The Manufacturing Process

PSA’s and Tapes

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Introduction

PSA Tapes were first introduced about 150 years ago.

Initially medical tape

and dressing was developed and a U.S. Patent was

issued in 1846.

PSA’s are widely used since the 19 th century.

Industrial Tapes were introduced between the 1920 ,s

and 1930,s .

Hot Melt adhesives were introduced in the 1940,s .

PSA Tapes are used for many different Applications.

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What is pressure sensitive adhesive ?

Pressure sensitive adhesive, is adhesive which forms a bond

when pressure is applied to bond it with the adherent. This is a

material that holds two surfaces together solely by surface contact,

which is achieved by slight initial external pressure. These

adhesives require no activation with water, solvent or heat, and

firmly adhere to many dissimilar surfaces with minimal pressure.

Aggressive and permanently tacky at room temperature, PSAs can

be used for bonding materials such as plastic, paper, metal, glass,

and wood.

As the name "pressure sensitive" suggests, the bond is influenced

by the amount of pressure that is applied on the adhesive to the

surface.

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Pressure sensitive adhesives are designed with a balance between

flow and

resistance to flow.

The bond forms because the adhesive is soft enough to flow,

or wet, the adherent.

The bond has strength because the adhesive is hard enough to

resist flow when stress is applied to the bond.

PSAs exhibit viscoelastic (viscous and elastic) properties, both of

which are used for proper bonding.

Pressure sensitive adhesives are characterized by their shear

holding. The ability to hold in a shear mode is related to the

formulation, coating thickness, rub-down, temperature, etc.

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Factors affecting ?

Surface factors , such as smoothness, surface energy, removal of

contaminants, etc. also , play important role in proper bonding.

PSAs are usually designed to form a bond and hold properly at

room temperatures. PSAs typically reduce or lose their tack at low

temperatures and reduce their shear holding ability at high

temperatures; special adhesives are made to function at high or low

temperatures. It is important to choose an adhesive formulation

which is designed for its intended use conditions.

Once the adhesive and the adherent are in contact, there are

molecular interactions such as , van der Walls forces , involved in

the bond, which contribute significantly to the ultimate bond

strength.

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Common Adhesive Types and Their Properties

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Convenient & fast means of application. Ease of removability without damage of the substrate. Wide choice. Suitable for a number of applications. Easy printability. Easy laminate / bond ability Easy cut ability , die- cut ability. Structural integrity. Dimensional stability. Shape retention.

PSA Tapes Key features

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Unique Characteristics

Provide temporary and permanent holding application. Provide insulation , thermal as well as electrical. Provide sound and vibration proofing. Cheaper packaging solution. Mounting. Assembling. Sealing Splicing. Medical / surgical mounting.

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For many years, rubber/resin formulations have been available that combine

natural or synthetic rubber with tackifying resins, oils, antioxidants, or other

ingredients as needed. They are typically either solvent-based or used in hot

melts, and the aggressive nature of rubber adhesives makes excellent

bonding easy to achieve.

These adhesives are known for their high level of adhesion to a variety of

substrates and facestocks, as well as their high coatability. Rubber-based

adhesives provide high tack and peel, and make excellent general-purpose

adhesives, because of their ability to adhere well to several non-polar, low-

energy surfaces, including polyethylene and polypropylene. In general, rubber-

based adhesives are often a more economical choice compared to most

acrylics.

Disadvantages of rubber-based adhesives include limited effectiveness when

exposed to certain chemicals, UV rays, or high temperatures (over

150°F/66°C). In addition, they are more susceptible to oxidation and may

darken, lose their tack, and become brittle if overexposed. Also, rubber/resin

adhesives may turn soft and gummy if plasticizers, used in most polyvinyl

chloride films (PVC), migrate into the adhesive.

Rubber Base

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The other type of adhesive chemistry commonly used in PSAs is acrylic.

Acrylic adhesives can either be solvent- or water-based, and are formulated by

reacting monomers with the desired properties, which are then typically

crosslinked to form the type of polymer needed. Monomers are the building

blocks of polymers and are considered to be either “soft” or “hard.” The

combination of hard and soft monomers can be adjusted based on the level of

adhesive (polymer) performance needed.

