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  1. Applications of Pressure-Sensitive Adhesive Solutions for Batteries

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    EV Battery Graphic

    Pressure-sensitive adhesives (PSAs) have long provided a reliable and affordable way to assemble cartons and seal packages and bags. More recently, they have become indispensable for high-capacity battery applications, such as EVs, due to several unique characteristics. For example, PSAs are flexible, lightweight, quick to apply and form a bond, not vulnerable to vibrations or impact, and can be formulated for high heat resistance. They are also versatile and can be applied as transfer tape, single- or double-coated with a carrier, and with or without liners.

    As vehicle powertrain electrification continues to grow and EV demand increases, the need for adhesive-for-battery materials is also expanding. PSAs have a range of uses including dielectric insulation, flame retardance, mounting and spacing, thermal management, and more. What’s more, these advanced adhesive materials are compatible with automated manufacturing processes and equipment.

    TPC Converting is a leading supplier for the EV industry. We offer a variety of options for tapes and die-cut products that can be used to adhere and seal battery cell and system components.

    Here, we’ll look at what makes EV battery tapes and other PSAs powerful tools in battery pack technology, and some common ways they are used.

    Thermal Management

    EV battery packs contain thermal interface materials that dissipate heat and maintain safe operating temperatures. Materials like ceramic and mica help control excess heat propagation, while graphite heat spreader sheets dissipate heat within cells. These materials can be adhered with PSA tape for a permanent, lightweight bond.

    Flame retardant adhesives help prevent thermal runaway and fire within battery systems. Certain adhesives can also be used to laminate or encapsulate thermal management materials to keep them free from dust and lint, further reducing the risk of fire.

    TPC’s selection of thermal management PSA materials includes:

    • UL 94 VTM-0 flammability compliant materials
    • Silicone-free materials
    • Secure and effective bonding
    • High flame retardance
    • Halogen-free materials (optional)

    Electrical Insulation

    EV batteries have specific breakdown voltage requirements that call for adequate electrical insulation. PSA tapes with facestock and filmic carriers have high dielectric strength and offer excellent insulation with both steel and aluminum components and busbars.

    Flexible PET carrier material makes it possible to fully wrap components for secure protection, and they are compatible with automated manufacturing processes, including vision inspection cameras.

    These products feature:

    • Non-flammable materials
    • 100% secure sealing
    • High breakdown voltage levels
    • VDA 19.1 cleanliness rating

    Mounting, Spacing, and Sealing

    Pressure-sensitive adhesives for EV battery packs must firmly secure a wide range of components in place inside and between cells, including flame barriers and insulation sheets, heat spreader plates, spacers, gaskets and seals, and battery enclosure components. Cables and wires can also be wrapped or secured with adhesive tapes to organize them and protect them from abrasions.

    The advantages of using PSA materials for mounting and securing components include:

    • High malleability
    • Improved gap filling
    • Effective LSE-material bonding
    • Electrical insulation & flame retardance
    • Clearer identification of high-voltage wires
    • Secure bundling and fixation
    • Excellent abrasion protection

    Grounding and EMI Shielding

    PSAs are used to adhere conductive foams that ground battery systems by isolating them from the vehicle chassis. Foams also provide protection from electromagnetic interference (EMI) from nearby electronics by blocking or filtering EM radiation or filling any tiny gaps between components that can occur even with the tightest tolerances and excellent part fit.

    Unlike glue, adhesive tapes stay where they are applied for precise placement of these critical materials without leakage or runout. They are also flexible and adjust to contours, corners, and other profiles.

    Contact TPC Converting for PSAs for EV Battery Applications

    Effective thermal management, electrical insulation, and component mounting are essential to keeping battery cells and packs safe and functional during operation. TPC Converting supplies a range of EV tape materials and custom die cut product capabilities for EV and other automotive applications.

    Contact us to learn about our products and services, or to discuss your EV battery or e-mobility application.

  2. Revolutionizing Die-Cut Adhesive Application Through Automation

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    Rotating knives for cutting a self-adhesive label into several narrow ribbons. Equipment for the production of self-adhesive labels. Rotary die cutting machine with slitting blade. Selective focus.

