AEROSIL® Fumed Silica in

Waterbased Adhesives & Sealants

Technical Information 1324
1 Introduction 2  AEROSIL® Fumed Silica in
Pressure Sensitive Adhesives
AEROSIL® Fumed Silica has long been used in adhesives and Pressure sensitive adhesives, PSAs, are used to adhere labels,
sealants to provide thixotropy and reinforcement. In the area tapes and films to a variety of substrates. They are commonly
of waterborne systems, the use has primarily been in sealants. used in industrial, consumer and medical applications. Strength
The unique combination of properties that AEROSIL® Fumed and tack are key elements of the adhesive performance while
Silica provides applies to waterborne adhesives as well. the viscosity affects the thickness of the applied film.

AEROSIL® is a synthetic amorphous silica that modifies flow The Pressure Sensitive Tape Council (PSTC) has developed a
behavior through its structure of aggregated particles. It number of test methods to determine adhesion-in-peel, shear
increases viscosity and influences the flow, leveling as well as strength and tack. These basic tests were used to compare
sag. When replacing traditional thickeners such as cellulosics, the performance of AEROSIL® 200 and AERODISP® W 7520.
associative thickeners and clays with AEROSIL®, additional Other AEROSIL® fumed metal oxides were tested and may
reinforcement properties are achieved. The same structure that be suitable for specific applications where alternative surface
controls viscosity also sets up an internal network of inorganic areas or surface treatments may be a benefit.
particles that improve the bulk properties of the dried film.

Adhesion of a material is a combination of its cohesive and

adhesive properties. Each must be balanced to obtain the
desired performance. Poor adhesive or cohesive properties
may result in early failure of the adhesive. AEROSIL® Fumed
Silica enhances the cohesive properties of the film thus build-
ing a more integrated bond line.

Evonik offers AEROSIL® Fumed Silica either as powders

(AEROSIL®) or as liquid dispersions under the trade name
AERODISP®. Powders are available in various hydrophilic and
hydrophobic grades. Surface treated products offer additional
unique features. AEROSIL® hydrophobic fumed silica grades
are offered in different levels of hydrophobicity and carry the
“R” designation. AERODISP® Fumed Silica dispersions elimi-
nate the dispersing step that is required when working with
powder fumed silicas. AERODISP® dispersions also impart the PSA color tape
combined properties of reinforcement and viscosity.

A short survey of polymers was made and the study included

UCAR® Latex 9037 (acrylic copolymer) from Dow Chemical
Company, and Flexcryl® AF 2066 and 260 B (emulsion poly-
mers based on vinyl acetate, ethy-lene and butyl acrylate) from
Air Products and Chemicals, Inc.. To each of these, levels of
1, 2, 3, 4, and 5 % of dry fumed silica to polymer solids were
added and compared to a control without silica.

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2.1  180 ° Shear Adhesion Results Shear Adhesion, Flexcryl® AF 2066
AEROSIL® Fumed Silica improves shear strength of adhesives
by increasing the cohesive properties of the film. As with any
shear adhesion test, the total force is a sum of adhesive and
cohesive properties. The three latexes were tested with the
PSTC method’s arrangement of a ½ inch x ½ inch x 1000 gram
configuration on stainless steel panels.

Shear Adhesion

Flexcryl® 260 B also shows improvement for both dispersion

and powder forms of fumed silica.

Shear Adhesion, Flexcryl® 260 B

Shear adhesion for UCAR® Latex 9037 improved in both

scenarios – when using the powder as well as when using the
dispersion. The improvement was more pronounced when
using AERODISP® W 7520 instead of the powder.

Shear Adhesion, UCAR® Latex 9037

2.2  Adhesion-in-Peel Results
Adhesion-in-peel is related both to the adhesive and cohesive
properties of the film. Formulation changes that negatively
impact the tack properties (see below) can also affect the
adhesive properties. However, the addition of a fumed silica
improving shear (see above) can balance these properties out.

Flexcryl® AF 2066 also shows an improvement in 180° Shear

times with the dispersion. In this case, the AEROSIL® 200 does
not add to adhesion. This may be due to a number of factors,
including shear sensitivity of the emulsion.

