Solutions for Release Coating Success: Syl-Off brand Silicone Release Coatings from Dow Corning. RELIABILITY in. every INNOVATION

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1 Solutions for Release Coating Success: Syl-Off brand Silicone Release Coatings from Dow Corning RELIABILITY in every INNOVATION

2 The Syl-Off brand Silicone Release Coating Line Dow Corning s Syl-Off silicone release coating line contains eight distinct families of release coating technology. These families are designed to give you the ultimate in processing and performance flexibility. (100% Solids) Coatings 1. catalyzed 2. Low-platinum catalyzed Advantage Series 3. catalyzed for films (9100 Series) 4. catalyzed The most important element in the release coating selection Emulsion Coatings and formulation process is the dialogue that takes place between 7. catalyzed the person who best understands 8. catalyzed your application (you) and one of Dow Corning s silicone release coating experts. Solvent Emulsion for Films Solvent-Based Coatings 5. catalyzed 6. catalyzed Within these families, you will find a comprehensive range of base coatings, crosslinkers and catalysts, plus a variety of additives to help you: Reduce misting at the coating head for safer processing and faster line speeds Improve adhesion to difficult substrates Increase cure speed Attain an infinite variety of release force vs. peel speed performance profiles 2

3 Exploring Your Opportunities Here are some basic questions to keep in mind as you explore the release coating opportunities described in this brochure. 1. Are you limited to the use of existing coating equipment? 2. Are you restricted in your use of solvents? Or do you already have effective solvent-recovery equipment in place? 3. What type of substrate are you coating? Porous or nonporous? Film or paper? 4. How sensitive is your substrate to damage by solvents, water, heat, drying? 5. Will the coating be used in a label, tape, composite or foodcontact application? 6. What type of adhesive will your coating be used against? How to Use This Guide This guide compares and contrasts the silicone release coating technologies available from Dow Corning. It is designed to: Give you a general understanding of the product families into which our coatings are grouped Help you determine which Syl-Off release coating family most closely meets the needs of your application Selecting the right coating family for your use is simply a matter of prioritizing your needs and deciding what you can or cannot afford to trade to meet them. If you have processing equipment constraints, Table 1 will tell you which delivery systems are most appropriate for your operation. If you need to coat a particular substrate, Table 2 will tell you which families, as a general rule, work best on that substrate. If your coating decision is application-driven, Table 3 will help you make an appropriate match. If your coating must perform against a particular adhesive, Table 4 will direct you to the most compatible coating families. If your application has precise release force versus peel speed (release force profile) requirements, Figures 1 through 3 will help you identify families of coatings with suitable performance profiles. 7. What are your release force requirements across the peel speed range? Applying these questions to the tables and figures that follow will help you narrow your search. 3

4 Table 1. Processing Equipment Compatibility Application Equipment Delivery System Conventional Precision 1 Size Press 2 Solvent Emulsion Primary mode of application Can be applied with this type of equipment Conventional equipment includes Meyer rod, direct gravure, air knife, squeeze roll, reverse roll, slot die extrusion, etc. Precision equipment includes threeroll offset differential gravure and multi-roll smooth roll coaters. 1. When using offset roller systems to apply platinum-catalyzed coatings, care should be taken with the choice of the rubber-coated rolls. Materials used to vulcanize the rubber may inhibit the cure of the silicone coating. 2. coatings are designed to be coated as supplied using precision coating equipment; however, they may also be blended with aliphatic solvents to a desired solids concentration and applied using conventional solvent coating equipment. Table 2. Substrate Compatibility Uncoated Papers Coated/Treated Papers Syl-Off Coating Family Uncoated Kraft Board Parchment Super- Calendered Kraft Glassine Clay-Coated Kraft 4 Poly-Coated Kraft 1,2 Plastic Films 1,2 Metal Foil 3 3 for Films (9100 Series) Low (Advantage Series) 3 3 Solvent-Based 3 3 Solvent-Based Emulsion 3 3 Emulsion Most appropriate for use with Can be used with, but contact a Dow Corning specialist for recommendations 1. Some resins used to make poly-coated kraft and films can inhibit cure. Suitability for use with the chosen silicone release coating should be evaluated before commercial application. 2. Anchorage of silicone release coatings to these substrates can be affected by the substrate. Corona treatment can improve anchorage but may not be effective in all cases. Suitability for use with the chosen silicone release coating should be evaluated before commercial application. 3. Precoat found on most glassines or super-calendered krafts can adversely affect cure; compatibility should be thoroughly tested before commercial application. 4. Compatibility of the silicone coating and the clay coating should be thoroughly tested before commercial application. 4