    Die cutting is a versatile method for cutting distinct shapes from a roll or sheet of adhesive-backed materials including foams, woven and non-woven textiles, silicone, rubbers, abrasives, paper, foils, plastic, cork, and more. These die cut pieces are used in many applications such as: 

    • Protective films on screens or appliances 
    • Labels in various shapes and sizes
    • Gaskets and sealing rings 
    • Pads
    • Liners 
    • Sound or vibration-proofing material 
    • Insulating material

    During assembly, these cutouts must be positioned and applied carefully in exact locations on or inside products or components. When performed manually, this kind of task can be time-consuming and prone to human error, which leads to production bottlenecks and waste. Fortunately, automation is helping revolutionize the labor-intensive process of applying die cut materials. Not only does this reduce cycle times, but it also improves the accuracy and quality of application.

    Keep reading to learn more about the benefits of automating the die-cut adhesive application process.    

    Features of Automated Die-Cut Adhesive Applicator Equipment

    Automation is best for processes and operations that are highly repetitive and prone to human error. Peeling die-cuts from a backing and applying them with precision without wrinkles or bubbles, over and over, is a strong candidate for automation in high-volume production. Specialized applicator equipment has several key features that are well-suited to this type of work, such as:

    • Opportunity to Add Assembly Aids: Converting process capabilities allow for the integration of automated assembly aids like extended liners for easy removal, pull tabs for convenient access, and zone-coated adhesives for precise bonding areas.
    • High-Speed Operation: Automation equipment moves quickly along pre-programmed paths, and has built-in mechanisms designed to remove die cuts from backings or carrier strips efficiently. Machines also do not require breaks, and because each application is made correctly, no time is lost removing and fixing a misaligned piece. 
    • Precision and Repeatability: Because all of the movements of the machine are pre-programmed, they are easily repeated until the machine is told to stop. Die cuts or labels are fed into the machine from uniform rolls or sheets, so the steps involved do not change from batch to batch, achieving in-tolerance placement, sometimes within 0.002 in. It’s also possible to adjust the process as designs or products change. 
    • Advanced Automation Technology: Features like motion control, sensors, and conveyance advance items into position, prepare and apply the die cut or protective film with appropriate force. Precision application means there are no distortions or bubbles. Then, the finished item is quickly conveyed out of the machine as the next one is loaded.
    • Quick Changeover: Many automated solutions include a menu of product options or are compatible with QR codes to call up new sets of pre-programmed instructions to switch from one component or type of die cut to another.
    • Integrability: Automated applicator machines can often be integrated into an existing assembly or packaging line. In early stages of product development, they can serve as a key component in a new automated production plan. Of course, many can also be used as standalone equipment at a workstation. 
    • User-Friendly: Modern automation equipment is designed to be intuitive, with clear graphical user interfaces (GUIs) and simple controls. Automated equipment is intended to simplify operator tasks for streamlined loading and unloading reels or stacks of die cuts, preparing a new batch of products to be labeled, or easily switching from one task to another. 

    Benefits of Automating the Application of Die-Cut Adhesives

    If you’re looking to increase the accuracy, efficiency, and consistency of your die-cut adhesive application process, then now is the perfect time to consider automation. Benefits include:

    • Less Waste: Automated equipment improves the precision and quality of die cut applications, which results in fewer misaligned or damaged pieces, less waste, and less time spent removing and reapplying incorrect die cuts.   
    • Ease of Use: User-friendly designs and GUIs reduce the learning curve needed to become proficient with the automated process and the machine. This allows personnel to feel comfortable working with it and helps them “buy in” to automation in their daily work. 
    • Versatility: A dedicated machine can be used exclusively for one type of product or die cut material, or it can be used with multiple shapes or types of die cuts and substrates. Fast and simple changeover makes this equipment flexible. 
    • Cost Efficiency: Investing in a robust automated system to apply die cuts allows you to scale production or expand product offerings without compromising on quality or adding staff. 
    • Fast Cycle Times: While manual adhesive application is a meticulous, time-consuming process, automated applicators streamline the process with pre-programmed movements that prepare and apply die cuts and labels efficiently. 
    • Labor Management: Time and labor saved due to automation allow personnel to oversee multiple pieces of machinery or be redeployed to higher-value tasks.

