Double sided Pressure Sensitive Adhesive Tape

248 Pages·2014·10.07 MB·English

by  Martin Nilsson Lind

Double-Sided Pressure
Sensitive Adhesive Tape -
“As a Non-Drill Solution in Bathroom

Environments”

Martin Nilsson Lind
Daniel Petersson
Erik Petersson

Department of Mechanical Engineering
Blekinge Institute of Technology
Karlskrona
Sweden
2014

Master of Science thesis in Mechanical Engineering

in cooperation with

Testimonials

Martin Nilsson Lind, Daniel Petersson and Erik Petersson have from 140116
to 140613 been working with a master thesis regarding Non-Drill solutions at
IKEA Components AB.

Martin, Daniel and Erik has worked with development and testing of non-drill
solutions to be used in bathroom environment. The students have during these
months build an impressive knowledge of double sided tapes. They have
made an extensive amount of tests and been in contact with many potential
suppliers within the industry. Martin, Daniel and Erik have been working very
independently and delivered results beyond expectations.

By implementing the tape tested, validated and offered trough one of the
remaining suppliers that were mapped by the students – IKEA would save
600.000 EUR per year. It would, at the same time, greatly improve quality of
the final product. The biggest contribution is however still all the valuable
input for future designs of hangers, hooks and handles to be compatible with
double sided tape as anon-drill solution. This gives endless possibilities for
many IKEA designers and developers in the coming years.

We are pleasured to leave Martin, Daniel and Erik our best recommendations
Abstract
The IKEA customers are looking for new solutions to mount products in their
homes and IKEA has embraced the request for this type of applications in
bathroom environments as it is of the largest challenges for the customer.
Double sided tape has been identified as a possible solution, hence why this
project was put together. The research aims to give the reader a deeper
understanding regarding double sided tape and the influences of external
variables such as material, substrate and surface tension to mention a few.

Extensive tests have been carried out where samples from double sided tape
suppliers are examined. The test that was developed and carried out in this
project aimed to include some of IKEA´s most commonly used materials
together with common substrates in bathroom environments. The test data
was compiled and the outcome was used to give recommendations to IKEA
regarding future product development when using double sided tape and also
recommend suitable tape suppliers for continued cooperation.

Key Words: PSA, Double sided Tapes, Tack, Adhesion, Cohesion,
Pressure Sensitive Adhesives, Non drill, Bathrooms
Abstrakt
IKEA-kunder söker efter nya lösningar för att montera upp produkter i sina
hem, detta har IKEA tagit till sig och anser att badrumsmiljö är den tuffaste
utmaningen att börja med. Dubbelhäftande tejp har identifierats som en möjlig
lösning och detta projekt siktar på att undersöka ämnet. Syftet med rapporten
är att försöka ge läsaren en djupare förståelse gällande dubbelhäftande tejp
samt lyfta fram påverkan från yttre variabler så som material, substrat och
ytenergi för att nämna några.

Omfattande tester har utförts där prover från dubbelhäftande tejpleverantörer
har undersökts. Testmetoden som togs fram och användes under projektet
hade för avsikt att testa de vanligaste materialen inom IKEA samt de
vanligaste förekommande substraten i badrumsmiljöer. Testdata analyserades
och resultatet användes för att ge IKEA rekommendationer på framtida
produktutvecklingsaspekter samt till att identifiera lämpliga tejpleverantörer
för fortsatt samarbete inom området för dubbelhäftande tejp.

Nyckelord: PSA, Tryckkänslig, Dubbelsidig Tejp, Klibbighet,
Vidhäftning, Kohesion, Tryckkänsliga Lim, Ingen Borrning, Badrum
Acknowledgments
The master thesis is the outcome of a collaboration between Blekinge Institute
of Technology (BTH) & IKEA Components. The project has given us the
opportunity to apply our knowledge on areas previously unknown to us,
which required us to actively expand our knowledge within this particular
field by interacting with truly wonderful people within and outside of IKEA.

The contributions of the BTH engineering has been valuable, their insightful
feedback and support have been of outmost importance to the success of the
project and its development. A special thanks go out to Stefan Sjödahl from
BTH for his continuous feedback and support.

We would also like to acknowledge the assistance and feedback provided by
Carmen Stoicescu and her colleagues Okan Demirci & Tiberiu Potop at IKEA
of Sweden, HFB 6 – Bathroom Organisers. Their encouragement and
enthusiasm has pushed the project past our own expectations and we are ever
so grateful for that.

