Making the Choice Between Acrylic Emulsion, Thermosetting Acrylic, and Solvent Acrylic PSA Tapes
One of the defining features of acrylic pressure-sensitive adhesive (PSA) tapes are their versatility and durability. The general rule of thumb usually goes “when in doubt, use acrylic PSA tapes.” At the same time, there are a wide range of acrylic pressure sensitive adhesive types that have a wide variety of performance characteristics. So, while it’s a helpful rule, it is unnecessary when you work with the right adhesive tape converter. We can help you choose the perfect PSA tape for any application. When it comes to acrylic PSA tapes, the three manufacturing coating options for specialty applications include acrylic emulsion, thermosetting acrylic, and solvent acrylic. Each of these types of adhesives has unique properties that make them suitable for specific applications, offering engineers and designers a range of options tailored to their requirements.
What Is Acrylic Emulsion PSA Tape?
Acrylic emulsion PSA tapes are created by emulsifying acrylic polymers in a water-based solution. The formulation is coated onto backings or liner stock and the water carrier is dried with the use of heat and air flow. This environmentally friendly production method has gained popularity in industries looking for sustainable adhesive solutions.
The most well-known properties of acrylic emulsion PSA tapes include:
Environmentally Friendly: they are produced in a manner that results in low volatile organic compound (VOC) emissions, making them safer for the environment with less off gassing in use.
Moderate Adhesion: they offer a balanced adhesive strength suitable for general-purpose applications.
Flexibility: acrylic emulsion PSA tapes can be produced to be less aggressive than solvent-based adhesives, providing easier removability in specific applications.
The Pros of Acrylic Emulsion Tapes:
Environmentally safe production process.
Low VOC and low odor in use.
Cost-effective for large-scale use.
Simple and straightforward to apply.
The Drawbacks of Using Acrylic Emulsion Tapes:
Limited resistance to extreme heat and moisture.
Inadequate strength for heavy load and high-stress applications.
When to Use Acrylic Emulsion Tapes
When should you use acrylic emulsion tapes? These PSA tapes are best known for their use in light duty applications that include:
Indoor Use: these tapes are commonly used for lightweight bonding tasks such as laminating, packaging, and general assembly.
Eco-Friendly Industries: they are widely adopted in industries like paper, graphics, and labeling, where environmental concerns are a priority.
Low VOC, Low Odor: with less off-gassing and odor, these tapes are often used in automotive and transportation interior applications.
General-Purpose Bonding: acrylic emulsion tapes are ideal for non-demanding environments that don’t require extreme durability.
What Is Thermosetting Acrylic PSA Tape?
Thermosetting acrylic PSA tapes are engineered as 100% solids that soften with heat to allow coating of the adhesives. There are a variety of curing methods to create a crosslinked molecular structure. This process creates better strength and durability, making these types of acrylic PSA tapes ideal for more demanding environments.
The most well-known properties of thermosetting acrylic PSA tapes include:
Exceptional Heat Resistance: if engineered to do so, these PSA tapes can withstand high temperatures, maintaining bond strength even in high-heat environments.
Chemical Resistance: they are resistant to a wide range of chemicals, including solvents and oils.
Crosslinked Durability: the curing process promotes long-term adhesion, even under heavy loads and environmental stress.
Permanent Bonding: once cured, thermosetting acrylic PSA tapes form a highly durable adhesive bond.
The Pros of Using Thermosetting Acrylic PSA Tapes:
Thermal stability for high-temperature applications.
Excellent chemical resistance for harsh environments.
Long-lasting, durable bonds that endure mechanical and environmental stress.
Environmentally friendly compared to solvent-based adhesives.
Can be produced as low VOC and low odor products
The Drawbacks of Using Thermosetting Acrylic PSA Tapes:
Higher initial cost compared to acrylic emulsion PSA tapes.
Performance can be highly engineered but often are challenged to live up to the total performance of solvent borne formulations.
When to Use Thermosetting Acrylic PSA Tapes
Thermosetting acrylic PSA tapes are specialized for specific industries and applications, including:
Automotive Industry: used for applications like bonding interior panels, sealing engine components, and attaching emblems.
Aerospace Applications: perfect for high-temperature environments where reliability is paramount.
Electronics Assembly: secures components subject to heat, such as circuit boards or LED assemblies.
Metal and Glass Bonding: they are excellent for adhering to hard-to-bond materials in construction and industrial manufacturing.
What Is Solvent Acrylic PSA Tape?
Solvent acrylic PSA tapes are produced by dissolving acrylic polymers in a solvent solution, which creates a highly versatile and high-performance adhesive. The solvent is evaporated during production, leaving behind a strong adhesive layer.
The most well-known properties of solvent acrylic PSA tapes include:
High Adhesion: these PSA tapes bond effectively to both high and low surface energy substrates, such as plastics, metals, and painted surfaces.
Wide Ranging Temperature Resistance: these products can withstand temperature extremes on either end of the temperature scale.
Environmental Resistance: they provide excellent durability against moisture, UV exposure, and extreme temperatures.
Versatility: solvent acrylic PSA tapes perform consistently across a wide range of indoor and outdoor environments.
The Pros of Solvent Acrylic PSA Tapes:
Excellent adhesive strength across diverse substrates.
Outstanding resistance to environmental factors like UV light, heat, and moisture.
Robust resistance to temperature extremes
Excellent solvent and chemical resistance
Highly durable for both indoor and outdoor use.
The Cons of Solvent Acrylic PSA Tapes:
Highest manufacturing costs due to the use of solvents.
Elevated VOC emissions, making it less environmentally friendly.
Global capacity of Solvent based PSA tapes is not increasing due to environmental restrictions which will continue to pressure the lead times and delivery.
When to Use Solvent Acrylic PSA Tapes
Because of their high adhesive strength and environmental resistance, Solvent acrylic PSA tapes are often used in harsh environments. They are commonly used in:
Construction: used for weatherproofing, sealing joints, and attaching panels in building applications.
Automotive: used for bonding trim, attaching emblems, and creating weather-resistant seals.
Industrial Use: these acrylic PSA are common in manufacturing environments requiring reliable performance in demanding conditions.
Outdoor Applications: solvent acrylic PSA tapes are an excellent choice for signage, HVAC systems, and areas with high exposure to environmental stressors.
Choosing the Right Acrylic PSA Tape for Your Application
Selecting the correct type of acrylic PSA tape depends on the specific demands of your project. While choosing the right tape requires a detailed look at your application, its environment, and what you are trying to achieve in terms of bonding, there are some general rules you can follow:
For eco-friendly, light-duty tasks, acrylic emulsion tapes are cost-effective, environmentally sound, and good for indoor and temporary uses.
For more high-performance needs, thermosetting acrylic tapes are the gold standard for applications requiring thermal stability, chemical resistance, and long-term durability.
For outdoor and versatile applications, solvent acrylic tapes provide the best combination of adhesion strength, environmental resistance, and durability. They are ideal for industrial and construction environments.
Each of these acrylic PSA tapes have their own unique strengths and weaknesses, allowing for customizable solutions based on your specific requirements. This allows you to find a PSA tape that creates a reliable bond, reduces your costs, and improves your overall performance.