5 Table 3. Application Compatibility Syl-Off Coating Family Low (Advantage Series) Solvent-Based Solvent-Based Emulsion Emulsion PSA Release Table 4. Adhesive Compatibility Application Two-Sided In-Line Processes Differential Packaging Many Syl-Off silicone release coating materials are appropriate for use in food-contact applications. Contact your Dow Corning Global Connection for local regulatory information and product advice. Most appropriate for use with Can be used with, but contact a Dow Corning specialist for recommendations Compatible Adhesives Syl-Off Coating Family Water-Based Acrylic Solvent-Based Acrylic Solvent-Based Rubber (SBR) Hot Melt Low (Advantage Series) Solvent-Based Solvent-Based Emulsion Emulsion 5

6 Figure 1. Comparative Release Force Profiles Solvent-Based Acrylic Adhesive (tesa 7475 Acrylic Tape) A B C D E F platinum (end-blocked polymer) platinum (multifunctional polymer) rhodium Solvent-based platinum; solvent-based tin Emulsion platinum Emulsion tin Figure 2. Comparative Release Force Profiles Solvent-Based Rubber (SBR) Adhesive (tesa 7476 Rubber Tape) A B C D E F platinum (end-blocked polymer) platinum (multifunctional polymer) rhodium Solvent-based platinum; solvent-based tin Emulsion platinum Emulsion tin Figure 3. Comparative Release Force Profiles Hot Melt Adhesive (Hot Melt Tape) A B C D E F platinum (end-blocked polymer) platinum (multifunctional polymer) rhodium Solvent-based platinum; solvent-based tin Emulsion platinum Emulsion tin 6

7 Syl-Off Silicone Release Coating Families: -Catalyzed Addition Cure Including 9100 Series for films. Premium release; comparatively fast, low-temperature cure; outstanding process control capability; does not interact with solvent-based rubber (SBR). (See pages 9-10 for cure chemistry information.) Low- Advantage Series Comparable performance and processing characteristics; enables significantly lower platinum usage; reduces vulnerability to swings in platinum metal prices; no compromise in bath life, anchorage, line speed or release stability. (See pages 9-10 for cure chemistry information.) -Catalyzed Addition Cure Premium release; slower, high-temperature cure; robust processing; far less prone to adhesive lockup than platinumcatalyzed coatings. (See pages 9-10 for cure chemistry information.) Delivery Systems (100% solids) silicone release coatings raise fewer environmental, health, safety and regulatory concerns than solvent-based coatings. Expensive solvent recovery equipment is not required, and there are important performance advantages. for Films Solvent Emulsion Unlike solvent-based and emulsion coatings, they contain no carrier that must be driven off. Consequently, faster line speeds can be achieved. These coatings are best suited for use on calendered or coated papers and films with a smooth surface, since they have the potential for soak-in on porous papers. coatings are less likely to damage films than solvent-based coatings, but may require corona treatment or additives to achieve the same level of anchorage. The major drawback of solventless coatings is the need for precision coating equipment (such as three-roll offset differential gravure or multi-roll smooth roll coaters) to achieve the kind of low coat weights necessary to make an economical release liner. Technology Breakthrough High Speed Crosslinkers New coating equipment is making it possible to apply silicone release coatings at increasingly faster line speeds. Faster line speeds can lead to increased productivity and, consequently, more profitable operations. Unfortunately, the faster the coating line, the greater the potential for silicone mist to form at the coating head. Although silicone mist formation can occur with any coating and any coater at some line speed, the problem has been most common with solventless release coatings. The solventless platinum family offers you excellent processing and performance flexibility. It is also the area where Dow Corning possesses the greatest custom manufacturing capability. In response, Dow Corning has introduced a line of Syl-Off brand solventless high speed crosslinkers that significantly reduce mist at the coating head. Included in this line is a Syl-Off Advantage Series high speed crosslinker that reduces mist and enables record-breaking line speeds in operations where cost control is a priority. This crosslinker is designed specifically for use with Advantage Series low-platinum release coatings. In addition to permitting increased line speeds, mist reduction provides a safer working environment and can decrease maintenance costs associated with silicone build-up in ventilation systems, drive motors and ovens. What is more, these benefits come with no sacrifice in cure, anchorage, coverage or release performance. Syl-Off high speed crosslinkers have demonstrated robust performance with all Syl-Off solventless silicone release coating components. 7