    Contact TPC Converting to Learn More About Automating Die-Cut Adhesive Application

    Since 1967, the TPC Converting team has been an innovator in protective solutions. We work with customers in industries including construction, transportation, automotive, e-mobility, and appliances, to find efficient, cost-effective adhesive products and application processes. 

    Contact us to learn about our die cut adhesive capabilities and how automation can help take your operations to the next level.

  3. How Die-Cut Adhesive Tape Improves Manufacturing Production

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    Precision die cutting is a versatile converting service that can improve your manufacturing process efficiency. At TPC Converting, we offer precision die-cutting services for adhesive tapes so that your production line runs smoothly and cost-effectively. The following are some of the main benefits of adhesive tape converting in the manufacturing industry.

    Improve Efficiency

    Adhesive tape converters like TPC Converting simplify manufacturing production processes by consolidating multiple steps into a single, convenient operation. Without efficient converting operations, companies traditionally would have to cut out each adhesive part, send it to another facility for lamination, transfer it to packaging, and then send it out to the final customer.

    The right converter can instead design a solution that completes all of these steps in one facility with consistent efficiency. The converter can provide die-cut tapes in the exact dimensions you need, reducing waste and streamlining your assembly processes. These savings translate to minimized labor costs and enhanced productivity.

    Converters can further customize die-cut adhesives upon request with:

    • Pull Tabs: Ideal for smaller shapes, these non-adhesive protrusions allow users to easily pull apart the adhesive.
    • Extended Liners: These are non-adhesive backings larger in width than the adhesive part. These features make it easier to grab and remove the liner as necessary.

    Certain industries that require greater fastening efficiency benefit more from these customizations, including the appliance, automotive, and specialty vehicle industries.

    Replace Mechanical Fasteners and Glue

    Another advantage of using die-cut adhesives is the ability to eliminate the hassle of mechanical fasteners. For certain applications, very-high bond (VHB) tapes are more efficient, affordable, and consistent than mechanical fasteners. These die-cut adhesives typically form much stronger bonds than mechanical fasteners. The main reason for this is that die-cut adhesives evenly distribute stress loads along the entire bonded surface, whereas mechanical fasteners focus adhesion in one location through a rivet or bolt.

    Another benefit is avoiding the mess that can come with liquid glue adhesives while increasing the accuracy and precision of application. Die-cut adhesive tapes are easy to install and produce a cleaner look, which translates into a good-looking end product.

    Customize Solutions

    A reputable adhesive tape converter will work closely with you to determine what you need for your application, considering any unique assembly challenges. The converter can recommend or customize adhesives of the right shape, size, and other specifications. Your converter should also provide you with plenty of samples to help you select the right choice based on the results they yield, which helps the converter continually optimize each solution.

    Reduce Drilling and Welding

    Die-cut adhesives also eliminate time-consuming and costly processes like welding and drilling. By doing away with these manual processes, your assembly line becomes quieter and safer, with no hazardous metal fragments or broken drill bits.

    Automate the Application of Die-Cut Materials

    Skilled adhesive tape converters like TPC Converting can also help with assembly automation. Benefits of automated die-cut adhesive application include:

    • Pressure-sensitive adhesive (PSA) tapes provide a specific coat weight and an instant strong bond.
    • The tight tolerances of die-cutting maximize repeatability.
    • Automation can apply adhesives, lubricants, and sealants of all types with high accuracy.
    • Automated adhesive application minimizes material waste.

    Contact TPC Converting for Die-Cut Adhesive Tapes

    If you want to experience the benefits of tape converting for your manufacturing process, the experts at TPC Converting are ready to help. We can develop custom adhesive tapes to your specifications, helping you automate and increase the overall efficiency of your operations. Contact us today to learn more about what our solutions can do for you.

  4. Why Are Tapes Better Than Glue?

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    Tape and glue are two common bonding methods that are used throughout numerous industries. While there are many suitable uses for liquid adhesives like glue, advancements in converting, laminating, and printing techniques have made tape highly versatile and effective. Also referred to as pressure-sensitive adhesive, PSA tape, or self-stick tape, these products are made by adding an adhesive material to a backing, such as plastic, paper, metal foil, or cloth.

