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Pressure-Sensitive Adhesives: An Introductory Course

Article · June 2003


DOI: 10.1557/mrs2003.124

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ties of these adhesives must be much more

Pressure-Sensitive finely tuned than those of conventional


adhesives. It is the goal of this article to
give a general picture of the main material
requirements for obtaining PSA properties.

Adhesives: An Classes of Pressure-Sensitive


Adhesives
In practice, as will be developed in more
detail in the section on material require-

Introductory Course ments, all commercial PSAs are based on


polymers, mainly coming from three fami-
lies: acrylics, styrenic block copolymers,
and natural rubber. There are also niche
Costantino Creton markets for silicone PSAs, where low-
temperature use or high-temperature sta-
bility is required and cost is not an issue.
Historically, the first PSAs were rubber-
Abstract based. They remain the cheapest to pro-
Self-adhesive materials are called, in the adhesives trade, “pressure-sensitive duce and also the simplest to formulate,
adhesives” (PSAs). PSAs are designed to stick on almost any surface by simple contact since they are typically compounds of
under light pressure. This special class of adhesives does not undergo any physical natural rubber and a low-molecular-weight
transformation or chemical reaction during the bonding process. Because of this, the tackifying resin, miscible with the rubber
rheological properties of the adhesive must be finely tuned for the application, combining in approximately equal proportions. Earlier
a carefully chosen polymer architecture and monomer composition with the proper versions were not cross-linked, but today
addition of small molecules called tackifying resins. PSAs are soft, deformable solids a cross-linking step is generally performed
and, depending on the formulation, easily form bridging fibrils between two surfaces to avoid flow.
upon debonding. They are safe to use and easy to handle and thus are increasingly Acrylic PSAs provide more latitude for
replacing more conventional types of adhesives. In this article, we review both the optimization and formulation. They are
primary material characteristics of PSAs and the main physical principles that make typically random copolymers of a long
them work effectively. side-chain acrylic (n-butyl acrylate or
2-ethylhexyl acrylate) with a low glass-
Keywords: acrylics, block copolymers, peel, polymers, pressure-sensitive adhesives, transition temperature Tg, a short side-chain
tackifying resins. acrylic such as methyl acrylate to adjust
the Tg, and acrylic acid to improve adhesion
and optimize elongational properties (i.e.,
Introduction their mechanical response to deformation
Among the different classes of adhesives, larly easy and safe to use, since no solvent in uniaxial extension). Small-molecule ad-
pressure-sensitive adhesives (PSAs) are evaporation or chemical reaction takes ditives such as tackifiers can be included,
perhaps the most common type found in place and bonding can be done at room essentially to adjust the Tg and optimize
consumer products. Self-adhesive tapes and temperature. dissipative properties, but they are not
labels of all kinds are ubiquitous in every- Similar to all classes of adhesives, PSAs necessary for a useful acrylic PSA. As for
day life. However, until recently, the under- must be able to form a bond, that is, estab- natural rubber PSAs, a cross-linking step
standing of the materials science and lish molecular contact (even on a rough (electron-beam or UV irradiation), once the
engineering of PSAs and, in particular, the surface) and then sustain a minimum level adhesive has been coated, is generally used
specific role played by the different com- of stress upon debonding. All other classes to prevent creep.
ponents in them was very limited outside of adhesives, however, form the bond in PSAs based on styrenic block copolymers
of the companies involved in their manu- the liquid state and then are tested in the are the latest type to have come on the
facture, and the interested reader had to solid state, with the transition occurring market. They are generally blends of styrene-
refer to general technological texts.1,2 Al- by chemical reaction, change in tempera- isoprene-styrene (SIS) triblocks and styrene-
though PSAs are designed to join two ture, UV irradiation, or another change in isoprene diblocks compounded with a
surfaces together, they differ from other the structure of the adhesive. By contrast, low-molecular-weight but high-Tg resin
adhesives in several ways. First, PSAs are modern PSAs are soft, viscoelastic solids based on C5 rings that is miscible with the
typically used as nonstructural adhesives; that obtain their unique properties simply isoprene phase but immiscible with the
they do not compete with epoxies for from the hysteresis of the thermodynamic styrene phase. It is important to note that
structural applications. Second, PSAs typi- work of adhesion. That is, there is a differ- a tackifying resin is a necessary compo-
cally stick to a surface upon contact with- ence (adhesion hysteresis) between the nent for this class of PSA.7–10
out any chemical reaction.3 It is interesting energy gained in forming the interactions In order to obtain usable PSA properties,
to note that the term pressure-sensitive and the energy dissipated during the frac- the proportion of styrene in the com-
really should be pressure-insensitive, since ture of these same bonds. At least for short pounded PSA must be on the order of
PSAs do not need the application of much contact times, the only interface forces ac- 4–12%, the molecular weight of the styrene
pressure to stick, and the measured ad- tive in PSA adhesion are van der Waals block must be above 10–11 kg/mol to stay
hesion is then rather insensitive to the forces.4–6 immiscible with the isoprene phase, and
compressive pressure applied upon bond- In order to possess these unique charac- the weight fraction of polymer in the
ing. This property makes PSAs particu- teristics, however, the mechanical proper- blend must typically vary between 25%

