The concepts and terminology used in the pressure sensitive market can be confusing. In this story, Jim Hingst explains the vocabulary and basics of adhesives.
By Jim Hingst
Early in my career I remember how excruciating it was to listen to the presentations of the manufacturing or R&D techies on the subject of pressure sensitive materials. Jargon, such as cross-linking, dyne levels, peel, quick stick or wet out, was totally foreign to me. From time to time I must have looked like the wide-eyed, yet dumbfounded Cocker Spaniel, with my head listing to one side, attentively hearing the words, but not quite grasping the meaning of the message.
Early in my career I remember how excruciating it was to listen to the presentations of the manufacturing or R&D techies on the subject of pressure sensitive materials. Jargon, such as cross-linking, dyne levels, peel, quick stick or wet out, was totally foreign to me. From time to time I must have looked like the wide-eyed, yet dumbfounded Cocker Spaniel, with my head listing to one side, attentively hearing the words, but not quite grasping the meaning of the message.
Understanding
the sticky business can be challenging even for those with considerable
experience. Pressure sensitive
constructions combine a variety of components, including an assortment of
adhesives, release liners and facestocks and carriers. The extensive range of adhesive-coated films,
foils, papers and foam products sold to the graphic arts industry includes cast vinyl and calendered vinyl, metalized specialty films, premasks and application
tapes, double-sided foam tapes, supported mounting tapes, unsupported transfer
adhesives and overlaminates.
The
reason that most people have difficulty understanding pressure sensitive basics
is that few manufacturers have formal training programs. And many of those that
do, often don’t do a very good job of
it. The purpose of this article is to answer some of the questions that sign
makers may have about pressure sensitive materials by providing an overview of
the basic concepts and a translation of
some of the jargon. That way, you can talk techie too and baffle your peers
with your newly acquired vocabulary and technical expertise.
An
adhesive is any material that bonds two
substrates. The egg yolk that fuses my plates together when I don’t do the
breakfast dishes is an adhesive. The sap that oozes from a cut in a pine tree
is another common adhesive found in
nature. Natural latex, which is the milky fluid that comes from plants, such
as rubber trees, is used in making the adhesive for the application tape in
your shop. In addition to the natural adhesives, there are also synthetic rubber and acrylic adhesives. During WWII,
natural rubber was scarce. This
necessity gave birth to the invention of synthetic rubbers.
Synthetic
adhesives are related to plastics. Both plastics and synthetic and natural
rubber adhesives are composed of gigantic molecules called polymers. These polymers are composed of
thousands of small molecules called monomers.
The chemical reaction used to
combine the monomers into a macromolecule is called polymerization. The
polymerized synthetic resin used to make
the adhesive on your cast or calendared
vinyl, for example, is an acrylic resin.
The
macromolecule chains formed in the polymerization process can be joined together by a bonds called cross-links. The degree to which the polymer
chains of an adhesive are crosslinked affects its internal or cohesive
strength. (Cohesive, of course, means that a material sticks together. As an
interesting aside, did you know that there are materials called cohesives? Unlike adhesives, cohesives stick to nothing
other than themselves. Cohesives, which
are used in the packaging field, are coated to facestocks such as corrugated
board. When the cohesive product is wrapped around a book or a video tape, the cohesive will not
stick to the product, but only sticks to itself to form an inexpensive mailing
package.)
Now
back to cross-links. A more highly
crosslinked adhesive typically has more memory. So if you apply pressure to an
adhesive and stretch it in one direction, the highly cross-linked
adhesive has enough elasticity or memory to return to its original state. As
crosslinking increases, the viscosity of
the adhesive increases. (Viscosity is the friction or resistance that occurs as
layers of fluid slide against each other.)
The harder, more viscous adhesives, exhibit lower initial tack. That makes them great for hot weather applications. Conversely, adhesives with less cross-linking are softer, flow more readily and higher tack but lower ultimate adhesion. To many, it doesn’t make sense that the sticky vinyl will not stick as well as the less sticky vinyl! While this sounds like some Zen riddle from a “Kung Fu” episode, it’s one of those strange but true paradoxes of life. Tack and adhesion are not the same.
The
structure of these macromolecules also affects how the adhesive performs.