8 Solvent-Based Syl-Off Silicone Release Coating Families: -Catalyzed Addition Cure Premium release; fast, lowtemperature cure; nonmigrating; nonblocking suitable for two-sided differential release applications; does not interact with solvent-based rubber (SBR); good for use with water-based acrylic adhesives. (See pages 9-10 for cure chemistry information.) -Catalyzed Condensation Cure A wide range of release forces possible; robust process resistant to substrate inhibition and catalyst poisoning; does not interact with acrylics. (See page 11 for cure chemistry information.) Solvent Solvent-based coatings have a long history of successful use on films and smooth, hardsurfaced papers with a high degree of solvent holdout. In fact, paper soak-in can be less of a problem with solvent-based coatings than with solventless. And it is easy to get good coverage at very low coat weights (an important economic consideration) using simple, conventional coating equipment such as Meyer rods and direct gravures. Another plus is that solvents have a tendency to slightly swell some film surfaces, improving anchorage. for Films Solvent Emulsion One drawback is that there is the potential for film or paper coating damage. The other drawback is that solvent systems generate more environmental, health, safety and regulatory concerns than solvent-free systems. However, if you already have incineration or solvent-recovery equipment in place and are operating within regulatory guidelines, solvent-based coatings can be an attractive choice. Emulsion Syl-Off Silicone Release Coating Families: -Catalyzed Addition Cure Premium release; fast, lowtemperature cure; nonmigrating; nonblocking suitable for two-sided differential applications; does not interact with solvent-based rubber (SBR). (See pages 9-10 for cure chemistry information.) Emulsion With silicone emulsion (water-based) coatings, uniform, low coat weights can be obtained on simple solvent coating equipment. Unlike solvent-based coatings, however, emulsions can also be used in size press operations and with an air knife. Thickeners can be added that allow emulsion coatings to be used on more-porous papers that would be considered unsuitable for solvent-based or solventless silicone systems. Thickeners increase coating viscosity, which reduces penetration and prevents rupturing of the emulsion film during drying. -Catalyzed Condensation Cure Naturally high release; robust process resistant to substrate inhibition and catalyst poisoning; does not interact with acrylics. (See page 11 for cure chemistry information.) for Films Solvent Emulsion Unfortunately, the wetting and drying process tends to stress the paper. The most common problems are buckling, curling and cockeling. If maintaining paper smoothness is essential to the success of the application, solventless or solvent-based coatings may be preferable. If smoothness is secondary to paper cost savings and the need to use solvent-type coating equipment, emulsion coatings are a good choice. 8

