Precursor composite material, method for producing a precursor composite material, method for producing a composite material and use of a precursor composite material and of a composite material

Abstract

A precursor composite material (60) is provided, having a layer sequence (50) comprising an adhesive layer (20), a carrier layer (10) on the adhesive layer (20), a release layer (40) on the carrier layer (10) and a parting layer (30) on the release layer (40), wherein the layer sequence (50) is arranged in such a way that the side of the adhesive layer (20) facing away from the layer sequence (50) is arranged at least in sub-regions on the side of the parting layer (30) facing away from the layer sequence (50). Further provided are a composite material, a method for producing the precursor composite material, a method for producing the composite material and a use of the precursor composite material and of the composite material.

Claims

1. A precursor composite material having a layer sequence, comprising an adhesive layer, a carrier layer on the adhesive layer, a release layer on the carrier layer and a parting layer on the release layer, wherein the layer sequence is wound such that at least a sub-region of the side of the adhesive layer facing away from the layer sequence is arranged on the side of the parting layer facing away from the layer sequence, wherein an adhesive force is present between the adhesive layer and the parting layer, said adhesive force being greater than a delamination force between the carrier layer and the release layer.

2. The precursor composite material according to claim 1, wherein the release layer has a thickness of less than 40 ?m and/or the carrier layer has a thickness of less than 20 ?m.

3. The precursor composite material according to claim 1, wherein the adhesive layer has a material selected from a group comprising pressure-sensitive adhesives.

4. The precursor composite material according to claim 1, wherein the release layer has a material selected from a group comprising polyamide, polystyrene, thermoplastic elastomers, polystyrene copolymers, polyester, polyester copolymers, polyolefins, combinations thereof and combinations of polyamide, polystyrene, thermoplastic elastomers, polystyrene copolymers, polyesters, polyester copolymers and/or polyolefins with adhesion promotors.

5. The precursor composite material according to claim 1, wherein the carrier layer has a material selected from a group comprising polyolefins, polyolefin copolymers, thermoplastic elastomers and combinations thereof.

6. The precursor composite material according to claim 1, wherein the parting layer has a material selected from a group comprising silicone, hardened polysiloxane and thermoplastic silicone elastomer.

7. A composite material, produced from the precursor composite material according to claim 1, comprising a release layer, a parting layer on the release layer, an adhesive layer on the parting layer and a carrier layer on the adhesive layer.

8. A method for producing the composite material according to claim 7 comprising the steps: A) Providing a layer sequence, comprising an adhesive layer, a carrier layer on the adhesive layer, a release layer on the carrier layer and a parting layer on the release layer; B) Winding the layer sequence such that at least a sub-region of the side of the adhesive layer facing away from the layer sequence and the side of the parting layer facing away from the layer sequence to produce a precursor composite material; and C) Delaminating the carrier layer and the release layer of the precursor composite material to produce a composite material.

9. A method for producing the precursor composite material according to claim 1, comprising the steps: A) Providing a layer sequence, comprising an adhesive layer, a carrier layer on the adhesive layer, a release layer on the carrier layer and a parting layer on the release layer; and B) Winding the layer sequence such that at least a sub-region of the side of the adhesive layer facing away from the layer sequence is arranged on the side of the parting layer facing away from the layer sequence.

10. The method according to claim 9, wherein step A) comprises the steps: A1) Coextruding at least the carrier layer and the release layer; and A2) Coating at least the carrier layer with the adhesive layer.

11. The method according to claim 10, wherein the carrier layer and the release layer are coextruded in step A1) and the carrier layer is coated with the adhesive layer and the release layer with the parting layer in step A2), or wherein the parting layer, the release layer and the carrier layer are coextruded in step A1) and the carrier layer is coated with the adhesive layer in step A2).

12. A label, sticker or a component in a hygienic laminate, comprising a composite material of claim 7.

Description

(1) Further advantages, advantageous embodiments and developments result in the following in connection with the embodiments described by the illustrations.

