Synergistic effects of various hollow particles on mechanical and adhesive properties of impact protection film

Pressure sensitive adhesive films are widely used for their attach and detach convenience and easy and quick part fixing, making them indispensable in various industrial applications. The integration of microcellular foaming techniques further enhances these films by improving their impact strength, toughness, and lightweight characteristics. This study presents a novel approach to developing adhesive foam films for impact protection by incorporating a synergistic combination of thermoplastic swellable polymer (TSP) particles, hollow glass spheres (HGS), and organic–inorganic hybrid (OIH) particles. The effects of varying particle compositions and mixing ratios on the adhesive, mechanical, and thermal properties of the foam films were systematically evaluated. Comprehensive testing, including peel strength, compression force deflection (CFD), and ball drop impact absorption, identified optimal formulations and processing conditions. Advanced surface characterization using Scanning Electron Microscopy (SEM), Energy-Dispersive X-Ray Spectroscopy (EDX), and Atomic Force Microscopy (AFM) provided critical insights into particle migration, distribution, and their influence on the films' performance. Thermal treatment was shown to play a pivotal role in enhancing surface smoothness and adhesive strength by facilitating particle redistribution. The findings underscore the importance of tailored particle interactions in achieving high-performance thermoplastic foam films with superior impact resistance, mechanical resilience, and adhesive properties.