9 Thermal Cure Chemistries Dow Corning offers two thermal cure chemistries: addition cure, catalyzed by platinum or rhodium; and condensation cure, catalyzed by tin. Dow Corning technical experts worldwide are known for their ability to help customers overcome obstacles and resolve technical concerns. They can help you design the ideal release coating formulation for your application. Addition Cure Addition-cure chemistry offers the widest range of cure time and temperature options. It has been successfully applied to solventless, solvent-based and emulsion coatings alike. In this cure system (Figure 4), the addition of a silicon hydride group across a vinyl (or hexenyl) group is catalyzed by a few parts per million of an organoreactive platinum (or rhodium) complex. There are no leaving groups, so nothing is evolved during cure. And post-cure (if any) is minimal. Figure 4. Addition-Cure Reaction Pt, Rh Pt (Rh) SiCH = CH 2 + SiH SiCH 2 CH 2 Si Polymer Options for Addition- Cure Syl-Off Silicone Release Coating Families: -Catalyzed Offers the widest range of product choices; four complete product lines: - Vinyl-based - Vinyl-based for films (9100 Series) - Vinyl-based low platinum (Advantage Series) - Hexenyl-based There is also a choice of inhibitor systems for optimizing bath life and cure rate. -Catalyzed Vinyl polymers only. Solvent-Based - Catalyzed Coatings based on highmolecular-weight vinyl polymers. Emulsion -Catalyzed Coatings based on vinyl polymers. Vinyl Polymers Addition-cure coatings based on vinyl polymers (Si-CH=CH 2 ) offer premium release and fast, low-temperature cure. for Films Solvent Emulsion VINYL HEXENYL VINYL VINYL VINYL VINYL VINYL Especially for Films Dow Corning recently introduced a new line of vinyl-based, thermal-cure solventless release coatings (Syl-Off 9100 Series) specially designed for use on filmic substrates. With 9100 Series, it is now possible to coat many different types and grades of films from temperature-sensitive substrates to low-cost unprimed polyester using proven, costefficient thermal-cure technology. Hexenyl Polymers Coatings based on hexenyl polymers (Si-CH 2 -CH 2 -CH 2 -CH 2 -CH=CH 2 ) also offer premium release. Under equivalent conditions, hexenyl polymer coatings cure faster, more completely or at lower temperatures than vinyl coatings. 9

10 -Catalyzed Addition- Cure Syl-Off Silicone Release Coating Families: Fewer environmental, health, safety and regulatory concerns than solvent-based coatings; a wide range of release performance; precision coating equipment required; corona treatment or use of specific crosslinker may be required to improve anchorage to films; no diluent to be removed less substrate damage, faster line speeds possible. Solvent-Based Low coat weights easy to obtain on conventional equipment; good anchorage to films; paper soak-in can be less of a problem than with solventless. Emulsion Environmental, health, safety, regulatory and performance benefits of solventless; low coat weights can be obtained on conventional equipment; possible to coat porous, low-cost papers; wetting/drying process stresses paper; poor anchorage to films. -Catalyzed Addition- Cure Syl-Off Silicone Release Coating Families: Fewer environmental, health, safety and regulatory concerns than solvent-based coatings; a wide range of release performance; precision coating equipment required; no diluent to be removed less substrate damage, faster line speeds possible. Challenges such as application equipment restrictions, substrate inhibition, catalyst-adhesive interaction and catalyst poisoning can all be overcome by modifying the coating formulation or controlling processing conditions. Catalyzed All platinum-catalyzed addition-cure coatings offer fast cure at low to moderate temperatures. And, within the solventless family, there is the added advantage of being able to maximize bath life (while minimizing cure time) within defined temperature ranges. This is accomplished by inhibiting the catalyst in a controlled manner. for Films Solvent Emulsion Compared with tin-catalyzed condensation-cure, platinum-catalyzed addition-cure chemistry: Yields faster, more complete cure at low temperatures Is less prone to silicone migration Is nonreversible and consequently nonblocking Generates a more durable coating with more stable/predictable release Offers more avenues for controlling bath life and release performance Plus, with Dow Corning s Syl-Off Advantage Series solventless, low-platinum coating system, it is now possible to reduce platinum usage and thereby control costs. Advantage Series features new base polymers and crosslinkers with proprietary architectures plus a choice of release modifiers, catalysts and inhibitor systems that make it possible to control costs without compromising bath life, anchorage, line speed or release stability. -catalyzed coatings have two drawbacks, however: 1) susceptibility to catalyst poisoning, and 2) the potential for interaction with acrylics. Materials that can poison platinum-catalyzed addition-cure coatings include amines, sulphides, phosphides and the organotin salts. Catalyzed -catalyzed addition-cure coatings are unique to Dow Corning, and the cure chemistry is exceptionally robust. -catalyzed coatings are far less prone to adhesive lockup than platinum-catalyzed coatings. However, they do cure more slowly and at a higher temperature, making them unsuitable for temperature-sensitive substrates. for Films Solvent Emulsion 10