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Dow Chemical’s acrylic UCAR® Latex 9037 is intended for Adhesion-in-Peel, Flexcryl® AF 2066
clear decal applications. One application is for screen printed
signs for the side of trucks. Clarity is obviously important as is
strength to prevent peeling. AERODISP® 7520 results in better
retention of inherent adhesive properties when tested in peel
than AEROSIL® 200.

Adhesion-in-Peel, UCAR® Latex 9037

Air Products’ Flexcryl® AF 2066 was also designed for

clear label applications. Use of AEROSIL® 200 and
AERODISP® W 7520 show a steady decrease in peel adhesion,
but less with the dispersion. Finally, Flexcryl® 260 B from Air
Products was also tested. This is a general purpose adhesive
designed for paper and label applications. For this latex, both
powder and dispersion perform similarly with a slight decrease
at higher loading levels.
Adhesion-in-Peel

Adhesion-in-Peel, Flexcryl® 260 B

2.3  Loop Tack

The addition of any powder into a PSA film has the potential to
severely impact the tack.

The UCAR® Latex 9037 shows only a moderate drop in tack

with the dispersion over the full range of loading tested.
The powder begins to show a significant loss of tack at higher
loading levels.

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 Loop Tack, UCAR® Latex 9037 Loop Tack, Flexcryl® 260 B

With Flexcryl® AF 2066, the loss of tack for both materials was Again, both powder and dispersion show a decline in tack, but
about even with a slight advantage to the dispersion. less with Flexcryl® powder in this case.

Loop Tack, Flexcryl® AF 2066

Loop Tack Test

2.4 Conclusions
In pressure sensitive adhesives, the use of AERODISP® Fumed
Silica dispersion is generally better than using the equivalent
AEROSIL® Fumed Silica. The results also indicate that each
latex must be studied as results may vary. While improving
shear results, fumed silica does slightly diminish the tack and
adhesion-in-peel results so care must be taken when these
properties are important.

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3  Subfloor Construction Adhesive

In the construction industry, solvent based adhesives make up a Wood Sub Floor Sample Preparation
large portion of the market, in particular the subfloor adhesive.
The performance requirements of this type of adhesive are
such that wet and frozen lumber must be adequately bonded.
The American Plywood Association has written a specification
to cover this, AFG-01 Adhesives for Field-Gluing Plywood to
Wood Framing, and is often cited. ASTM International’s
Committee D 14 Adhesives has developed D 3498 Standard
Specification for Adhesives for Field-Gluing Plywood to Lumber
Framing for Floor Systems. However, for everyday development
of adhesives, wood lap shears are most commonly used to
evaluate tensile strength.

Raw Material Supplier Pct.

Weight (wet)

Acronal® DS 2159 Styrene-acrylic BASF 56.7

copolymer

Sodium Dispersant various 0.1

Tripolyphosphate

Pigment Dispersant BASF 0.1

Disperser N

Foamaster NXZ Defoamer Cognis 0.05

Snowtack 301 A Tackifying Eka Nobel 3.6

resin dispersion

Ethylene glycol Freeze-thaw various 3.0

stabilizer

A formulation was obtained from BASF for a subfloor Eastman DBA Cosolvent Eastman 2.3
Chemical
construction adhesive that claims performance that meets the
Duramite CaCO3, IMERYS 11.4
two standards mentioned. It is based on Acronal® DS 2159, a 6 micron
50 % solids emulsion and contains Acrysol® ASE-60 as a thick-
Nuclay Kaolin clay BASF 22.7
ener. All formulations were made in a double planetary mixer
Acrysol® ASE-60 Polyacrylic acid Rohm 0.3
and were vacuum deaired prior to transfer. thickener, and Haas
28 % solids

AEROSIL® R 972 was used to replace the Acrysol® ASE-60 for

rheology and for the added benefit of reinforcement.
A loading level of 0.25 to 0.31 % on the total, 0.88 to 1.09 %
on the polymer solids was found to be sufficient to optimize
the rheological and adhesive properties.