434 MRS BULLETIN/JUNE 2003


Pressure-Sensitive Adhesives: An Introductory Course

and 45%. Because of the use of mutually stantial cavity growth along the interface,
immiscible blocks, these PSAs are really followed by a coalescence process only
nanophase-separated, with styrene do- occurred on low-adhesion surfaces; and
mains dispersed in an isoprene matrix. finally, the formation of fibrils was only
These styrene domains provide physical possible if coalescence of the cavities did
cross-links, which give these PSAs a supe- not occur. The final elongation of the fibrils
rior resistance to creep. at detachment was directly related to the
elongational properties of the adhesive, as
How Do They Work? discussed by others in the interpretation
For many years, the mechanisms by of peel test results.21–24 Given this general
which PSAs adhere to almost any sub- picture of how PSAs work, let us now con-
strate remained rather mysterious. Com- sider what the key material requirements
panies proceeded mostly empirically from Figure 1. Schematic illustration of a are to control the debonding mechanisms.
formulation to application, using a variety tack test performed with a cylindrical,
of trade tests designed to closely match flat-ended probe. Material Requirements
the conditions the PSA would be sub- From an applications point of view, PSAs
jected to in a particular application but the need to possess three important proper-
results of which could not be easily trans- interface with the probe into the bulk of ties. First of all, some degree of stickiness:
ported to another. The usual recipe one the layer, as shown in Figure 2.15 The in order to form a good bond on almost
could use was that the PSAs should have widespread presence of cavities caused any surface, a PSA must be sticky upon
an elastic modulus below a certain thresh- the force to drop, and if the cavities did simple contact, a property generally called
old called the Dahlquist criterion11 and a not coalesce, the walls between these cavi- tack. Second, all PSAs are peeled from a
large value of the viscous component of ties became the fibrils observed by Zosel. surface, either before use or during use, if
the elastic modulus to dissipate energy It therefore became obvious that the de- they are removable: a controlled peel force
upon debonding.12 Furthermore, due to the bonding mechanism was rather compli- as a function of peel velocity and precise
complicated nature of the materials (some- cated and could be divided into stages: control of the residue left on the surface
thing between a solid and a liquid), few initiation by cavitation, cavity growth, are also requirements. Finally, permanent
academic studies went beyond making and finally fibril formation and stability.15 PSAs are subjected to stresses for long
correlations between a specific molecular Several years of further studies6,9,16–20 pro- periods of time, and creep must be mini-
structure and a macroscopic property. It is vided, little by little, a more complete pic- mized. Each one of these application re-
chiefly thanks to a BASF scientist, Albrecht ture of the main controlling factors: the quirements can only be met with specific
Zosel, that a mechanistic approach was first peak of stress was due to a process of material properties, and often commercial
developed toward the understanding of cavity growth in a rubbery elastic medium formulations are the result of a compro-
PSA adhesion.5,13,14 and therefore was chiefly controlled by mise. The main requirement in terms of
Like all adhesives, PSAs work because the elastic modulus of the adhesive; sub- molecular structure is that all PSAs must
the separation of two surfaces requires a
certain amount of energy dissipation. This
energy dissipation can be readily measured
with a peel test, but early experiments
quickly showed that the peel force de-
pended on peel velocity, peel angle, and
adhesive thickness, implying a strong
coupling between geometry and mechani-
cal properties. Zosel developed a simple
test in which a cylindrical flat-ended
probe is indented into a thin layer of
adhesive and subsequently removed, as
schematically described in Figure 1. The
force and position of the probe are continu-
ously recorded during the test, and the
entire curve can be analyzed. The distinc-
tive plateau observed after the maximum
force peak shown in Figure 1 was clearly
identified as being caused by the forma-
tion of fibrils during detachment.13 Only
those PSAs displaying high peel forces
showed the formation of these fibrils.
However, the molecular parameters con-
trolling the first peak and the mechanism
responsible for the drop in the force were
only elucidated much later, when a probe
tester fitted with a video camera was
developed. The real-time observation tool Figure 2. (a) Schematic illustration of a probe test setup, showing possible observation
showed that the force peak was due to the angles for the (b) cavitation and (c) fibrillation processes occurring during debonding of
formation of cavities growing from the pressure-sensitive adhesives (PSAs).