    When it comes to tape vs. glue, in many applications tapes deliver more durable performance than glue, among other benefits. From quick bonding times to environmental sustainability and more, learn all the ways in which tapes are better than glue.

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    1. Tapes Are More Versatile

    Tapes are extremely versatile and come in a variety of sizes, strengths, and colors. There is a tape product tailored to the needs of virtually any type of project, with examples such as:

    • Double-sided tape
    • Custom packaging tape
    • Fabric tape
    • Silicone tape
    • Waterproof tape

    Tape’s versatility is not only due to the wide array of material options but also because of its easily customizable manufacturing process. Using die-cutting equipment, tape can be cut into any geometry or size. It’s also possible to laminate multiple materials together to create custom double-sided, multi-material tapes. These techniques can create a vast array of adhesive tapes. For example, pressure-sensitive adhesive can be added to the back of a material like foam or light-gauge aluminum.

    In addition, while many glues are created for general bonding purposes, tapes can be better customized to specific needs. Certain characteristics, like UV resistance or substrate compatibility, are more easily achieved using tape.

    2. Tapes Last Longer

    No matter what purpose you need an adhesive for, your solution must be able to withstand storage time and environmental conditions. Unfortunately, this presents a problem for many liquid adhesives. Glue tends to lose its effectiveness much more quickly than tape and breaks down during storage more easily. UV light or air exposure quickly dries out glue as the liquid solvents evaporate.

    Tape, on the other hand, is easily stacked and stored for long periods. It doesn’t require special storage conditions like airtight lockers or flammability cabinets. As long as they’re kept away from moisture, optimal performance is guaranteed for a long time.

    3. Tapes Bond Faster

    5. While liquid adhesives require a variety of extended curing times, tape bonds immediately. The physical interaction between tape’s adhesive layer and the substrate creates an immediate and durable bond: Simply peel, stick, and press. With glue products, the solvent needs to evaporate before a lasting bond can form. In some cases, an oven is required to accelerate this process and achieve the required bond strength. Hours or even days must pass before some types of glue reach their final cured state.

    4. Tapes Create Less Mess and Waste

    Since tapes have a uniform thickness, can be die cut according to exact specifications, and remain in optimal condition for long periods of time, they create much less waste than glue. With tape, after using a small amount, the remaining roll will still be usable for the next project. In contrast, glue can dry out, expire, become contaminated, or leak. If storage conditions are not highly controlled, glue is easily wasted.

    5. Tapes Are More Eco-Friendly

    Many glues use volatile organic solvents (VOCs) that harm the environment and people’s health as they evaporate. According to the EPA, VOCs from glues and adhesives can cause anything from allergic skin reactions to organ damage, cancer, and more—in addition to harming the environment. Tapes, on the other hand, are solvent-free, making them a more sustainable choice. In addition, since die-cut tapes are cut to fit each application’s requirements and remain usable even after storage, they create much less landfill waste than glue.

    6. Tapes Save Space

    Using tapes does not require additional equipment, so facilities can save square footage for other purposes. Tapes also do not require designated floor space for cure time, since tapes cure instantly.

Explore Tape Options at TPC Converting

If you’re considering tape or glue for an upcoming project, TPC Converting can help you find the right solution. While glue is necessary for certain applications, there is a vast number of projects where tape is the more suitable option. For reliable and easy-to-use bonding, custom tapes offer the ideal solution.

At TPC Converting, we help customers obtain effective, attractive, and cost-effective tape products, developed to meet their specific application requirements. To get started, contact us or request a quote today.

  • Common Converting Applications in the Appliance Industry

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    Adhesives, films, tapes, and gaskets are widely used in the appliance industry for applications ranging from assembly to protective panels to sound and vibration dampening and more. Converting operations like die and laser cutting, laminating, sheeting, and slitting make it efficient and cost-effective to manufacture these custom materials.

    Here we’ll look at the most common applications for conversion products in the appliance industry.

