Tape Casting Additives

 

 

Polymer Innovations has developed a complete set of specialized additives that are custom-tailored for compatibility with our Water Based Binder System. Using these additives with our Water Based Binders allows you to engineer a slurry formulation to accommodate most ceramics, thicknesses, tape casters, casting surfaces and other conditions and variables. We also offer additives that are specifically designed for use with solvent based binder systems.

 

 

 

 

Defoamers:

DF002

 

By far our most popular and most effective defoamer, DF002 is highly compatible with our Water Based Binder System and is very useful with a wide variety of powders. This is a non-silicone, mild defoamer with 100% solids which burns out cleanly with very little residue. Typical levels are .05% up to 2% of slurry/slip formula weight, and it can be advantageous to add this defoamer in the 1st and/or 2nd stages of milling. DF002 is not particularly powerful but usually performs adequately and excessive levels do not normally cause problems within a slurry or cast tape.

 

 

DF001

 

DF001 is a very powerful modified silicone copolymer especially effective for casting thicker tapes rather than thinner tapes. DF001 works by joining small bubbles into larger bubbles which are then easier to break during de-airing. When casting thick it can be beneficial to use DF001 and DF002 together to eradicate bubbles and foam. DF001 has 100% solids and may leave some silica residue. DF001 is a concentration-sensitive defoamer, so typical level in slurry/slip is .05 to .25 weight %. Using too much DF001 can result in tape defects such as 'fish eyes' or craters - especially in thinner tapes, so it is especially useful for certain tapes which are not sensitive to cosmetics. Using too much of this additive or using it with certain ceramic powders can cause fish eye type defects, so DF002 (normally more forgiving) is recommended for more critical tapes.

 

 

 

 

Plasticizers:

PL002

 

Slightly basic, water soluble plasticizer similar to PL001 but more reactive with WB Binders. This plasticizer is 100% solids and can be very effective for increasing the ease of tape lamination. Using PL002 will result in a softer ceramic tape, so it is also useful for increasing tackiness and making cleaner cuts during chip dicing. PL002 has the ability to increase binder dispersion power if included in 1st stage of milling. Due to higher pH, PL002 can make dried tapes more susceptible to water attack. Typical usage levels are .2% to 1.5% of slurry weight.

 

 

PL008

 

Another relatively high pH, water soluble plasticizer/modifier that can be slightly more forgiving than the other PL's.

This product has both amine and alcohol functionality and can be used to increase viscosity stability and dispersability with certain reactive powders. PL008 is a great substitute for PL005, as it costs less and is slightly less reactive. Solids are 95% and typical usage levels are between .2% and .5%.

 

 

PL005

 

Very high pH plasticizer which is highly reactive with the WB Binder Series, which can help manage some otherwise very difficult powders. If highly reactive or low pH powders are causing problems such as binder precipitation or adverse tape reaction, it can be very helpful to include PL005 in the formula - more specifically adding water & PL005 and mixing before adding powder then binder. PL005 also increases the dispersion power of the WB4101 if it is included during the grinding stage (can also increase the effectiveness of the DS- Series dispersing additives when used together) and also helps in effective dispersion of nano powders. Due to high pH can make dried tapes more susceptible to water attack. PL005 is 100% solids and typical usage levels are .2% to 1% of slurry weight.

 

 

PL001

 

The same plasticizer pre-formulated (7%) into our most widely used Binder, WB4101. This neutral pH, water soluble plasticizer is very useful for increasing tape softness, flexibility and lamination characteristics. PL001 is 100% solids and typical usage levels are .2% to 1.5% of slurry weight.

 

 

PL029

 

PL029 is a non-phthalate, REACH compliant and non-hazardous liquid additive for solvent based polyvinyl butyral (PVB) and certain acrylic tape casting binders, and is very useful for replacing restricted phthalate plasticizers. Plasticizer efficiency and volatility is similar or slightly better than other common phthalate plasticizers, and PL029 will burn out cleanly in reducing and oxidizing atmospheres. PL029 is our answer for the REACH approved DOP/BBP direct replacement issue facing manufacturers around the world. Using this product will result in a ceramic tape that is softer and easier to laminate, and should be implemented in a 1:1 ratio when replacing DOP/BBP then fine tuned based on the results.

 

 

 

 

Dispersing Additives:

DS005

 

DS005 is a strong general purpose dispersant designed to be used in water or water/solvent mixtures. It is highly compatible with WB4101 and WB series Water Based Binder Systems and will not greatly reduce the strength of the resulting green tape as is common with many other traditional dispersants. A typical level would be about .3 to 2% based on the weight of the inorganic to be dispersed. The addition of PL005 to the formula at a ratio of about .5 to 1% based on the amount of DS005 can further increase the dispersing power, especially in first stage milling. Solids content of DS005 is 50%.

 

 

DS001

 

DS001 is a strong general purpose dispersant designed to be used in water or water/solvent mixtures. It is highly compatible with WB4101 and WB series Water Based Binder Systems and will not greatly reduce the strength of the resulting green tape (as is common with many other traditional dispersants). A typical level would be about .25 to 2% based on the weight of the inorganic to be dispersed. The addition of PL005 to the formula at a ratio of about .5 to 1 based on DS001 can further increase the dispersing power. Solids content of DS001 is 40%.

 

 

DS002

 

DS002 is a very strong and effective phosphate ester based synthetic dispersing agent widely compatible with aqueous and solvent based systems. This additive is compatible with our Water Based binders but more popular in solvent based systems, since using DS002 may result in lower of tape strength with our water based systems. Solids content of 100% and typical usage level of .5% up to 1.5% of slurry/slip formula weight.