Crosslinking polymers improves the cohesive strength (internal strength of the

adhesive, or the ability to stick to itself) of the acrylic formulation and can be

accomplished in one of three ways: the use of thermal heat energy; by self-

curing when a solvent is removed during the drying process; or through UV or

EB non-thermal radiation.

In general, acrylics are relatively firm and durable, but are not as aggressive

as rubber-based adhesives. An acrylic adhesive can be modified to alter its

adhesion properties based on the selection of monomers used, the level of

polymerization created, or by adding tackifying resins or other chemicals.

Acrylic base

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The advantages of acrylic adhesives are typically the opposite of rubber

adhesives. Acrylics provide excellent temperature, UV and oxidation

resistance; therefore, they are often the preferred choice for outdoor

applications. They resist the negative plasticizing action that can occur with

rubber and hold up well to chemical exposure. Acrylic-based adhesives are

very durable and have clarity and color stability. Acrylics bond well to polar

surfaces like metal, glass, polyesters and polycarbonates, and have high peel,

tack, and shear.

Disadvantages of acrylics usually include poor adhesion to low-energy

surfaces, such as polyethylene and polypropylene, as well as lower overall

adhesion compared to rubber unless the adhesive is highly engineered. In

general, acrylics are often more expensive than rubber-based adhesives.

Acrylic base

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Silicone adhesives are another chemical option for PSAs but are less common

than rubber or acrylic. These specialized adhesives consist of silicone

polymers that provide adhesion to silicon and other hard-to-adhere-to

materials. Silicone-based adhesives can maintain adhesion over a range of

temperatures; however, beyond their ability to adhere to difficult surfaces, their

overall adhesive strength is low. Silicone adhesives are also more expensive.

Silicone base

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Characteristics of pressure sensitive adhesive ?

Adhesion : Tack, Peel Resistance, Cohesive strength /

or Shear resistance.

Converting Properties : Printability, ability to

Laminate, Cut ability, Die-cut ability.

End Use Application : Ageing Resistance, Chemical

and water resistance, bonding and de bonding properties,

Process ability.

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Adhesion :

Tack, is the Wet ability of adhesive

is nothing but to form a bond in a short time , with little pressure . hence the

adhesive needs to have good flow.

Tack depends upon 1. Viscosity

The ability of the adhesive to flow and cover the applied surface to form a bond.

2. Modulus of elasticity

The modulus decided the de-bond ability of the adhesive without any kind of

adhesive failure , like leaving residue on the applied surface.

3. Time , temperature and external strain.

3.(a).Time and Temperature

Has direct effect on the performance of the PSA. Time and Temperature influence

the flow characteristics of the PSA

3.(b).External strain.

Tack depends on the peel off force and the speed of peel off. As the speed increases

the tack value tends to increase.

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Adhesion :

Tack,

Tack is the initial attraction of an adhesive to a substrate—the instant grab of the adhesive, with no external pressure applied. Sometimes tack is referred to as "quick stick" or "thumb appeal." Tack properties are typically measured using the loop tack test

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Adhesion :

Peel Resistance,

Peel is the force required to pull off the Adhesive from the applied surface

The peel strength depends upon , 1.Viscosity

Viscosity has a direct effect on the peel strength. As the viscosity increases the peel

strength increases.

2.Modulus of elasticity

The modulus decided the de-bondability of the adhesive. Lower the modulus ,

easier is the removability of the product.

3.Time , temperature and external strain.

3.(a ).Time and Temperature

Has direct effect on the performance of the PSA. Time and Temperature influence

the peel str . of the PSA. More the dwell time more is the peel , but the peel

decreases as the temp increases.

3.(b).External strain.

Peel depends on the speed of peel off . As the speed increases the peel value

tends to increase. 28-01-2013 16

Adhesion :

Peel Resistance, The measure of bond strength between an adhesive and a substrate is defined as adhesion. It is important to note that this is the measure of bond strength after pressure is applied to the adhesive, allowing for wet-out onto the substrate. Adhesion properties are typically measured using the 180° or 90° peel adhesion test method

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Adhesion :

Cohesive strength or Shear resistance. Shear/cohesive is the holding power of adhesive is nothing but the resistance

to shear stress.