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3.1  Viscosity Testing 3.2  Lap Shear Adhesion and Water Resistance
Viscosity using a Brookfield HA-T spindle E at 5 rpm was taken Adhesion was compared using lap shears similar to ASTM D 1002
24 hours after the material was compounded and compared. but made of poplar. A 1 x 2 inch area (25 by 50 mm) was
The control (Acrysol® ASE-60) had a viscosity of 160,000 cPs. adhered and tensile strength determined by dynamic loading.
A crosshead speed of 0.05 in/min (1.27 mm/min) was used
and the peak load noted with the final results reported in psi
Subfloor Adhesive Viscosity (cPs) by Silica Amount (MPa). Strength development was determined by testing at
intervals of 24 hours, 48 hours and 7 days.

Subfloor Adhesive ASTM D 1002 Lap Shear Strength

Loading levels up to 0.62 % AEROSIL® R 972 ranged from

110,000 to 190,000 cPs. At 1.24 % loading, the viscosity
climbed to 590,000 cPs. This indicates that AEROSIL® R 972 may
be used in the same relative amounts as an alkali swellable
thickener and even to twice the amount without serious impact
to the viscosity of the system.
With AEROSIL® R 972 loading up to 0.31 %, strength develop-
ment is as good as or better than the control (ASE-60). Above
Wood Floor Preservation is a function of Adhesive Water Resistance
that loading, the shear strength begins to decline. This is likely
due to too much of the polymer being tied up with wetting
the fumed silica. At 0.25 % loading, the 7 day results are the
highest at 398 psi (2.74 MPa) compared to 307 psi (2.12 MPa)
for the control, an almost 30 % increase in shear strength.
Additionally, several samples were cured for 14 days at room
temperature and then immersed in water for 72 hours prior to
testing to determine relative water resistance. The same lap
shear assembly and test speed was used.

Subfloor Adhesive D 1002, 72 hour Water Soak

Shear Strength
psi MPa

Control (ASE-60) 26.5 0.18

AEROSIL R 972, 0.31 %

® 62.1 0.43

AEROSIL® R 972, 0.62 % 42.2 0.29

AEROSIL R 972, 1.24 %

® 35.0 0.24

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3.3  AEROSIL® and Dynasylan® Synergy 3.4 Conclusions
Dynasylan® Silanes are known to add value to latex sealant for- AEROSIL® R 972 fumed silica can effectively replace alkali
mulations. US Patent 4,340,524 – Bullman, 1982, specifically swellable polymer thickeners and provide the added benefit of
discusses the use of γ-glycidyloxypropyltrimethoxysilane improved water resistance. With this replacement, the pH of
(Dynasylan® GLYMO silane) and its benefits. In the area of the system is not as critical and can be reduced to the range
waterborne adhesives, the use has been limited primarily due in which silane adhesion promoters can be used to further
to the traditional methods of rheology control. More often, an enhance the formulation.
alkali swellable thickener is used that requires the pH range of
the system to be between 8 and 10 for optimal viscosity build.
This detracts from the useful shelf life of silane coupling agents
as the hydrolysis rate is accelerated in this pH range.

With the use of AEROSIL® Fumed Silica for rheology and

reinforcement, the pH of the adhesive can be controlled
more precisely and adjusted to more neutral conditions. This
increases the stability of the silane in the system. Additionally,
the use of ethoxy-functional silanes may further enhance shelf-
life properties.

Subfloor Adhesive ASTM D1002 Lap Shears with Silane

AEROSIL® R 972 was used again, at a loading level of 0.25 %,

along with 0.50 % silane on the total formulation (2 % on poly-
mer solids). Dynasylan® GLYMO and GLYEO were the silanes
chosen for this evaluation. Poplar lap shears were made with 2
inch2 surface area overlap, allowed to dry at room temperature
for 14 days, and then submerged in deionized water for three
days prior to testing. The results showed improvements when
using silane, especially the Dynasylan® GLYEO.

ASTM D 3498 testing of these four formulations show

that they all pass the 150 psi minimum requirement for the
specification.