(2) FIGS. 1a and 1b show schematic side views of a precursor composite material pursuant to one embodiment,

(3) FIG. 2 shows the schematic side view of a precursor composite material pursuant to a further embodiment,

(4) FIG. 3 shows the schematic side view of a composite material,

(5) FIGS. 4a, 4b and 4c show schematic side views of coextruded layers of the precursor composite material,

(6) FIGS. 5a, 5b and 5c show schematic side views of layer sequences of the precursor composite material pursuant to various embodiments,

(7) FIGS. 6a, 6b and 6c show schematic side views of precursor composite materials pursuant to various embodiments,

(8) FIGS. 7a and 7b show schematic side views of the method for producing a composite material using the precursor composite material,

(9) FIGS. 8a and 8b show the schematic side view and schematic top view of a hygienic laminate.

(10) Identical, similar or seemingly identical elements in the embodiments can each be furnished with the same reference numerals. The elements shown and the size ratios thereof relative to each other should not be viewed as true-to-scale; instead individual elements, such as layers and areas, for example, can be shown exaggeratedly large for the sake of better representation or better understanding.

(11) FIGS. 1a and 1b show schematic side views of a precursor composite material 60. Shown in each case are excerpts of the precursor composite material 60. FIG. 1b shows the layer sequence 50 of the precursor composite material 60, which is present in a wound manner. FIG. 1a also shows the layer sequence 50, which is present in a wound manner, but as cross-section through the winding, and therefore a plurality of layer sequences 50 arranged on top of each other are to be seen. Depending on the size of the winding, many more layer sequences 50 can be present arranged on top of each other in the winding.

(12) Each layer sequence 50 has an adhesive layer 20, a carrier layer 10, a release layer 40 and a parting layer 30. The latter are arranged on top of each other in such a way that they have joint limiting surfaces relative to each other. Due to the arrangement on top of each other, the parting layer 30 and the adhesive layer 20 additionally have a joint limiting surface, at least in sub-regions 25 of the layer sequence.

(13) The materials of the adhesive layer 20 are selected in such a way that the adhesive force between adhesive layer 20 and parting layer 30 is greater than the delamination force between the carrier layer and the release layer 40. The material of the adhesive layer 20 is a pressure-sensitive adhesive that remains permanently adhesive and/or highly viscous once applied to the carrier layer. The material of the parting layer 30 can be silicone, hardened polysiloxane or a thermoplastic silicone elastomer. The carrier layer 10 can comprise polyethylene, polypropylene, polypropylene copolymers of thermoplastic elastomers. The release layer 40 has, for example, polyethylene, polypropylene, polyamide, thermoplastic elastomers, polystyrene, polystyrene copolymers, polyester and/or polyester copolymers as material.

(14) The thickness of the carrier layer 10 equals less than 20 ?m, preferably less than 15 ?m, more preferably less than 10 ?m, most preferably less than 5 ?m. The thickness of the release layer 40 equals less than 40 ?m, preferably less than 30 ?m, more preferably less than 20 ?m and most preferably less than 15 ?m.

(15) For example, the adhesive layer 20 is made out of the pressure-sensitive adhesive Solucryl 147 produced by Henkel (an acrylic copolymer), the carrier layer 10 of a polyether copolymer-based TPE-U Pearlthane Clear 15N85 produced by Merquinsa, the release layer 40 of the low-density polyethylene Lupolen 2420 F produced by LyondellBasell and the parting layer 30 of a silicone based on Tego RC 902 (98%) and Tego Photoinitiator A 18 (2%) produced by EVONIK.

(16) FIG. 2 shows a further embodiment of the precursor composite material 60 in schematic side view. This illustration should also be understood as a section of a precursor composite material 60 in which two layer sequences 50 arranged on top of each other are to be seen. Depending on the arrangement of the precursor composite material or thickness of the winding of the precursor composite material 60, a plurality of layer sequences 50 can also be arranged on top of each other.

