，通过共聚物的挤塑来制取。膜的厚度范围为0.1毫米-0.4毫米，其厚度通常取决于剥离衬里所需强度，膜的操作是否容易，衬里所需的柔软性等因素的考虑。
剥离膜的制取也可将共聚物挤塑在基材上，或将共聚物与一种或多种其它聚合物共挤压，从而形成具有附加强度和/或劲度的多层膜。适用的基材包括：纤维素材料(如纸，纺织物和无纺织物)，薄膜(如耐纶，聚酯，聚烯烃和ABS树脂)，以及由金属，陶瓷，或塑料等材料制成的片材。共聚物膜也可用合适的层叠胶粘剂使其粘附于基材上。基材也可是适用于热成型或真空成型的片材，从而形成可容纳压敏胶粘剂涂布元件的具有剥离表面的托盘。
共聚物膜在基层上的厚度应足以提供所需的剥离力，并可以小于自承片材。膜通常被挤压在具有各种表面(如消光的或抛光的)的骤冷卷筒上，从而在剥离衬里上提供无光或有光泽的表面。骤冷卷筒可用材料(如TeflonTM或等离子涂层)进行处理或涂布，以防止挤出物粘附于卷筒表面。硅橡胶卷筒也可用于此目的。挤塑膜也可挤压在骤冷卷筒和光滑的聚酯膜之间，从而使其一面有光泽，另一面无光，或者挤出在两个聚酯层之间，从而得到两个有光泽的表面。
多层膜也可用已知的共挤压法制取，可与共聚物一起进行共挤压的其它聚合物包括：聚烯烃(如聚丙烯，聚乙烯，聚丁烯，及其混合物)，以及聚酯。与聚烯烃一起共挤压尤其适用于制取可再循环或再使用的衬里。
在多层膜结构中，可选用显示不同剥离力的聚合物和共聚物，即使压敏胶粘剂从一面剥离所需的力显著地低于从另一面剥离所需的力。
用于与第一层共聚物一起共挤压的优选聚合物包括聚丁烯均聚物和共聚物。聚丁烯均聚物尤其优选用于剥离膜的第二层，因为它们给膜提供了强度，而且也用作高差别剥离力衬里。适用于基层或剥离膜第二层的均聚物是聚丁烯，适用的聚丁烯均聚物和共聚物可购自Shell Chemical Co.，其商标为DU-RAFLEX。人们观察到丙烯酸酯基压敏胶粘剂从聚丁烯表面剥离所需的力大于从聚乙烯共聚物表面剥离的力。
在某些应用中，要求衬里宽度略大于压敏胶粘剂宽度，压敏胶粘剂较厚的(即厚度超过0.5mm)的情况尤其是这样，较厚的压敏胶粘剂在缠绕于卷筒上时会稍微流动，而衬里宽度较大就有助于防止胶粘剂流出到相邻一圈胶粘带上而引起胶粘带的粘连。
对于这些应用，优选使用这样的基材或共挤压材料，它们形成的膜在短时间(即小于一秒)受力时，其伸长回复率小于100％。例如，如果长度为1.0cm的膜被拉伸到2.0cm长，释放后，则该膜回复后长度超过1.0cm。
在制取压敏胶粘转移带的典型工艺过程中，胶粘剂组合物被涂布在剥离衬里上。然后胶粘剂固化在衬里上形成凝胶化膜，带有胶粘剂的剥离衬里卷绕在大的卷筒上。另一种方法，可将胶粘剂涂布和固化在一个衬里上，然后在转换前转移在不同的衬里上。胶粘剂涂布片材再通过切割大卷料和把胶粘带缠绕在宽度窄的芯轴上使其转换成窄的卷料以供客户使用。
在原片材(大于0.5mm)的转换过程中，切割刀或刀片从片材的背面切入。当刀片切入衬里和胶粘剂时，在刀片的宽度方向施加的力足以使衬里和胶粘剂伸展。胶粘剂是弹性的，在切割后回缩到切条宽度，而衬里的回复率小于100％，从而衬里的宽度略大于胶粘剂的宽度。
已发现在剥离膜的第二层中，聚丁烯均聚物和含微量(即小于5％)共聚单体(如乙烯)的聚丁烯共聚物特别适合于提供具有低应力回复率的膜。虽然不想作理论解释，但看来在切割过程受力或拉伸时，聚丁烯发生了应变结晶，结晶阻止了伸长的回复。本发明的衬里可用作丙烯酸酯基压敏粘合剂的剥离膜。这些胶粘剂包括具有1～20碳原子(较好为4～12碳原子)的非叔醇的单官能不饱和丙烯酸或甲基丙烯酸酯单体的均聚物和共聚物。可任选地包括某种共聚单体以提高胶粘剂的内聚强度。用于制取共聚物的共聚单体的均聚物玻璃化转变温度通常高于丙烯酸酯均聚物的玻璃化转变温度。