Generally, adhesives with long molecules
are harder, yet more pliable and build quickly to high ultimate adhesion. These
long molecules are so gangly that it’s
difficult for them to arrange themselves in a nice, neat orderly pattern.
Instead, they’re like a big jumbled, tangled plate of spaghetti. And that’s
good. The entanglement of the molecules creates greater internal
strength, compared to polymers that are arranged in an orderly but stiff
crystalline structure.
Pressure sensitive products work a little differently than some of the other
adhesives you’ve likely used, such as
contact cements, cold glues, hot melt glues, epoxies and silicones. Not all adhesives bond to substrates in the same way. When I worked in the packaging
field, the cold glues used to seal corrugated boxes or folding
cartons, formed a bond in part by being
absorbed by the paper substrate. Other adhesives bonds are formed by a
chemical reaction between the adhesive and the adherend (that’s the material
that you’re trying to stick to).
Pressure sensitive adhesives bond by molecular attraction and by mechanically
interlocking with the substrate. In this process, the adhesive flows into the
microscopic pores on the surface of the substrate. To form a good bond, the adhesive must readily flow over or “wet out” the
substrate’s surface. How well the adhesive
wets out depends on forces which
pull in opposite directions.
One force is the natural molecular affinity that
occurs between two different materials.
Fighting this magnetic attraction are the internal or cohesive forces of
adhesive. The surface energy of the substrate determines how strongly the
adhesive is attracted to it. High
surface energy materials have microscopic pores with higher and more pronounced
peaks and valleys than the smoother
surface of low energy materials.
Here’s a list of some high energy and low energy
materials, with their corresponding dyne levels (dyne levels are numerical
values of the surface energy).
Low energy materials
Substrate Dyne Level
Polystyrene 36
Polyethylene 31
Polypropylene 29
High energy materials
Substrate Dyne Level
Stainless
steel 700-1100
Glass 250-500
Polyurethane
Paint 43
Polycarbonate 42
Rigid
PVC 39
Acrylic 38
In describing how an adhesive on wets out on low
energy and high energy surfaces, the most common comparison that the techies
use is with the newly waxed paint car finish and the unwaxed finished. Low
energy surfaces are similar to the newly waxed car. Just as
sprinkled water beads up on the wax, the adhesive does not flow out on
the substrate. On the car which has not
been waxed the water spreads out, just as an adhesive readily wets out a high
energy surface.
The wet out of the water on the unwaxed car is visible
by the naked eye. The microscopic wet out of an adhesive, of course, can’t be
seen. The wetting out of a pressure
sensitive material is affected by time,
temperature and pressure. As time progresses, the adhesive naturally
continues to flow into the microscopic pores. And as it does, ultimate adhesion increases. This process
accelerates as temperature rises. But,
colder temperatures retard wet out.
At room temperature, a pressure sensitive will only
start to wet out after pressure is applied. After all, they call these materials pressure sensitive for a
reason. Room temperature represents the ideal application environment. Of course, sometimes pressure sensitive
vinyl sticks without pressure, resulting
in deformation of the graphic. When this happens, the terms used (other than a litany of
expletives uttered by the frustrated
and angry installer) are preadhesion or pretack.
At other times pressure sensitives won’t stick no
matter how much pressure is used for any number of reasons. For example,
adhesion failure can occur if you try to
apply a graphic when its too cold. Or if the surface isn’t properly cleaned. Or
if the adhesive does not have an affinity for the application substrate (for
example, acrylic adhesives don’t work wet on untreated polypropylene and
polyethylene).
When All Else Fails, Read The Instructions.
To select the best pressure sensitive product for a
particular application, you must consider the environment to which the tape or vinyl will be subjected
such as UV light, extremes off heat and cold, exposure to water and chemicals,
application temperatures, durability requirements and cost considerations.
To avoid
problems with a vinyl or any other pressure sensitive, check the specs,
the manufacturer’s product information bulletin and the application
instructions. This should provide you with all of the information you
need including application temperature range, service temperature range, peel
adhesion, cleaning recommendations and information regarding application
surfaces. If you still have questions, call your distributor or the
manufacturer for the answers.
