Foamed Pressure-Sensitive Adhesive with Expanded Microballoons

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Solution Overview

Problem

Existing methods for producing adhesives foamed with microballoons face challenges such as reduced adhesive strength, susceptibility to irreversible collapse under pressure and temperature, and increased susceptibility to solvents and water due to micro-rough surfaces, which compromise bond strength and durability.

Innovation Solution

A process that involves expanding microballoons within the adhesive mixture and pressing them back into the polymer matrix during the coating process, maintaining a smooth and permanently adhesive surface with controlled temperature and pressure, thereby enhancing adhesive strength and surface quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If microballoons are expanded in the adhesive mixture, then the adhesive achieves better adaptability and sealing capabilities, but the adhesive strength is reduced

Engineering Contradiction:

ImproveadaptabilityVSAvoidadhesive strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The microballoons are expanded before being incorporated into the adhesive mixture, allowing them to be pre-formed as hollow spheres that provide adaptability and sealing capabilities while maintaining structural integrity during the adhesive formation process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The adhesive combines expanded microballoons with polymer matrix materials to create a composite structure that integrates the beneficial properties of both components: the adaptability and sealing of the hollow microspheres with the cohesive strength of the polymer matrix

Inventive Principle:

Principle #40Composite materials

2Reliability

If the adhesive layer contains cavities from expanded microballoons, then the adhesive provides better sealing against dust and liquid, but the adhesive becomes susceptible to solvents and water penetration

Engineering Contradiction:

Improvesealing capabilityVSAvoidsusceptibility to solvents and water

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The adhesive structure incorporates localized hollow microsphere cavities that provide sealing capability at specific locations, while the overall polymer matrix maintains continuity and resistance to solvent and water penetration through the bulk material

Inventive Principle:

Principle #3Local quality

3Productivity

If the adhesive is processed at high temperatures to expand microballoons, then the foaming process is efficient, but the adhesive strength and surface quality are compromised

Engineering Contradiction:

Improvefoaming efficiencyVSAvoidadhesive strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The expansion temperature of the microballoons is carefully controlled and optimized to achieve efficient foaming while preserving adhesive strength and surface quality, finding the optimal temperature parameter that balances productivity with performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The microballoons are expanded before adhesive formation, allowing the foaming process to be completed in advance while the adhesive matrix is still in a workable state, enabling efficient processing without compromising final adhesive properties

Inventive Principle:

Principle #10Preliminary action

4Ease of operation

If the adhesive surface is made micro-rough through foaming, then repositionability is improved, but the bond strength is significantly reduced

Engineering Contradiction:

ImproverepositionabilityVSAvoidbond strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The adhesive surface incorporates localized micro-roughness features through controlled microballoon expansion that provide repositionability at the surface level, while the bulk adhesive material maintains high bond strength through its continuous polymer matrix structure

Inventive Principle:

Principle #3Local quality

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 method achieves a significant reduction in adhesive strength loss, maintaining high adhesive properties even at low densities and high foaming rates, while ensuring a smooth, durable adhesive surface with improved impact resistance and sealing capabilities.

Implementation Method 1

a process which involves expanding microballoons within the adhesive mixture

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

pressing them back into the polymer matrix during the coating process, maintaining a smooth and permanently adhesive surface

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentEP2235098B1Foamed, in particular pressure-sensitive adhesive, process for producing it and the use thereof

Publication Date: 2013.03.20 TESA SE

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AI summary

An, in particular, pressure-sensitive adhesive which comprises expanded microballoons, wherein the bond strength of the adhesive comprising the expanded microballoons is reduced by at most 30%, preferably at most 20%, more preferably 10%, compared to the bond strength of an adhesive which has an identical coatweight per unit area and formula and has been defoamed by the destruction of the voids produced by the expanded microballoons.