The shear depends upon 1.Viscosity

Increase in Mol.wt of a polymer increases the viscosity .The increase in viscosity

increases the shear strength.

2.Modulus of elasticity

The modulus decided the de-bond ability of the adhesive without any kind of

adhesive failure , like leaving residue on the applied surface. masticated rubber

posses a lower elastic modulus as compared to raw rubber obtained from

coagulated latex. The mastication processes reduces the modulus of the polymer but

does not alter the Glass Transition Temp. the reduction is modulus , results in

lowering the shear str.

3.Time , temperature and external strain.

Shear resistance of an adhesive depends on it’s internal cohesion , which is a

function of the inherent viscosity or modulus. Shear resistance is thus dependent on

the factors affecting the viscosity and modulus. 28-01-2013 18

Adhesion :

Cohesive strength or Shear resistance. The internal or cohesive strength of an adhesive film is known as shear. This is not a measure of the bond between the adhesive and a substrate, but rather a measure of the internal strength of the adhesive itself. Shear properties are typically quantified using the static shear test method

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The adhesive plays a very crucial role in terms of performance of the product. The real technology lies in striking a balance of the three main properties of adhesive , like the Peel strength , the tack and the shear strength.

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Co-related to Adhesives , like WB Acrylic / GP HMPSA For application , such as Packaging Tapes

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Co-related to Adhesives , like SB Acrylic For application , such as Application Tapes, holding Tapes, Foam Tapes

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Further classification of pressure sensitive adhesive ?

Water-based PSA (WB PSA) – a PSA applied in aqueous emulsion form and dried to form the adhesive film Solvent-based PSA (SB PSA) – a PSA applied in solvent solution form and dried to form the adhesive film Hot-melt PSA (HM PSA) – a PSA applied as a 100% solids, thermoplastic composition in the molten state Calendered PSA – a PSA applied as a 100% solids composition in a calendering operation

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Water-based PSA (WB PSA)

Rubber Latex

Acrylic

Nat. Rubber Latex

Syn. Rubber Latex

Ready to Use

Modified / compounded

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Solvent-based PSA (SB PSA)

Rubber

Silicone

Nat. Rubber

Syn. Rubber

SBR

Butyl Acrylic

Silicone Ready to use

Acrylic Ready to use

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Hot-melt PSA (HM PSA)

SIS

EVA

SBS

SIBS

PU

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Calendered PSA

Rubber Nat. Rubber

Syn. Rubber

SBR

Butyl

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PS Adhesive Compounding

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Water-based PSA (WB PSA)

Rubber Base

Ingredients Parts per 100 Adhesive Application

Nat ./ Syn. Rubber Latex

100 Packaging Tapes Surface protection Tapes Sponge Rubber Tapes

Tackifing Agent Dispersion

100

Rheology Modifier 001

Anti Foaming Agent 000.5

Cross Linking Agent

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Water-based PSA (WB PSA)

Acrylic Ready to Use for BOPP / Paper Packaging Tapes

Modified Acrylic

Ingredients Parts per 100 Adhesive Application

Acrylic PSA 100 Surface protection Tapes Foam Tapes HvAc Tapes , like Alu Foil , FSK , Alu Glass

Tackifing Agent Dispersion

100

Rheology Modifier 001

Anti Foaming Agent 000.5

Cross Linking Agent 001

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Solvent-based PSA (SB PSA)

Ingredients Parts per 100 Adhesive Application

Nat ./ Syn. Rubber 100 Electrical insulation Tapes Surface protection Tapes Sponge Rubber Tapes

