Performance Liner for Digitally Printed PSA Films

AIMCAL Fall Technical Conference

10/7/07

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Overview

n Liner Development for Graphics/Signage

n New requirements for Digital Printers

n Manufacturing targets for Base Paper Production

n Focus on the treatment of the non-silicone side to optimize for end use application

n Verify through SEM microscopy and surface stain testing

n Comparisons to “standard” liners

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Evolution

n Liners for Graphics and Signage

n Roll to Roll applications

n 78# clay coated liner

n 90#/96# PCK layflat liner

n Converting method

n Plotter Cutters

n Vacuum Tables

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Evolution - Various Liners

n Clay coated base for Cast Vinyln Commercial Graphics

n 2 mil, 3 mil film for fleet marking,

n Films for indoor/outdoor signs etc

n Floor graphics

n Reflective Products n Reflective Tapes

n Traffic Control markings

n Reflective Signage

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Evolution Cont.

n Base paper for 78# liner

n Traditional carrier

n Layflat carrier

n Clay 2 Sided liner

n Base paper for PS Stamp

n Modified 78# carrier

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Digital Printers

n Wide format printing

n Indoor/Outdoor Graphics

n Backlit Signage

n Floor Graphics

n Four, six or eight colors

n Letter cutting

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Digital Printers - Why not a standard liner?

n Wide format printing - layflat

n In register feeding - no slippage

n Soft, ink reactive substrates - no transfer

n Elevated temperatures - stability

n Economics - best value

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Digital Printers cont.

n Traditional 78#

n Limited layflat

n Backside transfern Silicone

n Logo print

n Traditional PCK

n Feeding issues -> slippage

n Backside transfer

n Heat softening

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Digital Printers - Define the liner requirements

n Top downn Silicone system

n Release, stability, coverage

n Base Papern Good layflat

n Exact, precise feeding

n Adequate strength

n Consistent, uniform caliper

n Zero ink/silicone transfer

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Technical Approach Rawstock Run Average8/27/06 - 8/27/07

n Basis Weight

n Units -> #/3000 sq. feet

n Target 64.5

n Actual -> 65.5

n Low -> 63.9

n High -> 67.5

n Std dev.-> 0.65

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Technical Approach Rawstock Run Average8/27/06 - 8/27/07

n Caliper

n Units -> mils

n Target 5.2 (non supered)

n Actual -> 5.15

n Low -> 4.825

n High -> 5.375

n Std. Dev. -> 0.07125

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Technical Approach Rawstock Run Average8/27/06 - 8/27/07

n Tear Strength

n Units -> grams

n Targets -> MD 77, CD 94

n Actual -> MD 77.1, CD 93.8

n Low -> MD 66, CD 76

n High -> MD 90 CD 109

n Std Dev. -> MD 5.51 CD 7.21

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Technical Approach Rawstock Run Average8/27/06 - 8/27/07

n Tensile

n Units -> #/inch

n Targets -> MD 50, CD 20

n Actual -> MD 51.4, CD 21.3

n Low -> MD 38, CD 16

n High -> MD 61, CD 26

n Std Dev. -> MD 4.01, CD 1.76

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Technical Approach Rawstock Run Average8/27/06 - 8/27/07

n Scott Internal Bond (SIB)

n Units -> lbs/sq inch

n Target -> 0.15

n Actual -> 0.16

n Low -> 0.11

n High -> 0.23

n Std Dev. -> 0.029

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Technical Approach Rawstock Run Average8/27/06 - 8/27/07

n MB Video Formation

n Units - Subjective scale (0-100)n Target -> 30

n Actual -> 34.4

n Low ->30

n High -> 38.4

n Std. Dev -> 1.63

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Technical Approach Rawstock Run Average8/27/06 - 8/27/07

n Furnish

n Softwood/ Hardwood Blend

n Target

n 45% Pine (softwood, think strength)

n 35% Short (hardwood, think formation)

n 20% Broke (machine recycled, think layflat)

n Adjusted to meet Physical properties

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Technical Approach Basestock Run Average8/27/06 - 8/27/07

n Clay coatingn 1st head coating for Silicone Holdout

n Composition (Proprietary Ground coat)n High holdout, film forming binders - 25%

n Smooth clay, small particle size - 75%

n Coat weight targetn 7#/ 3000 sq feet

n Applicationn Smooth rod

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Technical Approach Basestock Run Average8/27/06 - 8/27/07

n Clay Coatingn 2nd head coating

n Designed for layflat, feeding, and offset

n Composition (Proprietary)n “Open” coating

n 10-15% binder, 85-90% clay

n Coat weight target

n 9#/3000 sq feet

n Applicationn Smooth rod

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Technical Approach Basestock Run Average8/27/06 - 8/27/07

n Supercalendering after coating

n 8 nips -> full stack supering

n Alternating synthetic/steel rolls

n Moderate pressure

n 15% bulk reduction

n Smoothness

n Roll quality/Roll hardness (distortion)