9
4  AEROSIL® Fumed Silica in Waterborne Sealants

AEROSIL® Fumed Silica is well known for its performance in As light travels through the sealant, it strikes the fumed silica
waterborne sealants. Chang’s patent (U.S. Patent 4,626,567) particles and is reflected back to the observer, creating a
granted in 1986 includes the use of hydrophilic or hydrophobic translucent effect. This effect can be minimized by optimizing
fumed silica in water-resistant, clear and color acrylic sealants. the size and thus, the refractive index of the particles through
In 1992, Goldstein (5,124,384) discusses improvements in proper dispersion. High energy is required to disperse fumed
clarity of transparent latex caulks when matching refractive silica in powder form. The mechanical shear can destabilize
indices of fumed silica with those of the other formulation the emulsion polymer, thus “breaking” the emulsion during the
components. Even better clarity can be achieved with manufacturing process. Surfactants can prevent destabilization
AERODISP® Fumed Silica dispersions. but have a negative impact on water resistance, adhesion
& blushing.

The use of AERODISP® Fumed Silica dispersions eliminates

the high energy dispersing process and reduces cycle times.
Special milling procedures and pH control make these products
stable. Their solids content is a function of the surface area
of the fumed silica they contain and is inversely proportional.
AERODISP® Fumed Silica dispersions are commercially avail-
able in solids contents ranging from 15 to 30 %. For example,
AERODISP® W 7330 N is offered at a 30 % weight solids and
an approximate pH of 10, and AERODISP® W 7520 at 20 %
weight solids.

Tests were performed with a clear sealant formulation based

on UCAR® Latex 9192, a high solids acrylic emulsion polymer.
While the formulation mainly consists of latex, it also contains
other ingredients to improve processing, UV stability, freeze-
thaw characteristics, rheology and adhesion. Additional ingre-
dients may also be added to improve flexibility, tooling and
application. When using dispersions, it is important to keep in
mind that the water is a volatile component that needs to be
accounted for in the formulation. This may require replacing
ingredients such as mineral spirits, with less volatile organic
compounds that will aid in tooling and open time properties.

Clarity of waterborne sealants is predominantly affected by

the fumed silica and how well it is dispersed. High speed
dispersing equipment is required to break up the agglomerates
and reduce the fumed silica to its aggregate structure. This
structure improves the cohesive properties of the sealant but,
depending on the particle size, may negatively impact the light
transmission through the sealant.

10
 Formulation Suggestion K-2230, The Dow Chemical Company

Raw Material Weight (g) Weight Percent

UCAR™ Latex 9192 Acrylic copolymer, 65 % solids 895.0 92.98

TERGITOL™ Nonylphenol ethoxylate 1.4 0.15
NP-4 Nonionic Surfactant
Foamaster NXZ Defoamer 3.2 0.33

Propylene Glycol 26.0 2.70

UCAR™ Filmer IBT 2,2,4-trimethyl-1,3-pentanediol monisobutyrate 7.7 0.80

Mineral Spirits 15.0 1.56

Tinuvin 1130 UV Stabilizer 50 %: a-[3-[3-(2H-Benzotriazol-2-yl)-5-(1,1-dimethylethyl)- 0.6 0.06

4-hydroxyphenyl]-1-oxopropyl]-w-hydroxypoly(oxo-1,2-ethanediyl);
38 %: a-[3-[3-(2H-Benzotriazol-2-yl)-5-(1,1-dimethylethyl)-
4-hydroxyphenyl]-1-oxopropyl]-w-[3-[3-(2H-benzotriazol-
2-yl)-5-(1,1-dimethylethyl)-4-hydroxyphenyl]-1-oxopropoxy]
poly(oxy-1,2-ethanediyl);

