For appliances, PS films and adhesives are versatile problem-solversBy Shirley Monte and Michelle OstiguyToday’s appliances are a marvel of design ingenuity and advanced hi-tech capability. They are also a showcase for the versatility of pressure-sensitive (PS) films and adhesives, which are found on, under and within the appliance, meeting both aesthetic and functional needs. PS products are a boon to today’s OEM and brand owner in terms of the variety of tasks these materials can handle and the number of problems they can solve. In the end, the successful implementation of all of these applications is reflective of the brand itself. Let’s consider a few.
PS films and adhesives can contend with the tortures of the appliance environment, including vibration, heat, cold, moisture, soap, grease and bleach. |
First, the nameplate: Primarily the brand identity of the appliance, it not only needs to be attractive and distinctive to capture the eye of the consumer, but also it needs durability to withstand environmental stresses such as abrasion and cleaning. The combination of polyester material — noted for its durability and printability — and a permanent acrylic laminating adhesive is the ideal solution. It assures the nameplate remains intact, legible and new-looking for the life of the appliance. The right adhesive will produce a rock-solid bond to prevent the nameplate from dropping off or shifting position two, three or 10 years into the appliance life. A new-looking nameplate on an old appliance sends the right message about the enduring quality of the brand.
PS materials offer the OEM and brand owner cost effective solutions to achieve brand aesthetics as well. For example, an epoxy “dome” label achieves a desired high-end, raised nameplate at minimal cost when compared to metal domes. Another cost saving option is brushed silver polyester. Used instead of a metal nameplate, it offers the same unique look at a much lower cost.
A second major use is for product and parts identification on the appliance’s back, underside and interior. The printed polyester labels carry safety warnings, electric ratings, operating instructions, warranty details, UL recognition or CSA acceptance, and other essential information to the consumer. A typical electric appliance may include a half dozen or more printed PS film labels. You’ll find them inside the dryer door, on the refrigerator’s compressor and motor, and attached to wires or tubes on the washer back. For labeling applications, PS films and adhesives — unlike paper — can contend with the tortures of the appliance environment, including vibration, heat, cold, moisture, soap, grease and bleach.
Pressure-sensitive films are also used on parts during the assembly or ‘Work In Process’ phase. Bar-coded labels on parts are printed and scanned during the assembly for tracking production time and quality control. Most important, these PS labels allow an OEM to identify problems or product failures before a part gets too far down the assembly line.
Pressure-sensitive films and adhesives often constitute key elements of the appliance’s inner workings and performance. Gaskets are one area, helping to provide a watertight seal, for example. High-performance pressure-sensitive adhesives work well in high and low temperature environments, leading to a successful bond to tough surfaces such as powder-coated paints and thermoform plastics. The same adhesives are used to hold foam firmly in place in areas that must be opened and closed repeatedly, such as the appliance door or panel. The foam has good rebound characteristics for these applications, while the adhesive keeps the application from moving or falling off over time, further enhancing appliance performance.
Noise and vibration damping is another use. Many consumers seek dishwashers, washing machines, mixers and blenders that whisper rather than rumble. Viscoelastic polymers between layers of steel or plastic form a constrained layer damping system that absorbs noise and vibration. To be most successful in satisfying the “quiet appliance” preference, noise frequency, temperature and application surfaces need to be carefully considered to determine the best adhesive for the damping system.
Options range from high-performance tacky silicones that perform well in areas of the appliance that get both hot and cold and on hard-to-bond-to surfaces such as thermoplastic polyolefins (TPOs), to a flock nylon material with an acrylic adhesive that is used selectively in areas with relatively low temperature variations. In the latter, the flock material often is used in strips to solve buzz, squeak and rattle issues throughout the appliance. The material compresses, expands and shifts to fill in space between the plastic layers as the temperature changes during consumer use.
Also in the area of performance, PS films and adhesives play a critical role in assembly of appliance parts. Tacky silicone adhesives similar to those used in sound and vibration damping are used in the assembly of parts in high temperature (up to 500°F / 260°C) environments. This performance capability makes certain PS adhesives suitable for use in ovens, washers and dryers. Double-coated transfer tapes also serve well in appliance assembly, allowing the bonding of two incompatible surfaces such as different types of metals, or a metal and plastic. A PS manufacturer can customize a double-sided tape with a different adhesive on each side, creating optimal bonding performance on two different surfaces.
For performance-related applications — gaskets, noise/vibration damping, parts assembly and bonding — the OEM engineer should consult the film/adhesive product manufacturer at the earliest stages of design. This will make cost-effective solutions more likely. For example, early collaboration can assure an optimum match between the adhesive’s damping characteristics and the specific frequency and temperature range that must be addressed to eliminate unwanted noise and vibration.
PS films also contribute at the point-of-sale, in eye-catching window ads, banners and graphic advertising on the floor. Graphics produced with PS films and a low tack removable adhesive can be used to place ad messages on the appliance surface itself. Certain films can even mimic the surface texture and color of a stainless steel stove or refrigerator.
The future will hold even more possibilities for how PS films and adhesives are used. For example, you may see anti-microbial film laminates for food protection in refrigerators.
Be ready! Look for a PS film product supplier that keeps a pulse on such developments, and whose innovative thinking can advance your appliance design efforts. An experienced company that offers a wide range of proven products for each application, plus the ability to custom-build a PS film/adhesive solution if needed, is your best ally.
Shirley Monte is business development manager for the performance products business team at FLEXcon.
Michelle Ostiguy is product manager for the product identification business team at FLEXcon.ADVERTISEMENT