The Ultimate Guide to Foam Tape: Selection, Application, and Materials
Types of Foam Tape
Introduction: Why Foam Tape is the Unsung Hero of Sealing and Mounting
Foam tape is an incredibly versatile adhesive product used across countless industries, from HVAC, automotive manufacturing, filtration systems, enclosures, data centers, electronics, packaging, to construction. Whether you need to create a durable seal against the elements, dampen vibrations in machinery, or mount a sign securely, there is a foam tape engineered for the job.
At Pres On, we understand that choosing the right foam tape can be complex, with many variables like material, adhesive type, and application conditions to consider. This comprehensive guide is designed to provide you with all the knowledge you need, empowering you to select the perfect foam tape for your specific project.
What is Foam Tape?
Foam tape is a pressure-sensitive, self-adhesive product made from a foam backing (or carrier) and coated with a powerful adhesive. It is available with adhesive on one or both sides, and its soft, conformable nature allows it to fill gaps and bond irregular surfaces where other adhesives or mechanical don’t do the job.
Understanding the Anatomy of Foam Tape
- Foam Carrier: The foam is what gives the tape its key properties, including cushioning, vibration dampening, and gap-filling capabilities. Foam density (soft, medium, or firm) affects its cushioning and strength. Open or Closed Cell affects its ability to create a waterproof or air tight seal. Various attributes such as UL ratings and FMVSS testing give the foams various flammability ratings. Various temperature ratings, color, and compression set are all included as filtered options within preson.com so you can find the best foam product for your application.
- Adhesive: The adhesive is what ensures a strong bond to various surfaces. The type of adhesive (e.g., acrylic, rubber) determines the tape’s temperature resistance, peel and sheer strength, and long-term durability.
- Release Liner: A protective liner, typically paper, covers the adhesive side(s) and is peeled away during application.
The Different Types of Foam Tape By Material
- Polyethylene (PE) Foam Tape: A versatile, general-purpose foam, often used for mounting and sealing. It offers good conformability and is typically best for indoor use, but some variants are suitable for outdoors. Great closed cell product for filters, cleanrooms, and packaging.
- PVC Vinyl Foam Tape: A closed-cell foam that provides excellent resistance to UV, ozone, and chemicals. It offers great impact cushioning and is ideal for long-term outdoor use, such as window glazing.
- Neoprene/EPDM Blends: Known for UL Ratings, superior durability and resistance to heat, closed cell, and weather, making them a cost-effective choice for many general purpose applications including enclosures.
- EPDM Foam Tape: Known for UV Resistance, superior durability, closed cell, excellent resistance to heat, flammability ratings, and rebound making them choice for outdoor applications and enclosures.
- Neoprene: Not a blend, a true 100% neoprene foam. Known for better chemical resistance, it’s superior durability and temperature range makes it a superior foam when a true neoprene foam tape is required.
- Nitrile Foam Tape: Known for meeting a wide variety of technical specs and ratings, from UL and flammability tests to UL Greenguard. This closed cell, soft, weather-resistant foam is a great affordable gasket tape for sealing up to 1″ thick gaps on indoor and outdoor HVAC units and air ducts as well as a variety of applications.
- Silicone Foam Tape: A highly-specialized tape known for its extreme temperature resistance, flexibility, and strong adhesion. Ideal for demanding indoor and outdoor conditions.
- Open Cell Foam Tape: An ultra soft gasket tape with open cell structure. A budget friendly gasket tape that is used in applications where sealing water or air is not a requirement (comparing to closed cell foams). Often used in packaging, vibration control, and cushioning applications, but may also be used in the filtration industry as a gap filling ly-specialized tape known for its extreme temperature resistance, flexibility, and strong adhesion. Ideal for demanding indoor and outdoor conditions.
By Adhesive
Pres-On offers a superior direct coat adhesive on most of our products. The direct wet coat adhesive allows for adhesive to flow (as a liquid) into the cells of the foam, giving it a superior bond compared to laminated transfer tapes, which are essentially double sided tapes that a stuck on the back of a foam. Once cured the wet coat adhesive prevents the adhesive from delaminating off the foam as it is not a laminated process. Additionally, the wet coat adhesive allows for the foam to be more flexible and conformable as it is not bound by a filmed supported laminated transfer tape. Learn more about Pres-On’s Wet Coat Adhesive Advantage
- Rubber-Based Adhesive: Offers a high-tack, strong initial bond and is cost-effective, but is generally less durable outdoors.
