Cable Harness Adhesive Tape Resolving Flagging and Unwindability
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Solution Overview
Problem
Existing adhesive tapes for cable harnesses in motor vehicles face challenges in achieving easy unwindability while maintaining good flagging resistance and cable compatibility, particularly at high temperatures, with properties like peel adhesion and unwind force often being mutually exclusive.
Innovation Solution
An adhesive tape comprising a textile carrier with a pressure-sensitive adhesive made from a polymer dispersion, formed through emulsion polymerization of specific monomers, including (meth)acrylic and ethylenically unsaturated monomers, with a tan delta maximum between -25°C and -15°C and a value of 0.38 to 0.55 at 130°C, and enhanced with tackifiers, ensuring robust bonding and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the adhesive tape uses high peel adhesion to ensure robust bonding, then the flagging resistance improves, but the unwind force increases making the tape harder to unwind
Solution Approach 1:
The adhesive composition parameters are precisely controlled with specific ratios of (meth)acrylic monomers (60-80 wt%), ethylenically unsaturated monomers (10-30 wt%), and functional monomers (5-15 wt%), along with controlled polymerization conditions to achieve the optimal balance between peel adhesion and unwindability. The tan delta maximum between -25°C and -15°C and value of 0.38 to 0.55 at 130°C are specific parameter targets that resolve the contradiction.
Solution Approach 2:
The adhesive is formulated as a composite system combining multiple monomer types and tackifiers to achieve synergistic effects. The combination of (meth)acrylic monomers for adhesion, ethylenically unsaturated monomers for flexibility, functional monomers for bonding, and tackifiers for instantaneous tack creates a composite material that balances flagging resistance with easy unwindability.
2Reliability
If the adhesive tape maintains high peel adhesion at elevated temperatures, then cable compatibility improves, but the adhesive may become too soft reducing bonding strength
Solution Approach 1:
The adhesive's glass transition temperature and viscoelastic properties are controlled through specific monomer selection and ratios, ensuring the adhesive remains within optimal bonding parameters at elevated temperatures. The tan delta value of 0.38 to 0.55 at 130°C specifically targets maintaining bonding strength at high temperatures while the functional monomers enhance cable compatibility.
Solution Approach 2:
The adhesive exhibits different mechanical properties at different temperatures, being softer at low temperatures for easy application and unwinding, while maintaining appropriate stiffness and bonding strength at elevated temperatures through its controlled viscoelastic response characterized by the specific tan delta parameters.
3Reliability
If the adhesive tape uses complete overlap wrapping to ensure coverage, then protective function improves, but the tape ends stand up undesirably due to static forces
Solution Approach 1:
The adhesive's instantaneous peel adhesion (tack) is optimized through the specific composition and polymerization parameters, allowing the tape to conform smoothly to itself during complete overlap wrapping without standing up. The controlled viscoelastic properties ensure the adhesive can accommodate the static forces during wrapping while maintaining smooth contact.
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
The adhesive tape exhibits improved flagging resistance, high peel adhesion, and maintains cable compatibility even at elevated temperatures, allowing for efficient and durable jacketing of cable harnesses without undue flagging or embrittlement.
Implementation Method 1
adhesive tapes are employed in order to bundle a multiplicity of electrical leads... to obtain protective functions... good instantaneous peel adhesion (tack) to this substrate... the anchoring on the substrate and the internal strength of the adhesive must both be such that the adhesive bond is robust even under the effect of tension
Implementation Method 2
a pressure sensitive adhesive, applied on at least one side of the carrier, in the form of a dried polymer dispersion, the polymer being obtained by emulsion polymerization of a monomer mixture
Data Source
AI summary
Adhesive tapes and methods for wrapping cables comprise a textile carrier, optionally provided on an underside with an applied film, and a pressure sensitive adhesive, applied on at least one side of the carrier, in the form of a dried polymer dispersion comprising a polymer being obtained by emulsion polymerization of a monomer mixture comprising: (a) at least one (meth)acrylic monomer individually yielding a first homopolymer having a glass transition temperature (Tg) of −40° C. or less; (b) at least one ethylenically unsaturated monomer individually yielding a second homopolymer having a Tg of 15° C. or higher; (c) at least one ethylenically unsaturated monomer having an acid and/or a hydroxyl functional group; and (d) a chain transfer agent, wherein monomers (a) to (d) are different from each other, and the polymer is mixed with one or more tackifiers.