MRS BULLETIN/JUNE 2003 435


Pressure-Sensitive Adhesives: An Introductory Course

be based on polymers well above their Tg. through two main molecular design tools:
Typically, in order to be tacky at a given controlled chemical cross-links or physical
usage temperature, the Tg of the adhesive cross-links. However, the requirements to
must be 25–45C below that temperature maximize resistance to creep are not the
and be as broad as possible to maximize same that maximize peel force. In a shear
viscoelastic dissipation at the low-modulus experiment, no fibrils are formed, and the
end of the glass transition. Differences in optimum degree of cross-linking is dis-
properties can only then be obtained with placed toward more cross-linking than for
variations in Tg, molecular weight, or mo- the peel force. The upper limit in degree of
lecular architecture and supramolecular cross-linking is given there by the resistance
structure. In addition, formulation plays to crack propagation: if the PSA is too
a significant part in the optimization of highly cross-linked, it becomes too elastic
viscoelastic properties, and small molecules (as determined by the ratio tan   G/G
are invariably added to the base polymers. in a rheology experiment), and the adhe-
Figure 3. Elastic component of the
The stickiness to the touch of a PSA is shear modulus G for a pure styrene-
sion hysteresis is not large enough to cause
related to its ability to form bridging fibrils isoprene-styrene (SIS) triblock copolymer crack blunting. Therefore, the inevitable
when the PSA is pulled away, as demon- containing 30 wt% triblock (open presence of a small defect leads to a quick
strated by a probe test (Figure 2). The re- circles), and a 4060 blend of SIS adhesive failure.
quired property for obtaining this fibril triblock and tackifying resin (open
formation on a standard test surface such triangles). Nanostructured PSAs
as steel is a resistance to fracture by crack It is worthwhile to spend a little time
propagation. In other words, if failure is discussing the structure and specific prop-
initiated by a small crack (at the edge or in peel force. Often, this is achieved by a sig- erties of PSAs based on block copolymers.
the center of the contact area), it should nificant broadening of the G peak associ- These PSAs are widespread in the adhesive-
not be able to propagate but rather should ated with the glass transition.9 tape industry, essentially because of their
blunt.25,26 If adhesive forces are provided 2. The PSA must be able to strain-harden ease of production in thin-film form by the
by van der Waals forces alone, this crack at high levels of strain (viscous fluids such hot-melt process (as discussed later in the
blunting, which causes the formation of as honey or tar are sticky but are not use- article). The first studies on their proper-
fibrils, is observed for materials with a ful PSAs). This property fulfills the typical ties date back to the late 1970s.8,34–36 They
Young’s modulus E below 0.1 MPa. Such requirement of an adhesive to fail without are, however, also used because of their
a low modulus puts PSAs in the category leaving a sticky residue on the surface. unique properties as adhesives.
of elastomers or gels. As discussed previ- Although all PSAs exhibit some degree As we now understand, SIS block co-
ously, the same requirement of low modu- of strain hardening in elongation, the level polymers undergo a microphase separa-
lus is dictated by the necessity to form a of elongational strain where strain harden- tion if the respective blocks are sufficiently
good bond with a rough surface under a ing sets in and how progressive this strain long.37 Compounding the block copoly-
