Pressure Sensitive Adhesive Tape With Intermittent Coating

Solution Overview

Problem

Existing pressure sensitive adhesive (PSA) tapes often use excessive resin coatings, leading to wastage and increased costs, as thick coatings are required to ensure adhesion, and manual separation of the release liner can be difficult and time-consuming.

Innovation Solution

A tape material with a thin flexible substrate featuring a pressure sensitive adhesive applied in an intermittent pattern, supported by a lightweight open mesh, and optionally with slits in the substrate, allowing for reduced resin usage and easier liner removal through differential release values and mesh reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thick PSA resin coating is applied to cover the release liner, then adhesion reliability is improved, but resin consumption increases and cost increases

Engineering Contradiction:

Improveadhesion reliabilityVSAvoidresin consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The PSA coating is applied in discrete segments or strips rather than as a continuous coating across the entire release liner. This segmentation allows the adhesive to be concentrated in specific areas where bonding is needed, reducing overall resin consumption while maintaining adhesion reliability in those critical zones.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention applies PSA coating only in specific local areas of the release liner where adhesion is required, rather than uniformly across the entire surface. This localized application optimizes resin usage by placing adhesive material precisely where it serves its function, reducing waste while ensuring reliable bonding at critical locations.

Inventive Principle:

Principle #3Local quality

2Reliability

If a thick PSA resin coating is applied to cover the release liner, then adhesion reliability is improved, but manufacturing cost increases

Engineering Contradiction:

Improveadhesion reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The PSA coating is applied in discrete segments or strips rather than as a continuous coating across the entire release liner. This segmentation allows the adhesive to be concentrated in specific areas where bonding is needed, reducing overall resin consumption while maintaining adhesion reliability in those critical zones.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention applies PSA coating only in specific local areas of the release liner where adhesion is required, rather than uniformly across the entire surface. This localized application optimizes resin usage by placing adhesive material precisely where it serves its function, reducing waste while ensuring reliable bonding at critical locations.

Inventive Principle:

Principle #3Local quality

3Reliability

If the release liner is made with high adhesion properties, then PSA bonding strength is improved, but liner removal becomes difficult and time-consuming

Engineering Contradiction:

ImprovePSA bonding strengthVSAvoidliner removal ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

By segmenting the PSA coating into discrete strips, the invention creates natural separation points along the release liner. These gaps between coated strips allow the liner to be more easily grasped and removed, reducing the time and effort required for liner removal while maintaining strong bonding in the coated areas.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention extracts or removes portions of the PSA coating to create gaps between strips. This extraction of adhesive material in specific areas provides access points for gripping and pulling the release liner, facilitating easier removal without compromising the bonding strength in the remaining coated regions.

Inventive Principle:

Principle #2Taking out (Extraction)

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 reduces resin consumption by applying adhesive only where needed, facilitates easier removal of the release liner due to gaps and slits, and enhances adhesive properties with UV-cured acrylic PSA, resulting in a cost-effective and efficient PSA tape with improved usability.

Implementation Method 1

The PSA may be an ultra-violet light-cured acrylic PSA

Methodology Applied

Scientific EffectUV-curing: Photopolymerisation

Data Source

PatentUS9151040B2Tape material and roll comprising pressure sensitive adhesive

Publication Date: 2015.10.06 ZEPHYROS INC

AI summary

A tape material comprising: a thin flexible substrate; and a pressure sensitive adhesive (PSA) substance carried on a single side of the substrate, the PSA substance being provided in an intermittent pattern along a length of the substrate.