Automotive

By Max VanRaaphorst, business development manager for eMobility, energy storage and automotive at Avery Dennison Performance Tapes North America

The automotive industry has seen monumental changes in the past few decades, especially now given the global drive towards electromobility, as well as consumer demand for automation and connectivity. Increasingly, engineers are turning to pressure-sensitive adhesive tapes to address the many challenges faced by the modern automotive industry.

Pressure-sensitive adhesives are helping OEMs revolutionise how we go down the road. Once upon a time (not so long ago, really), car interiors were primarily analogue and manual. Windows were rolled down and seats were adjusted by hand. Mirrors were simply rectangles of polished glass that showed what was behind you. Entertainment options were limited to an AM/FM radio and maybe a tape deck – if you didn't like what was playing, you counted license plates. Analogue gauges indicated the speed, fuel level and engine temperature. Trips were hot in the summer, cold in the winter and could be uncomfortable and boring. 

Modern infotainment systems, LCD screens, Bluetooth^® connectivity, heated seats and steering wheels, heads-up displays, satellite navigation, luxurious creature comforts, downloadable performance upgrades and recall fixes and automatic everything were merely a twinkle in car designers’ eyes. At the time, they seemed as futuristic as interstellar travel and teleportation.

Modern cars have evolved dramatically from those of past decades. They stand to evolve even more in years to come. OEMs are finding that plush and electrified interiors – even in modestly-priced cars – are powerful differentiators in a crowded automotive marketplace. 

Very soon, the cabin experience is expected to take the spotlight away from automotive elements that have traditionally dominated headlines, including engine performance, exterior design and powertrains. The rapidly evolving ACES megatrends – automation, connectivity, electrification and shared services – will change the configuration of cars and allow vehicle occupants to enjoy new experiences during trips.  

The easy-to-remember ACES acronym was developed by the Center for Automotive Research to define the four key technological trends defining driving in the future.

Automation – much of driving will one day be managed by the car itself through a combination of sensors tied into a central processor. As the driver will no longer need to focus on the road ahead, interior layouts can undergo radical change.

Connectivity – cars will become integrated into our digital ecosystems. Imagine more streamlined connections between our cars, devices, homes, other cars, even the road itself. 

Electrification – even the few modestly-priced electric cars of today have performance characteristics that meet or exceed that of most gasoline-powered vehicles. As powertrain performance becomes less relevant, OEMs will increasingly turn to interior features to differentiate their makes and models.

Shared services – the industry seeing the infancy of shared services today with the popularity of ride-hailing providers such as Uber and Lyft. In the future, the definition of vehicle ownership will become somewhat blurred with the proliferation of services that allow vehicles to be shared by countless riders. Interiors will need not only to be easily customisable to the needs of a broader range of people but have even greater durability.

Design challenges of the modern age

Vehicle designers and engineers are working to develop interiors that are in step with these trends. As they push the envelope with technology, solutions must address some critical design challenges.

Design and assembly – engineers need solutions that are cost-effective, lightweight, durable and easy to work with on an assembly line; durability – solutions must perform at peak levels for the vehicle's lifetime; vision and sensing management – modern vehicle systems rely on various visual technologies, including radar, lidar, VTX (video transmitter) and view/touchscreens. These technologies must work effectively in a wide range of environments, with varying levels of light and the likelihood of exposure to temperature extremes, chemicals or fuels, road salt and other contaminants. 

Unintended consequences – this design revolution has, in turn, created new challenges. Think of them as unintended consequences. For instance, vehicles packed with electronics have increased flammability and electrical arcing concerns. Another challenge is an increase in ‘buzz, squeak and rattle’ issues in electric vehicles (EVs) caused by the absence of the car’s traditional source of background noise – the internal combustion engine.

Modern interiors feature pressure-sensitive adhesive tapes

Tapes are now used in various interior applications. These include mounting electronic mirrors and displays, bonding positive temperature coefficient (PTC) heaters to warm sensitive electronics, mounting sensors within seats and steering wheels and as a solution for bonding wire harnesses to interior surfaces. 

They’ve gained favour because they address the challenges listed above. Lightweight tapes can replace bulkier mechanical fasteners. They’re easy to apply and are often easily repositionable. Adhesive tapes themselves are long-lasting and can be engineered to resist environmental factors. When paired with specific materials, they can help reduce glare, improve the durability of electronics by sealing and filling gaps as well as reduce vibrations and noise.

As engineers turn to pressure-sensitive adhesive tapes, opportunities for tape converters will proliferate. Converters can play a critical role by providing lamination of materials; creating multilayer composites; die cutting; and creating part presentations, prototypes and samples. Now more than ever, the industry needs converters’ expertise and ability to produce these essential materials at scale.