Our client, a medical device manufacturer, required a latex component delivered on rolls for automatic dispensing. The diaphragm, however, did not require adhesive. How would the diaphragm stay on the liner without adhesive?
Our AWT experts searched for an ultra-removable adhesive that contained a high differential release (one side of the adhesive or liner could be removed more easily than the other side). This differential release is most often controlled by the silicone content applied to the release liner. In this case, an ultra-removable adhesive allowed the part to be removed from the carrier without any adhesive residue. The tight release between the adhesive and the liner allowed the adhesive to stay on the liner after the part was removed.
Tolerances remained tight. The part has a 0.003 tolerance in the x, y and z dimensions. Maintaining this while working with the elastic properties of natural rubber and ensuring compliance within the lot was a considerable challenge.
AWT made certain the rubber was under the least amount of tension possible – its own weight. After converting, a sample population was measured. That data was then used to statistically calculate the mean, standard deviation and upper and lower control limits. Because the mean (plus or minus three times the standard deviation) was within the upper and lower specification limits, we had a 99.8% assurance that all parts will fall within this range. Understanding our customer’s requirements allowed us to succeed together and reach a common goal!