Tape Technologies for Sustainable Solutions

Saint-Gobain has developed its roadmap to achieving net zero carbon by addressing all CO₂ scopes, including direct carbon emissions (scope 1), electricity-related emissions (scope 2), and all other emissions (scope 3). All business units are implementing strategies to minimise their environmental footprint at the plant level and address scope 3 emissions across the supply chain, both upstream and downstream. 

Tape Solutions is actively pursuing industrial processes that generate less CO₂ (e.g. solvent-free UV-cured acrylics), installing solar panels at plant sites (most recently at our Waakirchen facility), and ensuring R&D teams design products based on the decarbonisation of raw materials. At our Hoosick Falls plant, solid waste is reduced through the recycling of silicone and PTFE film scrap. Recycled silicone products are transformed into more basic silicone raw materials. Additionally, recycled PTFE is reused in micronised coating (anti-seize coatings) for industrial and mechanical applications (bolt coatings) or ground into powder and incorporated into gaskets/seals for chemical pipes. Localised production and distribution of materials further streamlines manufacturing, creating more cost-effective and successful projects. Providing tapes in various configurations such as rolls, sheets, spools, and precise die-cut parts facilitates transportation, assembly, and the manufacturing process. This optimisation of configurations reduces waste within the supply chain. 

The Tape Solutions team is fostering an eco-conscious culture through the implementation of sustainability-related education and the formation of green teams. Furthermore, world-class manufacturing (WCM) teams have been established to address complexities, ensure efficiencies, and achieve goals of durability, reusability, and upgradability across our entire value chain. New and existing products are being carefully evaluated for sustainability by our Product Stewardship team.

Enabling Sustainability in Key Market Areas

With construction accounting for approximately 37% of global carbon emissions in 2022, mobility for around 23%, and industry for about 29%, focusing on sustainable improvements in these three markets is crucial. Often, foams and tapes provide effective enhancements to a product or project’s ecological footprint due to their numerous benefits, such as flexibility, dismountability, versatility, insulation, and reduced-weight properties.

Whether for the building envelope or interior applications, our products address sealing, bonding, fireproofing, water storage, visual and acoustic challenges to support sustainability trends. 

Examples include:

1. Special bonding tapes are utilised as flashing around windows, doors and roofing to reduce the need for mechanical fasteners, ensure resistance to environmental conditions and achieve high energy efficiency. Bonding tapes applied within lightweight façade construction to secure attachments, bond stiffener bars to cladding and keep panels in place. These tapes can extend the lifespan of building materials.
2. Gasketing foams or Norseal® Bio-based PUR (polyurethane) foams are ideal for sealing and protecting windows, doors, roofs and panels to improve air/water tightness and protect from environmental factors. When compressed, they perform as gasketing interface materials between construction elements. The use of tapes in efficient design reduces energy demand.
3. Materials such as high-performance silicone or polyurethane foams prevent leakage in or out of system boundaries within the heating, cooling and ventilation (HVAC) of buildings. Preventing this leakage is critical for insulation and energy efficiency. These solutions help maintain optimal thermal comfort and consistent air quality, enhancing the health and safety of occupants.
4. Intumescent gasketing foams have a unique combination of expandable fire-resistant materials and compressible, resilient and vibration-dampening features. These properties block poisonous gases and heat, protecting buildings and those inside.
5. UV-cured acrylics are utilised in construction to ensure better performance of building materials such as roof underlayments, water-resistive barriers and casings. These materials are compatible with most building materials, free of solvents and often perform better across wider temperature ranges.

Solutions for sustainable mobility

Foam and tape products help drive sustainable innovations while ensuring comfort, safety and performance within the mobility market. Examples include:

1. Thermally conductive, insulated and intumescent materials or silicone and micro-cellular polyurethane foams are utilised in either EV compression/tolerance pads, thermal runaway protection, pack sealing/gasketing/cushioning, electrical insulation or thermal interface materials. With these materials, engineers can design next generation EV batteries that optimise loading cycles, reach further, last longer and have shorter and more efficient charging.
2. Insulation, wire harnessing and permanent adhesive bonding for structural panels, emblems and exterior attachments support EV charging station networks. Our sealing materials protect charging station components from environmental impact. Thermally conductive, insulated and intumescent materials protect from dissipation of excess heat generated during charging cycles. These materials enhance performance, durability and promote the expansion of the charging infrastructure. This is key for the widespread adoption of EVs, which are roughly three times more energy efficient than traditional Internal Combustion Engine (ICE) vehicles.
3. Lightweight solutions such as acrylic and polyurethane tapes for attaching emblems and nameplates, body side mouldings, wheel flares and pillar appliques improve vehicle design. Bonding tapes eliminate the need for mechanical fasteners, liquid adhesives and welds, while simplifying manufacturing processes to reduce CO₂ emissions. When utilised in lieu of mechanical fasteners, tapes prevent corrosion and enhance the longevity of the vehicle.
4. Our portfolio of silicone foams was enhanced to better target lightweight applications in rail or aerospace, resulting in less fuel usage because of weight reduction. Solutions for thermal insulation, intake gasketing, access panel and HVAC sealing protect passengers from fire or toxic smoke. They provide reliable protection from vibration, corrosion and fluids, expanding the longevity and durability of these and other modes of transportation.

Solutions that support industry CO2 reduction

Localisation of production, manufacturing 4.0, product performance enhancements and sustainability are key challenges for the industrial market. Below are examples of how our products can boost sustainability: 

1. Silicone products can aid in automation processes such as those utilised by robotics. Materials can be retrofitted and adapted to enhance performance, while features such as surface texture and roughness can be improved to meet needs of robotics handling. UHMW, abrasion, impact and chemically resistant, is utilised as an optical guide for robotics. This product is easily replaced without using lubrication or additional equipment. UHMW tapes create smoother operation, extend the life of machinery and utilise less energy.
2. Tailored materials fulfil application-specific cushioning, compression, protection and insulation needs of current and future Li-ion BESS for stationary grid energy storage. With a charge and discharge cycle efficiency of approximately 90%, utilisation of BESS systems guarantees a reliable supply of renewable energy. BESS systems can release energy when needed most and store it during low-demand periods. They are critical to preventing brownouts or voltage variation.
3. Tape solutions products are used for tool protection and mould release in wind energy composite moulding to support cleaner, relatively secure and more affordable sources of energy. Utilising tape products to make wind turbine blades can produce 20 blades compared to only 5 when using traditional technology. This enables faster scale-up of renewable energy and contributes less waste.
4. Tape products are used to protect edges from solar laminates, used in manufacturing facilities. The tapes prevent breakage and support UL ratings of solar systems. They also secure and bond the solar panel junction boxes. Products can be optimised to improve efficiency and performance of renewable energy solutions like solar panels.

Next Steps in Tape Technologies

No matter the application or market, it is essential that our products demonstrate consistent, long-lasting and reliable performance while meeting specific application requirements. Foam and tape solutions have a significant impact on energy efficiency, extending product lifespan, generating renewable energy, eliminating waste, and overall improvements in health, safety, comfort and well-being.

The work towards sustainable initiatives has only just begun. A collaborative approach that includes the entire supply chain can deliver sustainability and ensure the superior functionality of more sustainable products, solutions and processes. Connect with our team today to gain a personal, focused and agile collaborator, backed by the world-class expertise and resources of Saint-Gobain. Our regional R&D centres allow us to serve our customers locally, with global solutions and the latest technologies.