Research Grants/Fellowships/SBIR

Final Report: Solventless, Electron Beam-Cured Acrylate Coating Formulations for Flexible Magnetic Media Manufacture

EPA Grant Number: R826728
Title: Solventless, Electron Beam-Cured Acrylate Coating Formulations for Flexible Magnetic Media Manufacture
Investigators: Nikles, David E.
Institution: University of Alabama at Birmingham
EPA Project Officer: Richards, April
Project Period: October 1, 1998 through September 30, 2001
Project Amount: $285,000
RFA: Technology for a Sustainable Environment (1998) RFA Text |  Recipients Lists
Research Category: Sustainability , Pollution Prevention/Sustainable Development



The objective of this research was to lead the flexible magnetic media industry into the 21st century by providing new tape and floppy disk manufacturing processes that prevent air pollution. Our goal was to replace the organic solvents used in the coating process with a mixture of liquid acrylate monomers. The monomers serve as the solvent to disperse the magnetic pigments and dissolve any other ingredients, rendering fluidity and coatability to the formulation. Upon electron beam irradiation, the acrylates polymerize to give a solid binder with the requisite mechanical properties. The object of this research project is to identify the binder materials package that enables the solventless coating process.

Summary/Accomplishments (Outputs/Outcomes):

Research has focused on solving our most challenging problem, which is dispersion on the rheology of the dispersions. We are seeking methods to achieve solventless acrylate dispersions with a magnetic particle loading greater than 30 volume percent. Significant progress has been made toward realizing solventless, radiation-cured coating formulations for magnetic tape manufacture. A series of trimethoxysilanes was bound to the surface of commercial magnetic particles, through videotape grade cobalt-modified -Fe2O3 of state-of-the-art iron particles. The silanes made covalent bonds with surface hydroxyl groups on the particles. Solventless formulations were prepared using particles treated with coupling agents. The particle loading was up to 40 weight percent. The viscosity for the solventless formulations showed an exponential decrease as a function of increasing shear rate. This was similar to the shear-thinning behavior observed for conventional solvent-based formulations. New acrylate functionalized silane coupling agents, either branched or polymeric, were synthesized. Using a long spacer between the silane functional group and the branch point relieved steric crowding for the branched coupling agents. Fully pigmented, solventless acrylate formulations can be cured by UV irradiation, provided the film thickness was 1 micron or less.

Journal Articles on this Report : 8 Displayed | Download in RIS Format

Other project views: All 16 publications 11 publications in selected types All 8 journal articles
Type Citation Project Document Sources
Journal Article Farahat MS, Nikles DE. Novel binder systems derived from poly(ethylene terephthalate) PET waste for solventless magnetic tape manufacturing: Investigation on the mechanical properties of the methacrylated oligoesters. Polymer Preprints 2001;42(2):558-559. R826728 (Final)
not available
Journal Article Farahat MS, Nikles DE. On the UV curability and mechanical properties of novel binder systems derived from poly(ethylene terephthalate) PET waste for solventless magnetic tape manufacturing; 1. Acrylated oligoesters. Macromolecular Materials Engineering 2001;286(11):695-704. R826728 (Final)
R827121 (2001)
R827121 (Final)
not available
Journal Article Hait SB, Nikles DE. Synthesis and characterization of copoly(acrylate)s with silane functional groups in the side chains. Polymer Preprints 2000;41(2):1305-1306. R826728 (2000)
R826728 (Final)
not available
Journal Article Hait SB, Nikles DE. Synthesis of amine-quinone polyurethanes with amine-quinone group in the backbone and acrylate group in the side chain of the polymer. Polymer Preprints 2001;42(2):674-675. R826728 (Final)
not available
Journal Article Hait SB, Huh JY, Nikles DE. Synthesis of side chain amine-quinone polyurethanes and their use to inhibit the corrosion of iron particles. Polymer Preprints 2001;42(2):676-677. R826728 (Final)
not available
Journal Article Huh JY, Woo T, Nikles DE. Effect of silane coupling agents on rheological properties of solventless magnetic ink. Polymeric Materials: Science and Engineering 2001;85:387-388. R826728 (Final)
not available
Journal Article Nikles SM, Piao M, Lane AM, Nikles DE. Ethyl lactate: A green solvent for magnetic tape coating. Green Chemistry 2001;3(3):109-113. R826728 (Final)
R827121 (2001)
R827121 (Final)
not available
Journal Article Woo T, Huh JY, Nikles DE. Surface chemistry and dispersion of magnetic pigment for a solventless process. Ieee Transactions on Magnetics 2001;37(4):1634-1636 R826728 (Final)
R827121 (2001)
R827121 (Final)
not available
Supplemental Keywords:

air, VOC, solvents, pollution prevention, green chemistry, clean technologies, environmentally conscious manufacturing, chemistry, engineering, electronics., RFA, Industry Sectors, Scientific Discipline, Air, Sustainable Industry/Business, air toxics, Environmental Chemistry, Manufacturing - NAIC 31-33, Sustainable Environment, Technology for Sustainable Environment, indoor air, tropospheric ozone, cleaner production, electron beam-cured vinyl ether coating formulations, flexible magnetic media manufacture, sustainable development, waste minimization, waste reduction, stratospheric ozone, environmentally conscious manufacturing, coupling agent, hazardous emissions, air pollution control, green process systems, acrylate coating, treatment, environmental exposure, solvent substitute, liquid acrylate monomers, innovative technology, indoor air quality, industrial innovations, pollution prevention, source reduction, polymer design

Progress and Final Reports:
Original Abstract
2000 Progress Report