Pressure sensitive adhesive constructions

• US 6,299,956 B1
• Filed: 12/04/1998
• Issued: 10/09/2001
• Est. Priority Date: 02/05/1985
• Status: Expired due to Fees

• Current Assignee: Avery Dennison Corporation
• Original Assignee: Avery Dennison Corporation
• Inventors: Freedman, Melvin S.
• Primary Examiner(s): Nakarani, D. S.
• Assistant Examiner(s): TARAZANO, DONALD LAWRENCE
• Application Number:
  US09/205,956
• Time in Patent Office: 1,040 Days
• Field of Search: 428/343, 428/354, 428/352, 428/41.7, 428/41.8, 428/308.4, 428/515, 428/516, 428/42.3, 428/161, 428/174, 428/409, 428/518, 156/183, 156/209
• US Class Current: 428/41.8
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/19 the layers being joined at their edges
• CPC Class Codes: B29K 2995/0072 Roughness, e.g. anti-slip
• CPC Class Codes: B29K 2995/0081 Tear strength
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: C09J 2203/334 as a label
• CPC Class Codes: C09J 2301/162 the carrier being a laminate constituted by plastic layers only
• CPC Class Codes: C09J 2301/302 the adhesive being pressure-sensitive, i.e. tacky at temperatures inferior to 30°C
• CPC Class Codes: C09J 2423/006 in the substrate
• CPC Class Codes: C09J 2427/006 in the substrate
• CPC Class Codes: C09J 2431/006 in the substrate
• CPC Class Codes: C09J 7/243 Ethylene or propylene polymers
• CPC Class Codes: C09J 7/245 Vinyl resins, e.g. polyvinyl chloride [PVC]
• CPC Class Codes: G09F 2003/0257 Multilayer
• CPC Class Codes: G09F 3/02 Forms or constructions layered products B32B
• CPC Class Codes: Y10S 428/91 Product with molecular orientation
• CPC Class Codes: Y10T 156/1023 Surface deformation only [e.g., embossing]
• CPC Class Codes: Y10T 156/108 Flash, trim or excess removal
• CPC Class Codes: Y10T 428/14 : Layer or component removable to expose adhesive
• CPC Class Codes: Y10T 428/1452 : Polymer derived only from ethylenically unsaturated monomer
• CPC Class Codes: Y10T 428/1462 : Polymer derived from material having at least one acrylic or alkacrylic group or the nitrile or amide derivative thereof [e.g., acrylamide, acrylate ester, etc.]
• CPC Class Codes: Y10T 428/1476 : Release layer
• CPC Class Codes: Y10T 428/1486 : Ornamental, decorative, pattern, or indicia
• CPC Class Codes: Y10T 428/1495 : Adhesive is on removable layer
• CPC Class Codes: Y10T 428/24521 : with component conforming to contour of nonplanar surface
• CPC Class Codes: Y10T 428/2486 : with outer strippable or release layer
• CPC Class Codes: Y10T 428/2495 : Thickness [relative or absolute]
• CPC Class Codes: Y10T 428/24967 : Absolute thicknesses specified
• CPC Class Codes: Y10T 428/24975 : No layer or component greater than 5 mils thick
• CPC Class Codes: Y10T 428/26 : Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/28 : Web or sheet containing structurally defined element or component and having an adhesive outermost layer
• CPC Class Codes: Y10T 428/2839 : with release or antistick coating
• CPC Class Codes: Y10T 428/2848 : Three or more layers
• CPC Class Codes: Y10T 428/31 : Surface property or characteristic of web, sheet or block
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31909 : Next to second addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31913 : Monoolefin polymer
• CPC Class Codes: Y10T 428/3192 : Next to vinyl or vinylidene chloride polymer
• CPC Class Codes: Y10T 428/31928 : Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31938 : Polymer of monoethylenically unsaturated hydrocarbon

Abstract

Film-forming means are coextruded to form all plastic multilayer liners and facestocks for pressure-sensitive labels, tapes, decals, signs, bumper stickers, and other products formed from sheet and roll stock. Fill means in a charge for the liner coextrusion affects stiffness and dimensional stability of the liner and/or affects the roughness of a liner face or faces. The film materials of the layers of the constructions are selected according to the cost/benefit characteristics of candidate materials considering the functional or operational requirements of the layer in question.