    Appliance Assembly

    Some appliance assembly tasks are well-suited to adhesives or tapes. Die cutting is used to make adhesive strips, polyester film panels, and gaskets in custom shapes and sizes. Using adhesives for home appliance assembly can boost productivity since these materials can often be applied using automated assembly systems such as dispensers or rollers.

    Common applications of converted materials in appliance assembly include:

    • Permanently adhering components, like nameplates or handles
    • Temporarily holding components or subassemblies in place between assembly steps, such as tacking panels or screens in place
    • Very high bond (VHB) adhesive materials used as alternatives to clips or fasteners
    • Bonding membranes between switch layers
    • Neoprene rubber appliance gaskets for dampening vibrations and noise
    • Gaskets or tapes for sealing internal connections

    Improved Visual Appeal

    In addition to performance, aesthetic appeal is a primary goal in appliance design. That can come from purely decorative elements as well as the pleasing appearance of a shiny, flawless finish. Decals, labels, and plastic film strips or sheets protect exterior panels during storage, transportation, and installation. They also provide opportunities for eye-catching branding, simple directions, or highlighting product features and functionalities.

    Converting operations like die-cutting, lamination, and sheeting are used in cutting film to size, applying protective layers to labels, and cutting complex shapes to fit components precisely.

    Some examples include:

    • Thin plastic sheeting applied to panels and surfaces to protect exterior finishes
    • Laminated safety or warning labels on cords or access panels
    • Temporary film covers that protect touch screens from scratches
    • Decorative decals and labels with branding, images, or instructions
    • Adhesive film covers on smooth glass cooktops or polished handles to preserve “like new” finishes

    Enhanced Product Protection

    Laminating involves applying a thin polymer or other coating layer to paper or another substrate to make it water-resistant, more durable, or textured. In addition to adding visual elements to an appliance, such as a decal, laminated materials provide protection from liquid ingress, corrosion, dirt, scratches, and even minor dings or dents.

    Other ways to improve product protection with converted materials include:

    • Custom-cut protective films
    • Foam gaskets to keep internal components and doors from moving and damaging each other
    • Rubber or plastic adhesive “feet” on the underside of cabinets or enclosures
    • Tapes for securing protective packaging, like cardboard or paper, between appliance doors, inside drawers, or to hold racks and cords in place during transportation
    • Plastic or laminated materials can strengthen delicate components and provide protection from moisture and dirt

    Acoustic and Vibration Dampening

    Appliances can create considerable noise and vibration during regular operation. Because they are often located near primary living spaces in a home, it’s important to minimize these as much as possible. Continued vibrations within an appliance can also damage it or shorten its service life. Custom die-cut gaskets, pads, and coverings made from foams of different densities are useful in dampening noise and movement in appliances.

    Sample applications for foam gaskets include:

    • Die-cut insulating mats and blankets in and around dishwashers to minimize vibration and noise
    • Foam gaskets applied to component mating surfaces to minimize rubbing
    • Gaskets and pipe or hose covers to limit rattling and squeaking in HVAC equipment
    • Padding and linings inside motor, pump, or fan enclosures

    Thermal Management

    Thermal insulation reduces heat transfer between components within appliances to ensure optimal performance. It also blocks excessive appliance heat from reaching neighboring furniture, cupboards, or fixtures.

    Die-cut gaskets and padding help regulate thermal energy and in doing so, they promote energy efficiency. Foils and other non-combustible, non-porous materials can reduce the risk of fire, control condensation, and maintain consistent operating temperatures.

    Some examples of thermal management applications include:

    • Gaskets and hose coverings in A/C and furnace units
    • Die-cut insulating pads wrapped around dishwasher tubs and slide-in ranges
    • Temperature-regulating foam strips in electronic devices

    Contact TPC Converting for Appliance Industry Tapes, Films, and More

    TPC Converting’s converting capabilities include custom laser and die cutting, lamination, slitting and rewinding, sheeting, stacking, and prototyping. We focus on efficient and cost-effective production for every project through established supplier relationships, value-added services, and time studies. As an ISO 9001:2015 certified company, we are committed to providing quality products and services time and again.

    Contact us to speak with a specialist about custom converting services for your appliance industry applications.