Here’s a list of some things that can affect adhesion:
- Substrate contamination – The surface must be clean and dry. If the substrate is contaminated with dirt, oxidation, plasticizers or release agents, adhesion failure often results.
- Texture of the surface – Bonding a sign or nameplate to a rough surface requires a thick double-sided foam tape or a thick transfer adhesive.
- Porosity of the substrate – Porous sign substrates should be sealed or any moisture absorbed by the substrate could adversely affect the bond of the adhesive.
- Thermal expansion – Different rates of expansion of two different substrates can break the adhesive bond. For example, mounting an expanded PVC sign to a metal building fascia. The sign blank will expand or contract at a much greater rate than the metal.
The Pressure Sensitive Sandwich.
The
pressure required to make a pressure sensitive material work isn’t its only
unique characteristic. What also distinguishes pressure sensitives from other
adhesive families is that they are composed of multi-layered constructions
called a “pressure-sensitive sandwich”.
Just as you can order many different types of sandwiches at your local
deli; there are many different
constructions of the pressure sensitive sandwich. These constructions that can be divided into two
broad categories: self-wound products and
linered products.
The
simplest self-wound construction would consist merely of an adhesive applied to
a facestock, such as paper or a plastic film. This category of products
includes masking tape, paper and film application tapes and self-wound
overlaminates. Two variations of this
construction are to prime the second
surface of the facestock (that’s the
side with the adhesive) and/or to release coat the first surface of the
facestock.
The
reasons that you prime the facestock are similar to the reasons that you prime
paint a surface before you apply your finish coat. Priming seals the surface,
if you’re coating a paper facestock. . By sealing the paper, less adhesive
soaks into the facestock, so more adhesive stays on the surface. This results
in more consistent performance throughout the roll. Because the adhesive is on
the top of the paper, there is more adhesive mass. That greater mass results in an improvement
in the cold flow of the adhesive.
Another
reason for priming is that it better
“anchors“ or bonds the adhesive to the
facestock. Better adhesive anchorage
means that if adhesive touches adhesive there will be less adhesive
delamination, when you pull the two apart. Also, with better anchorage there’s less adhesive transfer the substrate after a
tape is removed.
Priming better anchors the adhesive to the facestock and prevents the adhesive from delaminating. |
Some
self-wound constructions are also release coated to provide an easier unwind of
the roll and to prevent the tape from blocking on the roll. Blocking is the
term used when a self-wound product sticks together and does not unwind. Release coating can also reduce the
chattering noise that sometime occurs when a self-wound overlaminate
unwinds. Some self wound products masking tapes, application tapes, surface protection
films and self-wound overlaminates.
Linered materials are any products that
include a siliconized release liner in its construction, such as cast and
calendared vinyl, double-sided foam tapes, supported and unsupported transfer
adhesives, and linered overlaminates. The release liner serves several
different functions:
1) The release liner protects the adhesive of the pressure
sensitive material.
2) The release liner stabilizes the construction during
conversion operations.
3) The smoothness of the release liner affects the smoothness of
the adhesive coating. Film liners are
very smooth, which smoothes the adhesive, giving it the clarity needed for
products such as overlaminating films.
Release
liners are constructed of a variety of base materials, such as polyester
and polypropylene films, and densified kraft and polycoated kraft papers. With liners, as with anything else in life there are pluses and
minuses to each option. Liners also come
in several thickness. 44# and 50# liners are supple yet strong enough for printing on roll label presses. 78# liners,
commonly used in the sign industry, have the needed flexibility for
plotter cutting. 96# poly-coated liners are ideal for screen printers. The heavier paper not only lays flatter on the press, but the poly-coating
prevents the absorption of moisture, so the liner doesn’t grow, throwing registration
off.
Of
all of the linered pressure-sensitive
products on the market, the most basic are single liner, unsupported
transfer adhesives, which are also called transfer tapes. (Note: a transfer
tape is not the same as an application tape.) Transfer tapes merely consist of
adhesive applied to a release liner. Some folks refer to this as glue on a
roll. A fancier version of this is a transfer tape with two liners. This
requires the user to remove one of the liners prior to application of the adhesive
to a print, nameplate or graphic panel.