light pressure.27,28 hardening is are key material parameters mer with a tackifying resin miscible with
If one recalls that the elastic modulus of in PSA design. For homopolymers and the isoprene phase yields a structure of
an elastomer is related to its average mo- random copolymers, the degree of strain physical cross-links provided by the
lecular weight between entanglements hardening is controlled through a suitable glassy styrene domains in an elastomeric
(Me),29,30 it becomes clear that suitable elas- choice of molecular-weight distribution isopreneresin matrix. This type of struc-
tomers for a PSA application must have a and degree of cross-linking.33 Experimen- ture gives, at room temperature, a PSA
large Me value.14 This can be achieved by tally, the optimum degree of cross-linking that is very solidlike at low frequencies
polymers such as poly(n-butyl acrylate) corresponds approximately to slightly (absolutely no Newtonian viscosity) while
or poly(2-ethylhexyl acrylate) or by above the gel point: a typical PSA contains at the same time very viscoelastic at high
adding miscible small-molecule tackifiers about 50–70% of insoluble fraction. The frequencies. These “nanostructured” mate-
to elastomers such as natural rubber or SIS gel point is defined as the degree of cross- rials possess a superior resistance to creep
block copolymers. These tackifiers essen- linking at which the elastic and viscous while maintaining a very high peel force
tially dilute the entanglement network moduli are equal over a range of test fre- and acceptable tack. In terms of molecular
and lower the modulus of the PSA in the quencies. By increasing or decreasing the design, an important parameter is the
plateau region, as shown in Figure 3. The gel fraction, it is possible to modify the ratio between isoprene chains bridging
test frequency was 1 Hz in this figure.31,32 onset of strain hardening and control fibril two styrene domains (typically triblocks)
However, a low elastic modulus, while extension and, therefore, the peel force. and nonbridging isoprene chains (triblocks
being necessary for tackiness, is not suffi- Finally, another property that some of SIS in a loop or “hairpin” configuration
cient for control of the peel force, and PSAs must have is good resistance to a or diblocks). Large-strain tensile deforma-
therefore two more properties guiding continuous shear force, since many appli- tion is greatly influenced by this connec-
molecular design must be included: cations, while not being strictly speaking tivity between domains, and the strain
1. For the material to be a useful PSA, the structural, must sustain a moderate level hardening is controlled by the extent and
viscous component G of the shear modu- of stress for a very long time. Examples length of the bridges between these
lus at the test frequency must be relatively include PSAs used to fasten components styrene blocks,10,38 as shown in Figure 4.
high (on the order of the elastic compo- inside a digital camera, and the PSA that It is also worthwhile to note that there are
nent G for permanent PSAs and 10–30% holds the rear-view mirror of your car in current efforts to design heterogeneous
of the elastic component for the removable place. This requirement assumes PSAs to nanostructured acrylic PSAs using emul-
ones). This requirement presupposes a ma- be solids and therefore to have no meas- sion polymerization to make core-shell
terial that will dissipate energy through urable Newtonian viscosity at the usage particles that retain their original structure
deformation, causing a moderate to high temperature. Again, this can be achieved once the PSA film is formed.39,40