  • How Pressure-Sensitive Adhesives Play a Crucial Role in the E-Mobility Space

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    The automotive industry has relied on pressure-sensitive adhesive (PSA) tapes for decades. The shift to electric mobility (e-mobility) and other advancements in the automotive sector have made PSA products more critical than ever due to their strength, functionality, and versatility.

    Pressure-sensitive adhesives can improve the dielectric strength, reduce the flammability, and optimize the design of e-mobility components. These properties support the industry’s goals of cutting costs, minimizing charging times, improving safety, and enhancing driving range.

    Learn more about the benefits of PSA tapes for e-mobility.

    Improve Safety

    One of the main advantages of using PSA materials in the automotive industry is the ability to support safety, which is a top priority especially in EV battery manufacturing operations. Lithium-ion batteries are flammable and must be assembled and packaged correctly. Otherwise, they can pose a risk to drivers and passengers, potentially leading to low consumer confidence in EVs and costly recalls.

    It’s possible to mitigate these risks through the use of PSA tapes that work specifically for EV batteries. Tape materials like silicone, rubber, and acrylic offer protection against thermal runaway and other fire hazards. They also comply with regulations around flammability, such as UL 94 VTM-0.

    PSA products are compatible with many materials and cell types. As single components, pressure-sensitive tapes do not require mixing nozzles or the additional processing time of other adhesive solutions. Individual battery cells and pouch cells can be wrapped in PSA tapes and compression pads to protect them against vibration and impacts. The insulation and protection of these EV battery adhesives prevent damage during charging and discharging. Acrylic foam tapes may also be used as gaskets, due to their ability to form a watertight seal.

    Support Thermal Interface Materials

    Another advantage of pressure-sensitive adhesives is the ability to support thermal interface materials (TIMs), which are key components in EV batteries as they allow for efficient heat transfer. When attached to chiller plates or heat sinks, TIM adhesives will help cool battery cells and modules.

    Examples of viable PSA solutions here would include high wet-out adhesives that reduce the thermal impedance between the system’s heat source and the TIM. Other solutions could include:

    • Flame-retardant PSA materials
    • Acrylic adhesives for use with non-silicone materials
    • Silicone-based PSAs for silicone materials

    Boost Manufacturing Efficiency

    PSA tapes also increase the efficiency of manufacturing for various products, including gaskets, cell-to-cell bonding, electrical insulation, and compression pads. Specifically, tape adhesives for batteries improve the manufacturing efficiency of cell-to-cell bonding by forming high-strength bonds with speed and ease. Automated tape applicators, such as those available from TPC Converting, further improve production efficiency for e-mobility components.

    Additionally, unlike other types of adhesive materials, PSA tapes offer instant curing to create a fast, strong solution ideal for both bonding and assembly. As a result, manufacturers can substitute mechanical fasteners with tapes, which are more lightweight, thin, and easily repositioned.

    Another potential application for PSA tapes is bonding flexible bus bars, forming a durable bond with flame resistance and sufficient insulation.

    Reduce Noise

    Another key concern for EV component manufacturers is reducing noise, vibration, and harshness (NVH). PSA tapes can help with this by reducing rattling, squeaking, and buzzing in various parts of the vehicle.

    Contact TPC Converting for Pressure-Sensitive Adhesives

    Looking for high-quality PSA tapes or other types of adhesives for your application? You’ll find the options you need when you turn to TPC Converting. We offer a selection of high-quality PSA tape materials, as well as films, foams, and paper packaging products for nearly any application.

    In addition to supplying adhesives for EV batteries, we provide converting services for our customers to make nearly any type of product from a wide range of raw materials. Based on our customers’ project requirements, we can provide die cutting, precision cutting, precision rewinding and slitting, laminating, and more using state-of-the-art equipment and a selection of materials, including paper, foam, tapes, and plastic films.

    With over 55 years of experience, we’re ready to match the best solutions to your next project. Reach out to us today to find the right PSA for your application or learn more about our capabilities.

  • How Die Cut Materials Are Used in Automotive Manufacturing

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    Precision die cutting is used to produce a wide variety of automotive components to improve the comfort, reliability, efficiency, and safety of vehicles. Offering improved flexibility and customizability, die cut materials are used in everything from EV batteries and noise reduction components to heat shielding and electronics. Keep reading to learn more about the various applications of die cut materials in the automotive industry.