11 -Catalyzed Condensation- Cure Syl-Off Silicone Release Coating Families: Solvent-Based Low coat weights easy to obtain on conventional equipment; good anchorage to films. Emulsion Fewer environmental, health, safety, and regulatory concerns than solvent-based coatings; wetting/drying process stresses paper; poor anchorage to films. Condensation Cure Catalyzed The tin-catalyzed condensation reaction (see Figure 5) has long been the workhorse of the release coating industry. Coatings consist of a silanol-functional polymer, a diluent and a silicon-hydride crosslinker. Although tin-catalyzed coatings will cure at room temperature, cure is generally initiated at elevated temperatures by a tin-salt catalyst. Cure takes place relatively slowly generally speaking, the lower the temperature, the slower the cure. Once initial cure is complete, a period of post-cure is required to complete the reaction. SiH + SiOH Sn SiOSi + H 2 -catalyzed condensation-cure chemistry offers important advantages: The catalyst is relatively inexpensive The coating is very robust, resistant both to substrate inhibition and catalyst poisoning for Films Solvent Emulsion Figure 5. Condensation-Cure Reaction Sn However, blocking, which is the tendency of a liner coated on both sides to bond to itself during storage, can occur; this generally rules out two-sided applications. There is also a greater potential for silicone migration with this chemistry. 11

12 Your Global Connection Dow Corning has sales offices, manufacturing sites, and science and technology laboratories around the globe. Telephone numbers of locations near you are available on the Web at dowcorning.com/contactus. For More Information For product data sheets, selection guides, and an overview of Dow Corning s comprehensive line of products and services for the pressure sensitive industry, visit dowcorning.com/psi. Photos: Front Cover: AV18755, AV21096, AV20819, AV21007, AV21097; Page 2: AV15390; Page 7: AV18755; Page 9: AV05321 HANDLING PRECAUTIONS PRODUCT SAFETY INFORMATION REQUIRED FOR SAFE USE IS NOT INCLUDED IN THIS DOCUMENT. BEFORE HANDLING, READ PRODUCT AND MATERIAL SAFETY DATA SHEETS AND CONTAINER LABELS FOR SAFE USE, PHYSICAL AND HEALTH HAZARD INFORMATION. THE MATERIAL SAFETY DATA SHEET IS AVAILABLE ON THE DOW CORNING WEBSITE AT DOWCORNING.COM, OR FROM YOUR DOW CORNING SALES APPLICATION ENGINEER, OR DISTRIBUTOR, OR BY CALLING DOW CORNING CUSTOMER SERVICE. LIMITED WARRANTY INFORMATION PLEASE READ CAREFULLY The information contained herein is offered in good faith and is believed to be accurate. However, because conditions and methods of use of our products are beyond our control, this information should not be used in substitution for customer s tests to ensure that our products are safe, effective and fully satisfactory for the intended end use. Suggestions of use shall not be taken as inducements to infringe any patent. Dow Corning s sole warranty is that our products will meet the sales specifications in effect at the time of shipment. Your exclusive remedy for breach of such warranty is limited to refund of purchase price or replacement of any product shown to be other than as warranted. DOW CORNING SPECIFICALLY DISCLAIMS ANY OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY. DOW CORNING DISCLAIMS LIABILITY FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. Dow Corning and Syl-Off are registered trademarks of Dow Corning Corporation. We help you invent the future is a trademark of Dow Corning Corporation. All other trademarks are the property of their respective owners. 2004, 2005, 2007, 2013 Dow Corning Corporation. All rights reserved. Printed in USA AGP13186 Form No E-01

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