Transfer tapes are often used in the
manufacture of polycarbonate control
panels. These panels are printed
sub-surface, which means that the
polycarbonate film is printed in reverse on its second surface or underside.
The transfer tape is then laminated to the printed side. The release liner protects the adhesive on
the panel, until the time of
application. The two most popular thickness of adhesive used for this
application are 2 mil, for smooth surface applications and 5 mil for rough
surfaces.
A
supported transferred adhesive gets its name from the film carrier that’s
sandwiched between two layers of adhesive. In the digital graphics market this
product is usually called a mounting
tape. The carrier serves a number of functions.
First, it stabilizes the tape during the lamination process. It also provides additional rigidity to the
print. And it allows the use of two different adhesives. Commonly, a mounting
tape consists of the following layers: release liner; removable or some other
type of adhesive, film carrier, permanent adhesive, and the release liner. The permanent adhesive is applied to the graphic, while the other side is
applied to the substrate.
There
are dozens of double sided foam tape constructions to satisfied an array of
applications. Typically, these foam tapes consist of a foam carrier, coated on
both sides with adhesive, and with the
adhesive on at least one side protected with a release liner. The foam carrier consists of cells which are
similar to enclosed bubbles. This is
called closed cell construction. This type of foam tape forms an excellent
moisture barrier. In contrast, if the foam carrier has the structure of a
sponge, in which it appears that the bubbles have burst, the construction is
called open cell. This construction, as you might imagine, sucks up water like
a sponge.
There
are many different types of foam carriers, which can make product selection
confusing. The different types of carriers include high density polyethylene,
neoprene, acrylic, urethane and vinyl.
The key difference among types of foam carriers is the internal strength
or shear strength of the material.
Last,
but certainly not least of the linered products, are paper and film products
used in the sign, screen print and label industries. In addition to cast and calendared vinyl, there
are several products using a variety
of other facestocks, such as
polyester, polypropropelene, and paper.
The typical construction is a siliconized release liner, adhesive,
occasionally a liner, the facestock and sometimes a top coating or corona
treatment (which increases surface energy) to improve ink anchorage.
Rubber or Acrylic Adhesive.
Will
that be rubber or acrylic adhesive on your pressure sensitive sandwich?
Adhesive systems fall into two broad categories: rubber adhesive systems and
acrylic adhesive systems. Each system
has its own unique characteristics. Rubber based adhesives are very soft and
wet out well. Because these soft
adhesives flow very readily they coat the substrate and provide very high “quick stick” to a surface. This quick stick characteristic is also described as instant tack or loop tack. Because rubber adhesives wet out
better than acrylics, they require less pressure during application to form a
bond. The tacky quality of rubber-based
system also allows them to stick to a wider variety of surfaces.
The
tackiness of the adhesive make it an excellent choice when you are trying to
stick to a low energy plastic. So if you had to make a decal
for a manufacturer of polypropylene outhouses, as I once did, a
vinyl with a rubber based adhesive will probably adhere well to this plastic substrate,
whereas a vinyl with an acrylic adhesive is likely to fall off, unless the
plastic had been either corona treated or flame treated. Rubber-based adhesive also exhibit consistent
adhesion to the adherend, meaning that adhesion values don’t grow over time the
way acrylic adhesives do. This is why rubber based adhesives are used in the
making premasks, because the adhesive
bond does not build on the vinyl graphics, during long-term storage. If it did,
you would have difficulty removing the premask.
One weakness of rubber based adhesives is that
they are very susceptible to plasticizer migration. So there’s a good chance that if you applied
a vinyl graphic with a rubber based adhesive to a vinyl banner or flexible sign
face material, the plasticizers in the banner could soften the adhesive to the point of failure.
Another disadvantage of rubber based
adhesives is that they are susceptible to UV degradation and oxidation. As oxidation or UV degradation progresses, the rubber polymer starts to
break down. Over time adhesive failure can occur. Oxidation also causes the
rubber-based adhesives to yellow. That’s why your application tape yellows when
it’s exposed to light. The yellowing
caused by the slight degradation of the
adhesive usually isn’t enough to be an issue.
