By Shrikant AthavalePrathith Consultants

Pune – 411038www.psadhesive.com

Innovative Method of manufacturing

Adhesive Tapes

Here is a Innovative method of Manufacturing Self adhesive Tapes .This method is exclusively developed for handling Temperature sensitive Films, mechanically weaker substrates like non woven , lower GSM papers , foils , foam etc.

A Innovative method of manufacture of PVC Insulation tape / Non Woven fabric based Surgical tape , which has maximum sale , in Indian Market , which is used for Domestic Electrical Insulation purpose. Allmost 70% of the total requirement of this tape is Imported from China , because it is viable at very cheaper price as compared to the Indian manufacturers product. Hence there is a big scope to manufacture this product , locally , at a very cost effective price , and explore the market m and to put an break to the Import of this product.

PURPOSE OF INVENTION:

Advantages

1. Very cost effective2. Lot more easy to operate and with faster

processing speeds3. Will reduce wastage to a great extent. 4. Require much lower Heat energy .5. Retain of Mechanical properties. 6. Saving in the Capital cost. 7. Flexibility to use , differ kinds of PSA’s.

Very cost effective ?

Faster processing speeds Lower wastage Requires much lower Heat energy for processing No Primer coating No Chilling Retain original Mechanical properties Lower Capital Investment Require less space , to Install The flexibility to use , differ kinds of PSA’s.

Lot more easy to operate and with faster processing speeds

The newly designed machine will be lot more easy to operate and with faster processing speeds

Will reduce wastage to a great extent.

The invented process will reduce wastage to a great extent.

Require much lower Heat energy .

The new processing method , will required much lower Heat energy for processing , due to the Innovative design , some existing processes like Primer coating, Coated Film Chilling etc. will be totally eliminated

Retain of Mechanical properties.

The PVC Film/ Non woven Fabric will retain its original Mechanical properties , because it is never exposed to the Draying Heat , a most crucial requirement in the existing Process.

Saving in the Capital cost.

There will be a lot of saving in the Capital Investment , since the Machine is very much compact than the existing one , it will require less space , to Install, and the electrical energy consumption , will be reduced almost to 50% of the existing Procedure/ process.

Flexibility to use , differ kinds of PSA’s.

One more advantage is , the flexibility to use , differ kinds of Pressure sensitive Adhesive. At the moment , with the existing technology , only Solvent based Rubber adhesive is permissible to use , due to the limitations , built in the process itself. With the Invented method , there will be a choice to select adhesive , which can be , Water Based, Solvent Based (Prevailing ) , or Hot melt , Adhesives.

Description of the Invention

The Invented process of manufacturing the PVC Tape / Surgical Non woven , paper Tape , is very simple. This method is generally termed as transfer Coating method.In this said process The Silicone Release Coated paper / Film is coated , with adhesive , and then dried , if it’s water base or Solvent base , and the same is laminated with the PVC Film at the Lamination station .In case if Hotmelt adhesive is used than there is no question of drying at all , since the adhesive do not contain any solvent.Once the film is laminated with the adhesive coated Silicone paper , The laminate moves towards the Rewinding station. Here the Silicone paper is delaminated from the film , and the same is rewound on a separate Shaft. However the Film which is now adhesive coated and delaminated w, from the silicone paper is , wound on a separate rewind shaft , equipped with 4 station turret

The PVC / Non woven fabric is carona treated , ( prior to lamination with Silicone Paper) , which is a mechanical process only , and requires no extra raw materials , like Rubber based primer ,( Dissolved in solvent ) , The film is also treated with a release coating , for easy unwinding later on , the release coating is entirely based on water based system.The machine sketches for both , the existing process , as well as the Invented process , are attached for ready reference.

The PVC Tape , mainly used for , low tension , Domestic , Electrical Insulation , is manufactured as follows. PVC film is coated with , a Rubber based primer in solvent solution form , with approx. 2.5 gm / sq. mtr of coating ( Dry Wt. ) , on a Gravure coating machine , then it passes through a drying tunnel to evaporate the solvent . The Primed Film is then , coated with a Rubber Based ( Solvent dissolved ) Adhesive , on a comma coating station, with a coat weight of approx. 90 gm/ sq. mtr ( Dry ) , and then it is passed through the drying tunnel , to evaporate the solvent. The dryed file is then passed through the Freezing Tunnel , to cool down the film to room temperature , so that the in built stresses are relaxed.

The Existing Process

The cooled film is then rewound into rolls on a turrent Rewinder , to make rolls of exact length in meters. The tape log rolls as produced above are method is then conditioned at elevated temperature of around 48 deg C for a minimum period of 18 hours , for further stress relaxation process. The rolls conditioned as above are then sliced into , required widths like , 18 / 24 mm as per requirement , and then packed and are ready for sales.

Flow Chart for existing process

PVC Film Primer

Primed PVC Film

Primed PVC Film Rubber Based Adhesive

Adhesive coated PVC

Our Invention is so different form the existing process , and the same is as follows. With the Invented method there is a choice of selection of Adhesive system . The is substantial saving , if Hotmelt adhesive is used , as the adhesive coating weight , is reduced from 90 gm/ sq. mtr. To mere , 35 gm/ sq. mtr .By using , the specialy compounded Water base adhesive , the cost is reduced considerably , due to the fact that this adhesive will be atleast 25% cheaper than the Solvent based one.Secondly the Water based adhesive is totally environmentally friendly , and hence there are no VOC related issues.

Our Invention

One more major cost reduction is due .Thanks to the Newly Invented Process , where there No Primer used at all. The priming process is done , based on a Electro mechanical method called Carona Treatment, For this treatment , no raw material is consumed , and the electrical energy consumption is very much on lower or is negligible The process is very simple and there is another advantage , also in built. Since the film is not exposed to Heat , there are No in built stresses , and the film retains it’s original Mechanical properties.Since , there are No in built Stresses , the Annealing or conditioning process , is totally eliminated , which is a must for the existing way of this tape manufacture . The equipment is far more cost effective , requires much lower capital Investment , lower Shop floor area for manufacturing, lower electrical energy consumption, much lower coating of adhesive , no primer coating . All the equipment can be are manufacturerd in India as per our machine design. The complete Machine sketch is attached for ready ref.

Our Invention

The equipment is far more cost effective , requires much lower capital Investment , lower Shop floor area for manufacturing, lower electrical energy consumption, much lower coating of adhesive , no primer coating . All the equipment can be are manufacturerd in India as per our machine design. The complete Machine sketch is attached for ready ref.

Our Invention

Flow Chart for new process

PVC Film

CARONA tREATMENT

Carona PVC Film

Rubber Based AdhesiveAdhesive coated PVC

PVC Film

Carona PVC Film

NON WOVEN SURGICAL TAPEUSING HM PSA

PVC Tapeusing WB PSA

PVC TAPEUSING HM PSA

Non Woven Surgical Tapeusing WB PSA

For more details on the machine design, Adhesive Formulations, especially for Water Borne PSA for these tapes contact us on

Email : shrikantathavale@psadhesive.comOr Mobile : 07588288204OrVisit us on : www.psadhesive.com

Thank you