436 MRS BULLETIN/JUNE 2003


Pressure-Sensitive Adhesives: An Introductory Course

Easy Release of PSAs fibrils, so a low-adhesion surface must be However, in this case, the goal must be
from Surfaces able to suppress this fibrillation process. achieved by varying the composition and
An interesting and complementary Recent experiments20 have shown that this molecular architecture of the adhesive
problem arising from the preparation of lack of fibrillation implies that the multiple alone. This typically implies a reduction in
PSAs is the issue of protecting the PSA cracks nucleating at the interface (Fig- the value of G relative to G so that crack
before use. By definition, PSAs are sticky ure 2) no longer blunt but coalesce. Such a propagation becomes less dissipative and
and, therefore, dust particles in the air can coalescence process is shown in Figure 5 fibrillation is minimized. Basically, one
easily stick to the surface, making manipu- for tensile probe test curves of tack. This seeks to obtain the minimization of fibril
lation difficult once the sticky surface is ex- lack of crack blunting leads to a complete formation on any given surface.
posed. Adhesive-tape manufacturers solve or partial suppression of the fibrillation
the problem by adhering the sticky side of stage and is therefore a very good way to Manufacturing Adhesives
the tape to the back surface of the tape in control a macroscopic adhesion parameter Although we have focused here on the
rolls, while adhesive labels normally are such as the peel force. At a more mecha- properties of the adhesives, many require-
sold in contact with a protective film. nistic level, separation of the adhesive ments in terms of molecular structure or
How does the back surface of adhesive from the substrate is generally caused by a formulation actually stem from the neces-
tape or the protective film of a label work? tensile force applied in the direction per- sity of producing PSA products at high
In this case, it is absolutely necessary not pendicular to the interface. For cavities to speed and reasonable cost.
only for the adhesive to peel cleanly from coalesce, the lateral crack-propagation ve- PSA films are produced essentially by
the protective surface but also to retain its locity must be high relative to the vertical three methods:
properties once it is applied to the target crack-propagation velocity, and this means  From solution by coating and solvent
surface. In practice, adhesion must be sig- a low level of instantaneous energy dissi- evaporation. This is the more traditional
nificantly higher on the back of a tape than pation by viscous flow at the edge of the method, but it is now only used where
on the protective film of a label (other- crack: this is where adhesion is important. specific performance of solution systems
wise, the tape would unroll under its own Interestingly, surfaces causing high cavity- cannot be obtained by other means.
weight), and accordingly, different mate- growth rates and therefore low adhesion  From latexes, that is, emulsions of small
rials are used for both cases. Poly(vinyl have in common a low resistance to inter- particles by coating and water evapora-
carbamates) provide good surfaces for the facial friction.41,42 This low resistance to tion. This is the typical method used for
back side of tapes, while highly cross- interfacial friction requires a high level of labels based on acrylic polymers.
linked silicones are used for the protective molecular mobility of the surface,43 so that  From hot melts. This method implies
films for labels. the PSA effectively is adhered to a molecu- that the manufacturing is performed with-
How does a release coating work? Re- larly fluid but macroscopically solid layer. out solvent. In order to work, the viscosity
calling the section on the mechanisms of Removable adhesives work under the must be reasonably low during the coating
debonding of PSAs, the high adhesion same principle, that is, suppression or at process and achieve its end-use properties
comes essentially from the formation of least minimization of the fibrillation stage. later on through a decrease in temperature

Figure 4. Tensile probe test curves


of nominal stress (  F/A0 ) versus
nominal strain [  (h  h0 )/h0 , where
h and h0 are the deformed and
undeformed thicknesses of the adhesive
film, respectively] for three polymer
blends. All tests were performed at a
probe retraction velocity of 100 m/s on
a 100- m-thick layer. The percentage of
diblock styrene-isoprene in the polymer
part of the blend was varied from 0% to
19% to 42%, while the weight ratio of
total polymer (diblock  triblock) to Figure 5. Tensile probe test curves of nominal stress versus nominal strain (“tack”) for the
resin was kept at 3070 for all three same type of PSA as shown in Figure 4, based on a triblock copolymer and a tackifying
samples. Note the important effect of resin, on two surfaces. The bottom micrograph is polished steel, and the top is a release
the variable amount of diblock on the surface; both have a diameter of 10 mm. Note the very different debonding patterns for
plateau part of the curve representing both surfaces and the complete absence of a fibrillation plateau on the  – curve of
the fibrillation process. the adhesive on the release surface.

MRS BULLETIN/JUNE 2003 437


Pressure-Sensitive Adhesives: An Introductory Course

or a cross-linking and polymerization re-


action. It is the preferred method for all
PSAs based on block copolymers, in which
case the phase-separated structure under-
goes a “melting” transition when the tem-
perature is raised above the Tg of the
styrene phase.
For the reasons explained earlier, the
first two coating methods must be fol-
lowed by a cross-linking step that is nor-
mally accomplished either by temperature
or radiation. Radiation curing can be per-
formed either by UV exposure, in which
case the polymerization and cross-linking
proceed simultaneously and suitable photo-
initiators must be used, or by electron-beam
irradiation, where typically the polymer is
already formed. Radiation curing has the
distinct advantage over thermal curing of
allowing very short reaction times.44