(17) The carrier layer 10 in this example contains two partial layers in each case, a first carrier layer 11 and a second carrier layer 12. The first carrier layer 11 can comprise a polymer, such as polyethylene, polypropylene, polypropylene copolymers, thermoplastic elastomers or combinations thereof. The second carrier layer 12 can comprise a polyethylene, polypropylene, polypropylene copolymers as well as thermoplastic elastomers and combinations thereof. The combination of a plurality of carrier layers serves to configure the softness of the carrier layer. This can, for example, be of relevance when the carrier layer in a hygienic laminate has the function of an underwear-protecting film, which needs to be soft when used. If a thermoplastic elastomer, TPE-E or TPE-U for example, is used as material for the carrier layers, the carrier layer is also breathable.

(18) Furthermore, the release layer 40 is subdivided into three partial layers and comprises the first release layer 41, the second release layer 42 as well as the third release layer 43. The first release layer 41 has, for example, a polymer selected from a group comprising polyethylene, polypropylene, polyamide, thermoplastic elastomers, polystyrene, polystyrene copolymers, polyester and polyester copolymers. The second release layer 42 comprises a polymer serving as an adhesion promoter. The third release layer 43 can in turn comprise, for example, polymers, such as polyethylene or polyolefins. The subdivision of the release layer 40 into three partial layers serves to modify the stiffness or softness of the release layer 40. In addition, when polyamide is used as material for the release layer 40, the costs of the release layer can be reduced, in that the expensive polyamide is replaced by the sequence polyolefin/adhesion promotor/polyamide. The thicknesses of the carrier layer 10 and of the release layer 40 are equivalent to the thicknesses as stated with regard to FIGS. 1a and 1b.

(19) When using the precursor composite material or when using the composite material produced from the precursor composite material, the parting layer 30 serves as protective coating of the adhesive layer 30 and enables simple removal. The adhesive layer 20 can thus be adhered when used on an application surface, such as textiles, for example.

(20) The adhesive layer 20 in an exemplary structure is made out of the pressure-sensitive adhesive Solucryl 147 produced by Henkel, the carrier layer 10 of the high-density polyethylene Hostalen GF 9045 F produced by LyondellBasell, the parting layer 30 of a silicone on the basis of Tego RC 902 (98%) and Tego Photoinitiator A 18 (2%) produced by EVONIK and the release layer 40 of three partial layers, wherein the first release layer 41 is made out of the polyamide Durethan C 38 F produced by Lanxess in a thickness of 1 ?m to 10 ?m, the second release layer 42 of the adhesion-promoting homopolypropylene-based polymer Admer QB 520 E produced by Mitsui Chemicals in a thickness of 1 ?m to 10 ?m and the third release layer 43 of a polyolefin or high-density polyethylene, such as Hostalen GF 9045 F, produced by LyondellBasell in a thickness of 1 ?m to 30 ?m.

(21) FIG. 3 shows the schematic side view of a composite material 70. The latter comprises a release layer 40, a parting layer 30 on the release layer 40, an adhesive layer 20 on the parting layer as well as a carrier layer 10 on the adhesive layer 20. Such a composite material 70 is produced from the precursor composite material 60, and therefore the materials and layer thicknesses of the layers indicated with regard to the precursor composite material also apply to the layers of the composite material 70. Thus, above all, the carrier layer 10 and/or the release layer 40 are designed in a particularly thin manner, which makes the composite material 70 suitable for use in a hygienic laminate or as a label, for example. In particular, the use in a hygienic laminate leads to an improved wearing comfort due to the thin layers 10 and 40.