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Technical Approach Basestock Run Average8/27/06 - 8/27/07

n Basestock Properties

n Moisture

n Units ->%

n Target -> 4

n Average -> 4.1

n Min. -> 3

n Max -> 6.4

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Technical Approach Basestock Run Average8/27/06 - 8/27/07

n Basestock Properties

n Caliper

n Units -> mils

n Target -> 4.5

n Average -> 4.65

n Min/Max -> 4.275/5.35R

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Technical Approach Basestock Run Average8/27/06 - 8/27/07

n Basestock Properties

n Gloss

n Units -> %

n Felt (silicone side) target -> 65

n Felt average -> 66.9

n Felt min/max -> 50R/76

n Wire target -> 35

n Wire average -> 38.5

n Wire min/max -> 26/57

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Technical Approach Basestock Run Average8/27/06 - 8/27/07

n Basestock Properties

n Smoothness PPS

n Units -> PPSU (air flow rate over surface)

n Felt side (silicone) target -> 1.5

n Felt side average -> 1.6

n Felt side min/max -> 1/2.5

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Technical Approach Basestock Run Average8/27/06 - 8/27/07

n Basestock Properties

n Densometer

n Units -> Seconds

n Target -> 200,000

n Average -> 177,212

n Min/Max -> 10,800R/641,000

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Technical Approach Basestock Run Average8/27/06 - 8/27/07

n Basestock Properties

n Dyed Oil Holdout -Check

n Functional side - high holdout, pinhole free

n Backside - low holdout

n Visual standards

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Dyed Oil TestingSilicone Liners

n Controlled viscosity Mineral oil

n Applied to the surface for 30 seconds

n Wiped off with clean paper wipe

n Dyed for easy stain interpretation

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Dyed oil Testing

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Digital LinerDyed oil - Silicone Side

n High holdout clay coating.

n Very little evidence of oil absorption

n No pinholes

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Digital LinerSEM Photograph - Silicone

n Clay coated surface

n Heavily coated

n Supercalendered

n Complete coverage

n Uniform coverage

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Modified 78# LinerDyed oil - Backside

n Lightweight application of clay

n 2-3#/3300 sq. feet

n Not supercalendered

n Mottled, blotchy absorption

n Indicates light application of coating

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Modified 78# LinerSEM Photograph - Backside

n 3# Clay coating on back

n Fibers are covered, but still visible through clay

n Surface is rough, uneven

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78# BacksideDyed Oil

n Light application of clay -> wash coat

n 2-3#/3300 sq.feet

n Uneven absorption

n Dye stain characterize by blotchy areas of high absorption and light areas of low absorption.

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78# LinerSEM Photograph - Backside

n 3# Clay coating

n Supercalendering flattens (densifies) the fibers and clay

n Smoother but still uneven

n Holes in the coating apparent

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Digital LinerBackside

n Even absorption, even color

n Deep color, good absorption

n Indicates even coat weight

n Indicates even distribution of clay

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Digital LinerSEM Photograph - Backside

n Heavy clay coating

n Supercalendered for smoothness

n Good uniform coverage

n Even distribution of coating

n Complete fiber coverage

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Technical Approach - Liner

n Silicone coatingn Choice of Silicone

n Solventless for water based adhesivesn Pt catalyzed, high crosslink density

n Flat release profile vs. peel speed

n Higher COF surface

n Remoisturized to 3.5% target

n Finished with slight reverse curl

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Technical Approach - Liner

n Silicone coating

n Choice of Silicone

n Solventless - solvent adhesives

n Pt Catalyzed

n Slip additive for low COF

n Acts like solvent tin for adhesive creep

n Remoisturized to 3.5%

n Reverse curl for layflat

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Technical Approach - Liner

n Silicone Coating

n Choice of Silicone

n UV system for water based adhesives

n Epoxy cure - low extractables

n High COF

n UV cure, no heat -> 4 - 4.5% moisture

n Very stable release

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Technical Approach - Liner

n Silicone Coating

n Choice of Silicone

n Emulsion for water based adhesives

n High crosslink density - flat release profile

n Low COF, allows for some adhesive creep

n Very smooth surface - uniform adhesive coating

n Able to be “tinted”

n Remoisturized to 3.5%

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Tinted LinerEmulsion Silicone

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Finished Product

n Silicone options

n Available in Solventless, Emulsion or UV

n Customizable for a variety of release requirements

n UV allows for higher liner moisture

n Emulsion provides a smoother surface and can be tinted

n Solventless can perform like a solvent tin system

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Finished Product

n Basestock

n Good layflat n 3.5 -4.5% moisture

n Heavy clay coating on backside for stability/balance

n Backside coatingn Allows for good anchorage of Logo print (no ghosting or

transfer)

n Accounts for any residual silicone (no transfer to film print surface)

n Provides excellent feeding

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Layflat Testing

n Adhesive coat, laminate vinyl

n Cut samples to 8” x 8”squares

n Test at 70 deg F. 50% RH

n Test high humidity > 80%

n Test at low humidity< 25%

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Modified 78#Layflat

n Wavy edges on all sides

n Uneven edge curl

n Edge “darts” extending into the middle of the sample

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Modified 78#Layflat cont.

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78# LinerLayflat

n Slight waviness, not as bad as “modified” 78#

n Edge darts extending into the middle of the sample

n Slight lift, at corners.

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78# LinerLayflat cont.

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Digital LinerLayflat

n Uniform edges

n No evidence of waviness or cockle

n Slight lifting on edges, but consistent on all sides

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Digital LinerLayflat cont.

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Finished Product

n Basestock cont.

n Good caliper profiles -dye cutting, letter cutting

n Good SIB - no delamination with weeding

n Good strength for adhesive coating and converting

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