Pressure Sensitive Adhesive Foam Low VOC Tackifier
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Solution Overview
Problem
There is a need for a cost-effective pressure sensitive adhesive foam that reduces volatile organic compounds (VOC) levels while maintaining excellent adhesion characteristics, particularly in industrial applications where high cohesive strength and resistance to elevated temperatures are required, while also addressing fogging and thermal stability issues.
Innovation Solution
A pressure sensitive adhesive foam comprising a rubber-based elastomeric material and hydrocarbon tackifiers with low VOC and fogging values, combined with a polyisobutylene plasticizer, and optionally crosslinking agents, to achieve a balance of adhesive and cohesive properties, thermal stability, and reduced outgassing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If acrylate-based pressure sensitive adhesives are used to achieve good adhesion performance, then adhesive properties are improved, but volatile organic compound (VOC) levels increase due to low molecular weight organic residuals
Solution Approach 1:
The patent changes the chemical composition parameters by using rubber-based elastomers instead of acrylate polymers, and selects hydrocarbon tackifiers with specific molecular weight ranges (300-10,000 g/mol) to optimize the balance between adhesive performance and VOC reduction. The plasticizer content is also parameterized at 1-40 wt% to control flexibility and adhesion while minimizing volatile residuals.
Solution Approach 2:
The invention creates a composite adhesive system combining rubber-based elastomers, hydrocarbon tackifiers, and polyisobutylene plasticizers. This composite formulation achieves synergistic effects where the rubber provides cohesive strength, the tackifier enhances adhesion, and the plasticizer ensures flexibility, all while maintaining low VOC levels through careful material selection.
2Productivity
If the adhesive foam is made thinner to reduce material usage, then productivity is improved, but adhesion to rough or irregular surfaces deteriorates
Solution Approach 1:
The patent utilizes a foam structure with controlled porosity to provide conformability to rough surfaces. The foam cells allow the adhesive to flex and conform to surface irregularities, maintaining contact and adhesion even at reduced thicknesses. This porous architecture enables the adhesive to bridge gaps and accommodate surface variations without requiring excessive material thickness.
3Reliability
If conventional hydrocarbon tackifiers are used to improve adhesion, then adhesive strength is improved, but fogging and thermal stability deteriorate due to high VOC values
Solution Approach 1:
The patent carefully selects hydrocarbon tackifiers with specific molecular weight parameters (300-10,000 g/mol) to optimize performance. This parameter control ensures the tackifier provides sufficient adhesive strength while minimizing volatility and fogging. The molecular weight range is specifically chosen to balance adhesion promotion with reduced vapor pressure and improved thermal stability.
Solution Approach 2:
The invention applies different functional components in optimized proportions: hydrocarbon tackifiers (5-60 wt%) for adhesion, rubber-based elastomers (20-80 wt%) for cohesive strength, and polyisobutylene plasticizers (1-40 wt%) for flexibility. This local quality distribution ensures each component performs its specific function effectively while the overall formulation maintains low VOC and fogging levels.
4Reliability
If thicker conformable pressure sensitive adhesive foams are used to improve adhesion to rough surfaces, then adhesion performance is improved, but cohesive strength at elevated temperatures deteriorates
Solution Approach 1:
The patent creates a composite foam structure where rubber-based elastomers provide thermal stability and cohesive strength, while the foam architecture maintains conformability. The rubber matrix retains its mechanical properties at elevated temperatures (70°C to 90°C), preventing the adhesive from becoming too soft or losing cohesive integrity, even when formulated for conformability to rough surfaces.
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 solution provides pressure sensitive adhesive foams with significantly reduced VOC levels, improved adhesion, cohesive strength, and thermal stability, making them suitable for industrial applications such as automotive and electronic industries, while minimizing fogging and outgassing issues.
Implementation Method 1
a polyisobutylene plasticizer
Implementation Method 2
hydrocarbon tackifiers with low VOC and fogging values, combined with a polyisobutylene plasticizer
Implementation Method 3
a rubber-based elastomeric material and at least one hydrocarbon tackifier
Data Source
AI summary
The present disclosure relates to a pressure sensitive adhesive foam comprising a rubber-based elastomeric material and at least one hydrocarbon tackifier, wherein the hydrocarbon tackifier(s) have a Volatile Organic Compound (VOC) value of less than 1000 ppm and a Volatile Fogging Compound (FOG) value of less than 1500 ppm, when measured by thermogravimetric analysis according to the weight loss test methods described in the experimental section. The present disclosure also relates to a method of manufacturing such a pressure sensitive adhesive foam and uses thereof.