Double-Sided Adhesive Tape Coextrusion Process
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Solution Overview
Problem
The production of double-sided pressure-sensitive adhesive tapes is costly and inefficient due to the need for multiple process steps, including solvent-based methods that can lead to bubble formation and the requirement for laminating carrier materials, which slows down the process and increases expenses.
Innovation Solution
A method using coextrusion technology to produce a double-sided pressure-sensitive adhesive tape in a single process step, where two identical or different hot melt adhesives, a carrier film, and a release film are extruded together, with optional primer layers, and then crosslinked physically or radiation-chemically to form a composite tape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solvent-based coating methods are used to produce pressure-sensitive adhesive layers, then adhesive properties can be achieved, but bubble formation occurs during drying and production cost increases
Solution Approach 1:
The patent changes the fundamental parameter of adhesive application from solvent-based to solvent-free hot melt technology. This eliminates the drying process that causes bubble formation while maintaining adhesive effectiveness through controlled cooling and solidification of the hot melt adhesive material.
Solution Approach 2:
The patent utilizes phase transition of hot melt adhesive from liquid (melt) state during application to solid state during cooling. This phase change allows the adhesive to be applied in a fluid state for proper bonding, then solidifies to provide structural integrity without requiring a drying process that would cause bubbles.
2Ease of manufacture
If multiple process steps including lamination are used to produce double-sided adhesive tape, then complete product structure is achieved, but production speed decreases and cost increases
Solution Approach 1:
The patent combines multiple separate manufacturing steps (adhesive application to first carrier, lamination of second carrier, adhesive application to second carrier) into a single integrated hot melt coating process. The hot melt adhesive is applied to both sides of the carrier film simultaneously or sequentially in one continuous operation, eliminating the need for separate lamination steps and significantly increasing production speed.
Solution Approach 2:
The hot melt coating system performs multiple functions in one process: it applies adhesive to both sides of the carrier film, provides immediate bonding upon contact with the second carrier, and eliminates the need for separate lamination equipment. This multi-functional approach streamlines the manufacturing process and improves productivity.
3Reliability
If polyacrylate pressure-sensitive adhesives are used, then stability to UV light, oxygen and ozone is improved, but production cost increases due to expensive processing
Solution Approach 1:
The patent changes the processing parameter from expensive solvent-based coating or complex multi-step lamination to cost-effective hot melt coating. This parameter change maintains the use of stable polyacrylate adhesives while dramatically reducing production costs through process simplification and elimination of expensive solvents and lamination steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the efficient production of double-sided pressure-sensitive adhesive tapes with improved cost-effectiveness and reduced complexity, enabling the tapes to be used in the electronics sector with enhanced adhesive properties and ease of use.
Implementation Method 1
the pressure-sensitive adhesives are crosslinked by physical and/or radiation-chemical treatment
Data Source
Figure 1
AI summary
For the production of a double-sided pressure-sensitive adhesive tape, having a closed and open side, possessing a carrier film (e) provided on both sides with a pressure-sensitive adhesive layer (c, c'), the carrier film (e) being a filmlike carrier film not based on rubber, and there being at least one release film located on the closed side, on the one pressure-sensitive adhesive layer (c), it is envisaged that, from the melt, two identical or different pressure-sensitive adhesives for the pressure-sensitive adhesive layers (c, c'), a film-forming polymer for the carrier film (e), and a film-forming polymer for the release film be formed, that these components be combined to form a composite, and that the pressure-sensitive adhesives be crosslinked by means of physical and/or radiation-chemical treatment.