适用的丙烯酸酯单体包括：丙烯酸(2-乙基己基)酯，丙烯酸异辛酯，丙烯酸异壬酯，丙烯酸正丁酯，丙烯酸癸酯，丙烯酸十二酯，及其混合物。优选的单体包括：丙烯酸异辛酯，丙烯酸正丁酯，及其混合物。
适用的增强共聚单体包括：丙烯酸，甲基丙烯酸，衣康酸，丙烯酰胺，取代的丙烯酰胺，N-乙烯基吡咯烷酮，N-乙烯基己内酰胺，丙烯酸异冰片酯，以及丙烯酸环己酯。优选的共聚单体包括：N-乙烯基己内酰胺，取代的丙烯酰胺(如N，N-二甲基丙烯酰胺)，以及丙烯酸异丁酯。
在实施本发明中使用了合适的引发剂未制取压敏胶粘剂。所选用的引发剂的类型和数量要与所作用的聚合反应的类型相适应，例如，光引发剂(如苯偶酰二甲基缩酮)可用于经紫外线光聚合的胶粘剂，其用量是每一百份单体为0.1～5份，2，2′-偶氮二异丁腈可用于溶剂聚合，其用量是每一百份单体为0.1～0.2份。
压敏胶粘剂也可包括添加剂，例如，交联剂，填料，气体，发泡剂，玻璃或聚合物微球，二氧化硅，碳酸钙纤维，表面活性剂等。添加剂的用量应足以产生所要求的性能。
压敏胶粘剂也可含有热固性树脂(如环氧树脂和聚氨酯树脂)，这些热固性树脂在压敏胶粘带施于表面后可热固化形成热固性胶粘剂。
压敏胶粘剂可采用工业上已知的方法来制取，包括：溶剂聚合，采用电子束、伽玛辐射、和紫外线辐射等的辐射聚合，乳液聚合等。制取压敏胶粘剂的方法揭示在如美国专利No.Re 24,906(Ulrich)中。
下列非限定性实例是用来说明本发明的具体实施例。测试方法
90°剥离角的剥离力
剥离衬里膜被切割成尺寸为2.54×40.64cm的条片，压敏胶粘带试样被层合在宽5.08cm×长30.48cm的金属板上。然后，剥离衬里膜用6.8kg辊辊压二次，使它层合于胶粘剂。试样再在室温(21℃)下陈化三小时。此后，试样被放置在剥离粘力测试机中，剥离衬里从90°剥离角、按228.6cm/min和30.48cm/min的剥离速率进行剥离，纪录的结果以g/2.54cm为单位。实施例1-3
剥离膜的制备是通过把乙烯和丁烯-1的低密度共聚物挤压成厚度约0.11mm，所用的共聚物列于表1中。挤压是用1.905cm单螺杆挤压机，其L/D为25∶1，口模宽为20.32cm。口模温度保持在约204℃，熔体温度范围为182℃～193℃。膜被挤压在两层未经处理的聚酯膜之间，从而制得两面都有光泽表面的膜。测定剥离衬里对于内溶剂聚合制得的丙烯酸酯基压敏胶粘剂(如美国专利No.Re.24,906所述)的粘合力，该丙烯酸酯基压敏胶粘剂的组合物为90份丙烯酸异辛酯和10份丙烯酸。剥离力数值如表1所示。
比较实施例C-1
测定在与实施例1-3相同胶粘剂上的硅氧烷涂层剥离纸，其结果示于表1中。
                                  表    1
实施例 共聚物规格    共聚物密度g/cc           剥离力(g/2.54cm)
  228.6cm/min   30.48g/min
    1  EXACT 3022     0.905     31.3     43.1
    2  EXACT 4003     0.895     24.9     22.0
    3  EXACT 4006     0.880     14.6     9.4
    C  硅氧烷衬里       -     45.7     41.1
*试样以228.6cm/min速率剥离，然后再层合，陈化30分钟，以30.48cm/min速率测试。实施例4