In
contrast to rubber adhesives, acrylic adhesives withstand higher
temperatures, exhibit good shear and
resist the degrading effects of UV
light, plasticizers and chemicals. What
they don’t do well is stick to low energy surfaces.
Although
acrylic adhesives are more costly than rubber adhesives, their value is that
they have a much wider range of
performance characteristics. And let’s face it, sign shop owners and screen
printers have a wide range of special needs and applications. That’s why vinyl
manufacturers, such as Avery, provide their customers with an extensive menu of
products, which includes vinyl films with
permanent, removable and
repositionable adhesives. Adhesives are blended to provide the end users
with products with specific attributes.
For example, highly aggressive permanent adhesives can be coated on
brittle, ultra-destructible films to produce safety labels. This construction
is so fragile that it destructs, coming off in tiny pieces, when someone
attempts to remove it. Repositionable
vinyl films make graphics application significantly easier because the
installer can snap a material back of the substrate and then reinstall the
material without damage to the graphic.
The latest improvement in
repositionable films features adhesive with a microstructure of tiny
tunnels These tunnels make graphics
application easier because they provide
channels through which air can escape.
Voila! Bubble-free vinyl application.
Coating Technology.
Rubber
and acrylic adhesives come is several varieties, such as emulsion, solvent, hot
melt and UV cured. In the sign industry the only technologies which are widely
used are solvent and emulsion.
When
components of an adhesive system combine with a solvent, the solvent dissolves the mixture and evenly dispenses the solution
components to form a solution. Solvent-based systems have been the mainstay of
the pressure-sensitive industry for ages. The issues with which manufacturers
must deal today are recovery and disposal of the solvents.
By comparison, a water-based adhesive system
is an emulsion. Fine particles of the
solid components of the adhesive system
are suspended in water. The
rubber based adhesives which are coated on paper application tapes are
emulsion. But acrylic emulsions have been used for years, and are becoming more
popular, because they are more cost-effective and there are no VOCs.
Product Testing.
Product
evaluation includes a wide range of tests, from visual inspection to precise
measurements. One of the tests that vinyl and overlaminate manufacturers conduct is an inspection of the
clarity and color of the adhesive.
In
performing light transmission analysis,
the measured light transmitted
through the test sample is compared with a reference sample. The clarity
of the adhesive is important for
signage applications, such as window
graphics applications.
The
torture tests that the techies conduct to evaluate the physical properties of an adhesive are sometimes
called destructive tests. The two most common tests that are used in evaluating
a cast or calendared vinyl are tack and
peel.
These tests are conducted according to guidelines established by the Pressure Sensitive Tape Council. Two widely used tests are PSTC-1 and PSTC-5.
PSTC-1
tests the ultimate adhesion. In this test, a strip of cast or calendared vinyl
or application is applied to a stainless steel substrate. Grabbing an edge of the sample strip, the
film or tape is pulled 180º against
itself. The test equipment measures the amount of force required to peel the
tape from the panel. To test the growth
of adhesion over time, manufacturers will also check samples at other time
intervals, such as 24 hours, 72 hours, 7
days and 2 weeks.
PSCT-5
tests the loop tack or quick stick of the adhesive. In this test, the two ends
of the sample strip are place in the jaws of the test equipment, to form a loop
of material, with the sticky side out. The test machine touches the loop of
material against the stainless steel plate and measures the amount of force
that is required to pull the two apart. This instant tack test tells the technician how aggressive the
adhesive is. For vinyl manufacturers
this test gives the techie an idea of how repostitionable a vinyl marking will
be during application. Another way to test the tack of an adhesive is to
conduct a rolling ball test. A ball is rolled down the groove in a piece of
metal, which is shaped somewhat like a
playground slide. At the end of the metal slide is the test sample. The technician
will then measure how far the ball rolls on the sample pieces. The ball will roll farther on a harder
adhesive, than one which is soft and tacky.
Other
specialized test equipment measures the force required to peel a pressure
sensitive film from the release liner. This is called the release value. In developing a product, a manufacturer will
test values at different times to check for any changes. High release values will reveal difficulty in
transferring a vinyl graphic from the liner, which can be a problem for the
applicator in the field.
At the other end of the spectrum, low release values indicates poor stability of the film on the liner. In this case the vinyl can slip on the liner during plotter cutting.
