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The following article was contributed by a Thomas Insights Market Expert. The views expressed in this article reflect the perspectives of the Market Expert and do not necessarily reflect the perspectives of Thomas. 

When working with automotive pressure-sensitive adhesives (PSAs) — or most any purchase in the supply chain, for that matter — three factors weigh heavily on the buying decision:

Finding the right materials, at the right price point, with a reliable unit volume is a straightforward goal, but it often takes some time. Suppliers can have dizzying catalogs of films and tapes to sift through with nuanced differentiators that make it tough to compare specs tit-for-tat. You may go into the search with a clear idea of the automotive design problem you need to solve but less certainty about the ideal polymer or adhesive formula. A lower price point might not provide much value if the material is poorly matched to the task. 

Modern automotive PSAs are versatile, too. Every area of the vehicle will have some specialized options: matte black vinyl paint replacement tapes window sashes and door pillars, for instance. However, as synthetic adhesives have evolved, their material advantages have begun to expand and overlap across multiple use cases and purposes.

Synthetic films and foams are two of the most common carriers (or cores, or backings) for automotive PSAs. Each style has unique properties that will suit it to certain tasks or substrates, and both have the ability to accommodate single or double-sided adhesion. Acrylic, silicone, rubber, or other adhesive layers will also affect the strengths and value of the PSAs.

Neither film nor foam is specifically “better.” The perfect selection comes down to a harmonious match of carrier, adhesive, substrate, purpose, and anticipated environmental stresses. To settle on the correct PSA for your project, we must start with an examination of the qualities and resistances of each polymer.

Most of the options below can actually vary wildly in forms and properties, depending on the specific formulation. It’s generally possible to find each one in transparent, colored, printed, matte, glossy, or other finishes as necessary. What holds this group together is that they’re straight-edged, thin-gauged, and better suited for smooth substrates than rough or uneven surfaces. Films are also the material of choice when you need transparent adhesives.

Here’s just a sampling of film material options and potential advantages:

Whereas films are best used to shield surfaces from scratches, rough frictional contact, and corrosive liquids, foams are better at filling gaps, dampening vibrations, and creating flexible bonds, even on irregular, textured, or rough surfaces. In protective roles, foam will not withstand abrasive forces like a film but serves as a shock absorber, diffusing vibrations and impact stresses across the full bonded surface.

There are also two primary styles of foam PSA: open-celled and close-celled. The former will allow air and liquids to pass through, and the latter will not. Closed-cell foam tapes are an excellent option for gasketing and moisture sealing applications.

Here are several of the more common materials for foam automotive PSAs:

The purpose of the PSA is likely the first filter in your decision-making process. In general, films offer the best performance when you need an adhesive to be thin, clear, printed, or to act as a shield against liquid or abrasion. Foam PSAs are at their best when their flexibility comes into play, as with gap filling, shock absorption, sound dampening, or stretchable bonding between substrates with dissimilar thermal expansion properties.

For example, if you need a temporary protective solution — such as in packaging or shipping of auto parts — the economical price point and abrasion resistance of a polyethylene film, when paired with a low-tack adhesive layer that will leave no residue, makes for an easy choice.

However, if you’re trying to bond two rough or textured surfaces, a double-sided film tape will not perform nearly as well as a gap-filling foam tape. Flexible foams will hug uneven surfaces as the cells compress around and conform to irregularities, allowing better adhesive wet-out and bond strength.

Here is some brief advice on how to select the right automotive PSA for several common design problems and use cases:

This list provides food for thought, but there are many, many more potential considerations when selecting the right film or foam PSA for automotive purposes. It’s always best to consult with your supplier for guidance before requesting a quote on a particular PSA. They may have options you haven’t considered in their portfolio that could maximize the value of your purchase. Suppliers are highly motivated to earn your ongoing business, and they will be happy to work with you to find the best possible solution.

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