剥离衬里的制备是通过共挤压来得到一种薄膜，该膜具有一层厚度为0.051mm，密度为0.88g/cc的乙烯一丁烯共聚物(购自Exxon Chemical，其商品牌号为EXACTTM 4006)和一层厚度为0.127mm的聚丁烯(购自Shell Chem-ical Co.，其商品牌号为DuraflexTM 200。两层中都包含2％重量的红色颜料(购自AMPACET的#150020)。膜的每个组分各使用一个单螺杆挤压机。聚丁烯的机筒温度是149℃、177℃和204℃，而所述共聚物的机筒温度是171℃、182℃和193℃。口模温度保持在约204℃。膜被挤压在光滑的聚酯膜和经TeflonTM涂布的卷筒之间，使剥离膜的共聚物一面为无光表面，而剥离膜的聚丁烯一面是光泽表面。
两层胶粘带结构的制备如下。第一组合物由下列组分混合制成：
80份丙烯酸丁酯
20份N，N-二甲基丙烯酰胺
20份双酚A的二缩水甘油醚(购自Shell Chemical Co.，其商品牌号E-ponTM828)
80份双酚A的二缩水甘油基低聚物(购自Shell Chemicla Co)的EponTM1001
5份聚己内酯(购自Union Carbide，其商品牌号ToneTM P676)
0.05份己二醇二丙烯酸酯
0.16份苯偶酰二甲基缩酮(购自Sartomer，其商品牌号ESCACURETMKB-1)
0.6份发泡剂(购自杜邦公司，其商品牌号VazoTM 88)
0.15份3-缩水甘油氧基丙基三甲氧基硅烷
1.2份微粒化的邻苯二甲酸六咪唑合镍〔hexakis(imidazole)nickel phtha-late〕
0.4份四溴化碳
0.1份抗氧化剂(购自Ciba Geigy，其商品牌号IrganoxTM 1010)
2.8份微粒化的二聚氨基氰(购自SKW Chemical，其商品名DYHARDTM100)
4.0份玻璃泡(购自Minnesota Mining & Manufacturing Co.，其商品牌号C15-250)
4.0份二氧化硅(购自Cabot Corp.，其商品牌号Cab-O-Sil M5)
组合物被除气，并涂布在二个透明的经硅氧烷剥离处理过的聚酯膜之间，涂布的厚度为0.51mm。然后，用紫外灯在基片的两侧对经涂布的组合物进行辐照(灯的90％发射量在300～400nm之间，最大的发射量在351nm处)，从而形成片材。在基片上面的辐照强度和总能量分别为2.19mW/cm2和114mJ/cm2。在基片下面的辐照强度和总能量分别为2.04mW/cm2和106mJ/cm2。
第二组合物的制备过程是：将40份丙烯酸丁酯与40份N-乙烯基己内酰胺一起加热到约50℃，从而形成溶液。然后向溶液中加入下列物质：20份丙烯酸丁酯，80份双酚A的氢化二缩水甘油醚(购自Shell Chemical Co.，其商品牌号EponexTM1510)，80份甲基丙烯酸甲醇/甲基丙烯酸丁酯共聚物(购自Rohm&Haas，其商品牌号AcryloidTMB60)，O.14份苯偶酰二甲基缩酮，6份二聚氨基氰，3份2，4-二氨基-6〔2′-甲基咪唑基-(1′)〕乙基-S-三嗪(购自AirProducts，其商品牌号CurezolTM2MZ Azine)，以及4，5份二氧化硅(商品牌号Cab-O-SilTM M5)。然后组合物进行除气，从上述由第一组合物制成的片材中除去其中一层聚酯膜，并把经除气的第二组合物涂布在片材上，其涂布厚度为1.524mm。经涂布的组合物用硅氧烷涂覆的聚酯膜复盖，对基片如上所述进行辐照，在基片上面辐照的强度和总能量分别是2.25mW/cm2和458mJ/cm2，而在基片下面辐照的强度和总能量分别是2.09mW/cm2和426mJ/cm2。除去聚酯衬里，胶粘带被层合于剥离衬里上，使第一组合物层与共聚物表面接触，而第二组合物层与聚丁烯表面接触。
片材经切割后转换成1.8cm宽的带材，在切割过程中剥离衬里向宽度方向伸展，并且其伸展后不回复，这样导致这卷胶粘带的衬里比切割过的胶粘剂的每一边向外略伸出约0.79mm。