Claims

1. A pressure-sensitive adhesive construction comprising a substrate and a pressure sensitive adhesive layer wherein the adhesive layer has an upper surface and a lower surface, the upper surface of the adhesive layer is in contact with the substrate, and the lower surface of the adhesive layer has been roughened to a roughness of at least 10 Sheffield units by direct contact of the lower surface of the adhesive layer with a rough second surface.

2. The construction of claim 1 wherein the substrate comprises a pressure-sensitive adhesive facestock material.

3. The construction of claim 2 wherein the pressure-sensitive adhesive construction comprises facestock materials for labels, decals, signs and bumper stickers.

4. The construction of claim 1 wherein the rough second surface comprises the top surface of a release liner.

5. The construction of claim 4 wherein the liner comprises a polymeric material.

6. The construction of claim 5 wherein the release liner comprises at least two coextruded polymeric layers and a layer of a release coating.

7. The construction of claim 6 wherein the coextruded polymeric layers comprise polymers selected from the group consisting of polypropylene, acrylonitrile-butadiene-styrene copolymers, nylon, and polystyrene.

8. The construction of claim 5 wherein the release liner comprises at least a base or core layer and a roughened skin layer wherein the skin layer is roughened by presence of filler particles in the base or core layer.

9. The construction of claim 8 wherein the filler comprises material selected from the group consisting of wollastonite, glass fibers, talc, graphite platelets, graphite fibers, boron fibers, sapphire fibers, steel fibers, polymeric fibers and polyester fibers.

10. The construction of claim 8 wherein the filler comprises mica.

11. The construction of claim 4 wherein the top surface of the release liner has been roughened by matte finishing or by embossing of the top surface of the release liner.

12. The construction of claim 4 wherein the top surface of the release liner has been roughened by embossing the top surface of the release liner.

13. The construction of claim 4 wherein the release liner has an upper surface and a lower surface, and the surface has a roughness of up to about 150 Sheffield units.

14. The construction of claim 4 wherein the release liner has an upper surface and a lower surface, and the lower surface has a roughness of up to about 300 Sheffield units.

15. The construction of claim 1 wherein the roughness of the lower surface of the adhesive layer is sufficient to minimize air entrapment and the resultant formation of blisters or high spots when the substrate is adhesively applied to a second substrate.

16. The construction of claim 1 wherein the lower surface of the adhesive layer has a roughness of at least about 150 Sheffield units.

17. A multilayer pressure-sensitive adhesive construction for use in pressure-sensitive label, decal, sign or bumper sticker applications comprising a coextrudate of cojoined layers comprising a core or base layer of polymeric film material, at least one skin layer, said skin layer being on the faceside of the coextrudate and having an ink-printable surface, and a pressure-sensitive adhesive layer having an upper surface and a lower surface wherein the upper surface is combined with the side of the coextrudate opposite said faceside, and the lower surface of the pressure-sensitive adhesive layer is roughened to at least 10 Sheffield units.

18. The construction of claim 17 wherein the lower surface of the pressure-sensitive adhesive layer has been roughened by direct contact of the adhesive with a rough second surface.

19. The construction of claim 18 wherein the second rough surface is the top surface of a release liner.

20. The construction of claim 19 wherein the liner comprises a polymeric material.

21. The construction of claim 19 wherein the release liner comprises at least two coextruded polymeric layers.

22. The construction of claim 21 wherein the coextruded polymeric layers comprise polymers selected from the group consisting of polypropylene, acrylonitrile-butadiene-styrene copolymers, nylon, and polystyrene.

23. The construction of claim 19 wherein the release liner comprises at least a base or core layer and a roughened skin layer wherein the skin layer is roughened by the presence of filler particles in the base or core layer.

24. The construction of claim 23 wherein the filler comprises material selected from the group consisting of wollastonite, glass fibers, talc, graphite platelets, graphite fibers, boron fibers, sapphire fibers, steel fibers, polymeric fibers and polyester fibers.

25. The construction of claim 23 wherein the filler comprises mica.

26. The construction of claim 19 wherein the top surface of the release liner has been roughened by matte finishing or by embossing of the top surface.

27. The construction of claim 19 wherein the top surface of the release liner has been roughened by embossing the top surface of the release liner.

28. The construction of claim 17 wherein the roughness of the lower surface of the adhesive layer is sufficient to minimize air entrapment and the resultant formation of blisters or high spots when the substrate is adhesively applied to a second substrate.