The people at the IKEA Test Lab have been of great assistance during the
many weeks that were spent there during the testing phase, especially Sven-
Ingvar Johansson whose experience, know-how and willingness to assist us
never waived. The IKEA Components Trading team have also been a very
important part along the way, their input and experience have been invaluable.

Finally we want to thank Marcus Johansson and Josef Hernefrid along with
the rest of the team at IKEA Components in CB1, Complementary. Marcus’s
support throughout the project has been purely inspirational and his
contributions cannot be understated. By sharing his own experiences and
providing us with new angles of approaches he is been the most contributing
factor to the success of this project as well as our own growth and
development as engineers.

Martin Nilsson Lind
Daniel Petersson
Erik Petersson
Table of Content
1 Introduction ............................................................................ 1
1.1 Background ................................................................................... 1
1.2 Problem ......................................................................................... 2
1.3 Purpose .......................................................................................... 2
1.3.1 Problem Statements .......................................................... 2
1.4 Company Objectives ..................................................................... 3
1.5 Methods ......................................................................................... 5
1.5.1 Approach ........................................................................... 6
1.6 Delimitations ................................................................................. 8
1.7 Background of IKEA .................................................................... 8
Pre – Study

2 Introduction to Tape ............................................................ 10
2.1 The Structure of Single Sided PSA Tape .................................... 11
2.2 The Structure of Double Sided PSA Tape .................................. 12
2.3 Defining Pressure Sensitive Adhesives ....................................... 13
2.4 PSA Categorisation ..................................................................... 14
2.4.1 Rubber ............................................................................. 14
2.4.2 Acrylic ............................................................................. 17
2.4.3 Silicone ........................................................................... 21
2.4.4 Manufacturing Technologies .......................................... 23
2.5 Backing/Carrier ........................................................................... 24
2.5.1 Paper Backings ................................................................ 25
2.5.2 Filmic Backings .............................................................. 25
2.5.6 Foam Backings ................................................................ 27
2.5.7 Acrylic Core Backings .................................................... 27
2.6 Release Liners ............................................................................. 28
2.7 Summary Introduction to Tape ................................................... 29
3 PSA Tape - Main Properties ................................................ 30
3.1 Tack ............................................................................................. 31
3.1.1 Common Tack Measurement Methods ........................... 31
3.1.2 Factors Affecting Tack Properties .................................. 34
3.1.3 Effect of Coating Thickness ............................................ 35
3.1.4 Effect of Other Variables ................................................ 35
3.2 Adhesion ..................................................................................... 36
3.2.1 Common Adhesion Test Methods .................................. 36
3.2.1 Factors Affecting Adhesion ............................................ 37
3.2.2 Effect of Coating Thickness ........................................... 37
3.2.3 Effect of Other Variables ................................................ 39
3.3 Cohesion ..................................................................................... 40
3.3.1 Common Shear Strength Testing Methods ..................... 40
3.3.2 Factors Affecting Cohesion: ........................................... 41
3.4 Summary PSA – Main properties ............................................... 43
4 Substrates ............................................................................... 44
4.1 Surface Topography .................................................................... 44
4.2 Wetting – Surface Energy and Tension ...................................... 46
4.3 Surface Energy of Solids ............................................................ 48
4.4 Surface Preparation ..................................................................... 50
4.4.1 Increase Surface Energy of a Substrate .......................... 50
4.4.2 Surface Cleaning ............................................................. 52
4.4.3 Primers for Adhesive Bonding ....................................... 54
4.5 Work done by Adhesive Bonds .................................................. 56
4.5.1 With Respect to Surface Roughness ............................... 59
4.6 Summary Substrates.................................................................... 61
5 Cross-Linking ........................................................................ 62
5.1 Rubbers ....................................................................................... 62
5.2 Acrylics ....................................................................................... 63
5.3 Bond Strength in PSAs ............................................................... 64
5.4 Cross-Linking Factors ................................................................. 65
5.4.1 The Glass-Transition Temperature (Tg) ......................... 65
5.4.2 Monomer Selection ......................................................... 66
5.4.3 Molecular Weight ........................................................... 67
5.4.4 Polymerisation Methods ................................................. 68
5.4.5 Additives (Tackifiers & Plasticisers) .............................. 69
5.5 Summary Cross – Linking .......................................................... 70
6 Failure Scenarios – PSA Tape ............................................. 71
6.1 Adhesive Failure ......................................................................... 72
6.2 Cohesive Failure ......................................................................... 72
6.3 Combination of Adhesive and Cohesive Failure ........................ 73
6.4 Interfacial Failure ........................................................................ 73
6.5 Key Failure – Foam Tear ............................................................ 74
6.6 Oscillating Failure ....................................................................... 75
6.7 Adherend Failure ........................................................................ 75
6.8 Summary Failure Scenarios – PSA Tape .................................... 76
7 Safety and Environment ...................................................... 77
7.1 Safety Aspects – PSAs ................................................................ 77
7.2 Environmental Impacts ............................................................... 80
7.2.1 In-going Materials ........................................................... 80
7.3 Processes ..................................................................................... 81
7.3.1 Hot-Melt .......................................................................... 81
7.3.2 Solvent & Emulsion ........................................................ 82
7.4 Effect on Humans ........................................................................ 83
7.5 Effect on Environment ................................................................ 84
7.6 Sustainability ............................................................................... 86
7.7 Summary Safety and Environment ............................................. 88
8 Competitor Analysis ............................................................. 89
Planning for Testing

