A novel approach to graft acrylates onto commercial silicones for release film fabrications by two-step emulsion synthesis

In this study, a two-step emulsion polymerization method was specially designed so as to effectively graft acrylate monomers onto commercial silicones and improve the properties of release films. FT-IR, DSC and grafting ratio tests showed that the grafting reaction happened and a high grafting ratio can be achieved when the silicone content was more than 20%. According to SEM-EDX result, the “sea-island” structure on the surface of release films made by acrylate-modified silicone latexes was proven. The silicones formed the continuous “sea” structure and the grafted acrylate polymers formed the segregated “island” structure. The carbon and silicon distributions were not uniform through the cross-section of release films made by acrylate-modified silicone latexes. After acrylate modification, the surface tension of silicone release films increased from 19–21 mN/m (before acrylate modification) to 30 mN/m and the release force increased from 8.1 g/in. to 47 g/in. As a result, the properties of release films have been effectively improved by our novel method for advanced applications.