29. The construction of claim 17 including a second skin layer on the core or base layer between the core or base layer and the adhesive layer.

30. The construction of claim 17 wherein the coextrudate has a tie layer between the core or base layer and the at least one skin layer.

31. The construction of claim 29 wherein the coextrudate has a tie layer between said core or base layer and each skin layer.

32. The adhesive construction of claim 17 wherein the coextrudate of cojoined layers comprises a relatively thick core or base layer and a relatively thin skin layer.

33. The construction of claim 17 wherein the core or base layer of polymeric film material represents the bulk of the total material used in the construction.

34. The adhesive construction of claim 17 wherein the core or base layer has a stiffness of from about 10 to 100 Gurley.

35. The adhesive construction of claim 17 wherein the coextrudate of cojoined layers has a thickness of from about 1.5 to about 6.5 mils.

36. The adhesive construction of claim 17 wherein the skin layer comprises polyvinyl chloride, polyvinylidene chloride or fluoroplastic.

37. The adhesive construction of claim 17 wherein the skin layer comprises polyvinyl chloride.

38. The adhesive construction of claim 17 wherein the skin layer comprises polyvinylidene chloride.

39. The adhesive construction of claim 17 wherein the core layer comprises polyethylene of a specific gravity of from about 0.890 to about 0.965, or a propylene polymer or copolymer with a flex modulus range of between about 130,000 and 250,000 at 25°

C.

40. The construction of claim 19 wherein the release liner has a top surface and a bottom surface, and the roughness of the bottom surface is up to about 150 Sheffield units.

41. The construction of claim 19 wherein the release liner has an upper surface and a lower surface, and the lower surface has a roughness of up to about 300 Sheffield units.

42. A pressure sensitive adhesive construction comprising:

(1) a facestock having an upper ink printable surface and a lower surface wherein the upper surface comprises polyvinyl chloride,

(2) a layer of pressure sensitive adhesive having a lower surface roughened to a roughness of at least 10 Sheffield units, and an upper surface bonded to the lower surface of the facestock, and wherein the lower surface of the pressure sensitive adhesive layer has been roughened by direct contact with a rough first surface of a release liner having a rough first surface roughened by embossing the first surface, and a second surface having a roughness of less the 105 Sheffield units, and wherein the second surface of the liner comes into contact with the upper surface of the facestock when the construction is wound into a roll.

43. The adhesive construction of claim 42 wherein the facestock (1) comprises a relatively thick core or base layer of polymeric film material having an upper surface and a lower surface and at least one relatively thin skin layer comprising polyvinyl chloride which is adhered to the upper surface of the core or base layer.

44. The adhesive construction of claim 43 wherein the core or base layer of the facestock has a stiffness of from about 10 to about 100 Gurley.

51. The adhesive construction of claim 42 wherein the thickness of the facestock is from about 1.5 to about 6.5 mils.

45. A release liner comprising a layer of polymeric film material having an upper surface and a lower surface, and a release layer on the upper surface of the layer of polymeric material wherein the upper surface of the layer of polymeric film material has a roughness of at least 10 Sheffield units.

46. The release liner of claim 45 wherein the layer of polymeric film material is formed by extrusion.

47. The release liner of claim 45 wherein the surface of the layer of polymeric film material is roughened by the presence of filler particles in the layer of polymeric film material.

48. The release liner of claim 47 wherein the filler comprises a high aspect ratio material selected from the group consisting of wollastonite, glass fibers, talc, graphite platelets, graphite fibers, boron fibers, sapphire fibers, steel fibers, polymeric fibers and polyester fibers.

49. The release liner of claim 47 wherein the filler comprises mica.

50. The release liner of claim 47 wherein the upper surface of the layer of polymeric material is roughened by matte finishing or by embossing of the upper surface.

52. The release liner of claim 45 wherein the lower surface of the release liner has a roughness of up to about 150 Sheffield units.

53. The release liner of claim 45 wherein the lower surface of the release liner has a roughness of up to about 300 Sheffield units.

54. The release liner of claim 45 wherein the layer of polymeric film material comprises polyethylene having a specific gravity of between about 0.890 and about 0.965 or a propylene polymer or copolymer with a flex modulus range of between about 130,000 and 250,000 at 25°

C.