9 External Stakeholders .......................................................... 92
9.1 Supplier Mapping Approach ....................................................... 93
9.2 Supplier Document Development ............................................... 94
9.2.1 Development Approach .................................................. 95
9.3 Supplier Selection Process .......................................................... 96
9.3.1 Criteria explained ............................................................ 97
10 Concept Generation - Test Rig ............................................ 98
10.1 Final Test Rig ............................................................................ 102
11 Testing Scope....................................................................... 103
11.1 Reasoning behind Testing Methodology .................................. 103
11.2 Test Setup .................................................................................. 106
11.3 Prerequisites .............................................................................. 107
11.4 Test Cycles ................................................................................ 108
11.4.1 Test Phases .................................................................... 109
11.5 Test Preparation ........................................................................ 110
11.6 Bathroom Testing Environment ................................................ 111
11.6.1 Substrates ...................................................................... 112
11.6.2 Environments ................................................................ 112
11.6.3 Common Impurities ...................................................... 113
11.6.4 Temperature & Moisture ............................................... 113
11.7 Sample Selection Process .......................................................... 114
11.8 Summary Testing Scope ........................................................... 116
Results

12 Overall Performance and Analysis ................................... 118
12.1 Overall Performance ................................................................. 118
12.1.1 Overall Cycle Performance ........................................... 119
12.1.2 Product Failure Mode ................................................... 121
12.1.3 Individual Failure Mode ............................................... 122
12.1.4 Environment and substrate............................................ 124
12.2 Selective Analysis - Adhesives & Carriers ............................... 129
12.2.1 Adhesive Performance - Substrate ................................ 130
12.2.2 Adhesive Performance - Environment .......................... 131
12.2.3 Adhesive Performance - Product .................................. 132
12.2.4 Adhesive Performance - Chemical Resistance ............. 133
12.2.5 Carrier Performance - Substrate ................................... 134
12.2.6 Carrier Performance - Environment ............................. 135
12.2.7 Carrier Performance - Product ...................................... 136
12.2.8 Carrier Performance – Chemical Resistance ................ 137
12.3 The Master File – Test Results ................................................. 138
12.4 Summary Overall Performance and Analysis ........................... 138
13 Sample Based Performance and Analysis ........................ 139
Closing Analysis

14 Discussion ............................................................................. 142
14.1 Addressed Problem Statements................................................. 143
14.2 Result-based Discussion ........................................................... 144
14.2.1 Rubber VS. Acrylic Adhesive - Products ..................... 144
14.2.2 Impact of Environment ................................................. 146
14.2.3 Failure Scenarios of Tape Samples ............................... 148
14.2.4 Failure Scenarios of Products ....................................... 150
14.2.5 Analysis of Product – Environment - Substrate ........... 159
14.2.6 The Performance of PSA Rubber Tapes ....................... 160
14.3 Testing Method ......................................................................... 161
14.3.1 Equipment and Planning ............................................... 161
14.3.2 Preparation .................................................................... 162
14.3.3 Cleaning ........................................................................ 163
14.3.4 Removal ........................................................................ 163
14.4 Sample Data - Challenges ......................................................... 164