Foam Tape Product and Related Methods

Abstract

The present disclosure is directed to a foam tape product that does not require a release paper or other release material to prevent sticking on or within itself upon rolling. A method of manufacturing the foam tape product and kit are also provided.

We claim: 
     
         1 . A method of preparing a foam tape roll product comprising
 preparing an open-cell foam substrate having a first side and second, opposing side;   applying a pressure sensitive adhesive that is not ink imprintable to a first side of the foam substrate; and   applying a release coating composition to a second side of the foam substrate at a weight of from about 1.0 grams/100 cm 2  to about 1.9 grams/100 cm 2 , the release coating composition comprising a skin coat composition and an emulsion polymer composition,   wherein the foam tape roll product exhibits a peel strength of from about 0.3 pounds to about 0.5 pounds according to ASTM D1876.   
     
     
         2 . The method of  claim 1 , further comprising the steps of
 preparing the skin coat composition;   preparing the emulsion polymer composition; and   combining the skin coat composition and emulsion polymer composition to form the release coating composition.   
     
     
         3 . The method of  claim 1 , wherein the release coating composition is applied via knife over roll, spray, or screen coat. 
     
     
         4 . The method of  claim 1 , wherein the open-cell foam substrate is skived during production to expose an open cellular structure. 
     
     
         5 . The method of  claim 1 , wherein the skin coat composition comprises a polyurethane dispersion. 
     
     
         6 . The method of  claim 1 , wherein the emulsion polymer composition comprises an aqueous silicon fluid emulsion. 
     
     
         7 . The method of  claim 6 , wherein the aqueous silicon fluid emulsion comprises at least one base release polymer, a crosslinking component, and a catalyst. 
     
     
         8 . The method of  claim 1 , wherein the pressure sensitive adhesive comprises one or more acrylic, butyl rubber, ethylene-vinyl acetate (EVA), nitrile, silicone rubber, styrene block copolymer, styrene-isoprene-styrene, styrene-butadine-styrene, sytrene-ethylene/butylene-sytrene, styrene-ethylene/propylene, vinyl ethers, polychloroprene, or a combination thereof. 
     
     
         9 . The method of  claim 1 , wherein the foam tape roll product exhibits a thickness of from about 0.03 inches to about 1.50 inches. 
     
     
         10 . The method of  claim 1 , wherein the foam tape roll product exhibits a width of from about 0.03 inches to about 5.0 inches wide. 
     
     
         11 . The method of  claim 1 , wherein the density of the open-cell foam substrate is from about 5 lbs/ft 3  to about 40 lbs/ft 3 . 
     
     
         12 . The method of  claim 1 , wherein the release coating composition comprises from about 2.5 weight % to about 30 weight % of the aqueous emulsion polymer composition with the balance of the release coating composition comprising the skin coat composition. 
     
     
         13 . The method of  claim 12 , wherein the release coating composition comprises from about 10 weight % base release polymer to about 20 weight % base release polymer. 
     
     
         14 . The method of  claim 14 , wherein the density of the foam is from about 10 lbs/ft 3  to about 16 lbs/ft 3 . 
     
     
         15 . The method of  claim 1 , further comprising the step of drying the release coating composition. 
     
     
         16 . The method of  claim 15 , wherein the step of drying the release coating composition is carried out in an oven. 
     
     
         17 . The method of  claim 16 , wherein the oven is at a temperature of between about 90° C. and about 170° C. 
     
     
         18 . The method of  claim 16 , having an oven dwell time of from about 20 seconds to about 5 minutes.