Multilayer Pressure Sensitive Adhesive Foam Tape for Outdoor Bonding
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Solution Overview
Problem
Pressure-sensitive adhesive tapes face challenges in providing excellent adhesion and cohesion to difficult-to-bond substrates, particularly those with low and medium surface energy, under high stress conditions such as extreme temperatures and mechanical/chemical stress, which are common in automotive and aerospace applications.
Innovation Solution
A multilayer pressure-sensitive adhesive foam tape is developed, comprising a polymeric foam layer with two pressure-sensitive adhesive layers. The first layer is composed of a low Tg (meth)acrylate copolymer and a high Tg (meth)acrylate copolymer, while the second layer includes a linear or multi-arm block copolymer with high Tg tackifiers, designed to adhere to thermoplastic or thermosetting organic polymers used in automotive parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer pressure sensitive adhesive tape is used, then the structure is simple and manufacturing is easier, but the adhesion and cohesion performance under high stress conditions is insufficient
Solution Approach 1:
The adhesive tape is divided into multiple functional layers: a polymeric foam core layer and two pressure-sensitive adhesive layers (first and second). Each layer serves a specific function - the foam layer provides mechanical cushioning and stress distribution, while the adhesive layers provide bonding to substrates. This segmentation allows the tape to achieve superior adhesion and cohesion under high stress conditions compared to single-layer designs.
Solution Approach 2:
The invention uses composite material construction by combining different materials with complementary properties: the polymeric foam layer (providing mechanical resilience and stress distribution) is combined with pressure-sensitive adhesive layers containing specific polymer compositions (providing adhesion). This composite structure synergistically enhances both adhesion and cohesion performance under extreme temperatures and mechanical stress.
2Reliability
If adhesive tapes are designed for room temperature applications, then the adhesive properties are optimized for comfort, but the performance deteriorates under extreme temperatures and intense weathering conditions
Solution Approach 1:
The adhesive composition is specifically formulated with polymers having controlled glass transition temperatures (Tg). The first pressure-sensitive adhesive layer contains a low Tg (meth)acrylate copolymer (Tg ≤ 0°C) for flexibility and tack at lower temperatures, while the second layer contains a high Tg (meth)acrylate copolymer (Tg ≥ 50°C) for thermal stability and adhesion retention at elevated temperatures. This parameter optimization enables the tape to maintain reliable performance across extreme temperature ranges from -40°C to +90°C.
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 multilayer adhesive foam tape achieves outstanding adhesion and cohesion properties on challenging substrates, maintaining performance under intense weathering and mechanical stress conditions, effectively bonding automotive parts with improved resistance to heat and humidity.
Implementation Method 1
a first pressure sensitive adhesive layer adjacent to one major surface of the polymeric foam layer; a second pressure sensitive adhesive layer adjacent to the polymeric foam layer
Implementation Method 2
a polymeric foam layer comprising two major surfaces; wherein the first pressure sensitive adhesive layer, the polymeric foam layer and the second pressure sensitive adhesive layer are superimposed
Data Source
AI summary
The present disclosure relates to a method of adhering a first part to a second part, wherein the first part and the second part are used for outdoor applications and comprise a thermoplastic or a thermosetting organic polymer. The present disclosure is also directed to a composite assembly comprising: a) a first part and a second part used for outdoor applications and comprising a thermoplastic or a thermosetting organic polymer; and b) a multilayer pressure sensitive adhesive foam tape as described in the present disclosure, wherein the first pressure sensitive adhesive layer is adhered to the first part, and the second pressure sensitive adhesive layer is adhered to the second part.