Compressible foam tapes and method of manufacture thereof

• US 20030124337A1
• Filed: 12/12/2002
• Published: 07/03/2003
• Est. Priority Date: 07/26/2000
• Status: Active Grant

• Current Assignee: Brett W. Kilhenny, Bruce E. Price
• Original Assignee: Brett W. Kilhenny, Bruce E. Price
• Inventors: Kilhenny, Brett W., Price, Bruce E.
• Granted Patent: US 6,915,741 B2
• Time in Patent Office: Days
• US Class Current: 428/317.3
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B41N 6/00 Mounting boards; Sleeves Make-ready devices, e.g. underlays, overlays; Attaching by chemical means, e.g. vulcanising
• CPC Class Codes: C09J 2301/124 the adhesive layer being present on both sides of the carrier, e.g. double-sided adhesive tape
• CPC Class Codes: C09J 2400/243 in the substrate
• CPC Class Codes: C09J 2427/006 in the substrate
• CPC Class Codes: C09J 2467/006 in the substrate
• CPC Class Codes: C09J 2469/006 in the substrate
• CPC Class Codes: C09J 2475/006 in the substrate
• CPC Class Codes: C09J 2477/006 in the substrate
• CPC Class Codes: C09J 2479/086 in the substrate
• CPC Class Codes: C09J 7/29 Laminated material metallised plastics C09J7/22
• CPC Class Codes: Y10T 428/249979 Specified thickness of void-containing component [absolute or relative] or numerical cell dimension
• CPC Class Codes: Y10T 428/249983 As outermost component
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers

Abstract

An improved foam cushion tape comprises a compressible polyurethane foam layer having a first side and an opposite second side; a composite reinforcing film comprising an anchoring layer and a reinforcing layer, wherein the second side of the polyurethane foam is disposed on the anchoring layer of the reinforcing film; a first adhesive disposed on the first side of the compressible polyurethane foam; and a second adhesive disposed on the reinforcing layer of the composite reinforcing film. The anchoring layer comprises at least one non-olefinic polymer, such as polyvinylidene chloride (PVDC), polyurethane, nylon, or the like.

An economical method for the manufacture of thin, foam cushion tapes for flexographic printing is further provided, comprising casting a curable polyurethane foam composition directly onto the anchoring layer of a composite reinforcing film having a first anchoring layer and a second reinforcing layer, followed by curing the foam composition to form a compressible polyurethane foam.

Claims

1. A method for the manufacture of foam cushion tapes for flexographic printing, comprising

casting a curable polyurethane foam composition onto an anchoring layer of a composite reinforcing film having an anchoring layer and a reinforcing layer;

curing the foam composition to form a compressible polyurethane foam; and

coating the compressible polyurethane foam with an adhesive on a side of the compressible polyurethane foam opposite to the anchoring layer.

2. The method of claim 1, wherein the compressible polyurethane foam has a thickness of about 5 to about 60 mils (about 25 to about 1500 micrometers).

3. The method of claim 1, wherein the compressible polyurethane foam has a thickness of about 12 to about 17 mils (about 300 to about 425 micrometers).

4. The method of claim 1, wherein the anchoring layer is selected from the group consisting of polyvinylidene chloride, polyurethane, copolyester, and nylon, and the reinforcing layer is selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polyvinyl, polycarbonate, and polyetherimide.

5. The method of claim 1, wherein the anchoring layer comprises polyvinylidene chloride and the reinforcing layer comprises polyethylene terephthalate.

6. The method of claim 1, wherein the compressible polyurethane foam is open-celled.

7. The method of claim 1, further comprising co-extruding the anchoring layer and the reinforcing layer.

8. The method of claim 1, wherein the reinforcing layer is acid etched.

9. A foam cushion tape manufactured by the method of claim 1.

10. A method for the manufacture of foam cushion tapes for flexographic printing, comprising

casting a curable polyurethane foam composition onto an anchoring layer of a composite reinforcing film having a polyvinylidene anchoring layer and a polyethylene terephthalate reinforcing layer;

curing the foam composition to form a compressible, open celled polyurethane foam having a thickness of about 12 to about 17 mils (about 300 to about 425 micrometers); and

coating the polyurethane foam with an adhesive on a side of the polyurethane foam opposite to the anchoring layer.

11. A foam cushion tape manufactured by the method of claim 10.

12. A method for flexographic printing comprising:

using a foam cushion tape, wherein the foam cushion tape comprises;

a compressible polyurethane foam layer having a first side and an opposite second side;

a composite reinforcing film comprising an anchoring layer and a reinforcing layer, wherein the second side of the polyurethane foam is disposed on the anchoring layer of the composite reinforcing film;

a first adhesive disposed on the first side of the compressible polyurethane foam; and

a second adhesive disposed on the reinforcing layer of the composite reinforcing film; and

adhering the first adhesive layer to a printing cylinder, and adhering the second adhesive layer to a flexible printing plate.

13. A method for flexographic printing comprising:

using a foam cushion tape, wherein the foam cushion tape comprises;

a compressible, open-celled polyurethane foam layer having a first side and an opposite second side, wherein the compressible polyurethane foam has a thickness of about 5 to about 60 mils (about 125 to about 1500 micrometers);

a composite reinforcing film comprising;

an anchoring layer selected from the group consisting of polyurethane, nylon, copolyester, and polyvinylidene chloride; and

a reinforcing layer selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polyvinyl, polycarbonate, and polyetherimide;

wherein the second side of the polyurethane foam is disposed on the anchoring layer of the composite reinforcing film;

a first pressure sensitive adhesive disposed on the first side of the compressible polyurethane foam;

a second pressure sensitive adhesive disposed on the reinforcing layer of the composite reinforcing film; and

a release layer disposed on a side of the second adhesive layer opposite to the reinforcing layer, wherein the release layer comprises;

a release coating disposed on the second adhesive layer on a side opposite to the reinforcing layer;

an intermediate layer disposed on the release coating on a side opposite to the second adhesive layer; and

a liner disposed on the intermediate layer on a side opposite to the release coating;

adhering the first adhesive layer to a printing cylinder; and

adhering the second adhesive layer to a flexible printing plate.

14. A method for flexographic printing comprising:

using a foam cushion tape comprising;

a compressible, open-celled polyurethane foam layer having a first side and an opposite second side, wherein the compressible polyurethane foam has a thickness of about 5 to about 60 mils;

a composite reinforcing film comprising a polyvinylidene fluoride anchoring layer and a polyethylene terephthalate reinforcing layer, wherein the second side of the polyurethane foam is disposed on the anchoring layer of the composite reinforcing film;

a first pressure sensitive adhesive disposed on the first side of the compressible polyurethane foam;

a second pressure sensitive adhesive disposed on the reinforcing layer of the composite reinforcing film; and

a release layer disposed on a side of the second adhesive layer opposite to the reinforcing layer, wherein the release layer comprises;

an intermediate layer disposed on the release coating on a side opposite to the second adhesive layer;

a liner disposed on the intermediate layer on a side opposite to the release coating; and

a release coating disposed on the second adhesive layer on a side opposite to the reinforcing layer, wherein the release coating further comprises;

a second intermediate layer disposed on the liner on a side opposite to the intermediate layer; and

a second release coating disposed on the second intermediate layer on a side opposite to the liner;

adhering the first adhesive layer to a printing cylinder; and

adhering the second adhesive layer to a flexible printing plate.