 

 

DS004

 

DS004 is a high molecular weight solution of polymeric phosphate ester. It is considered a strong dispersant which can allow higher loading while retaining good slip and tape characteristics. Solids content of 60% and typical level of .5% up to 1.5% of slurry/slip formula weight. DS004 can be effective in our WB binder systems, but it is very popular with solvent based systems like PVB.

 

 

DS009

 

Another strong polymeric dispersant, but one which has different properties than the other dispersants in the product line. We always recommend DS009 if DS005 does not work well, and this dispersant can also be extremely useful with Zirconia ceramics. Solids are 65% and typical level of usage is .3% to 1.5% of slurry/slip formula weight.

 

 

 

 

Thick Casting Additives:

 

TK004 & TK005

 

TK004 and TK005 are designed to be used together in a 1:1 ratio. Typical usage level is approximately .4 or .5 weight % and solids of TK004 is 30% while solids of TK005 is 100%. These additives stabilize thick sections of cast tape during drying to allow defect free thick casts (>150 microns) free of cracking and settling. These additives can also stabilize small bubbles which may require more rigorous de-airing and/or defoaming additives (DF001 or a combination of DF001 + DF002 also works well). When added to the slurry/slip with the correct technique and order, they can greatly increase thick ceramic cast uniformity in tapes greater than 1mm thick. Please Note: Order of addition as well as speed of addition and mixing techniques are very important to make these additives work properly. For more details and correct addition procedures, please see our section on Thick Casting.

 

Videos: Slurry Preparation for Water Based THICK Tape Casting:

Step by step process for preparing slurry with PII's thick tape casting additives.

 

 

 

 

Steel Belt Release Additives:

BR021

 

BR021 is used as an external belt release additive for pre-coating on the steel belt to allow easy release of the cast tape from the belt. Only a very thin film is required for coating the steel belt. Typically a dilute solution of about 5-10% in hydrocarbon such as naptha or toluene is made and a very thin film applied to the steel belt by means of a felt wick type applicator far enough in front of the casting head so they solvents are dry before the doctor blade. BR021 can also be high-shear mixed into a water emulsion for application if hydrocarbons should be avoided. Solids are 100%.

 

 

BR008

 

BR008 is an internal belt release additive. When added to 1st or 2nd milling stage, it will help cast tapes release from steel belt casting surfaces. BR008 can also be added to slurry/slip formulations to increase tape flexibility. Pre-mixing BR008 with WB Binders should be avoided as it can cause temporary binder precipitation. Solids are 100% and typical level in slurry/slip is .5 to 1.5 weight %.

 

 

BR010

 

BR010 is a water based, silicone containing surface additive designed to improve surface imperfections during casting with WB4101 either in all water or mixed solvent/water systems. This modified silicone additive which increases wetting to SiPET films as well as powders, allowing for easier release of tapes from SiPET carrier films. Solids are 40% and typical level in slurry/slip is .05 to 2 weight %.

 

 

BR012

 

BR012 is an internal belt release additive similar to BR008 but typically needs some added solvents such as alcohol or MEK to replace some of the water in a formula for best compatibility. When added to 1st or 2nd milling stage, BR012 will help tapes release from steel belt casting surfaces. Pre-mixing BR012 with WB Binders should be avoided as it can cause temporary binder precipitation. Solids are 100% and typical level in slurry/slip is .25 to 1 weight %.

 

 

 

For more information on Belt Release Additives, click HERE.

 

 

 

 

Wetting Additives:

BR010

 

BR010 is a water based, silicone containing surface additive designed to improve surface imperfections during casting with WB4101 either in all water or mixed solvent/water (hybrid) systems. This modified silicone additive increases wetting to SiPET films as well as powders, allowing for easier release of tapes from SiPET carrier films. Solids are 40% and typical level in slurry/slip is .05 to 2 weight %.

 

 

WT007

 

WT007 is a modified silicone additive which is helpful in preventing pinholes, craters and mud crack defects in cast tape. It may increase foam and reduce ability to laminate, and it is particularly useful if thicker tapes are noticeably weaker than thinner tapes of the same formula. It is also helpful when tape casting with a Hybrid System (water base & solvent mix). Solids are 40% and typical level in slurry/slip is .05 to 2 weight %.

 

 

WT001

 

WT001 is a non-silicone additive that actually wets the surface of powders rather than increasing the wetability of SiPET film. WT001 can also act as a mild defoamer. Solids are 100% and typical level in slurry/slip is .05 to .25 weight %.

 

 

WT012

 

WT012 is a water based organo-silicone surface additive with the primary effect of increasing the wetability of the slurry on silicone treated PET film. Solids are 40% and typical level in slurry/slip is .05 to 2 weight %. WT012 can be very helpful with wetting on mylar.

 

 

WT005

 

WT005 is a modified silicone that is a very effective wetting agent. It allows higher film thickness and reduces air-draft sensitivity of various coatings. It is a solvent free additive. Solids are 100% and typical level in slurry/slip is .01 to .15 weight %.

 

 

WT006

 

WT006 is a water compatible acrylic leveling agent which can be helpful in eliminating pinholes and craters in cast tape. Solids are 50% and typical level in slurry/slip is .1 to .5 weight %.

 

 

 

 

Polymer Innovations also has additional Additives for other situations, so please contact us if you don't see the right Additive listed for your application.