- Acrylic-Based Adhesive: Provides a durable, weather-resistant, and high-strength bond that performs exceptionally well in high temperatures and UV exposure.
- Mylar Film with Adhesive: For applications that require dimensional stability, such as die-cut gaskets, Pres-On can produce our foam gasket tapes with a mylar film on the adhesive side. This allows for the foam to hold it’s dimensions after the liner paper is removed. Without the mylar film, the foam may appear to shrink when removed from the liner paper, but that is a natural process of the superior and more flexible wet coat adhesive. Either Rubber or Acrylic adhesive can be used with the Mylar film.
By Function
- Single-Sided Foam Tape: The adhesive is on one side. In gasket applications, the foam is mounted in place and compressed between components. The closed cell foams are excellent for sealing against air, dust, and moisture in applications like weatherstripping and insulation.
- Double-Sided Foam Tape: Adhesive is on both sides, making it ideal for permanent bonding for general purpose to lightweight mounting applications. Applications that replace fasteners can use High-Bond double sided tape such as Pres-On’s PHB series.
Common Applications for Foam Tape
- Sealing and Weatherstripping: For windows, doors, and hatches to protect against drafts, moisture, and pests.
- Gasketing: Creating durable seals in electronics, HVAC systems, and appliances.
- Bonding and Mounting: Replacing mechanical fasteners for signs, nameplates, and other components.
- Cushioning and Protection: Providing shock absorption for sensitive parts and protecting surfaces from impact.
- Vibration and Sound Dampening: Reducing noise and vibration in industrial machinery, vehicles, and electronics.
How to Choose the Right Foam Tape for Your Project
Choosing the right tape depends on several key factors:
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- Application: What is the primary purpose? Is it for sealing, mounting, or cushioning?
- Environment: Will the tape be used indoors or outdoors? Will it be exposed to UV light, moisture, or extreme temperatures?
- Substrate: What type of material are you bonding to? Different adhesives are formulated for different surfaces (e.g., metal, plastic, wood).
- Temperature Range: Consider the minimum and maximum temperatures the tape will need to withstand.
- Flammability: Is UL rating required? We offer UL 50, UL 94 foams.
- Open or Closed Cell: Is water and air tight gasketing required?
- Specialty Needs: Contact Pres-On’s technical team.
Foam Tape vs. Other Sealing and Mounting Options
Foam tape offers distinct advantages over alternative solutions:
- Compared to Sealants (Caulk, Liquid Gasket): Foam tape offers a clean, mess-free application with no drying time required. It also provides predictable compression and cushioning.
- Compared to Mechanical Fasteners (Screws, Rivets): Foam tape distributes stress more evenly across a bond line, reducing stress concentration. It also provides excellent vibration dampening and creates a better seal.
Frequently Asked Questions
- Is foam tape waterproof? Some varieties, particularly closed-cell foam tapes, are completely waterproof, while open-cell tapes are not.
- What is the difference between open-cell and closed-cell foam? Closed-cell foam does not absorb water and creates a stronger seal, while open-cell foam is more breathable and compressible.
- How do I prepare a surface for foam tape? Ensure the surface is clean, dry, and free of dust, oil, and other contaminants for maximum adhesion.
- Where to buy neoprene foam tape in bulk? Pres-On is an excellent source for bulk foam tape rolls.
- Where do I buy custom foam tape rolls? Pres-On makes custom sized foam tape rolls.
- How much is Neoprene foam tape? Prices vary based on thickness, width, length and density.
- Are you a foam tape distributor? No, we are a manufacturer. We sell to distributors and to OEMs in bulk quantities.
- Can I buy a single roll of foam tape? You can visit www.presbond.com for our single roll outlet, www.preson.com is the homepage for Pres-On where we provided technical data and contact information for customers buying large orders?
- Do you only make rolls? No, we produce foam die-cut gaskets with or without adhesive. We also make long length foam spools and foam sheets.
- Where is your product made? We make our foam tape in the USA, Bolingbrook, IL to be exact (a Chicago suburb)
- Is quality important? 100% Yes. There are multiple foam gasket tape manufacturers and distributors who supply low quality foams with laminated transfer tapes. Pres-On prides ourselves on making the highest quality foam tapes with an industry leading adhesive backing.
Ready to find the right foam tape for your project?
Explore Pres-On’s full line of foam gasket tapes and other sealing solutions today!