    EV Battery Materials

    Electric vehicle (EV) manufacturers rely on quality adhesives, tapes, and encapsulation materials to secure batteries in place and protect them from the elements. At TPC Converting, we design EV battery adhesives and tapes specifically to meet the rigors of EV operation. They can be used to provide superior adhesion, insulation, and structural support for nearly any kind of EV battery.

    Based on our customers’ needs, we offer the following precision die cut materials for EV batteries:

    • Cell-to-cell bonding
    • Thermal runaway protection
    • Compression pads
    • Pack seal and gasketing
    • Thermal interface materials (TIMs)
    • Cell wrapping
    • Flexible busbar adhesives
    • Polyethylene terephthalate (PET) film material encapsulation

    Bonding, Joining, and Fastening

    For some automotive applications, die cut adhesive materials can be used in lieu of mechanical fasteners. They offer a lightweight alternative that can improve aesthetics, reduce both bulk and weight, maximize the longevity of sensitive vehicle components, and reduce assembly costs.

    Common bonding, joining, and fastening applications where precision die cut adhesive products can be used in place of mechanical fasteners include:

    • Nameplate and emblem attachment
    • Exterior and interior trim attachment
    • Air and fluid management systems
    • Thermal management
    • Interior and exterior electronics
    • Structural components
    • Weatherstripping
    • Rear-view mirror and camera attachments
    • Noise, vibration, and harshness (NVH) reduction

    Noise Reduction

    Die cut parts are commonly used to manufacture acoustic insulation materials that dampen sound and vibrations for a more comfortable, quiet driving experience. The experts at TPC can custom die cut noise reduction materials based on your unique specifications, ensuring they fit seamlessly into the various components of the vehicle.

    Precision die cutting can be used to produce the following types of noise-reduction materials:

    • Foam pads for consoles and dashboards
    • Felt strips for interior trim pieces
    • Acoustic insulation for flooring and doors
    • Gaskets and seals for windows and doors
    • Sound-deadening solutions for speaker enclosures
    • Adhesive-backed foam tape for securing components that may vibrate
    • Anti-squeak strips for window and door frames
    • Vibration dampeners for engine components
    • Rubber bumpers that reduce rattling in moving components

    Heat Shielding

    Engines and other automotive components create heat while in operation. If improperly managed, this heat can transfer to other areas of the vehicle and cause various issues. For example, both premature seal and gasket failure and interior overheating can result from exposure to excessive heat over long periods of time.

    TPC Converting offers die-cut heat shields for various applications, including:

    • Floorboards
    • Starters
    • Fuel lines
    • Firewalls

    Electronics

    Die cut materials are often used to protect sensitive vehicle electronics from moisture, heat, and other harsh environmental factors. Common applications include:

    • Seals and gaskets for wire harnesses to prevent the entry of moisture, dust, and other contaminants from entering cables and wires
    • Pressure-sensitive films and tapes to hold wiring and components in place, preventing movement or vibration
    • Thermal gap pads, interface components, and other thermal management solutions that facilitate heat dissipation
    • Electrical insulating materials for mirror backings and other applications
    • Surface protection films that prevent scuffs, scratches, and other damage to delicate parts during transportation and installation
    • RFI and EMI shielding materials
    • Flexible graphite and other heat-spreading materials for touch screens and electronic displays
    • Low-emission adhesive tapes for attaching electronic components to automotive surfaces

    Paint & Coating Maskings

    Historically, masking techniques for automotive paint and coating applications involved manually cutting tape pieces by hand. This is a labor-intensive, time-consuming, and expensive process.

    Precision die cut adhesive tapes dramatically simplify the process while increasing its efficiency and accuracy. The result is a repeatably flawless paint or coating application.

    Contact TPC Converting for Automotive Die Cutting Services

    If you want to benefit from top-quality precision die cutting solutions for your automotive application, TPC Converting offers a range of products and solutions. We custom-tailor every solution, whether you need tapes, labels, films, or other die cut materials.

    For more information about our custom die cutting capabilities, or to get started on your custom automotive solution, contact TPC Converting today.