Tackifing Agent 1 100

Tackifing Agent 2 080

Filler 030

Plasticizer 005

Cross Linking Agent 002

Suitable Solvent 100

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Suitable Solvents

Solvent Chemical formula Boiling point Dielectric

constant Density

Dipole

moment

Non-polar solvents

Hexane CH3-CH2-CH2-

CH2-CH2-CH3 69 °C 1.88 0.655 g/ml 0.00 D

Benzene C6H6 80 °C 2.3 0.879 g/ml 0.00 D

Toluene C6H5-CH3 111 °C 2.38 0.867 g/ml 0.36 D

Polar aprotic solvents

Ethyl

acetate

CH3-C(=O)-O-

CH2-CH3 77 °C 6.02 0.894 g/ml 1.78 D

Acetone CH3-C(=O)-CH3 56 °C 21 0.786 g/ml 2.88 D

Polar protic solvents

Ethanol CH3-CH2-OH 79 °C 24.55 0.789 g/ml 1.69 D

Water H-O-H 100 °C 80 1.000 g/ml 1.85 D

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Hot-melt PSA (HM PSA)

SIS ready to use

EVA ready to use

SBS ready to use

SIBS ready to use

PU ready to use

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Calendered PSA

Rubber Nat. Rubber

Syn. Rubber

SBR

Butyl

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Characteristic Rubber-Based Acrylic Modified

Acrylic

Silicone

Cost Lowest Medium/high Medium/high Very high

Tack Medium/high Medium/low High Low

Temperature resistance Low High Low/moderate Very high

Adhesion Medium/high Moderate/high High Medium/low

Shear Medium/high Moderate/high Low Moderate

Solvent resistance Poor Good Low/moderate Excellent

Ultraviolet resistance Poor Excellent Poor Excellent

Plasticizer resistance Poor Moderate/good Poor/moderate Excellent

Low-surface-energy

materials

Excellent Poor/moderate Excellent Poor

High-surface-energy

materials

Excellent Excellent Excellent Moderate

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Types of PSA’ coated products

Tapes

Labels

Misc. Products

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Types of PSA’ Tapes

We are going to talk more about Tapes in this presentation

Single Side

Double Side

Reinforced

Unsupported

With liner

Without liner

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Construction of PSA’ Tapes

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PSA’ Tapes Single side adhesive

Without liner

Adhesive Substrate

With liner

Adhesive

Substrate liner

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PSA’ Tapes Double side adhesive

Adhesive Substrate

Adhesive Release Liner

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PSA’ Tapes reinforced

Adhesive Release Liner

Reinforcement

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PSA’ Tapes unsupported

Adhesive Release Liner

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variety of PSA’ Tapes

Packaging Tapes

Industrial Tapes

Automobile Tapes

Mounting Tapes

Surface protection Tapes

Electrical insulation Tapes

Surgical Tapes

Thermal insulation Tapes

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variety of PSA’ Tapes

Fabrics based

Foam based

Non woven based

Metal foil based

Film Based

BOPP PVC Poly Ester Poly Ethylene Poly Amide

Cotton Nylon Rayon Fiber Glass

Aluminum Copper

Paper based Kraft Crepe

Poly Ester PP

PU EVA Nitrile EPDM

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Double Coated

Adhesive Tapes

Unsupported

Adhesive Tapes

Foam Mounted

Tapes & Sealing

Products

Label Base Stocks

& Single Coated

Adhesive Tapes

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Pressure sensitive adhesive tape manufacturing process ?

Prior to the tape manufacturing process ,it is necessary

to understand the characteristics of the PSAs , and the

backing material / face stock / substrate and the

conditions under which they will be used

to satisfy end-use requirements without causing

process ability concerns ,

And this will lead to a successful product.

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Surface Contour. The contour of the substrate will influence product

selection (see Figure 3). For uses requiring conformability around irregular

angles, more flexible materials should be employed. Regardless of the

strength of the formulation, it is virtually impossible for an adhesive to

overcome a continuous stress placed on

it by a rigid material trying to return to its original form (memory). For such

applications, one should choose a conformable product with a tissue or

nonwoven carrier facestock or consider adding stress relief to the converted

part via scoring or perforation.

critical Issues are

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Surface Energy. The ability of an adhesive to wet out over the surface of a

material is related to its surface energy. Low-surface-energy (LSE) materials

do not allow the adhesive to wet out, whereas high-surface-energy materials

allow excellent wet-out and provide the best adhesion. Rubber-based

adhesives generally offer better adhesion to LSE substrates—a softer, better

flow. Some materials require special treatment—corona treatment, primers,

topcoats—to promote better adhesion. On some LSE materials, adhesion

levels will improve with longer adhesive dwell times.

critical Issues are

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PSA Tapes mainly consist of two main components , the carrier /

backing material and the Adhesive.