(22) The following FIGS. 4 to 7 explain the method for producing the precursor composite material 60 as well as the composite material 70 produced from the precursor composite material 60. FIGS. 4 to 6 refer to the production of the precursor composite material 60, FIG. 7 to the production of the composite material 70. Each of FIGS. 4 to 6 shows three embodiments of a precursor composite material 70 or the steps to the production thereof. FIGS. 4a, 5a and 6a refer to a first embodiment, FIGS. 4b, 5b and 6b refer to a second embodiment and FIGS. 4c, 5c and 6c refer to a third embodiment.

(23) FIG. 4 shows schematic side views of coextruded layers of the precursor composite material 60 after step A1). FIG. 4a shows a first embodiment, in which a carrier layer 10 and a release layer 40 are coextruded, FIG. 4b shows a second embodiment, in which the carrier layer 10 is composed of two partial layers and the release layer 40 is composed of three partial layers, and therefore a total of five coextruded layers are present after step A1). The respective materials of the individual layers are equivalent to those stated with regard to FIGS. 1 and 2. FIG. 4c shows a third embodiment, in which a first carrier layer 11 and a second carrier layer 12 as carrier layer 10, a first release layer 41 and a third release layer 43 as release layer 40, as well as a parting layer 30 are coextruded together. In such case, the parting layer 30 comprises a material selected from a hardened polysiloxane and a thermoplastic silicone elastomer. Such materials can be coextruded and thus also designed in a particularly thin manner.

(24) Schematic arrows in all of FIGS. 4a, 4b and 4c show where the controlled delamination for producing a composite material will later take place, i.e. in each case between the carrier layer 10 and the release layer 40, or between the second carrier layer 12 and the first release layer 41. The delamination is rendered possible due to the presence of an adhesive force between the adhesive layer 20 and the parting layer 30, said adhesive force being greater than the delamination force between the carrier layer 10 and the release layer 40.

(25) FIG. 5 shows the schematic side view of layer sequences of various embodiments of the precursor composite material 60. The method for producing the precursor composite material 60 is an intermediate product, which is obtained after step A).

(26) After the coextrusion of the carrier layer 10 and the release layer 40 shown in FIG. 4, during which the thickness of each is configured by tension, at least the carrier layer 10 is coated with an adhesive layer 20 in step A2). In the embodiment pursuant to FIG. 5 the carrier layer 10 is coated with the adhesive layer 20 and the release layer 40 with the parting layer 30. In such case, a silicone layer is used as parting layer 30. In the embodiment pursuant to FIG. 5 the first carrier layer 11 is coated with the adhesive layer 20 and the third release layer 43 also coated with a parting layer 30. In such case, the parting layer 30 is also a silicone layer. In the embodiment pursuant to FIG. 5c the carrier layer 30 has already been coextruded with the release layer 40 and the carrier layer 10, and therefore only one coating of the first carrier layer 11 with the adhesive layer 20 has taken place in step A2). In each case, the coatings preserve layer sequences 50, which can now also be further transformed at a lower thickness than carrier 10 and/or release layer 40, without any destruction of the thin layers occurring. In each of FIGS. 5a to 5c schematic arrows again show where the controlled delamination of the layers occurs during the further transformation of the precursor composite material into a composite material.

(27) FIG. 6 shows schematic side views of the finished precursor composite material 60 of the various embodiments after step B), i.e. after the arrangement of the layer sequence 50, and therefore the side of the adhesive layer 20 facing away from the layer sequence is arranged at least in sections on the side of the parting layer 30 facing away from the layer sequence. Each of the schematic side views of FIGS. 6a to 6c should also be understood as excerpts as, depending on the length and arrangement or winding of the layer sequence, considerably more layer sequences 50 can be arranged on top of each other. The individual layer sequences 50 of FIGS. 6a and 6b have already been explained above with regard to FIGS. 1a and 2. Each of the parting layers 30 is a silicone layer. The layer sequence 50, as shown in FIG. 6c, comprises parting layers 30, which comprise hardened polysiloxane or thermoplastic silicone elastomers as material, the release layer 40 further contains two partial layers, namely the first release layer 41 and the third release layer 43.