55. A pressure sensitive adhesive construction comprising:

(1) a facestock having an upper ink printable surface and a lower surface wherein the upper surface comprises polyvinyl chloride,

(2) a layer of pressure sensitive adhesive having a lower surface roughened to a roughness of at least about 10 Sheffield units, and an upper surface bonded to the lower surface of the facestock, and

(3) a release liner having a first surface in contact with the lower surface of the pressure sensitive adhesive layer and a second surface having a roughness of up to about 150 Sheffield units, and wherein the second surface of the liner comes into contact with the upper surface of the facestock when the construction is wound into a roll.

56. The adhesive construction of claim 55 wherein the facestock (1) comprises a relatively thick core or base layer of polymeric film material having an upper surface and a lower surface and at least one relatively thin skin layer comprising polyvinyl chloride which is adhered to the upper surface of the core or base layer.

57. The adhesive construction of claim 56 wherein the core or base layer of the facestock (1) has a stiffness of from about 10 to about 100 Gurley.

58. The adhesive construction of claim 55 wherein the thickness of the facestock (1) is from about 1.5 to about 6.5 mils.

59. A pressure sensitive adhesive construction comprising:

(1) a facestock having an upper ink printable surface and a lower surface wherein the upper surface comprises a polymeric film material,

(2) a layer of pressure sensitive adhesive having a lower surface roughened to a roughness of at least about 10 Sheffield units, and an upper surface bonded to the lower surface of the facestock, and

(3) a release liner having a first surface in contact with the lower surface of the pressure sensitive adhesive layer, and a second surface having a roughness of up to about 150 Sheffield units, and wherein the second surface of the liner comes into contact with the upper surface of the facestock when the construction is wound into a roll.

60. The adhesive construction of claim 59 wherein the polymeric film material of the facestock (1) is selected from polyethylene vinyl acetate, polyethylene methyl polyacrylic acid, polyethylene ethyl acrylate, polyethylene methyl acrylate, acrylonitrile butadiene styrene polymer, nylon, polybutylene, polystyrene, polyurethane, polysulfone, polyvinylidene chloride, polypropylene, polycarbonate, polymethyl pentene, styrene maleic anhydride polymer, styrene acrylonitrile polymer, ionomers based on sodium or zinc salts of ethylene/methacrylic acid, polymethyl methacrylates, cellulosics, fluoroplastics, polyacrylonitriles, and thermoplastic polyesters.

61. The adhesive construction of claim 59 wherein the facestock (1) comprises a relatively thick core or base layer of polymeric film material having an upper surface and a lower surface and at least one relatively thin skin layer comprising polyvinyl chloride which is adhered to the upper surface of the core or base layer.

62. The adhesive construction of claim 61 wherein the core or base layer of the facestock (1) has a stiffness of from about 10 to about 100 Gurley.

63. The adhesive construction of claim 59 wherein the thickness of the facestock (1) is from about 1.5 to about 6.5 mils.

64. The adhesive construction of claim 59 wherein the thickness of the liner (3) is from about 0.5 to about 6.5 mils.

65. A method of preparing a pressure-sensitive adhesive construction comprising a substrate and a pressure-sensitive adhesive layer wherein the adhesive layer has an upper surface and a lower surface, the upper surface of the adhesive layer is in contact with the substrate, and the lower surface of the adhesive layer has been roughened to a roughness of at least 10 Sheffield units, which method comprises preparing a construction comprising a substrate and the PSA layer, and thereafter contacting the lower surface of the adhesive layer with a rough second surface whereby the roughness of the second surface is imparted to the lower surface of the adhesive layer.

66. The method of claim 65 wherein the rough second surface comprises a top surface of a release liner.

67. The method of claim 66 wherein the liner comprises a polymeric material.

68. The method of claim 66 wherein the top surface of the release liner has been roughened by matte finishing or by embossing of the top surface of the release liner.

69. The method of claim 66 wherein the top surface of the release liner has been roughened by embossing the top surface of the release liner.

70. The method of claim 65 wherein the roughness of the lower surface of the adhesive layer is sufficient to minimize air entrapment and the resultant formation of blisters or high spots when the substrate is adhesively applied to a second substrate.

71. The method of claim 65 wherein the lower surface of the adhesive has been roughened to a roughness of at least 150 Sheffield units.

72. The method of claim 65 wherein the substrate comprises polyvinyl chloride.