Generally Tapes are produced by coating a carrier ( or backing

material ) , such as plastic films , fabrics, paper or foil with a adhesive ,

which is normally in liquid form. These adhesives contain solvents ,

such as water, or organic chemicals such as toluene, ethyl acetate etc,

as carriers.

The solvent is evaporated with help of hot air impregnation , so that a

dry adhesive film is formed , above the backing material with a firm

bond .

In some cases the back-side of the tape is coated for non adhesive or

release properties, which helps to have easy unwind property , with no

adhesive transfer.

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The Backing material

The backing material is the most important component of PSA Tapes . The

backing or carrier provided the necessary strength and body to tape product.

The backing has to be sufficiently strong . the backing needs to have

reasonably good tensile strength , elongation , conformability, moderate heat

resistance , chemical resistance, abrasion resistance etc.

The various backing materials that are common in use are shown above.

The backing materials need a primer coat or chemical or physical , surface

preparation / treatment before adhesive coating.

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Surface Treatment

Plastics Films are widely used in Packaging applications such as Self Adhesive

Tapes, Laminates, Printing etc.

As we know all these films are chemically inert and have very low surface

energy. The below mentioned table gives an idea about the surface tension of

various polymers.

Sr.No. Polymer Surface Tension of

Homo polymer in

Dynes/Cm2

1 Poly Ethylene PE 31

2 Poly Propylene PP 32

3 Poly iso butylene PIB 27

4 Polystyrene PS 33

5 Poly Tetra Fluro Ethylene PTFE 19

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Surface Treatment

From the above tables it is very clear that the polymer surfaces need treatment

to enhance the wettability , printability , and adhesion properties. Or in other

words the surface tension has to match that of the coating materials.

The common methods of surface treatment for films are

chemical etching

flame treatment

carona treatment

plasma treatment

however chemical etching method is outdated.

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Surface Treatment

Flame treatment

In this process propane or butane flame is used to treat the polymer surface.

Here the electron density is lower and therefore the ionization rate .

The higher temp in the flame poses a problem for most polymer surfaces.

Carona treatment

Here the atmospheric air is ionized by help of high voltage transformer.

The mechanism is like this. Two idler rollers form the two electrodes. High

voltage of high frequency is produced with the help of a transformer. The high

voltage applied to the two electrodes . one electrode ( Idler is insulated with

silicone rubber coating , which is a perfect di electric.

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Surface Treatment

Plasma Treatment

Radio frequency ( rf) glow discharge ( Cold gas plasma) of hydrogen in

combination with vapourised liquid provides unique sueface modification.

In this method gas molecules are excited by subjecting to an electric field ,

typically radio frequency energy.

The radio frequency creates free electrons . these electrons gain energy from

imposed field and collide with Nat gas molecules. The collision and transfer of

energy form no of reactive species.

These particles interact with solid surfaces placed in the plasma.

This leads to dramatic modification of the molecular structure.

Hydrogen in composition with liquid oxygen contributing co-reactant is used as

the plasma. This creates stable oxygen moieties which is chemically reactive.

This reactivity is ideal for forming tenacious bonds with selected adhesives.

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Advantages of plasma.

get higher treatment levels , upto 60 dynes/ cm2.

no surface degradation

low temp process

the surface treatment has a long life

back side treatment is eliminated

treatment is permanent

viable alternative for carona treatment is ineffective especially on PTFE

electronic bombardment is 100% greater than carona.

treatment is uniform through out the surface

treatment on higher thickness , thicker than 0125 inch is possible.

