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 : 6 Displayed | Download in RIS Format

Other project views: All 15 publications 8 publications in selected types All 6 journal articles
Type Citation Project Document Sources
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)
  • Abstract: Wiley-Abstract
  • Journal Article Hail 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 Han M, Nikles DE. Amine-quinone polyurethanes containing N-alkylated amine-quinone monomers. Journal of Polymer Science Part A: Polymer Chemistry 2000;38(18):3284-3292. R826728 (Final)
  • Abstract: Wiley-Abstract
  • Journal Article Nikles DE, Farahat MS. New motivation for the depolymerization products derived from poly(ethylene terephthalate) (PET) waste: a review. Macromolecular Materials and Engineering 2005;290(1):13-30. R826728 (Final)
  • Abstract: Wiley-Abstract
  • Journal Article Nikles SM, Piao M, Lane AM, Nikles DE. Ethyl lactate: a green solvent for magnetic tapecoating. Green Chemistry 2001;3(3):109-113. R826728 (Final)
    R827121 (2001)
    R827121 (Final)
  • Abstract: RSC-Abstract
  • 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)
  • Abstract: IEEE-Abstract
  • 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
  • 1999
  • 2000 Progress Report