(28) The schematic arrows in FIGS. 6a to 6c again show at what point a controlled delamination takes place in the event of the arrangement of the layer sequences 50 being dissolved, i.e. for example, in the event of the layer sequence 50 being unwound. Each illustration indicates at what point a composite material 70 will result in the event of the re-sorting or the delamination of the precursor composite material 60.

(29) FIGS. 7a and 7b shows the method for producing the composite material 70 from the precursor composite material 60 on the basis of a schematic side view of a wound precursor composite material 60. These illustrations should again be understood as excerpts. FIGS. 7a and 7b show the method on the basis of a precursor composite material 60, comprising a parting layer 30, a silicone layer in this case, a release layer 40, a carrier layer 10 as well as an adhesive layer 20. Analogous methods would also be applicable to layer sequences 50 of the precursor composite material 60, which each have a plurality of partial layers as carrier layer 10 and as release layer 40. During the controlled delamination of the precursor composite material 60 the combination of parting layer 30 and release layer 40 is initially unwound alone (FIG. 7a), which is particularly easy to achieve, as the delamination force between the carrier layer 10 and the release layer 40 is less than the adhesive force between the adhesive layer 20 and the parting layer 30 on which the adhesive layer is arranged in sub-regions of the layer sequence 50. As soon as half the layer sequence made up of parting layer 30 and release layer 40 has been unwound and the sub-region of the wound layer sequence in which the parting layer 30 is arranged on the adhesive layer 20 has been reached, the composite material 70, in which carrier layer 10, adhesive layer 20, parting layer 30 and release layer 40 are arranged on top of each other, is unwound, as here too the delamination force between the release layer 40 and the carrier layer 10 is again less than the adhesive force between the adhesive layer 20 and the parting layer 30. This allows the composite material 70 to be acquired from the precursor composite material 60 in a particularly easy manner (FIG. 7b).

(30) FIG. 8 shows the schematic side view (FIG. 8a) and a schematic top view (FIG. 8b) of a hygienic laminate in which a composite material 70, produced from the precursor composite material 60, is used.

(31) In FIG. 8a the composite material 70, consisting of release layer 40, parting layer 30 on the release layer 40, adhesive layer 20 on the parting layer 30 as well as a carrier layer 10 on the adhesive layer 20 is arranged in such a way that further layers of the hygienic laminate are arranged on the carrier layer 10. The latter comprise an adhesion 85, a suction core on the adhesion 85, a distribution layer 83 on the suction core 84, an adhesion 82 on the distribution layer 83 and a non-woven covering 81 on the adhesion 82. In such case, the carrier layer 10 can be designed as an underwear-protecting film. If the hygienic laminate is used by a consumer, the release film 40 can be removed together with the parting layer 30 and the hygienic laminate again removably attached to the adhesive layer 20 in the underwear.

(32) FIG. 8b shows a top view of the hygienic laminate 80 in which only the non-woven covering 81 is visible.

(33) When using the composite material as shown in FIG. 8, it is advantageous when the carrier layer 10 is designed in a breathable manner, which can be achieved by using TPE-U or TPE-E as material for the carrier layer 10.

(34) The invention is not restricted by the description on the basis of the embodiments. Instead, the invention comprises every new feature as well as every combination of features, which in particular includes every combination of features in the claims, even if such claim or such combination is not itself explicitly provided in the claims or embodiments.

LIST OF REFERENCE NUMERALS

(35) 10 Carrier layer 11 First carrier layer 12 Second carrier layer 20 Adhesive layer 25 Sub-region of the layer sequence, wherein the parting layer (30) and the adhesive layer (20) have a joint surface. 30 Parting layer 40 Release layer 41 First release layer 42 Second release layer 43 Third release layer 50 Layer sequence 60 Precursor composite material 70 Composite material 80 Hygienic laminate 81 Non-woven covering 82 Adhesion 83 Distribution layer 84 Suction core 85 Adhesion