In
many cases, test samples will be tested in their “as is” state compared to
their “aged”. The “as is” is when the tape or vinyl film sample comes
right off the roll. In the “aged” state the sample has been cooked in the oven,
for example, at 120º F for two weeks.
These aging tests are the technician’s crystal ball. By repeating the
original tests after aging, he will have
a good idea of how the product will perform after it has sat on a distributor’s
self for a couple of years. Some of the things that the vinyl people look for
are a drop in adhesion values, a drop in loop tack, an increase in release
values along with any change in the physical properties of the facestock.
In
testing the performance of double-sided foam tapes a few other tests are conducted: shear,
tensile and the one that usually gets a
laugh out of an audience – cleavage.
Shear
is the internal strength of the adhesive
or a foam carrier. A shear test measures
the parallel forces that are generated within an adhesive or a foam tape as,
for example, the tape holds the
weight of a heavy sign against a wall.
In testing the shear of a vinyl adhesive, a tape with a 500-1000 gram weight is
applied on top of the vinyl. If the adhesive does not hold the facestock to the
substrate for the specified time, the technician must determine the cause of
the failure. Was it a cohesive failure
or an adhesive failure?
While
shear measures parallel forces, tensile measures the perpendicular forces
imposed on an adhesive bond. Imagine
that you have grabbed the two side ends of a sign and are pulling away from the
building. In this example, the stress is distributed equally over the entire
area held by the adhesive or foam tape.
Now,
instead of pulling on the two sides of the sign, let’s suppose that you just
pull at one edge of the sign. In this case, all of your force is focused at
one point. If you can break the bond at this point, you’ll likely tear the sign
off of the wall, just as easily as you would unzip a zipper. Several times I have torn apart rigid demonstration panels held together with
high bonding foam tape, not because I’m exceptionally strong but because I
understood the concept of cleavage.
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Squeegee Technique. Nothing is more basic in vinyl application than the squeegee. But some squeegees work better than others. And there are right ways and wrong ways to use this simple tool. This video clip reviews squeegee selection, squeegee care and squeegee technique. Click to Link
Wet Applications. Dry applications are typically recommended for most vinyl applications. For those exceptions to the rule, this instructional video explains the right way to perform a wet application. Click to Link
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Transferring Frosted Window Graphics Films. Because frosted window films are highly textured, transferring cut vinyl graphics can be problematic. This video provides direction in selection of the right application tape and how to apply these films quickly, easily and without problems. Click to Link
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Vinyl Application Over Rivets. Applying vinyl graphics on vehicle surfaces with rivets is challenging for most sign makers. Vinyl failures to these surfaces are all too common. This video demonstrates some tips and procedures, used by professional decal installers, which will make these demanding applications easier and more trouble-free. Click to Link
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Applying Air Egress Vinyls. Vinyl films with air egress release liners have almost eliminated bubbles and wrinkles from applied graphics. Air egress release liners with their highly textured surface structure are problematic. Not much will stick to these liners other than the vinyl film. At RTape our best premask solution for air egress liners is a special Conform® tape called 4761RLA. Click to Link
About Jim Hingst: After fourteen years as Business Development Manager at RTape, Jim Hingst retired. He was involved in many facets of the company’s business, including marketing, sales, product development and technical service.
Hingst began his career 42 years ago in the graphic arts field creating and producing advertising and promotional materials for a large test equipment manufacturer. Working for offset printers, large format screen printers, vinyl film manufacturers, and application tape companies, his experience included estimating, production planning, purchasing and production art, as well as sales and marketing. In his capacity as a salesman, Hingst was recognized with numerous sales achievement awards.
Drawing on his experience in production and as graphics installation subcontractor, Hingst provided the industry with practical advice, publishing more than 150 articles for publications, such as Signs Canada, SignCraft, Signs of the Times, Screen Printing, Sign and Digital Graphics and Sign Builder Illustrated. He also posted more than 325 stories on his blog (hingstssignpost.blogspot.com). In 2007 Hingst’s book, Vinyl Sign Techniques, was published. Vinyl Sign Techniques is available at sign supply distributors and at Amazon.
© 2016 Jim Hingst
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