Choosing the Right Pressure-Sensitive Adhesive (PSA) for Tapes and Films

The adhesive chemistry behind a tape or film significantly affects how well it bonds, how long it holds and how easily it can be removed. That’s why understanding the differences between peel adhesion, shear strength and initial tack is so important when choosing a pressure-sensitive adhesive (PSA). Each of these properties influence tape performance across different applications and adhesive types.

What Are Pressure-Sensitive Adhesives?

Pressure-sensitive-adhesives are a type of adhesive that become permanently tacky and will adhere to surfaces by applying pressure once they are fully dried or cured. They can be liquid or supplied in finished form as labels, tapes and films.

The performance of PSA tapes, specifically, comes from their viscoelastic polymer structure. This allows the adhesive to flow slightly into a surface for contact while maintaining internal strength to resist stress. That balance enables PSA tapes to withstand forces like vibration and environmental exposure without losing adhesion.

Common PSA Adhesive Types Used in Films and Tapes

Acrylic pressure-sensitive adhesives are among the most versatile bonding solutions available. Acrylic PSA tapes are widely used because they offer a strong balance of shear strength and environmental resistance. They perform well across a broad temperature range and resist UV exposure, oxidation and many chemicals. While acrylic adhesives typically require dwell time (often up to 72 hours) to reach full bond strength, they form extremely durable, long-term bonds once fully set. Very high bond (VHB) acrylic foam tapes are engineered for demanding applications and are often used as an alternative to mechanical fasteners such as rivets or screws.

Synthetic hot-melt rubber PSAs are formulated from synthetic elastomers and are valued for their quick set time and cost-effectiveness. These adhesives deliver strong initial tack and rapid bonding, making them well suited for temporary applications, indoor environments or high-speed production lines. However, synthetic rubber adhesives tend to have limited resistance to heat, UV exposure, chemicals and humidity. As a result, they perform best in controlled, stable environments where long-term durability is not a critical requirement.

Natural rubber PSAs, derived from polyisoprene sourced from rubber trees, are a more premium adhesive structure within the rubber-based category. They offer exceptional initial tack, strong bonding and excellent removability, making them ideal for applications where clean removal and repositioning are important. Natural rubber adhesives also provide improved flexibility and better performance across a wider range of hot and cold temperatures compared to synthetic hot-melt rubbers. While they are more eco-friendly and highly effective for immediate bonding, natural rubber PSAs typically require additives such as resins to improve performance and have limitations when exposed to oils or prolonged high-heat conditions.

Silicone pressure-sensitive adhesives are designed for extreme conditions. They offer exceptional temperature resistance and maintain performance in environments where acrylic and rubber adhesives fail. Silicone PSA tapes also bond well to silicone substrates and many low surface energy materials. While silicone adhesives provide excellent environmental resistance and clean removal, they tend to have lower initial tack, higher cost and shorter shelf life compared to other PSA types.

Understanding Bond, Shear and Tack

Bond (or peel) adhesion refers to the force required to remove a tape from a surface after it has been applied for a period of time. For protective films, a low to moderate and consistent bond strength is often preferred to allow controlled removal without damaging the surface or leaving residue.

Shear strength describes the internal or cohesive strength of the adhesive. It measures how well the adhesive resists forces applied parallel to the bonded surface. High shear strength is critical in applications where the tape must hold weight over time without slipping or edge lifting.

Tack is the adhesive’s ability to grab a surface immediately upon contact with light pressure. High tack is beneficial for fast application and immediate handling, while lower tack allows for repositioning during installation.

Matching Adhesive Type to Performance Requirements

When long-term bonding and peel strength are the priority, acrylic PSA tapes (particularly high-performance acrylic foam tapes) are typically the best choice. These tapes are engineered to deliver strong, permanent bonds and maintain adhesion under environmental stress.

For applications that demand high shear strength, acrylic PSA tapes again offer superior performance due to their cohesive strength and durability. Silicone adhesives can also perform well in shear, especially in extreme temperature environments, but acrylic tapes generally provide higher overall strength for most industrial applications.

If immediate adhesion is the primary concern, rubber-based pressure-sensitive adhesives are often the preferred solution. Their high initial tack allows them to bond quickly with minimal dwell time, making them ideal for temporary protection and short-term use.

Other Factors That Influence PSA Tape Selection

In addition to adhesive chemistry, selecting the right PSA tape requires consideration of the substrate surface energy, surface roughness, operating temperature, humidity, chemical exposure, and UV exposure. It is also important to balance initial tack with long-term bond strength and to understand how peel and shear forces will affect the application over time. Testing remains one of the most effective ways to confirm that a chosen adhesive will perform as expected in its intended environment.

Final Thoughts

Choosing the right pressure-sensitive adhesive is about selecting the adhesive that best matches the application requirements. By understanding how peel adhesion, shear strength, and tack differ across acrylic, rubber, and silicone PSA tapes, converters and manufacturers can make informed decisions that improve performance, reliability, and overall product quality.

Applications of Pressure-Sensitive Adhesive Solutions for Batteries

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:

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:

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:

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.

How Die-Cut Adhesive Tape Improves Manufacturing Production

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.

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

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.