Curable Adhesive Tape with Foam Support and Liquid Activator
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Solution Overview
Problem
Existing adhesive systems with foam support layers lack improved strength and gap-spanning performance.
Innovation Solution
An adhesive system comprising a tape with a curable adhesive free-standing film adjacent to a curable foam support layer, where the activator is a liquid oxidizing agent at normal temperature and pressure, initiating cure upon contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a foam support layer is used in adhesive tapes, then the tape provides structural support and conformability, but the adhesive strength and gap-spanning performance are insufficient
Solution Approach 1:
The patent employs composite materials by combining a curable adhesive free-standing film with a curable foam support layer. The adhesive film contains a film-forming polymer, unsaturated free-radically polymerizable groups, and a transition metal cation, while the foam support layer provides structural backing. This composite structure enables both strong adhesive bonding and gap-spanning capability, resolving the contradiction between adhesive strength and system complexity.
Solution Approach 2:
The patent utilizes parameter changes by incorporating a transition metal cation that mediates redox reactions to initiate polymerization and crosslinking of the adhesive film. The cure mechanism transitions from a simple pressure-sensitive adhesive state to a crosslinked structural adhesive state upon contact with an oxidizing activator, enabling enhanced strength without increasing complexity.
2Temperature
If liquid components are used in the adhesive system, then the activator can initiate cure at normal temperature and pressure, but mixing liquid components is required
Solution Approach 1:
The patent applies preliminary action by pre-incorporating the transition metal cation and unsaturated free-radically polymerizable groups into the adhesive film during manufacturing. The film is prepared in a stable, non-liquid state with all necessary components already integrated, eliminating the need for on-site mixing of liquid components while still enabling cure at normal temperature and pressure when activated.
Solution Approach 2:
The transition metal cation serves as an intermediary that facilitates the cure process. It mediates the redox reaction between the oxidizing activator and the unsaturated groups in the adhesive film, enabling cure initiation without requiring direct mixing of liquid components. The metal cation acts as a catalyst that bridges the activator and the polymerizable groups.
3Stability of the object's composition
If the adhesive film is made free-standing, then it provides structural integrity independent of supporting material, but the film requires precise composition to achieve proper curing
Solution Approach 1:
The patent applies local quality by creating a free-standing adhesive film with specifically localized functional components: the film-forming polymer provides the continuous matrix, the unsaturated free-radically polymerizable groups are positioned to react with the activator, and the transition metal cation is incorporated as a catalytic site. This localized arrangement of functional groups within the film structure enables proper curing while maintaining structural integrity without requiring external supporting materials.
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 system achieves enhanced structural adhesive bonds with improved strength and gap-spanning performance, allowing for cure at normal temperature and pressure without the need for mixing liquid components.
Implementation Method 1
The curable adhesive free-standing film comprises a film-forming polymer or oligomer, a species comprising unsaturated free-radically polymerizable groups, and a transition metal cation. The activator includes an oxidizing agent. Upon contact, the oxidizing agent initiates cure of the curable adhesive free-standing film through a redox reaction mediated by the transition metal cation.
Implementation Method 2
The curable adhesive free-standing film comprises a species comprising unsaturated free-radically polymerizable groups. Upon contact with the oxidizing agent activator, these groups undergo polymerization to form a crosslinked adhesive network, achieving structural bonding.
Data Source
AI summary
An adhesive system comprising a tape and an activator, wherein the activator includes an oxidizing agent and is a liquid at normal temperature and pressure; and wherein the tape includes a curable adhesive free-standing film adjacent to a curable foam support layer, wherein the curable adhesive free-standing film comprises: a) a film-forming polymer or oligomer; b) a species comprising unsaturated free-radically polymerizable groups, which may be a) or a species other than a); and c) a transition metal cation.