Tinuvin 292 UV Stabilizer Hindered amine light stabilizer 0.6 0.06

Dynasylan® GLYMO silane γ-glycidyloxypropyltrimethoxysilane 0.6 0.06

AEROSIL® 200 Fumed Silica SiO2 2.0 0.21

Ammonium Hydroxide (28 %) NH 4OH 10.5 1.09

Total 962.6 100.00

Based on this formulation, AERODISP® W 7520 and

AERODISP® W 7330 N fumed silica dispersions were compared
to the standard AEROSIL® 200 at various loading levels. Of
most interest are the properties of tensile elongation and
clarity. Commonly, ASTM D 412 Standard Test Methods for
Vulcanized Rubber and Thermoplastic Elastomers–Tension is used
to study the diffe-rences in tensile elongation properties of
Elastomeric sealants. A specimen is cut in the shape of a dumb-
bell or “dog bone” and elongated at strain rate of 10 in/min.
Peak stress is reported along with the elongation at break as a
function of a percentage of the original length. Clarity is com-
pared visually by applying a layer of sealant on a black back-
ground, such as on a Leneta™ Chart.

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 Clear Latex Sealant Tensile Strength Clear Latex Sealant % Elongation at Break

Tensile strength was compared with loading levels of 0, 0.2 Due to the nature of fumed silica’s reinforcing properties,
(as called for), 0.4 and 0.8 % total loading on a solid fumed elongation at break is typically reduced with increased loading.
silica basis. The formulations with AEROSIL® 200 included no This is visible in the graph where products made with
additional water. Over this range of loading, the three products AEROSIL® 200 did not perform as well as those made with
performed similarly. Higher loading levels are usually not used AERODISP® dispersions. This is most likely a result of the
because of potentially higher viscosities. improved dispersion of the fumed silica particles. A visual
comparison of the three products/systems indicates that the
AERODISP® Fumed Silica dispersions also result in better
clarity than powdered products. In this particular formulation,
AERODISP® W 7520 performed slightly better than
AERODISP® W 7330 N, most likely because of the lower
specific surface area of AERODISP® W 7330 N.

Overall, the use of fumed silica dispersion such as

AERODISP® W 7330 N or AERODISP® W 7520 can improve
clarity without sacrificing physical properties.

The data above also demonstrate that AERODISP® products

improve the mechanical properties for elongation.

12
Particle Size Distribution of AERODISP® W 7330 N Conclusion:
„Overall, the inclusion of fumed silica dispersion such as
AERODISP® W 7330 N can provide for a clearer film without
sacrificing physical properties.“

The above data also demonstrates that the dispersed form

provides better mechanical properties for elongation than the
corresponding powder version. Additionally, an improvement
in the cohesive properties of the sealant as well as tensile
strength of the elastomeric polymer used for the sealant were
noted when using AERODISP® W 7520, AERODISP® W 7330 N
and AEROSIL® 200.

Viscosity Curve–AERODISP® W 7330 N

Physical properties of AERODISP® W 7330 N

Properties Unit Typical Value

SiO2 – Content Wt. % 30 ± 1.0

Stabilizing Agent Sodium Hydroxide

pH (DIN EN ISO 787/9) 9.5 – 10.5

Viscosity (DIN EN ISO 3219, 100 s , 23 °C)

-1
mPa · s ≤ 1000

Mean aggregate size (d-50 value, volume) µm 0.15

Density (20 °C) g/cm 3

1.20

13
Appendix –Testing Procedures
Several ASTM International documents are referenced in
this document. These are under copyright by ASTM and are
available either as individual documents or in a collection of
standards under the responsible committee. ASTM Committee
D 14, Adhesives, publishes the refe-renced documents in Book
15.06. ASTM Committee C 24, Building Seals and Sealants,
publishes the referenced documents in Book 04. 07.

ASTM International
100 Barr Harbor Drive
P. O. Box C 700
West Conshohocken, PA, 19428, USA
phone  +1 610 832-9585
fax  +1 610832-9555

The Pressure Sensitive Tape Council (PSTC) publishes

Test Methods for Pressure Sensitive Tapes.
This is a collection of relevant test methods developed
by the Council and some ASTM methods.

Pressure Sensitive Tape Council

P. O. Box 609
Northbrook, IL 60062, USA
phone  +1 847 562-2630
fax  +1 847 562-2631

14
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