Release coating composition and method of forming the same

1. A release coating composition comprising:

A. an aerosol suppressant having more than one SiO 4/2 unit and comprising a polymerization product of;

(1) a siloxane containing units of the chemical formula (SiO 4/2 )(R a R b 2 SiO 1/2 ) x

wherein R a is selected from the group of an alkyl moiety having from 1 to 6 carbon atoms, an alkenyl moiety having from 2 to 6 carbon atoms, and an alkynyl moiety having from 2 to 6 carbon atoms, R b is selected from the group of an alkyl moiety having from 1 to 6 carbon atoms, an aryl moiety, an alkoxy moiety, an acrylate moiety, and a methacrylate moiety, and x is a number from 1.05 to 2, and

(2) a cyclic polysiloxane,

wherein said siloxane and said cyclic polysiloxane are polymerized in the presence of a polymerization catalyst; and

wherein said aerosol suppressant has a viscosity of from 30,000 to 1,250,000 mPa·s at 25° C.; and

B. a curable polysiloxane.

2. A composition as set forth in claim 1 wherein said polymerization catalyst is selected from the group of strong acid catalysts, strong base catalysts, and combinations thereof.

3. A composition as set forth in claim 2 wherein said strong acid catalyst is further defined as trifluoromethane sulfonic acid.

4. A composition as set forth in claim 2 wherein said strong base catalyst is further defined as a phosphazene base catalyst.

5. A composition as set forth in claim 1 wherein said aerosol suppressant has more than one and less than 4 SiO 4/2 units.

6. A composition as set forth in claim 5 wherein said aerosol suppressant has from 2 to less than 4 SiO 4/2 units.

7. A composition as set forth in claim 1 wherein said aerosol suppressant further contains at least one R b 2 SiO 2/2 unit bonded to each of said more than one SiO 4/2 units.

8. A composition as set forth in claim 7 wherein said aerosol suppressant has four blocks of (CH 3 ) 2 SiO 2/2 units bonded to each of said more than one SiO 4/2 units.

9. A composition as set forth in claim 7 wherein said aerosol suppressant has from 1,000 to 5,000 (CH 3 ) 2 SiO 2/2 units.

10. A composition as set forth in claim 1 wherein said aerosol suppressant has eight R a R b 2 SiO 1/2 units.

11. A composition as set forth in claim 1 wherein said aerosol suppressant has a degree of polymerization from 1,000 to 4,000.

12. A composition as set forth in claim 1 wherein said aerosol suppressant is present in an amount from 1 to 5 parts by weight per 100 parts by weight of said composition.

13. A composition as set forth in claim 1 wherein said siloxane is polymerized with said cyclic polysiloxane in a weight ratio from 0.2:99.8 to 4:96.

14. A composition as set forth in claim 1 producing a mist of less than 50 mg/cubic meter when applied to a substrate at about 457 meters per minute.

15. A composition as set forth in claim 1 wherein said aerosol suppressant has four SiO 4/2 units, from 360 to 1,600 (CH 3 ) 2 SiO 2/2 units bonded to each of said four SiO 4/2 units, eight (CH 3 ) 2 (CH 2 CH)SiO 1/2 units terminally bonded to four of said (CH 3 ) 2 SiO 2/2 units, and is present in an amount from 1 to 5 parts by weight per 100 parts by weight of said composition, and wherein R a is a vinyl moiety, R b is a methyl moiety, said siloxane is polymerized with said cyclic polysiloxane in a weight ratio from 0.2:99.8 to 4:96, said cyclic polysiloxane is selected from the group of decamethylcyclopentasiloxane, octamethylcyclotetrasiloxane, and combinations thereof, said polymerization catalyst is a phosphazene base catalyst of the chemical formula:

((R c 2 N) 3 P═N) t (R c 2 N) 3-t P═NR d

wherein each of R c and R d are independently selected from the group of a hydrogen atom, a hydrocarbon, and combinations thereof and t is a number from 1 to 3, and said composition produces a mist of less than 50 mg/cubic meter when applied to a substrate at about 457 meters per minute.

16. A composition as set forth in claim 1 wherein said aerosol suppressant has a viscosity of from 30,000 to 120,000 mPa·s at 25° C.

17. A composition as set forth in claim 1 wherein said aerosol suppressant has a viscosity of from 30,000 to 600,000 mPa·s at 25° C.

18. A composition as set forth in claim 1 wherein said aerosol suppressant has two SiO 4/2 units.

19. A composition as set forth in claim 1 wherein x is 2.

20. A method of forming a release coating composition, said method comprising the steps of:

A. polymerizing a siloxane having units of the chemical formula (SiO 4/2 )(R a R b 2 SiO 1/2 ) x wherein R a is selected from the group of an alkyl moiety having from 1 to 6 carbon atoms, an alkenyl moiety having from 2 to 6 carbon atoms, and an alkynyl moiety having from 2 to 6 carbon atoms, R b is selected from the group of an alkyl moiety having from 1 to 6 carbon atoms, an aryl moiety, an alkoxy moiety, an acrylate moiety, and a methacrylate moiety, and x is a number from 1.05 to 2, with a cyclic polysiloxane in the presence of a polymerization catalyst to form an aerosol suppressant having more than one SiO 4/2 unit and having a viscosity of from 30,000 to 1,250,000 mPa·s at 25° C.; and

B. combining the aerosol suppressant and a curable polysiloxane to form the release coating composition.

21. A method as set forth in claim 20 wherein the polymerization catalyst is selected from the group of strong acid catalysts, strong base catalysts, and combinations thereof.

22. A method as set forth in claim 20 wherein the polymerization catalyst is further defined as a phosphazene base catalyst.

23. A method as set forth in claim 20 wherein the aerosol suppressant has more than one and less than 4 SiO 4/2 units.

24. A method as set forth in claim 20 wherein the composition produces a mist of less than 50 mg/cubic meter when applied to a substrate at about 457 meters per minute.

25. A method of coating a substrate in a release coating process, said method comprising the steps of:

A. polymerizing a siloxane having units of the chemical formula (SiO 4/2 )(R a R b 2 SiO 1/2 ) x wherein R a is selected from the group of an alkyl moiety having from 1 to 6 carbon atoms, an alkenyl moiety having from 2 to 6 carbon atoms, and an alkynyl moiety having from 2 to 6 carbon atoms, R b is selected from the group of an alkyl moiety having from 1 to 6 carbon atoms, an aryl moiety, an alkoxy moiety, an acrylate moiety, and a methacrylate moiety, and x is a number from 1.05 to 2, with a cyclic polysiloxane in the presence of a polymerization catalyst to form an aerosol suppressant having more than one SiO 4/2 unit and having a viscosity of from 30,000 to 1,250,000 mPa·s at 25° C.; and

B. combining the aerosol suppressant and a curable polysiloxane to form a release coating composition; and

C. applying the release coating composition to the substrate in the release coating process.

26. A method as set forth in claim 25 wherein the polymerization catalyst is selected from the group of strong acid catalysts, strong base catalysts, and combinations thereof.

27. A method as set forth in claim 25 wherein the polymerization catalyst is further defined as a phosphazene base catalyst.

28. A method as set forth in claim 25 wherein the aerosol suppressant has more than one and less than 4 SiO 4/2 units.

29. A method as set forth in claim 25 producing a mist of less than 50 mg/cubic meter when the composition is applied to the substrate at about 457 meters per minute.