Converting Laminating Tricks of The Trade Ramesh

Converting & Laminating Tricks of The Trade Ramesh Lhila, Technical Director, Venture Tape Rebecca Blose, Technical Manager, CCT Scott Lindberg - Technical Sales, Syntac Patrick Eaton, Technical Director, Syntac April 2008

Presentation Outline w Laminating Adhesives w Release Liners w Static Control in Web Handling w Handling Adhesive Build Up on Idler/Tools w Brief Overview of Topics Followed by Panel Discussion/Q&A

Laminating Adhesives

Laminating Adhesives Terminology w In Flexible Packaging Industry – “Liquid” Adhesive, Laminating Two Substrates w In GFA Related Industry – Transfer Tape or Double-Coated Tape Supplied on a Liner with Various Supports (Backing) • Film • Tissue • Scrim, Fabric etc.

Adhesive Types w Pressure Sensitive – Applied By Pressure and/or Supported By Heat • • Rubber- Resin Acrylic Silicone Other Specialty Including Blends w Heat Seal – Bonding Requires Heat • Broad Range of Materials

Adhesive Selection Factors w Tack and Peel w Cost • Rubber > Acrylic > Silicone w Cohesive Strength at Elevated Temperature w UV Resistance w Service Temperature Range • Silicone > Acrylic > Rubber

Substrate Factors w Substrate Chemistry • Surface Energy of the Material (Low or High) § May Need Heat and/or Pressure • Presence of Plasticizers, Oils, Slip Agent etc. § Adhesive Selection is Important • Surface Type § Metal, Plastics, Foam, Rubber etc. w Surface Quality • Smooth, Textured, or Porous § Need to Adjust Adhesive Thickness for Optimal Wet Out

Release Liners

Release Liner - Technology w Most Liners are Silicone Coated • Cured Via Thermal, U-V or E-B Processes w Specialty Liners • Fluoro-Silicone Chemistry Based w Non-Silicone Liners • Limited Applications

Release Liner - Technology w Release Coatings • Applied Via Emulsion, Solvent or 100% System w Release Level Controlled By • Type of Silicone Chemistry • Application Method • Control Release Additives

Release Liner - Substrates w Paper • • Super-calendered Kraft (SCK) Glassine Clay Coated MF, MG and Latex Saturated Paper w Poly Coated Paper (LDPE, HDPE, PP) • One-Side Poly Coated • Two-Side Poly Coated w Films • Polyolefin – LDPE, HDPE, BOPP, Cast PP • Polyester - PET

Liner Substrate Considerations w Paper Liner § Very Good Temperature Resistance • Super-calendered Kraft § Prone to Cockling in Humid Environment § Die Cuttable • Glassine § Good Caliper Control § Semi-Transparent § Excellent For Die Cutting • Clay Coated § Can Be Brittle § Somewhat Moisture Stable

Liner Substrate Considerations w Film Liners § Usually higher cost • Polyolefin and Blends § Soft, extensible, smooth, good tear resistance § Possible to get variety of colors § Temperature sensitive • Polyester § Handles high temperature, good tear resistance § Excellent die cutting surface § Excellent caliper control

Liner Substrate Considerations w Poly-coated Liner § Very good resistance to moisture and cockling § Can be gloss/matte (common) or gloss/gloss § Somewhat heat sensitive

Liner Release Considerations w Liner Release • Easy release needed for many low density PU and melamine foams § Need adhesive to stay with the foam • Tighter Release for Stiffer Materials § Do not want the liner to buckle • Stable Release § Prevent adhesive lockup on aging and high temperature exposure

Static Controls in Web Handling

Static / Static Electricity Relating to or producing Stationary Charges; Electrostatic May be observed as a small ‘spark’ that jumps from one surface to another from build-up between positively and negatively charged areas.

Concerns / Dangers Contamination: Attraction of dust and dirt particulates to your web. w Static Tinsel / String • quick & easy • must touch web w Carbon Fiber Brushes • technical, effective • very cost effective w Ionized Air / Static Blowers • neutralizes static charge w Ionized Bars • permanently mounted over web

Concerns / Dangers: w Safety: If a roll of paper, film or PSA tape is low to the floor or unwind equipment is not properly grounded, arch may jump & cause shocks and / or discomfort to your operators • Wrist Straps • Floor Mats • Heel Grounds w If any flammables; solvents, lubricants, adhesives, cleaners are present, must maintain a static free environment to prevent sparks from igniting (minimally) Note: Paper liner selection lowers risk of static. Much higher charge from film liners.

How to Handle Adhesive Build Up on Idlers / Tooling

Adhesive Build Up Deposit = Residue w Adhesive that is pulled away from the tape or web and builds up on unwanted surfaces • AKA edge pick, ooze w Increased Clean-Up, Change-Over and Labor Costs w Contamination of other webs • Typically impacts Rotary Die-Cutters • Not a lot of complaints with Steel Rule or Preco • None with Laser converting.

Prevention w Lubricants w Chemically Coated or Treated Dies and Rolls (initial cost, but longevity) w Knife Selection / Design w Oil Wells w Materials of Construction w Talcs / Powders (on edges of web Reduces pick/flow) w Die Packing – as tooling wears, need to prevent increase in ‘gapping’ w Environment (hot = flow; cold = stiffer) ENSURE THAT ANY prevention methods do not impact desired performance of your PSA or converted part.

Tape Selection May considerably impact the buildup or edge pick issues that plague the industry • Adhesive Thickness • Transfer Film versus Double-Coat § Carrier • Chemistry § Rubber versus Solvent

Environmental Factors Affecting PSA Tapes and Liners

Environment w Solvent & Chemicals • Adhesive swelling, softening or dissolve / deaden / degrade Crack / degrade release chemistry w Grease, Oil and Mold Releases • May impact adhesive and liner similarly: Creating a barrier between the PSA and liner and/ or PSA and substrate

Temperature Exposure w Low temperatures can have a negative effect on adhesives: • Firms and makes adhesives brittle • Reduce adhesive tack (winter months) • Increase shock sensitivity – Static between liner and PSA during converting Desire good glass transition w High temperatures can have a negative effect on adhesives: • Adhesive softening – Edge Ooze / Bleeding • Reduce shear strength • Reduce cohesive strength

Temperature Exposure w Humidity • Liner Cockling / Wrinkling (high) • Cracking / Breaking (low) • Increased static w UV Light Exposure w Cleanliness / Housekeeping • Contamination may also create barriers

Know the environment that your PSA will be exposed to in both you and your customer’s facility and end use application. Select the adhesive and liner that will be robust enough to BEST meet all above conditions!!!!

Questions