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Surface Contamination. The presence of surface contamination such as

skin oils and bodily fluids can prevent contact of the adhesive with the

substrate. There are many different types of surface contamination, most of

which are not visible to the eye but can be identified analytically. It may not

be possible to obtain an acceptable bond without cleaning the surface (e.g.,

through washing or flame treating). Surface contamination may be present if

one can detect loose material on the surface of a substrate or the material

feels slippery, greasy, or slimy. Contamination may also be suspected if

testing indicates poor bond strength and the adhesive feels "dead" after

removal from the substrate.

critical Issues are

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Pressure sensitive adhesive tape manufacturing process ?

Adhesive Coating

Rewinding and slitting or slicing

Testing

Packing

Drying

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Adhesive Coating For Water borne / Solvent borne adhesives

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Adhesive Coating For PVC Tape

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Adhesive Coating For Hot melt adhesives

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Coating machine Gravure

Coating Method

Can handle

Viscosity upto (

CPS )

Coating speed

mtr/min

Coating Weight (

gm/Sq.mtr.)

Myer Bar 10-200 200 3.-25.

Kiss 100-2000 700 3.-20.

Gravure 100-2000 700 3.-20. 28-01-2013 64

Coating Method

Can handle

Viscosity upto (

CPS )

Coating speed

mtr/min

Coating Weight (

gm/Sq.mtr.)

Hot Melt 500-20000 300 10-300

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Coating machine with Online Priming

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Coating machine Comma / reverse roll

Coating Method

Can handle

Viscosity upto (

CPS )

Coating speed

mtr/min

Coating Weight (

gm/Sq.mtr.)

Comma /

Reverse Roll

1000-6000 300 10-200

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Foam or Leather Sheet feed adhesive coating Machine

Coating Method

Can handle

Viscosity upto (

CPS )

Coating speed

mtr/min

Coating Weight (

gm/Sq.mtr.)

Comma /

Reverse Roll

1000-6000 300 10-200

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Foam or Leather Sheet feed lamination Machine

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Hot Melt adhesive Coating Mc Roller Type

Coating Method

Can handle

Viscosity upto (

CPS )

Coating speed

mtr/min

Coating Weight (

gm/Sq.mtr.)

Hot Melt 500-20000 300 10-300

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Hot Melt adhesive Coating Mc Nozzle Type

Coating Method

Can handle

Viscosity upto (

CPS )

Coating speed

mtr/min

Coating Weight (

gm/Sq.mtr.)

Hot Melt 500-20000 300 10-300

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PVC Tape coating Machine

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Drying

Drying of coatings removes the inert inactive solvent used to suspend , dissolve or disperse the active ingredients ( polymer , binder, pigments, slip agent, hardener , coating aids etc. ) , so that only the desired coating remains on the desired surface / substrate. Solvents could be water , or active organic materials Usually the drying process is a thermal one , in which heat is supplied , to the coated fluid and the solvent in it is vaporised.

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Drying

Coating - Drying Interactions The purpose of drying process is to produce a uniform dry coating from the applied wet coating , by evaporation of solvent . If wet coating applied is uniform then the dryer must immobilize it and maintain its uniformity throughout the drying process. Drying and Coating processes are interdependent and interactive. The requirements of coating process determine the drying parameters. The needs and limitations of dryer influence the coating process.

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Drying

A dryer designed to evaporate water differs significantly from one

intended for use with volatile organic solvent.

The bonder system influences the drying temp and air velocity.

A low viscosity formulation is far more susceptible to damage in the

dryer than a high viscosity one.

Lower air viscosity must be used in the drying process to avoid

moving the coating and damaging it.

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Drying

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Drying

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Drying

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Rewinding

Rewinding Machine

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Slitting / slicing

The three most common slitting

methods used are

Razor ,

Shear ,

and Crush (score)

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Slitting / slicing

Razer Cutting

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Slitting / slicing

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Slitting / slicing

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Slitting / slicing Machines

Slitting Machine

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Salvage Rewinding

Salvage Rewinder

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Packing

Shrink Pack

Box Seal

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Testing

Thickness

Coating weight Test

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Testing

Peel strength /

Tensile Strength

Shear test

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Please feel free to contact us For more Information Our website : www.psadhesive.com Personal Email : psatechno@gmail.com Cell : 00 91 9850242282

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