Applications Figure 6. Temporary protection of automobile paint and other components is routinely
For many people, the quintessential PSA provided by the use of polymer sheets (white areas in photograph) coated with a PSA, thus
offering safe adhesion and easy removability without affecting the optical surface quality of
application is adhesive tape or the self-
the car even after prolonged contact time under outdoor conditions. (Courtesy of tesa AG.)
adhesive label. While these applications
represent the largest volume of sales, they
generally do not require a fine-tuning of
properties, and the emphasis is on mini- for tapes, and acrylic water-based poly- ever, the presence of surfactants, which
mizing production costs. However, a variety mers dominate the label market. How- are not easy to eliminate,45,46 and the lesser
of other applications where more finely ever, high-end labeling applications and, control that one obtains over the molecular
tuned properties are needed are now in particular, outdoor applications are structure, precludes for the moment their
widely available. The applications can dominated by solution acrylics, with their access to the most demanding applica-
be roughly divided in three categories superior resistance to aging. tions. Ongoing research is aimed at im-
based on performance requirements: semi- Finally, double-sided tapes and foams proving properties to the same level as
structural permanent, permanent with no are increasingly used as an alternative to solution-cast acrylics.
real structural requirement, and removable. fastening with conventional chemically Along the same lines, an increasingly
Among the applications for removable reactive soft glues. In particular, the micro- widespread production method (at least
adhesives, a large industrial application electronics industry uses a large number for tapes) is hot-melt, or solventless, tech-
is the temporary protection of surfaces of PSA layers for the construction of nologies. In this type of manufacturing
(automobile bodies, windshields, and pre- components. process, the viscosity must be lowered
fabricated elements used in construction), In this case, the adhesive is often pre- enough for an easy and homogeneous
as illustrated in Figure 6. In this case, the foamed to introduce defects (small bubbles), coating without the use of any volatile
key technical problem is to maintain the which, by breaking the confinement with- compound while maintaining properties
easy removability of the protective film out having to nucleate a cavity, have supe- of the final product. Superior recyclability
and the lack of adhesive residue on the rior strength. Defects introduced throughout of this type of product is likely to become
car’s surface, even after three months of the adhesive layer reduce the stress on important in the future, due to environ-
outdoor aging in harsh conditions. An- interfacial defects, which typically fail cata- mental pressures.
other important application of removable strophically. These are high-end applica- From the point of view of end-use
PSAs is masking tape for painting appli- tions where maximizing the resistance to properties alone, the future trend for PSAs
cations. Finally, one should mention the creep of the adhesive under stress is very will be in the direction of heterogeneous
most consumer-friendly application of PSAs important. The phase-separated structure
polymer structures and also on the incor-
in our opinion, the Post-It note. In this of block-copolymer-based PSAs gives them
poration of additional functionalities such
case, a thin layer of adhesive must stick to a competitive advantage for this type of
as thermal or electrical conductivity or
paper and be easily removable. This requires application.
controlled drug release, as in nicotine
a particularly low level of adhesion, since
Future Trends patches, into a PSA matrix without alter-
the paper fibers are easily ripped apart.
Among permanent nonstructural PSAs, PSAs are now increasingly replacing ing its self-adhesive properties.
the main applications are labels in all their more traditional adhesives because of their
forms and packaging tapes. In both cases, ease of use and safe manipulation. Despite Acknowledgments
the requirement is good adhesion on paper the developments of energy-efficient We thank Dr. Bernd Luhmann from
or cardboard, which really means that de- solvent-recovery methods, environmental tesa AG for his careful reading of the
tachment cannot occur without permanent legislation drives research toward alterna- manuscript and helpful suggestions. We
damage to the surface of the cardboard or tive production methods to coating from acknowledge the financial support of the
to the label. PSAs based on block copoly- solution. Water-based acrylic emulsions are European Commission, under contract
mers have a large segment of the market widespread for general-use PSAs. How- G5RD-CT-2000-00202-DEFSAM.

438 MRS BULLETIN/JUNE 2003


Pressure-Sensitive Adhesives: An Introductory Course

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