在以30.49cm/min速率进行剥离时，胶粘带在聚丁烯侧的粘合力为36.0g/2.54cm，而在共聚物侧的粘合力为16.7g/2.54cm。实施例5
按实施例4所述制备二层胶粘带，所不同的是实施例4中的第一组合物的厚度改为0.762mm，以形成第一层。第一层用上述紫外灯辐照固化，其在基片上面的总能量和强度分别为170mJ/cm2和2.27mW/cm2，而在基片下面的总能量和强度分别为133mJ/cm2和1.77mW/cm2。
如实施例4所述，涂布在经固化后第一层上的第二组合物的厚度为1.524mm。如上所述使二层胶粘带固化，其在基片上面的总能量和强度分别为538mJ/cm2和2.34mW/cm2，而在基片下面的总能量和强度分别为482mJ/cm2和2.10mW/cm2。按实施例4所述将固化后的二层胶粘带层合于剥离衬里上。
本实施例的二层胶粘带特别适用于汽车顶部的槽密封上。

Claims (11)

1.一种片材，它包括：(i)一种含有丙烯酸酯基压敏胶粘剂聚合物的压敏胶粘剂膜，(ii)一种含有第一层的剥离膜，所述第一层含有密度不超过0.90g/cm3和CDBI大于70％的聚烯烃聚合物，所述压敏胶粘剂膜与所述剥离膜的第一层接触。
2.根据权利要求1的一种片材，其特征在于所述聚烯烃聚合物的密度不超过0.89g/cm3。
3.根据权利要求1的一种片材，其特征在于所述聚烯烃聚合物的密度不超过0.88g/cm3。
4.根据权利要求1的一种片材，其特征在于所述聚烯烃聚合物是乙烯和至少另一α-烯烃单体的共聚物。
5.根据权利要求4的一种片材，其特征在于所述α-烯烃是丁烯-1。
6.根据权利要求1的一种片材，其特征在于所述第一层基本上不含密度等于或大于0.91g/cm3的聚乙烯聚合物。
7.根据权利要求1的一种片材，其特征在于所述第一层主要由所述聚烯烃聚合物组成。
8.根据权利要求1的一种片材，其特征在于所述剥离膜还包括含有聚丁烯聚合物的第二层。
9.根据权利要求8的一种片材，其特征在于所述剥离膜的第一层和第二层是共挤压形成的。
10.根据权利要求1的一种片材，其特征在于呈卷绕状。
11.一种片材，它包括：(i)一种含有丙烯酸酯基压敏胶粘剂聚合物的压敏胶粘剂膜，(i)一种含有第一层和第二层的剥离膜，所述第一层含有密度不超过0.90g/cm3的聚烯烃聚合物，所述第二层含有聚丁烯均聚物或所含共聚单体量不超过5％的聚丁烯共聚物，所述压敏胶粘剂膜与所述剥离膜中的至少一层接触。
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US20010009706A1 (en) 2001-07-26
US6228449B1 (en) 2001-05-08
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CA2180434A1 (en) 1995-08-03
JP3776120B2 (ja) 2006-05-17
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EP0742814B1 (en) 2004-01-28
CN1139947A (zh) 1997-01-08
US6348249B2 (en) 2002-02-19
DE69532499D1 (de) 2004-03-04
WO1995020635A3 (en) 1995-08-24
KR100336189B1 (ko) 2002-11-20
KR970700741A (ko) 1997-02-12
DE69532499T2 (de) 2004-11-11
EP0742814A1 (en) 1996-11-20

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